ESAB Liquid Cooled Plasma Cutting Torch User manual

Brand: ESAB

Model: Liquid Cooled Plasma Cutting Torch

Category: Welding System

Type: User manual

October 15, 2002 Manual No. 0-2698

LIQUID COOLED

PLASMA CUTTING

TORCH

Instruction Manual

For Use With:

• PakMaster 150XL Power Supply

• Model PCH-120 Hand Torch

• Model PCM-120 Machine Torch

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-

ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

Liquid Cooled Plasma Cutting Torch

Model PCH-120 & PCM-120

Instruction Manual Number 0-2698

Published by

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written per-

mission 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 errors or omissions in

this Manual, whether such errors result from negligence, accident, or

any other cause.

Printed in the United States of America

Publication Date: October 15, 2002

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

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

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

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

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

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

SECTION 2:

INTRODUCTION & DESCRIPTION.................................................................................. 2-1

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

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

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

2.05 Introduction to Plasma.................................................................................. 2-3

SECTION 3:

INSTALLATION PROCEDURES ....................................................................................... 3-1

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

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

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

3.05 Connecting Torch ......................................................................................... 3-1

3.06 Setting Up Machine Torch ............................................................................ 3-2

3.07 Gas Selection............................................................................................... 3-2

3.08 Gas Connections ......................................................................................... 3-3

SECTION 4:

OPERATION ..................................................................................................................... 4-1

4.01 Introduction .................................................................................................. 4-1

4.02 Functional Overview..................................................................................... 4-1

4.03 Getting Started............................................................................................. 4-1

4.04 Torch Parts Selection ................................................................................... 4-1

4.05 Cut Quality ................................................................................................... 4-3

4.06 Operating the System .................................................................................. 4-4

4.07 Hand Torch Operation .................................................................................. 4-5

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

4.09 Recommended Cutting Speeds.................................................................... 4-8

4.10 Gouging ....................................................................................................... 4-8

TABLE OF CONTENTS (continued)

SECTION 5:

CUSTOMER/OPERATOR SERVICE................................................................................. 5-1

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

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

5.03 Common Operating Faults ........................................................................... 5-2

5.04 Inspection and Replacement Consumable Torch Parts ................................ 5-2

5.05 Troubleshooting Guide ................................................................................. 5-4

5.06 Servicing Hand Torch Components .............................................................. 5-6

5.07 Servicing Machine Torch Components ......................................................... 5-7

5.08 Torch And Leads Troubleshooting ................................................................ 5-8

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

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

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

6.03 Replacement Hand Torch Parts.................................................................... 6-2

6.04 Replacement Machine Torch Parts............................................................... 6-4

6.05 Torch Lead Component Replacement Parts (Unshielded Leads Only)......... 6-6

6.06 Complete Assembly Replacements.............................................................. 6-8

6.07 Spare Parts Kits ........................................................................................... 6-9

6.08 Options and Accessories........................................................................... 6-10

APPENDIX 1: CUTTING SPEED CHARTS ..............................................................................A-1

APPENDIX 2: SEQUENCE OF OPERATION BLOCK DIAGRAM.............................................A-6

Date: November 15, 2001 1-1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS 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. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional 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 in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formation regarding the kind and amount of fumes

and gases that may be dangerous to your health.

• For information on how to test for fumes and gases

in your workplace, refer to item 1 in Subsection 1.03,

Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects and, in some cases, cancer. (California Health

& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

GENERAL INFORMATION 1-2 Date: November 15, 2001

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

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

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable ma-

terial 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 under-

water 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 dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.

The plasma arc process produces very bright ultra violet

and infra red light. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

ments, U.S. Government Printing Office, Washington,

D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding So-

ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

from the Superintendent of Documents, U.S. Govern-

ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 1-3 GENERAL INFORMATION

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtain-

able from American National Standards Institute, 1430

Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-

TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-

tainable from American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, 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 Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED 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 WELD-

ING 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 Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

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

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD 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

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

GENERAL INFORMATION 1-4 Date: November 15, 2001

• Eloignez toute fumée et gaz de votre zone de respira-

tion. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air

si l’aération fournie ne permet pas d’éliminer la fumée

et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un ou

plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des gaz

pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une

zone où se trouvent des matières ou des gaz combus-

tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,

produit de la fumée ou des gaz pouvant contenir des

éléments reconnu dans L’état de la Californie, qui

peuvent causer des défauts de naissance et le cancer.

(La sécurité de santé en Californie et la code sécurité

Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voire mortels, pour l’opérateur

et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”;

portez des gants et des vêtements secs. Isolez-vous

de la pièce de travail ou des autres parties du circuit

de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la page

5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de

consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail. Protégez

toute telle matière qu’il est impossible de retirer de la

zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans

une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous

les pièces de travail en aluminium lorsqu’elles sont

coupées sous l’eau ou sur une table d’eau. NE PAS

couper les alliages en aluminium sous l’eau ou sur

une table d’eau à moins que le gas hydrogène peut

s’échapper ou se dissiper. Le gas hydrogène accumulé

explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de

plasma produit une lumière infra-rouge et des rayons

Date: November 15, 2001 1-5 GENERAL INFORMATION

ultra-violets très forts. Ces rayons d’arc nuiront à vos

yeux et brûleront votre peau si vous ne vous protégez

pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou

un écran de soudeur. Portez toujours des lunettes de

sécurité munies de parois latérales ou des lunettes de

protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur

approprié pour protéger votre peau contre les

étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection

en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant des

cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le

recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé

clairement. L’experience a démontrer que les filtres

moins foncés peuvent être utilisés quand l’arc est

caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

normalement acceptables. Vous dú4ez vous protéger les

oreilles contre les bruits forts afin d’éviter une perte

permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez

des tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres personnes

se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que

les décibels (le bruit) ne dépassent pas les niveaux

sûrs.

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus

récentes ayant été faites à celles-ci pour de plus amples

renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE

PROTECTION DE LA SANTÉ, 29CFR 1910,

disponible auprès du Superintendent of Documents,

U.S. Government Printing Office, Washington, D.C.

20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES

OPÉRATIONS DE COUPE ET DE SOUDAGE,

disponible auprès de la Société Américaine de

Soudage (American Welding Society), 550 N.W.

LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES

OPÉRATIONS DE COUPE ET DE SOUDAGE À

L’ARC ET AU GAZ, disponible auprès du Superin-

tendent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA

PROTECTION DES YEUX ET DU VISAGE AU TRA-

VAIL ET DANS LES ECOLES, disponible de l’Institut

Américain des Normes Nationales (American Na-

tional Standards Institute), 1430 Broadway, New York,

NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES

LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET

DE SOUDAGE, disponible auprès de l’American Na-

tional Standards Institute, 1430 Broadway, New York,

NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage

(AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES PRODUITS

COMBUSTIBLES, disponible auprès de la American

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

33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA COUPE ET LES

PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-

tional Fire Protection Association, Batterymarch Park,

Quincy, MA 02269

GENERAL INFORMATION 1-6 Date: November 15, 2001

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE

COUPE ET DE SOUDAGE, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13.Livret NWSA, BIBLIOGRAPHIE SUR LA

SÉCURITÉ DU SOUDAGE, disponible auprès de

l’Association Nationale de Fournitures de Soudage

(National Welding Supply Association), 1900 Arch

Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRATIQUES

SURES POUR LA PRÉPARATION À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

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

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION

RESPIRATOIRE, disponible auprès de l’American

National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 1-7 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’

(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for

the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit

and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing 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: Giorgio Bassi

Managing Director

Thermal Dynamics Europe

Via rio Fabbiani 8A

40067 Rastignano (BO)

Italy

GENERAL INFORMATION 1-8 Date: November 15, 2001

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics

Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in

workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges

to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the

customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

Manual 0-2698 2-1 INTRODUCTION & DESCRIPTION

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions

and maintenance procedures for the PCH/M-120 Liquid

Cooled Torch. Service of this equipment is restricted to

properly trained personnel; unqualified personnel are

strictly cautioned against attempting repairs or adjust-

ments not covered in this manual, at the risk of voiding

the Warranty.

Read this manual thoroughly. A complete understand-

ing of the characteristics and capabilities of this equip-

ment will assure the dependable operation for which it

was designed.

2.02 General Description

NOTE

Refer to Section 2.05, Introduction To Plasma, for

a more detailed description on plasma theory.

The Torch is a liquid cooled torch that provides cutting

capacity of up to 1-1/2 inches (38.1 mm) at 120 amperes.

In the torch, one torch lead provides plasma gas and one

lead provides secondary gas to the torch head. The leads

also provide the closed loop for the liquid coolant flow

from the Power Supply.

Plasma torches are similar in design to the common au-

tomotive spark plug. They consist of negative and posi-

tive sections which are separated by a center insulator.

Inside the torch, the pilot arc is initiated in the gap be-

tween the negatively charged electrode and the positively

charged tip. Once the pilot arc has ionized the plasma

gas, the superheated column of gas flows through the

small orifice in the torch tip, which is focused on the metal

to be cut.

2.03 Specifications & Design

Features

The following applies to the Torch only:

A. Torch Configurations and Dimensions

1. Hand Torch (PCH)

Torch is available with torch heads at 70° and 90°

to the torch handle. The hand torches include a

torch handle and multi-position torch switch as-

sembly.

2. Machine Torch (PCM)

Machine Torch (180°) is supplied with a metal rack

and pinion mounting assembly, Remote ON/OFF

Pendant (Unshielded Leads) or CNC Cable

(Shielded Leads).

17.4 in.

4.3 in.

(109.2mm)

2.5 in.

1.5 in.(38.1mm)

1.9 in. (48.3mm)

3.5 in.

14.3 in.

13.3 in.

3.3 in.

1.5 in.

1.4 in.

1.5 in.

1.4 in.

13.5 in.

A-02683

(337mm)

(342.9mm)

(38.1mm)

(363.2mm)

(35.6mm)

(83.8mm)

(38.1mm)

(88.9mm)

(35.6mm)

(44.2mm)

(86.4mm)

(68.5mm)

70˚

90˚

180˚

3.4 in.

Figure 2-1 Torch Dimensions and Configurations

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2698

B. Torch Leads Lengths

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

C. Cutting Range

Most materials up to 1- 1/2 inch (38.1 mm)

D. Pierce Rating

3/4 inch (19.05 mm)

E. Transfer Distance

3/8 inch (9.5 mm)

F. Torch Ratings

Ambient

Temperature

104° F

(40° C)

Duty Cycle

100% @ 120 Amps @ 0.6 gpm

(2.3 lpm) Coolant Flow Rate

Maximum Current

120 Amps

Voltage (V

peak

)

500V

Arc Striking Voltage

12 kV

Torch Ratings

G. Torch Parts

Gas Distributor, Electrode, Tip, Shield Cup

Water Tube Extension for Gouging Only

H. Gas Supply Requirements

1. Plasma

Gases: Compressed Air, Nitrogen (N2), Argon/

Hydrogen only

Pressure: 65 psi (4.5 bar)

CAUTION

Maximum input gas pressure must not exceed 125

psi (8.62 bar)

Cold Flow:

Cutting: 50-78 scfh (23.6-36.8 lpm)

Gouging: 85-95 scfh (40.1-44.8 lpm)

scfh = standard cubic feet per hour

NOTE

Cold flow is measured before the main arc is activated.

When pressure is set correctly, the plasma gas flow rate

is significantly lower when the arc is initiated.

2. Secondary

Gases: Compressed Air, Carbon Dioxide (CO2),

Nitrogen (N2) only

Pressure: 60 psi (4.1 bar)

CAUTION

Maximum input gas pressure must not exceed 125

psi (8.62 bar)

Cold Flow:

Cutting: 340 scfh (160.4 lpm)

Gouging: 235 scfh (110.9 lpm)

scfh = standard cubic feet per hour

I. Plasma Power Supply Used With

• PakMaster 150XL

J. Weight

• Hand Torch

25 ft (7.6 m) Leads - 11.4 lbs (5.17 kg)

50 ft (15.2 m) Leads - 20.4 lbs (9.25 kg)

• Machine Torch

25 ft (7.6 m) Leads - 12.8 lbs (5.81 kg)

50 ft (15.2 m) Leads - 20.8 lbs (9.43 kg)

Manual 0-2698 2-3 INTRODUCTION & DESCRIPTION

2.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is defined as a gas which has been heated to

an extremely high temperature and ionized so that it

becomes electrically conductive. The plasma arc cut-

ting and gouging process use this plasma to transfer

an electrical arc to the workpiece. The metal to be

cut or removed is melted by the heat of the arc and

then blown away.

While the goal of plasma arc cutting is separation of

the material, plasma arc gouging is used to remove

metals to a controlled depth and width.

In a plasma cutting torch a cool gas such as air or

nitrogen (N2) enters Zone B (refer to Figure 2-2),

where a pilot arc between the electrode and the torch

tip heats and ionizes the gas. The main cutting arc

then transfers to the workpiece through the column

of plasma gas in Zone C.

A-00002

Workpiece

Power

Supply

Figure 2-2 Theory of Operation

By forcing the plasma gas and electric arc through a

small orifice, the torch delivers a high concentration

of heat to a small area. The stiff, constricted plasma

arc is shown in Zone C (Figure 2-2). Direct current

(DC) straight polarity is used for plasma cutting, as

shown in the illustration.

B. Secondary Gas Flow

Zone A (Figure 2-2) is where secondary gas flows to

help cool the torch and and assist the high velocity

plasma gas in blowing the molten metal out of the

cut allowing for a fast, slag-free cut. Compressed air,

supplied by either a cylinder, plant air system or CO

is normally used as the secondary gas.

C. Coolant Flow

Liquid coolant is the primary means for cooling torch

parts. The coolant flows from the coolant recirculator,

through the coolant supply leads to the torch head

and returns through the return coolant leads.

D. Gas Distribution

The plasma gas flows into the torch through the

plasma (+) lead, through the gas distributor, around

the electrode, and out through the tip orifice.

The secondary gas flows into the torch through the

secondary gas hose, down around the outside of the

torch gas distributor, and out between the tip and

shield cup around the plasma arc.

E. Pilot Arc

When the torch is started a pilot arc is established

between the electrode and cutting tip. This pilot arc

creates a path for the main arc to transfer to the work.

F. CD (Capacitive Discharge)

Because direct current (DC) alone is not sufficient to

strike and maintain the pilot arc, high frequency is

also used. The CD jumps between the tip and elec-

trode with the DC following, then the CD turns off.

G. Main Cutting Arc

DC power is also used for the main cutting arc. The

negative output is connected to the torch electrode

through the torch lead. The positive output is con-

nected to the workpiece via the work cable and to

the torch through the plasma (+) lead.

H. Interlocks

Two pressure switches act as an interlock for the gas

supply. If supply pressure falls below minimum re-

quirements the pressure switches will open, shutting

off the power to the contactors, and the GAS indica-

tor, if supplied, will go out. When adequate gas sup-

ply pressure is available the pressure switches close,

allowing power to be resumed for cutting.

A flow switch acts as an interlock for the closed loop

coolant supply. If the flow switch does not activate,

then the Power Supply will not power on. The flow

switch will not activate if there is low coolant level,

or if the front end torch parts (tip or electrode) are

not installed.

INTRODUCTION & DESCRIPTION 2-4 Manual 0-2698

Manual 0-2698 3-1 INSTALLATION PROCEDURES

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

This section describes installation of the Torch. These

instructions apply to the Torch and Leads Assemblies

only; installation procedures for the Power Supply, Op-

tions, and Accessories are given in Manuals specifically

provided for those components.

The complete installation consists of:

1. Site Selection

2. Unpacking

3. Setting Up Torch

4. Connecting Torch

5. Gas Connections

6. Operator Training

3.02 Site Location

Select a clean, dry location with good ventilation and ad-

equate working space around all components.

Review the safety precautions in the front of this manual

to be sure that the location meets all safety requirements.

3.03 Unpacking

NOTE

Torches ordered as part of a system are factory as-

sembled to the power supply and are pacckaged in

one shipping carton.

Each component of the system is packaged and protected

with a carton and packing material to prevent damage

during shipping. Components are packaged as follows:

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identify

and account for each item.

3. Inspect each item for possible shipping damage. If

damage is evident, contact your distributor and/or

shipping company before proceeding with system

installation.

3.05 Connecting Torch

WARNING

Disconnect primary power at the source before dis-

assembling the torch or torch leads.

The Torch Leads must be properly installed to the

Power Supply for proper operation. Make all torch

connections to the Torch Bulkhead Panel per the fol-

lowing:

NOTE

Equipment ordered as a system will have the Torch

factory connected to the Power Supply.

1. Turn the two screw latches securing the front ac-

cess panel to the power supply front panel.

Bulkhead

Access

Panel

Screw

Latches

Torch Leads

Shield Stud

A-02684

Figure 3-2 Power Supply Front Access Panel

2. Lift up on the access panel to gain access to the

torch bulkhead panel.

3. Feed the Control Cable Fitting through the rub-

ber boot in the front panel.

NOTE

For hand torches, the Control Cable Fitting is part

of the torch leads assembly. For machine torches,

the Control Cable Fitting is separate from the torch

and connects to either a Remote Hand Pendant or

a CNC Computer or other device.

4. Feed the end of the torch leads through the rub-

ber boot in the front panel.

5. Connect Control Cable Fitting to Control Cable

Connector.

INSTALLATION PROCEDURES 3-2 Manual 0-2698

6. If installing a machine torch with shielded leads,

complete the following:

a. Remove one nut and star washer from the

Torch leads Shield Stud.

b. Place the ring lug on the torch leads shield wire

over the stud and secure with nut and star

washer.

7. Connect torch coolant and gas leads to connec-

tors, as indicated on bulkhead.

8. Close the access panel and turn the two latching

screws.

9. Connect the other end of the Control Cable to a

CNC device, if applicable.

A-02113

Secondary

Gas

Plasma (+)

Gas

Control Cable

Connector

Coolant

Return

Coolant

Supply (-)

CNC Control

Cable

Torch Leads

Shield Stud

Shield Wire

With Ring Lug

Figure 3-3 Torch Leads Connections

3.06 Setting Up Machine Torch

WARNING

Disconnect primary power at the source before dis-

assembling the torch or torch leads.

A Metal Mounting Tube with Rack and Pinion Assembly

is standard for machine torches. A Remote Hand Pen-

dant is included with unshielded leads; a CNC Interface

Cable is included with shielded leads.

1. Mount the torch assembly on the cutting table.

2. To obtain a clean vertical cut, use a square to align

the torch perpendicular to the surface of the work-

piece.

Rack and

Pinion Mounting

Assembly

Square

A-00660

Workpiece

Figure 3-4 Machine Torch Set-Up

3.07 Gas Selection

CAUTIONS

Maximum input gas pressure must not exceed 125

psi (8.6 bar)

Air supply must be free of oil, moisture, and other

contaminants. Excessive oil and moisture may

cause double-arcing, rapid tip wear, or even com-

plete torch failure. Contaminants may cause poor

cutting performance and rapid electrode wear.

The type of operation will determine the best gases to be

used. Refer to the following and select the plasma and

secondary gases that best fit the operation(s):

A. Plasma Gases

NOTE

Refer to Section 2.03, Specifications & Design Fea-

tures, for proper gas pressure and flow rate.

1. Compressed Air Plasma

• Most often used on ferrous or carbon base materi-

als to obtain good quality at faster cutting speeds.

• 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

will substantially reduce torch parts life.

• Provides satisfactory results on non-ferrous mate-

rials.

Manual 0-2698 3-3 INSTALLATION PROCEDURES

2. Nitrogen (N2) Plasma

• Provides cut quality similar to air on non-ferrous

materials such as stainless steel and aluminum.

• Can be used in place of air plasma with air second-

ary or carbon dioxide (CO

• Provides much better parts life than air.

• A good clean welding grade nitrogen should be

used.

3. Argon/Hydrogen (ArH

) Plasma

• Recommended for use on 3/4 inch (19 mm) and

thicker stainless steel. Recommended for 1/2 inch

(12 mm) and thicker non-ferrous materials. Ar/H

is not normally used for thinner non-ferrous mate-

rials because less expensive gases can achieve simi-

lar cut quality.

• Poor cut quality on ferrous materials.

• Provides faster cutting speeds and high cut quality

on thicker materials to offset the higher cost.

• A 65% argon/35% hydrogen mixture should be

used.

B. Secondary Gases

NOTE

Refer to Section 2.03, Specifications & Design Fea-

tures, for proper gas pressure and flow rate.

1. Compressed Air Secondary

• Air secondary is normally used when operating

with air plasma and occasionally with nitrogen

plasma.

• Improves cut quality on some ferrous materials.

• Inexpensive - reduces operating costs.

2. Carbon Dioxide (CO

) Secondary

•CO

secondary is used with nitrogen or Ar/H

plasma.

• Provides good cooling and maximizes torch parts

life.

• Provides good cut quality on ferrous or non-ferrous

material.

• May reduce smoke when used with Ar/H

plasma.

NOTE

When CO

is used as the secondary gas, twenty

(50 lb) cylinders must be manifolded together or a

bulk CO

system used to get the required flow rate

of 340 scfh. Shop compressed air is a good alterna-

tive if providing the required CO

flow rate is not

feasible.

3. Nitrogen (N2) Secondary

• Nitrogen secondary is used with Ar/H

plasma.

• Provides smooth finishes on non-ferrous materials.

• May be used with nitrogen plasma in order to oper-

ate from one compressed gas cylinder - but torch

parts life may be shorter than with CO

secondary.

• May reduce smoke when used with Ar/H

plasma.

3.08 Gas Connections

A. Connecting to Power Supply

Connect the gases to the power supply as described

in the power supply operating manual supplied with

the power supply.

CAUTION

Air supply must be free of oil, moisture, and other

contaminants. Excessive oil and moisture may

cause double-arcing, rapid tip wear, or even com-

plete torch failure. Contaminants may cause poor

cutting performance and rapid electrode wear.

B. Checking Air Quality

To test the quality of air, place a welding filter lens in

front of the torch and turn on the gas for 2-3 minutes.

Any oil or moisture in the air will be visible on the

lens. Do not initiate an arc!

C. Filtering

An inline pneumatic dryer/evaporator type air fil-

ter, capable of filtering to at least 5 microns, is required

when using air from a compressor. This type filter

will insure that moisture, oil, dirt, chips, rust particles,

and other contminants from the supply hose do not

enter the torch. For highly automated applications,

a refrigerated drier may be used.

NOTE

Do not use an air line filter with high pressure gas

cylinders.

INSTALLATION PROCEDURES 3-4 Manual 0-2698

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ESAB Liquid Cooled Plasma Cutting Torch User manual

Brand: ESAB

Model: Liquid Cooled Plasma Cutting Torch

Category: Welding System

Type: User manual

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ESAB Liquid Cooled Plasma Cutting Torch User manual

ESAB Liquid Cooled Plasma Cutting Torch User manual

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