Merlin Pak 15XC European Instruction Manual

Manual No. 0-2529October 6, 1999

MERLIN PAK 15XCPlasma Cutting System (European)

Instruction Manual

PAK 15XC 150 Amp EMC Power Supply PCH/M-150 Torch Assembly With Leads PCH/M-150 Spare Parts Kit Work Cable and Clamp Running Gear and Handle Air Line Filter Assembly (or) High

Pressure Regulators

WARNING

WARNING

Read and understand this entire Instruction Manual and youremployers safety practices before installing, operating, orservicing the equipment.

While the information contained in this Instruction Manualrepresents our best judgement, Thermal Dynamics Corporationassumes no liability for its use.

Merlin Pak 15XC European/EMC Plasma Cutting SystemInstruction Manual Number 0-2529

Published by:Thermal Dynamics CorporationIndustrial Park No. 2West Lebanon, New Hampshire, USA 03784(603) 298-5711

Copyright 1996 byThermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without writtenpermission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liabilityto any party for any loss or damage caused by any error oromission in the Merlin Pak 15XC European/EMC Plasma CuttingSystem Instruction Manual, whether such error results fromnegligence, accident, or any other cause.

Printed in the United States of America

October 6, 1999

TABLE OF CONTENTS

GENERAL INFORMATION ............................................................................................................. i

Notes, Cautions and Warnings .................................................................................. iImportant Safety Precautions .................................................................................... iPublications .............................................................................................................. iiNote, Attention et Avertissement ............................................................................. iiiPrecautions De Securite Importantes ...................................................................... iiiDocuments De Reference ....................................................................................... vDeclaration of Conformity ....................................................................................... viiStatement of Warranty ........................................................................................... viii

SECTION 1: INTRODUCTION & DESCRIPTION ..................................................................... 1-1

1.1 SYSTEM DESCRIPTION .............................................................................. 1-11.2 POWER SUPPLY SPECIFICATIONS ............................................................ 1-21.3 TORCH SPECIFICATIONS ........................................................................... 1-31.4 OPTIONS AND ACCESSORIES ................................................................... 1-51.5 THEORY OF OPERATION ............................................................................ 1-6

SECTION 2: INSTALLATION .................................................................................................... 2-1

2.1 UNPACKING THE SYSTEM .......................................................................... 2-12.2 LOCATION .................................................................................................... 2-22.3 PLASMA AND SECONDARY CONNECTIONS ............................................. 2-22.4 ELECTRICAL CONNECTIONS ..................................................................... 2-62.5 WORK AND GROUND CONNECTIONS....................................................... 2-82.6 COOLANT INSTALLATION ........................................................................... 2-92.7 AUXILIARY CONNECTIONS ...................................................................... 2-102.8 LIFTING THE POWER SUPPLY.................................................................. 2-12

SECTION 3: OPERATION ........................................................................................................ 3-1

3.1 OPERATING CONTROLS ............................................................................. 3-13.2 PRE-OPERATION SET-UP ........................................................................... 3-43.3 TORCH PARTS SELECTION ........................................................................ 3-53.4 GAS SELECTION FOR PLASMA CUTTING................................................. 3-83.5 PLASMA CUTTING OPERATION ............................................................... 3-123.6 HAND TORCH OPERATION ....................................................................... 3-163.7 MACHINE TORCH OPERATION ................................................................. 3-183.8 PIERCING ................................................................................................... 3-213.9 GOUGING OPERATION ............................................................................. 3-223.10 COMMON OPERATING ERRORS ............................................................ 3-253.11 CUTTING SPEEDS ................................................................................... 3-263.12 SEQUENCE OF OPERATION................................................................... 3-33

TABLE OF CONTENTS (continued)

SECTION 4: SERVICE ............................................................................................................. 4-1

4.1 TORCH MAINTENANCE ............................................................................... 4-14.2 HAND TORCH HEAD REPLACEMENT ........................................................ 4-24.3 MACHINE TORCH HEAD REPLACEMENT .................................................. 4-44.4 HAND TORCH SWITCH REPLACEMENT .................................................... 4-64.5 HAND TORCH LEADS REPLACEMENT ...................................................... 4-74.6 MACHINE TORCH LEADS REPLACEMENT ................................................ 4-94.7 LEADS EXTENSION KITS - HAND TORCH ............................................... 4-114.8 LEADS EXTENSION KITS - MACHINE TORCH ......................................... 4-134.9 POWER SUPPLY MAINTENANCE ............................................................. 4-164.10 TROUBLESHOOTING THEORY ............................................................... 4-174.11 TROUBLESHOOTING GUIDE ................................................................... 4-214.12 SERVICE AND TEST PROCEDURES ...................................................... 4-27

SECTION 5: PARTS LISTS....................................................................................................... 5-1

5.1 ABOUT THE PARTS LIST ............................................................................. 5-15.2 SYSTEM COMPONENTS AND ACCESSORIES .......................................... 5-25.3 ACCESS PANEL COMPONENTS ................................................................. 5-45.4 FRONT PANEL/CHASSIS COMPONENTS................................................... 5-55.5 REAR PANEL COMPONENTS ..................................................................... 5-65.6 BASE COMPONENTS .................................................................................. 5-85.7 UPPER CHASSIS COMPONENTS ............................................................. 5-105.8 MAIN HEATSINK COMPONENTS .............................................................. 5-125.9 TORCH COMPONENTS ............................................................................. 5-145.10 TORCH ACCESSORIES ........................................................................... 5-16

SECTION 6: ADDITIONAL INFORMATION .............................................................................. 6-1

6.1 LADDER DIAGRAM - 120 VAC ...................................................................... 6-16.2 LADDER DIAGRAM - 15 VDC ........................................................................ 6-26.3 DIGITAL CURRENT CONTROL INTERFACE ................................................ 6-36.4 CNC INTERFACE ......................................................................................... 6-46.5 POWER SUPPLY TO REMOTE CONTROL CABLE INTERFACE ................. 6-56.6 REMOTE CONTROL CHASSIS SCHEMATIC .............................................. 6-66.7 RECOMMENDED ROUTINE MAINTENANCE SCHEDULE

FOR LIQUID COOLED PLASMA CUTTING SYSTEMS .............................. 6-7

Date: 6/22/99 (Special) i GENERAL INFORMATION

GENERAL INFORMATION

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

NOTE

An operation, procedure, or background informa-tion which requires additional emphasis or is help-ful in efficient operation of the system.

CAUTION

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

WARNING

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

Important Safety Precautions

WARNINGS

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

Plasma arc cutting produces intense electric andmagnetic emissions that may interfere with theproper function of cardiac pacemakers, hearingaids, or other electronic health equipment. Per-sons who work near plasma arc cutting applica-tions should consult their medical health profes-sional and the manufacturer of the healthequipment to determine whether a hazard exists.

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

GASES AND FUMES

Gases and fumes produced during the plasma cuttingprocess can be dangerous and hazardous to your health.

Keep all fumes and gases from the breathing area.Keep your head out of the welding fume plume.

Use an air-supplied respirator if ventilation is notadequate to remove all fumes and gases.

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

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium

Always read the Material Safety Data Sheets (MSDS)that should be supplied with the material you areusing. These MSDSs will give you the informationregarding the kind and amount of fumes and gasesthat may be dangerous to your health.

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

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

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

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

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc processuses and produces high voltage electrical energy. Thiselectric energy can cause severe or fatal shock to the op-erator or others in the workplace.

Never touch any parts that are electrically live orhot.

Wear dry gloves and clothing. Insulate yourself fromthe work piece or other parts of the welding cir-cuit.

Repair or replace all worn or damaged parts.

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

Install and maintain equipment according to NECcode, refer to item 9 in Subsection, Publications.

GENERAL INFORMATION ii Date 6/22/99 (Special)

Disconnect power source before performing any ser-vice or repairs.

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

FIRE AND EXPLOSION

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

Be sure there is no combustible or flammable mate-rial in the workplace. Any material that cannot beremoved must be protected.

Ventilate all flammable or explosive vapors fromthe workplace.

Do not cut or weld on containers that may have heldcombustibles.

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

Hydrogen gas may be formed and trapped underaluminum workpieces when they are cut under-water or while using a water table. DO NOT cutaluminum alloys underwater or on a water tableunless the hydrogen gas can be eliminated or dis-sipated. Trapped hydrogen gas that is ignited willcause an explosion.

NOISE

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

To protect your hearing from loud noise, wear pro-tective ear plugs and/or ear muffs. Protect othersin the workplace.

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

For information on how to test for noise, see item 1in Subsection, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.The plasma arc process produces very bright ultra violetand infra red light. These arc rays will damage youreyes and burn your skin if you are not properly protected.

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

Wear welding gloves and suitable clothing to pro-tect your skin from the arc rays and sparks.

Keep helmet and safety glasses in good condition.Replace lenses when cracked, chipped or dirty.

Protect others in the work area from the arc rays.Use protective booths, screens or shields.

Use the shade of lens as suggested in the followingper ANSI/ASC Z49.1:

Minimum Protective SuggestedArc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearlyseen. Experience has shown that lighter filtersmay be used when the arc is hidden by the work-piece.

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

1. OSHA, SAFETY AND HEALTH STANDARDS,29CFR 1910, obtainable from the Superintendent ofDocuments, U.S. Government Printing Office, Wash-ington, D.C. 20402

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

3. NIOSH, SAFETY AND HEALTH IN ARC WELD-ING AND GAS WELDING AND CUTTING, obtain-able from the Superintendent of Documents, U.S.Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-CUPATION AND EDUCATIONAL EYE AND FACEPROTECTION, obtainable from American NationalStandards Institute, 1430 Broadway, New York, NY10018

5. ANSI Standard Z41.1, STANDARD FOR MENSSAFETY-TOE FOOTWEAR, obtainable from theAmerican National Standards Institute, 1430 Broad-way, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THEUSE OF CUTTING AND WELDING PROCESSES,obtainable from American National Standards Insti-tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTINGCONTAINERS WHICH HAVE HELD COMBUS-TIBLES, obtainable from American Welding Society,550 N.W. LeJeune Rd, Miami, FL 33126

Date: 6/22/99 (Special) iii GENERAL INFORMATION

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

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

10. NFPA Standard 51B, CUTTING AND WELDINGPROCESSES, obtainable from the National Fire Pro-tection Association, Batterymarch Park, Quincy, MA02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-PRESSED GASES IN CYLINDERS, obtainable fromthe Compressed Gas Association, 1235 JeffersonDavis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY INWELDING AND CUTTING, obtainable from the Ca-nadian Standards Association, Standards Sales, 178Rexdale Boulevard, Rexdale, Ontario, Canada M9W1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRA-PHY obtainable from the National Welding SupplyAssociation, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, REC-OMMENDED SAFE PRACTICES FOR THE PREPA-RATION FOR WELDING AND CUTTING OF CON-TAINERS AND PIPING THAT HAVE HELDHAZARDOUS SUBSTANCES, obtainable from theAmerican Welding Society, 550 N.W. LeJeune Rd,Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-TORY PROTECTION, obtainable from AmericanNational Standards Institute, 1430 Broadway, NewYork, NY 10018

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

NOTE

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

ATTENTION

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

AVERTISSEMENT

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

Precautions De Securite Importantes

AVERTISSEMENTS

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

Coupant larc au jet de plasma produit de lnergielectrique haute tension et des missionsmagntique qui peuvent interfrer la fonctionpropre dun pacemaker cardiaque, les appareilsauditif, ou autre matriel de sant electronique.Ceux qui travail prs dune application larc aujet de plasma devrait consulter leur membreprofessionel de mdication et le manufacturier dematriel de sant pour dterminer sil existe desrisques de sant.

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

FUME et GAZ

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

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

Utilisez un appareil respiratoire alimentation enair si laration fournie ne permet pas dliminer lafume et les gaz.

Les sortes de gaz et de fume provenant de larc deplasma dpendent du genre de mtal utilis, desrevtements se trouvant sur le mtal et des diffrents

GENERAL INFORMATION iv Date 6/22/99 (Special)

procds. Vous devez prendre soin lorsque vouscoupez ou soudez tout mtal pouvant contenir unou plusieurs des lments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre slniumbryllium manganse vanadium

Lisez toujours les fiches de donnes sur la scuritdes matires (sigle amricain MSDS); celles-cidevraient tre fournies avec le matriel que vousutilisez. Les MSDS contiennent des renseignementsquant la quantit et la nature de la fume et desgaz pouvant poser des dangers de sant.

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

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

Nutilisez pas le chalumeau au jet de plasma dansune zone o se trouvent des matires ou des gazcombustibles ou explosifs.

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

CHOC ELECTRIQUE

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

Ne touchez jamais une pice sous tension ouvive; portez des gants et des vtements secs.Isolez-vous de la pice de travail ou des autres par-ties du circuit de soudage.

Rparez ou remplacez toute pice use ouendommage.

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

Montez et maintenez le matriel conformment auCode lectrique national des Etats-Unis. (Voir lapage 5, article 9.)

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

Lisez et respectez toutes les consignes du Manuelde consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent rsulter des scorieschaudes, des tincelles ou de larc de plasma. Le procd larc de plasma produit du mtal, des tincelles, desscories chaudes pouvant mettre le feu aux matires com-bustibles ou provoquer lexplosion de fumesinflammables.

Soyez certain quaucune matire combustible ou in-flammable ne se trouve sur le lieu de travail.Protgez toute telle matire quil est impossible deretirer de la zone de travail.

Procurez une bonne aration de toutes les fumesinflammables ou explosives.

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

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

Le gas hydrogne peut se former ou saccumulersous les pices de travail en aluminium lorsquellessont coupes sous leau ou sur une table deau. NEPAS couper les alliages en aluminium sous leau ousur une table deau moins que le gas hydrognepeut schapper ou se dissiper. Le gas hydrogneaccumul explosera si enflamm.

RAYONS DARC DE PLASMA

Les rayons provenant de larc de plasma peuvent blesservos yeux et brler votre peau. Le procd larc de plasmaproduit une lumire infra-rouge et des rayons ultra-vio-lets trs forts. Ces rayons darc nuiront vos yeux etbrleront votre peau si vous ne vous protgez pascorrectement.

Pour protger vos yeux, portez toujours un casqueou un cran de soudeur. Portez toujours des lunettesde scurit munies de parois latrales ou des lu-nettes de protection ou une autre sorte de protec-tion oculaire.

Portez des gants de soudeur et un vtementprotecteur appropri pour protger votre peaucontre les tincelles et les rayons de larc.

Maintenez votre casque et vos lunettes de protec-tion en bon tat. Remplacez toute lentille sale oucomportant fissure ou rognure.

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

Date: 6/22/99 (Special) v GENERAL INFORMATION

Utilisez la nuance de lentille qui est suggre dansle recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance SuggereCourant Arc Protective Numro Numro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

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

BRUIT

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

Pour protger votre oue contre les bruits forts, portezdes tampons protecteurs et/ou des protectionsauriculaires. Protgez galement les autrespersonnes se trouvant sur le lieu de travail.

Il faut mesurer les niveaux sonores afin dassurerque les dcibels (le bruit) ne dpassent pas lesniveaux srs.

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

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

1. OSHA, NORMES DE SCURIT DU TRAVAIL ETDE PROTECTION DE LA SANT, 29CFR 1910,disponible auprs du Superintendent of Docu-ments, U.S. Government Printing Office, Washing-ton, D.C. 20402

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

3. NIOSH, LA SCURIT ET LA SANT LORS DESOPRATIONS DE COUPE ET DE SOUDAGE LARC ET AU GAZ, disponible auprs du Superin-tendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LAPROTECTION DES YEUX ET DU VISAGE AUTRAVAIL ET DANS LES ECOLES, disponible delInstitut Amricain des Normes Nationales (Ameri-can National Standards Institute), 1430 Broadway,New York, NY 10018

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

6. Norme ANSI Z49.2, PRVENTION DESINCENDIES LORS DE LEMPLOI DE PROCDSDE COUPE ET DE SOUDAGE, disponible auprsde lAmerican National Standards Institute, 1430Broadway, New York, NY 10018

7. Norme A6.0 de lAssociation Amricaine duSoudage (AWS), LE SOUDAGE ET LA COUPE DECONTENEURS AYANT RENFERM DESPRODUITS COMBUSTIBLES, disponible auprs dela American Welding Society, 550 N.W. LeJeune Rd.,Miami, FL 33126

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

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

10. Norme 51B de la NFPA, LES PROCDS DECOUPE ET DE SOUDAGE, disponible auprs dela National Fire Protection Association,Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANSRISQUE DES GAZ COMPRIMS EN CYLINDRES,disponible auprs de lAssociation des GazComprims (Compressed Gas Association), 1235Jefferson Davis Highway, Suite 501, Arlington, VA22202

12. Norme CSA W117.2, CODE DE SCURIT POURLE SOUDAGE ET LA COUPE, disponible auprsde lAssociation des Normes Canadiennes, Stan-dards Sales, 178 Rexdale Boulevard, Rexdale,Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SCURITDU SOUDAGE, disponible auprs de lAssociationNationale de Fournitures de Soudage (NationalWelding Supply Association), 1900 Arch Street,Philadelphia, PA 19103

GENERAL INFORMATION vi Date 6/22/99 (Special)

14. Norme AWSF4.1 de lAssociation Amricaine deSoudage, RECOMMANDATIONS DE PRA-TIQUES SURES POUR LA PRPARATION LACOUPE ET AU SOUDAGE DE CONTENEURSET TUYAUX AYANT RENFERM DESPRODUITS DANGEREUX , disponible auprs dela American Welding Society, 550 N.W. LeJeuneRd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-TION RESPIRATOIRE, disponible auprs delAmerican National Standards Institute, 1430Broadway, New York, NY 10018

Date: 6/22/99 (Special) vii GENERAL INFORMATION

Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: Industrial Park #2

West Lebanon, New Hampshire 03784USA

The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Direc-tive (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the Nationallegislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

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

National Standard and Technical Specifications

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

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

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

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

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

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design andmanufacturing process. This is to ensure the product is safe, when used according to instructions in this manual andrelated industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturingprocess to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in ourarea of manufacture.

Manufacturers responsible representative: Steve WardDirector of OperationsThermadyne UKChorley England

GENERAL INFORMATION viii Date 6/22/99 (Special)

Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal) warrants that its products will be free of defects inworkmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermalproducts as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,and maintained in accordance with Thermals specifications, instructions, recommendations and recognized standard industry practice,and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermals soleoption, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, butnot limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) forservice interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to anycontract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under anywarranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THESAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

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

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , Cougarand DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years fromdate of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from dateof sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, andwith the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to anauthorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the furtherlimitations on such two (2) year period (see chart below).

Parts

XL Plus Series & Parts PartsPAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

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

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 YearBut Not Limited To, Starting Circuit,Contactors, Relays, Solenoids, Pumps,Power Switching Semi-Conductors

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

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repairfacility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportationcharges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shallbe at the customers risk and expense. This warranty supersedes all previous Thermal warranties.

Effective May 6, 1999

Manual 0-2529 1 - 1 INTRODUCTION & DESCRIPTION

SECTION 1: INTRODUCTION & DESCRIPTION

1.1 SYSTEM DESCRIPTION

PAK 15XC 150 Amp Power Supplywith Running Gear and Handle

PCH-150 90 or 70 Hand Torch(or) PCM-150 Machine Torch with Mounting Assembly

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

PCH/M-150 Spare Parts Kit

25 ft (7.6 m) Work Cable and Clamp

Running Gear and Handle

Air Line Filter Assembly (or) High Pressure Regulators

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

The Merlin PAK 15XCSystem Includes:

Figure 1-A The Merlin PAK 15XC Plasma Arc Cutting/Gouging System

A-00875

PAK 15XC Power Supply

Work CableTorch Leads

PCM-150 Machine TorchSpare Parts Kit

Remote Control Panel

INTRODUCTION & DESCRIPTION 1 - 2 Manual 0-2529

1.2 POWER SUPPLY SPECIFICATIONS

Voltage Frequency Phase Amperage

380 50 or 60 Hz 3 44415 50 or 60 Hz 3 40

Table 2-A (page 2-7) contains information on power input,current ratings, circuit protection, and wire sizes.

Continuously adjustable from 50 to 150 amps

100% duty cycle.

Approximate Shipping Weight - 678 lbs (308 kg)

Input Power

Figure 1-B Power Supply Dimensions

Output Power

Duty Cycle

Shipping Weight

Enclosure Only:

Fully Assembled:Width: 28.50 in (0.72 m)Height: 43.38 in (1.10 m)Depth: 43.75 in (1.11 m)

38.38 in(0.98 m)

34.25 in(0.87 m)24.12 in

(0.61 m)

A-00876


1.3 TORCH SPECIFICATIONS

PCH-150 90 Hand Torch

PCH-150 70 Hand Torch

PCM-150 Machine Torch

Standard lengths of 25 ft (7.6 m) or 50 ft (15.2 m).Extendable in increments of 25 ft or 50 ft up to a maximumof 150 ft (45.7 m) with available leads extension packages(see Options and Accessories, page 1-5)

150 Amps Maximum, Direct Current Straight PolarityHand and Machine Torch rated at 100% Duty Cycle

Most materials up to 2.0 in (50.8 mm)

Torch Configurations

Torch Leads Lengths

Cutting Range

Current Rating

Plasma

Secon-dary

Gases

Compressed Air Oxygen (O2) Argon/Hydrogen

(Ar/H2) Nitrogen (N2)

Compressed Air Nitrogen (N2) Carbon Dioxide

(CO2)

Water

Hot Flow *

For Cutting:22-28 scfh

(10.4-13.2 lpm)For Gouging:

22-43 scfh(10.4-20.3 lpm)

For Cutting orGouging:220 scfh

(103 lpm)

8 gph(30.3 lph)

Pressure

50 psi(3.4 BAR,340 kPa)

50 psi(3.4 BAR,340 kPa)

Min.50 psi(3.4 BAR,340 kPa)

Gas Requirements

* Hot flow is measured with the main arc activated. Whenpressure is set correctly the plasma gas flow rate issignificantly higher until the arc is initiated.

PCH-150 90 Hand Torch (without Leads) - 1.0 lb (.45 kg)Weight

NOTE

(continued)


Figure 1-C PCH/M-150 Torch Dimensions

3.81 in(97 mm)

1.62 in(41 mm)

13.31 in(338 mm)

1.38 in(35 mm)

6.75 in (171 mm) Min.16.75 in (425 mm) Max.

17.65 in (448 mm)

1.62 in(41 mm)

A-02685

PCH-150 90o Hand Torch

PCH-150 70o Hand Torch13.87 in

(352 mm)

3.96 in(101 mm)

1.62 in(41 mm)

PCM-150 Machine Torch With RackAnd Pinion Mounting Assembly


1.4 OPTIONS AND ACCESSORIES

Power Supply Optionsand Accessories

Remote Control Panel - For machine torch systems, thelow profile operator control panel allows system controlfrom a remote location with 25 or 50 ft (7.6 or 15.2 m)cable included.

Remote Pendant Control - Hand-held remote contactorcontrol device for machine torch systems.

Computer Control Cable Kits - For interfacing thepower supply with a computer or auxiliary controldevice. Available in 5 or 10 ft (1.5 or 3.0 m) lengths.

SC-5 Standoff Control - For machine torch systems, theSC-5 automatically finds height and maintains torchstandoff with a high speed torch lifter motor.

High Pressure Regulators - Available for air, oxygen,argon/hydrogen, nitrogen, CO2, and water.

See System Components and Accessories (page 5-2) forordering information.

Spare Parts Kits - Kits contain replacement front-endtorch parts and tools. Spare parts kits are available forair cutting with hand or machine torch, multi-gascutting with hand or machine torch, or for gouging.

Leads Extension Packages - Available in 25 ft (7.6 m) or50 ft (15.2 m) lengths. For extending leads up to amaximum of 150 ft (45.7 m).

Metal Shield Cup - For durability in hand cutting.

See Torch Components (page 5-14) and Torch Accessories(page 5-16) for ordering information.

NOTE

Torch Optionsand Accessories

NOTE


1.5 THEORY OF OPERATION

Figure 1-D Theory of Operation

Plasma Arc Cutting andGouging

Plasma is a gas which is heated to an extremely hightemperature and ionized so that it becomes electricallyconductive. The plasma arc cutting process uses thisplasma to transfer an electric arc to a workpiece. Themetal to be cut is melted by the intense heat of the arc andthen blown away. The Thermal Arc Merlin PAK 15XC isa high performance plasma cutting system designed to cutmost metals up to two inches thick.

With a simple change of torch parts, the system can also beused for plasma arc gouging. Plasma arc gouging is usedto remove material to a controlled depth and width.

The Thermal Arc torch uses a cool plasma gas such ascompressed air, nitrogen, argon/hydrogen, or oxygen.The plasma gas flows into the torch through the plasmatorch lead and is channelled into Zone A (Figure 1-D),where a pilot arc between the torch electrode and tip heatsand ionizes the gas. The main cutting arc transfers to theworkpiece through the column of plasma gas as it flowsout through the torch tip orifice.

Plasma Gas Flow

A-00900

Power Supply

Workpiece

Coolant

Plasma Gas

Secondary GasZone A

Zone B

Zone D

Zone C

(-)

(+)


Plasma Gas Flow(continued)

By forcing the plasma gas and arc through a consrtictedorifice, the torch delivers a high concentration of heat to asmall area. The stiff, constricted plasma arc is shown inZone B (Figure 1-D). Direct current (DC) straight polarityis used for plasma cutting, as shown in the illustration.

The torch also uses a secondary gas (or water) whichassists the high velocity plasma gas in blowing moltenmetal from the area of the cut to create a fast, slag-free cut.The secondary flow (Zone C, Figure 1-D) also cools thetorch and minimizes heat input to the workpiece. Thesecondary flows into the torch through the secondary lead,down around the outside of the torch liner, and out be-tween the tip and shield cup around the plasma arc.Compressed air, supplied by either a cylinder or plant airsystem, nitrogen, CO2, or water can be used as the secon-dary. An exception to this is oxygen plasma operation,which requires no secondary.

The torch is liquid-cooled by an internal closed coolingsystem. De-ionized coolant is distributed from a reservoirin the power supply through the coolant supply lead. Atthe torch, the coolant is circulated around the torch tip andelectrode (Zone D, Figure 1-D), where the extra coolingeffect helps to increase parts life. The coolant then flowsback to the power supply through the return lead.

When the torch is started, a DC pilot arc is establishedbetween the electrode and cutting tip after a two-secondpre-flow delay. The pilot arc is initiated by a momentaryhigh frequency pulse. The pilot arc creates a path for themain cutting arc to transfer to the work. When the mainarc is established, the pilot arc shuts off. The pilot auto-matically restarts when the main arc stops, as long as thetorch remains activated.

The PAK 15XC accepts 380/415 VAC, 50 or 60 Hz, three-phase, line input. The power supply converts AC inputpower to DC power for the main cutting arc. The negativeoutput is connected to the torch electrode through thenegative torch lead. The positive output is connected tothe workpiece via the work cable and clamp connection.

All machine torch systems are shielded to minimize radiofrequency (RF) interference which results from the highfrequency arc initiation. These shielded systems are de-signed with features such as a wire for establishing anearth ground and shielded torch and control leads.

Secondary Flow

Coolant Flow

Pilot Arc

Main Cutting Arc

RF Shielding


The system has several built-in interlocks to provide safeand efficient operation. When an interlock shuts down thesystem, the torch switch (or control device) must be usedto restart the system.

The torch has a built-in parts-in-place interlock that pre-vents accidental torch starting when torch parts are notproperly installed. A flow switch on the coolant returnlead detects reduced coolant flow caused by impropertorch assembly. If not satisfied, the switch interruptspower to the tip and electrode.

Pressure switches act as an interlock for the gas supplies. Ifsupply pressure falls below minimum requirements thepressure switches will open, shutting off the power to thecontactors, and the GAS indicator will go out. Whenadequate supply pressure is available the pressureswitches close, allowing power to be resumed for cutting.

Thermal overload sensors are located in the transformerand main heatsink in the power supply. If one of thesecomponents is overheated the appropriate switch willopen up, causing the temperature light to turn from greento red and shutting off power to the main contactor. Whenthe overheated component cools down the switch willclose again and allow operation of the system.

Interlocks

Parts-In-Place Interlock

Gas Pressure Interlock

Thermal Interlock

Manual 0-2529 2 - 1 INSTALLATION

SECTION 2: INSTALLATION

2.1 UNPACKING THE SYSTEM

Figure 2-A Unpacking the System

The power supply is skid-mounted and protected with acarton and padding material to prevent damage duringshipment. The power supply, work cable, torch, and torchleads are factory-assembled and packaged together. Alsopacked with the system are:

Spare parts kit for the torch

Coolant de-ionizing cartridge

Air filter assembly (for air systems)

1. Remove all packing material.

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

3. Inspect each item for possible shipping damage. Ifdamage is evident, contact your distributor beforeproceeding with system installation.

The unit is mounted on the skid with two brackets. Toremove the unit from the skid, refer to Figure 2-A and:

4. Remove the six bolts connecting the brackets to thebase of the unit.

5. Roll the unit off the skid backwards (rear wheels first).

A-00953Three Bolts(Each Side)

Shipping Brackets

Shipping Pallet

INSTALLATION 2 - 2 Manual 0-2529

Compressed air, oxygen (O2), nitrogen (N2), or argon/hydrogen (Ar/H2).

Pressure 50 psi (3.5 BAR)

Flow 22 - 28 scfh (10.4 - 13.2 lpm) For Cutting22 - 43 scfh (10.4 - 20.3 lpm) For Gouging

Compressed Air, nitrogen (N2), or carbon dioxide (CO2).

Pressure 50 psi (3.5 BAR)

Flow 220 scfh (103 lpm) For Cutting or Gouging

Tap Water

Pressure Min. 50 psi (3.5 BAR)

Flow 8 gph (30.3 lph) For Cutting

See Gas Selection for Plasma Cutting (page 3-8) for de-tailed information on operation with various plasma andsecondary options.

Maximum input gas pressure to the power supply's inter-nal regulator must not exceed 125 psi (8.6 BAR).

2.2 LOCATION

Choosing the Location

CAUTION

Select a clean, dry location with good ventilation andadequate working space around all components.

The power supply is air cooled and air flow through thefront, rear, and side panels must not be obstructed. At leasttwo feet (0.61 m) of clearance should be provided on allsides.

Operation without proper air flow will inhibit propercooling and reduce duty cycle.

Review Operating Precautions (page iv) to be sure that theselected location meets all safety requirements.

2.3 PLASMA AND SECONDARY CONNECTIONS

NOTE

Secondary WaterRequirements

Secondary GasRequirements

Plasma Gas Requirements

CAUTION


Input Gas Connections(Air Operation)

Systems that are set up for operation with shop air requireinstallation of the air line filter on the plasma input fittingon the rear panel. These systems are shipped with thefollowing components:

(1) Air Line Filter Assembly (For Plasma Line)(2) Hex Nipples(1) 90 Female Elbow(1) 90 Street Elbow(1) Y-Hose Assembly

Refer to Figure 2-B and:

1. Thread the first hex nipple into the 90 female elbow.

2. Thread the other end of the hex nipple into the outletof the air filter assembly. Tighten both sides securely.

3. Thread the second hex nipple into the fitting on therear panel marked PLASMA.

4. Thread the 90 street elbow into the inlet side of the airfilter assembly.

Figure 2-B Air Line Filter Installation

Air Line Filter Installation

Secondary GasFitting

Y-HoseAssembly

From Supply

Female Elbow

Plasma GasFitting

Street Elbow

Air Filter Assembly(Plasma Line Only)

Hex Nipple

A-00902

Hex Nipple


5. Connect one side of the Y-hose assembly into the otherside of the 90 street elbow.

6. Thread the 90 female elbow onto the other end of thesecond hex nipple. Fasten both sides securely.

7. Connect the other side of the Y-hose assembly to thefitting on the rear panel marked SECONDARY.

8. Connect the supply line from the source to the Y-hoseassembly. The supply hose must be 3/8 in (10 mm)min. inside diameter to provide adequate air flow.

1. Examine the cylinder valves to be sure they are cleanand free of oil, grease or any foriegn material. Momen-tarily open each cylinder valve to blow out any dustwhich may be present.

2. Each cylinder must be equipped with an adjustablehigh-pressure regulator capable of pressures up to 125psi (8.6 BAR) maximum and flows of up to 220 scfh(103 lpm) for cutting or 470 scfh (222 lpm) for gouging.

Maximum input pressure to the power supply's internalregulator must not exceed 125 psi (8.6 BAR).

Refer to the regulator manufacturer's specifications forinstallation and maintenance procedures. Refer toSystem Components and Accessories (page 5-2) for alisting of available high-pressure regulators.

3. Connect the plasma supply hose (black) to the plasmagas cylinder and to the input fitting on the rear panelmarked PLASMA.

4. Connect the secondary supply hose (yellow) to thesecondary gas cylinder and to the input fitting on therear panel marked SECONDARY.

A typical 50 lb. CO2 cylinder can deliver a continuous flowrate of 35 scfh (16.5 lpm). To obtain the required flow ratefor the torch, it may be necessary to manifold several CO2cylinders. Continuous flow requirements will depend onthe specific application and duty cycle.

Air Line Filter Installation(continued)

Input Gas Connections(Multi-Gas Operation)

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

CAUTION

NOTE


Secondary WaterConnections

1. The water source must be capable of delivering aminimum water pressure of 50 psi (3.5 BAR) and flowof 8 gph (30.3 lph).

2. Connect the secondary water supply hose to the rearpanel fitting marked SEC. WATER.

The water source does not need to be deionized, but inwater systems with extremely high mineral content awater softener is recommended.

Figure 2-C Rear Panel Connections

NOTE

Plasma Gas

A-00874

Secondary Gas

Secondary Water

High FlowWater Shield

Remote InterfaceConnection


The PAK 15XC power supply is designed to accept a aninput voltage of 380/415 VAC.

The electrical power source must conform to local electriccode and the following recommended circuit protectionand wiring requirements (see Table 2-A, page 2-7).

1. Check the three-phase electrical power source for linevoltage and proper circuit protection and wiring (seeTable 2-A, page 2-7).

2.4 ELECTRICAL CONNECTIONS

Electrical Requirements

Electrical Connections

Refer to Figure 2-D (page 2-7) and:

2. Remove the left side panel of the power supply (asviewed from the front).

3. Check the bus bar configuration (factory installed) onthe input voltage terminal board . The bus bar con-figuration must correspond with the 380 VAC linevoltage.

4. Insert the primary power cable (customer supplied)through the strain relief in the rear panel of the powersupply.

5. Locate the four input connectors, flat washers, conicalspring washers, and hex locking nuts supplied withthe power supply.

6. Install the input connectors, supplied, onto each of theinput power line leads of the power cable.

7. Connect the input power connectors to the EMI InputPower Filter PC Board input studs with the suppliedhex locking nuts, conical spring washers, and flatwashers as follows:

Input ground wire to G1. LI input line to X1. L2 input line to Y1. L3 input line to Z1.

8. Tighten the nuts being careful not to over-tighten.Refer to the following WARNING.

WARNINGDisconnect primary power at the source before connect-ing the primary power cable to the power supply.

WARNINGDo Not over tighten the nuts securing the iput powercable connectors as damage to the PC Board can occur.


Figure 2-D Input Voltage Connections and Bus Bar Configuration

Input PowerFilter PC Board

and Bracket

Primary PowerCable

Strain ReliefFitting

Input GroundConnection

A-00896

L1L2

L3

INPUTVOLTAGE

380/415VAC

BUS BARCONNECTIONS

L1-3, 1-2L2-8, 6-7

L3-13, 11-12

InputConnector

Input Power Cable(One Line)

Slotted Screw

A-00908

PC BoardPower Stud

Flat Washer

Conical SpringWasher

Hex Locking Nut

Input Voltage ConnectorInstallation Detail

Table 2-A Line Voltages, Circuit Protection and Recommended Wire Size(Based on Table 310-16, 1987 National Electric Code).

Voltage Power Input Current Frequency Phase Recommended(Volts) (kVA) (Amps) (Hz) Fuse Size Wire Size

380 29 44 50 3 50 amps AWG 8415 29 40 50 3 45 amps AWG 8

380/415VAC

L1

L3

L2


2.5 WORK AND GROUND CONNECTIONS

Machine torch systems are equipped with shielded torchleads to minimize RF interference from high frequencypilot arc initiation. Follow these grounding procedureswhen installing machine torch systems:

1. Connect the ground wire (from the front panel) to asolid earth ground, which is created by driving acopper rod approximately 7 ft (2 m) into the earth.Locate the rod as close as possible to the power supply.Cut the ground wire to the appropriate length.

2. The power supply and work table should be groundedto the same earth ground. The control device should begrounded separately to a similar earth ground.

3. To minimize RF interference, torch leads should be runas far as possible from any CNC components, controllines, or primary power lines.

4. Connect work ground cables as shown (Figure 2-E).

Figure 2-E Proper Work and Ground Cable Connections

Standoff ControlConsole

CNC Control

Power SupplyRemote Panel

Standoff ControlRemote Panel

EarthGround

PowerSupply

WorkCable

Workpiece

Work Ground

EarthGround

Green Cable(Work Ground)

3-PhaseInput

A-00880


Figure 2-F Coolant Reservior and De-ionizing Cartridge

Refer to Figure 2-F and:

1. Locate the coolant de-ionizing cartridge and removefrom the plastic shipping bag.

2. Remove the plastic cover from the coolant reservoirfiller.

3. Place the de-ionizing cartridge into the basket in thecoolant reservoir.

4. Fill the reservoir to the line marked FULL on the rearpanel.

Use only Thermal Arc torch coolant. Use of any othercoolant can result in torch damage, insufficient thermalprotection, and/or pilot arc interference.

The deionizer cartridge should be checked periodically.The contents of the cartridge take on a light straw-coloredappearance when spent. Replace the cartridge when thematerial has completely changed color.

Coolant Installation

2.6 COOLANT INSTALLATION

CAUTION

Coolant ReservoirFiller Cap

DeionizerBag

Basket

Coolant Level IndicatorA-00872


Remote Operator ControlPanel Installation

The Remote Operator Control Panel consists of the controlpanel enclosure and cables required for connection.

1. Connect the control cable to the receptacle markedREMOTE (J15) on the rear panel.

2. Connect the other end of the control cable to thereceptacle marked PS (J37) on the remote operatorcontrol panel enclosure.

1. Connect the interface cable to the receptacle markedCNC (J29) on the remote operator control panel.

2. Connect the other end to the customer-supplied mo-tion control device (refer to the CNC Interface Sche-matic on page 6-4).

The SC-5 Standoff Control consists of a control panel, anelectronic unit, a voltage divider board, a torch liftermotor, and cables required for installation (see Figure 2-G,page 2-11). It is ordered and shipped separately and mustbe installed according to the SC-5 Standoff Control Instruc-tion Manual, which is included with the SC-5 unit.

Refer to the High-Flow Water Shield Instruction Manualand:

1. Connect the high-flow starter control cable to thereceptacle marked HI-FLOW WATER SHIELD on thepower supply rear panel. The receptacle is 115VAC toactivate the high-flow water shield.

2. To shut off the high-flow water shield remove thecontrol cable or disconnect power to the high-flowwater shield unit.

2.7 AUXILIARY CONNECTIONS

Computer Control InterfaceInstallation

SC-5 Standoff ControlInstallation

High-Flow Water ShieldInstallation


Figure 2-G Typical Mechanized System Installation and Cable Interconnection Diagram

NOTE - See Catalog Pages for ordering information.

Cable Description Letter Designation

SC-5 Remote to Console A

SC-5 Torch Lifter (Positioner) to Console B

SC-5 Console to Power Supply Remote C/F

SC-5 Console to Power Supply D

SC-5 Console to Work (Ground) E

SC-5 CONTROL CONSOLE

TORCHPOSITIONER

(LIFTER)

CNCCONTROL

POWER SUPPLY REMOTE CONTROL

SC-5 REMOTECONTROL

WORK GROUND

D

AC

F

E

BPOWERSUPPLY

A-00879


2.8 LIFTING THE POWER SUPPLY

Figure 2-H Lifting the Power Supply

WARNING Do not lift the power supply by the handles.

CAUTION Do not lift a power supply equipped with a cylinder rackrunning gear.

The recommended method for lifting the power supply isto use a forklift (see Figure 2-H). Approach from the frontor rear of the unit. Place the forks between the rear wheelsor the front casters. Center the forks under the unit andcarefully check for proper balance before lifting.

Approach From Front Or Rear

Do Not Lift From Sides

A-00873

Manual 0-2529 3 - 1 OPERATION

SECTION 3: OPERATION

3.1 OPERATING CONTROLS

Function

ON position activates all system control circuits.OFF position deactivates control circuits.

RUN position is used for torch operation.SET position is used for setting gas pressures.PURGE position is for purging the plasma gas line.

Selects output current from 50 to 150 amps (see CuttingSpeeds (page 3-26) for applications on various materialsand thicknesses). Current control is disabled when RemoteOperator Control Panel is used.

Green light indicates AC power is being supplied to thesystem when the ON/OFF switch is in ON position.

Green light indicates proper operating temperature. Redlight indicates overheating. Unit must be allowed to cool.

In SET position, yellow light in SET mode indicates gaspressure switches are satisfied when gas is flowing to thetorch. Light goes out in PURGE or RUN mode.

Yellow light indicates adequate coolant pressure.

Yellow light indicates proper coolant conductivity. Lightout indicates excessive coolant conductivity (resistivity lessthan 0.1 M). Replace coolant and de-ionizer cartridge.Yellow light indicates main contactor closure supplyingvoltage to the power supply output and cutting current isavailable. Torch switch must be closed.

Yellow light indicates pilot arc contactor closure. Lightgoes out when cutting arc is established and comes backon if cutting arc is interrupted.

Control Indicator

1. ON/OFF Switch

2. RUN/SET/PURGESwitch

3. Current Control

4. AC Power Indicator

5. TEMP Indicator

6. GAS Indicator

7. Coolant Pressure Indicator

8. Coolant ConductivityIndicator

9. DC Indicator

10. PILOT Indicator

Figure 3-A PAK 15XC Operating Control Panel

OFF

ON RUN

PURGE

SET

A-00887

AMPS50

75

150

125

100

AC TEMP GAS PRES.

COOLANT

COND. DC PILOT

1 2

3

4 5 67 8

9 10

OPERATION 3 - 2 Manual 0-2529

Function

Adjusts secondary gas pressure. Pull knob out and turnclockwise to increase secondary pressure to desired level.

Displays secondary pressure from 0 - 100 psi (0 - 6.9 BAR).

Selects secondary mode to gas, oxygen (no secondary), orwater. See Gas Selection (page 3-8) for applications onvarious materials and thicknesses.

Displays coolant pressure from 0 - 160 psi (0 - 11.0 BAR).

Displays plasma gas pressure from 0 - 100 psi (0 - 6.9BAR).

Adjusts plasma gas pressure. Pull knob out and turnclockwise to increase plasma pressure to desired level.

Figure 3-B PAK 15XC Upper Gauge Panel

Control Indicator

1. Secondary PressureControl

2. Secondary Pressure Gauge

3. Secondary Mode Selector

4. Coolant Pressure Gauge

5. Plasma Pressure Gauge

6. Plasma PressureControl


Function

Immediately de-activates pump, motor, and all controlcircuits (logic circuit and control panel LED display remainon).

None functional.

Activates gas flow, pilot arc, and main cutting arc.

Green light indicates remote control logic has received startsignal from control device (CNC or START switch).

Deactivates gas flow, pilot arc, and main cutting arc.

Sets output current level from 50 to 150 amps.

Displays actual output during cutting operation. Previewmode displays expected output before starting a cut ac-cording to the current setting. A decimal point to the rightof the display is lit whenever the meter is in preview mode.All three decimal points remain lit when displaying cornerslowdown output or operating in corner slowdown mode.Left and center decimal points blinking indicates PIP(parts-in-place) circuit not satisfied.

Sets corner slowdown (CSD) output from 50 to 150 amps.Push STOP button to display corner slowdown outputsetting on AMP meter. Refer to Machine Torch Operation(page 3-20) for operating instructions.

Provides an adjustable time delay (approximately 0-11seconds) which delays the CNC and 'OK-to-Move' signal,allowing time to pierce before the starting the cuttingmachine. Set PIERCE DELAY to zero for immediate 'OK-to-Move' signal.

None functional.

Control Indicator

1. E-STOP (Emergency Stop)

2. RUN/PURGE Switch

3. START Switch

4. Start Enable Indicator

5. STOP Switch

6. CURRENT ControlAdjustment

7. AMPS Meter

8. CSD (Corner Slowdown)Control Adjustment

9. PIERCE DELAY ControlAdjustment

10. LOW/HIGH SPEEDSwitch

Figure 3-C PAK 15XC Remote Operator Control Panel (RC6045)

PURGE

RUNE-STOP

START STOP

AAMPS

CURRENT

A

PIERCEDELAY

LOW HIGH

SPEED 0123

4 5 6 789

1011

CSD

1 2 3 5 7 6 8 9

104A-00575


3.2 PRE-OPERATION SET-UP

The pre-operation set-up procedure should be followed atthe beginning of each shift:

1. Check the coolant level indicator and add coolant ifnecessary (see Coolant Installation, page 2-9).

2. Check the torch for proper assembly (see Torch Main-tenance, page 4-1). Install proper torch parts for theapplication (see Torch Parts Selection, page 3-5).

3. Select the desired pre-flow, post-flow, and auto-restartsettings (see Machine Torch Operation, page 3-13). Thesystem is factory-set for normal auto-restart, whichallows the pilot arc to restart instantly when the cuttingarc is interrupted with the torch still activated. Thesystem is factory-set for two-second pre-flow and ten-second post-flow.

4. Check the power source for proper 380/415 VACthree-phase input voltage. Make sure the input poweris properly connected to the EMI input filter PC board(see Electrical Connections, page 2-6). Connect primarypower to the system (close main disconnect switch orplug unit in).

5. Select desired plasma and secondary (see Gas Selec-tion, page 3-8). Make sure gas sources meet require-ments (see Plasma and Secondary Connections, page 2-2). Check connections and turn plasma and secondarysupplies on.

6. Move the ON/OFF switch to ON position. An auto-matic forty second gas purge will let gas run to removeany condensation that may have accumulated in thetorch and leads while the system was shut down. Afterthe purge is complete, if the RUN/SET/PURGE switchis in SET position, gases will flow. If the switch is inPURGE position plasma gas only will flow. If theswitch is in RUN position there will be no gas flow.

7. Select the desired current output level. Refer to CuttingSpeeds (page 3-26).

8. Move the RUN/SET/PURGE switch to SET position.Set plasma and secondary pressures (see Plasma andSecondary Connections, page 2-2).

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

Coolant Check

Torch Check

Optional Auto-RestartSettings

Input Power Check

Plasma and SecondarySupply Check

Line Purge

Output Selection

Plasma and SecondaryPressure Settings


3.3 TORCH PARTS SELECTION


Shield Cup Selection Shield Cups (See Figure 3-D) Cat. No.

Ceramic Shield Cup (For Cutting) ........................ 9-5750

Metal Shield Cup (For Cutting) ............................. 9-5790

Touch Cup (For Height Sensing with SC-5) ........ 9-5758

Gouging Cup ............................................................ 9-5774

Figure 3-D Shield Cup Selection

Additional Line Purge 9. If additional purging of the plasma gas line is desired,move the RUN/SET/PURGE switch to PURGE posi-tion. In PURGE mode, with secondary mode selectorset to GAS, the GAS indicator will not come on becauseonly plasma gas runs and the secondary gas flowswitch is not satisfied.

10. Return the RUN/SET/PURGE switch to RUN.

The system is now ready for operation.

Metal Shield Cup(For Cutting)

Cat. No. 9-5790

Touch Cup(For Height Sensing

with SC-5)Cat. No. 9-5758

Ceramic Shield Cup(For Cutting)

Cat. No. 9-5750

Gouging CupCat. No. 9-5774



CAUTION Do not interchange parts. Make sure both the tip andelectrode in the torch correspond with the plasma gas andsecondary being used.

Cutting tips and electrodes can be identified by the ring(s)around the diameter (see Figure 3-E, page 3-7). Air tipsand electrodes have no rings, oxygen tips and electrodeshave one ring, nitrogen tips and multi-gas (N2 or Ar/H2)electrodes have two rings, and argon/hydrogen tipshave three rings.

Cutting Tips - Air Plasma Cat. No.

50 Amps (.043 in) ..................................................... 9-5748

100 Amps (.055 in) ................................................... 9-5747

150 Amps (.070 in) ................................................... 9-5746

Cutting Tips - O2 Plasma

50 Amps (.043 in) ..................................................... 9-5753

100 Amps (.057 in) ................................................... 9-5752

150 Amps (.070 in) ................................................... 9-5751

Cutting Tips - N2 Plasma

50 Amps (.043 in) ..................................................... 9-5765

100 Amps (.052 in) ................................................... 9-5766

150 Amps (.067 in) ................................................... 9-5767

Cutting Tips - ArH2 Plasma

150 Amps (.073 in) ................................................... 9-5775

Gouging Tips - Air or Multi-Gas

85 Amps (.078 in) ..................................................... 9-5756

150 Amps (.120 in) ................................................... 9-5755

Electrodes Cat. No.

Air Plasma - Cutting ............................................... 9-5749

Oxygen Plasma - Cutting ....................................... 9-5760

Multi-Gas (N2 or Ar/H2)- Cutting ........................ 9-5754

Tip Selection

Electrode Selection


Cutting Gouging

Air Plasma Oxygen Plasma Nitrogen Plasma Argon/Hydrogen Air or Multi-Gas

O2 Plasma50 Amp (.043) Tip

Cat. No. 9-5753


Cat. No. 9-5752


Cat. No. 9-5751

Air Plasma50 Amp (.043) Tip

Cat. No. 9-5748


Cat. No. 9-5747


Cat. No. 9-5746

N2 Plasma50 Amp (.043) Tip

Cat. No. 9-5765


Cat. No. 9-5766


Cat. No. 9-5767

ArH2 Plasma150 Amp (.073) Tip

Cat. No. 9-5775

Gouging TipAir or Multi-Gas

85 Amp (.078)Cat. No. 9-5756

Gouging TipAir or Multi-Gas150 Amp (.120)Cat. No. 9-5755

Air Plasma ElectrodeCutting or Gouging

Cat. No. 9-5749

O2 Plasma ElectrodeCutting or Gouging

Cat. No. 9-5760

N2 or Ar/H2 Plasma ElectrodeCutting or Gouging

Cat. No. 9-5754

For gouging, selectproper electrode tocorrespond to thetype of plasma gas

being used (same ascutting).

Figure 3-E Tip and Electrode Selection


3.4 GAS SELECTION FOR PLASMA CUTTING

Air plasma is normally used with air secondary.

Only clean, dry air is recommended for use as plasmagas. Any oil or moisture in the air supply can substan-tially reduce torch parts life.

Most often used on ferrous or carbon base materials toobtain good cutting quality at faster cutting speeds.

Provides satisfactory results on non-ferrous materials.

Can be used in place of air plasma with air secondary orCO2.

Provides much better parts life than air.

Provides better cut quality on non-ferrous materials suchas stainless steel and aluminum.

A good clean welding grade nitrogen should be used.

AIR PLASMA

NITROGEN PLASMA

ARGON/HYDROGENPLASMA

A 65% argon/35% hydrogen mixture should be used.

Recommended for use on thicker (1/2 inch and up) non-ferrous materials. Ar/H2 is not normally used for thin-ner non-ferrous materials because less expensive gasescan achieve similar cut quality.

Provides faster cutting speeds and high cut quality onthicker materials to offset a higher cost.

Poor cut quality on ferrous materials.

OXYGENPLASMA

Oxygen is recommended for cutting ferrous materials.

Provides faster cutting speeds.

Provides very smooth finishes and minimizes nitridebuild-up on cut surface (nitride build-up can causedifficulties in producing high quality welds if not re-moved).

Table 3-A Plasma Gas Selection for Plasma Cutting


Air secondary is normally used when operating with airplasma and occasionally with nitrogen plasma.

Inexpensive - reduces operating costs.

Improves cut quality on some ferrous materials.

AIR SECONDARY

CO2 secondary is used with nitrogen or Ar/H2 plasma.

Provides good cut quality on ferrous or non-ferrousmaterials.

May reduce smoke when used with Ar/H2 plasma.

CO2 SECONDARY

Nitrogen secondary is used with Ar/H2 plasma.

Provides smooth finishes on non-ferrous materials.

May be used with nitrogen plasma in order to operatefrom one compressed gas cylinder.

May reduce smoke when used with Ar/H2 plasma.

NITROGEN SECONDARY

Water secondary should be used only in mechanizedapplications - never in hand cutting!

Normally used with nitrogen, Ar/H2, or air plasma.

Provides very smooth cut surface.

Reduces smoke and heat input to the workpiece.

Effective up to 1 inch maximum material thickness.

Tap water provides low operating expense.

WATER SECONDARY

Table 3-B Secondary Selection for Plasma Cutting


Cut Quality Cut quality requirements differ depending on application.For instance, nitride build-up and bevel angle may bemajor factors when the surface that is cut will be weldedafter the cutting operation. Dross-free cutting is importantwhen finish cut quality is desired to avoid a secondarycleaning operation.

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

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

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

The amount of rounding on the top edge of the cut.

Molten material which is not blown away from the cutarea and re-solidify on the base of the plate. Excessivedross build-up may require a secondary clean-up opera-tion after the cutting process.

The width of the cut (or the width of material removedduring the cut).

Table 3-C (page 3-11) contains cut quality information foreach plasma and secondary combination on a variety ofmaterials and thicknesses.

Cut Surface

Nitride Deposits

Bevel Angle

Top-Edge Rounding

Dross Build-up

Kerf Width

Figure 3-F Cut Characteristics

Kerf WidthCut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007


Cut Characteristics:

Minimum bevel (0 - 4), minimum kerf (2 x tip orifice),little or no dross, smooth cut surface.

Slight bevel (0 - 10), slightly wider kerf (2-1/2 x tip ori-fice), some dross (easily removed), medium-smooth cutsurface, slight top edge rounding.

Excessive bevel (over 10), wide kerf (over 2-1/2 x tiporifice), medium to heavy dross, rough cut surface, topedge rounding.

Not Recommended.

Cut quality depends heavily on set-up and parameterssuch as torch standoff, alignment with the workpiece,cutting speed, gas pressures, and operator experience.

Description

Excellent

Good

Fair

NR

NOTE

GAS

Air PlasmaAir Secondary

Nitrogen PlasmaAir Secondary

or CO2 Secondary

Nitrogen PlasmaWater Secondary

Ar/H2 PlasmaN2 or CO2Secondary

Oxygen Plasma

Stainless Steel

Good/ExcellentGoodGood

Good/ExcellentGood/ExcellentGood/Excellent

GoodExcellent

NR

NRGood

Excellent

Good

TYPE OF MATERIAL

Carbon Steel

Good/ExcellentExcellentExcellent


ExcellentGoodNR

NRNRNR

Excellent

Aluminum

Good/ExcellentGoodGood


GoodGood/Excellent

NR

NRExcellentExcellent

NR

Table 3-C Cut Quality: Plasma and Secondary Gas Selectionfor Various Materials and Material Thicknesses

MATERIALTHICKNESS

GageGage to 1 in.

1 to 2 in.

GageGage to 1/2 in.

1/2 to 2 in.

Gage to 1/4 in.1/4 to 1 in.

1 to 2 in.

Gage to 1/4 in.1/4 to 1-1/4 in.

1/2 to 2 in.

Gage to 2 in.


3.5 PLASMA CUTTING OPERATION

Be sure the operator is equipped with proper gloves,clothing, eye and ear protection and that all precautions atthe front of this manual have been followed. Make sure nopart of the operators body comes in contact with theworkpiece when the torch switch is pressed.

WARNING

CAUTION The sparks from the cutting process can cause damage tocoated, painted or other surfaces such as glass, plastic, andmetal.

Do not interchange parts. Make sure both the tip andelectrode in the torch correspond with the plasma gas andsecondary being used. (See Torch Parts Selection on pages3-6 and 3-7).

CAUTION

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

The suggestions below should be followed in all cuttingand gouging operations:

1. Wait five minutes before setting the ON/OFF switch toOFF after operation. This allows the cooling fan to runto dissipate operating heat from the power supply.

2. For maximum parts life, do not operate the pilot arc anylonger than necessary.

3. Use care in handling torch leads and protect them fromdamage.

4. In continuous cutting applications using CO2, it is oftennecessary to manifold four to six cylinders together tomaintain adequate flow at operating pressures.

FREQUENTLY REVIEW THE SAFETY PRECAUTIONSAT THE FRONT OF THIS MANUAL.

It is not enough to simply move the ON/OFF switch onthe unit to OFF position when cutting operations havebeen completed. Always open the power supply discon-nect switch five minutes after the last cut is made.

NOTE

WARNING


The auto-restart function provides an immediate pilot arcrestart during post-flow if the torch is brought withinrange of the workpiece. The power supply can be set up toprovide a variety of optional auto-restart settings.

Auto-Restart On/Off - The auto-restart function can beswitched off completely so that the torch must be re-activated (via torch switch or control device) to restartthe pilot arc when the main arc is interrupted.

Auto-Restart Normal/Delayed - Normal mode pro-vides an immediate pilot arc restart when the main arcis interrupted. Delayed mode provides a gas pre-floweach time before the pilot arc restarts.

Pre-Flow Delay - Pre-flow is the time interval fromwhen the torch is activated (start of gas flow) to pilotarc initiation. Pre-flow duration is factory-set to twoseconds, but can be re-set to four, seven, or ten secondsas desired.

Post-Flow Delay - Gases continue to flow for a periodof time after the main cutting arc is interrupted and thetorch remains activated. Post-flow is factory-set to tenseconds, but can be re-set to five, twenty, or fortyseconds as desired.

In machine torch operation, optional auto-restart settingsmay be useful where:

1. The system is used for direct replacement of units nothaving auto-restart for use with motion control de-vices.

2. Torch parts life may improve without auto-restart insome applications by reducing excessive pilot arc time.

3. In some shape-cutting applications, immediatelyrestarting the main arc after the torch passes beyondthe desired cutting line (or between cuts) may not bedesirable.

4. Extended leads may require longer pre-flow duration.

5. Other special applications require various arrange-ments.

Pre-Flow Delay

Post-Flow Delay

Normal/Delayed

On/Off

Auto-Restart Options

Applications

(continued)


Four two-pole DIP switches located on the control logic PCboard control the auto-restart functions.

Auto-Restart(continued)

Auto-Restart SW1-1 SW1-2Mode Position Position

Normal 0 (Off) 0 (Off)

Disabled 0 (Off) 1 (On)1 (On) 0 (Off)1 (On) 1 (On)

On/Off (SW1)

Note: Either pole set to 1(on)disables auto-restart function

Auto-Restart SW2-1 SW2-2Mode Position Position

Normal 0 (Off) 0 (Off)

Delayed 0 (Off) 1 (On)1 (On) 0 (Off)1 (On) 1 (On)

Pre-Flow Time SW3-1 SW3-2(Seconds) Position Position

2 0 (Off) 0 (Off)4 0 (Off) 1 (On)7 1 (On) 0 (Off)

10 1 (On) 1 (On)

Post-Flow Time SW4-1 SW4-2(Seconds) Position Position

2.5 0 (Off) 1 (On)5 0 (Off) 0 (Off)

10 1 (On) 0 (Off)20 1 (On) 1 (Off)

Post-Flow Time SW4-1 SW4-2(Seconds) Position Position

5 0 (Off) 1 (On)10 0 (Off) 0 (Off)20 1 (On) 0 (Off)40 1 (On) 1 (Off)

Normal/Delayed (SW2)

Note: Either pole set to 1(on)sets auto-restart function

Pre-Flow Delay (SW3)

Post-Flow Delay (SW4)

For Hand CuttingSystems (A1845-01)

with 19x704 Logic PCB

Post-Flow Delay (SW4)

For Machine CuttingSystems (A1845-15)

with 19x910 Logic PCB


Figure 3-G Control Logic PC Board - Setting Auto-Restart Options


3.6 HAND TORCH OPERATION

Figure 3-H Cutting with a Hand Torch

Be sure the operator is equipped with proper gloves,clothing, eye and ear protection and that all precautions atthe front of this manual have been followed. Make sure nopart of the operators body comes in contact with theworkpiece when the torch switch is pressed.

WARNING

CAUTION

Plasma Cutting Operation(Hand Torch)

The sparks from the cutting process can cause damage tocoated, painted or other surfaces such as glass, plastic, andmetal.

Do not interchange parts. Make sure both the tip andelectrode in the torch correspond with the plasma gas andsecondary being used. (See Torch Parts Selection on pages3-6 and 3-7).

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

Cutting with a Hand Torch 1. The hand torch should be held in both hands for mak-ing long cuts. Choose the method that feels the mostcomfortable and works the best. Use the thumb toactuate the control switch on the torch handle.


Hand Torch Operation(continued)

2. To positively locate the line of the cut, position the torchover the workpiece, resting the front edge of the shieldcup on the edge where the cut is to start.

3. Lower the welding helmet. Press and hold the torchcontrol switch. After a two second gas purge, the pilotarc will start. The pilot arc will stay on as long as thetorch control switch is held.

4. With the pilot arc on the main cutting arc is establishedas soon as the torch is brought within 1/8 - 3/8 in(3 - 10 mm) of the workpiece. If the cutting arc is inter-rupted and the switch is still pressed, as when cuttingexpanded metal, the pilot arc will automatically restart.

Releasing the torch control switch will shut off either thepilot or main arc (depending on the mode of operation).

5. Cut with the torch held 1/8 - 3/8 in (3 - 10 mm) fromthe work. The torch should be held perpendicular to theworkpiece while cutting.

Use a standard ceramic or metal shield cup for handcutting. The touch cup (short shield cup) and gouging cupare NOT intended for hand cutting. Do not allow anexposed torch tip to contact the workpiece.

NOTE

CAUTION


3.7 MACHINE TORCH OPERATION

Cutting with aMachine Torch

1. A machine torch should be aligned perpendicular tothe surface of the workpiece to obtain a clean, verticalcut. Use a square to align the torch (see Figure 3-I).

2. Position the center of the torch over the edge of theworkpiece where the cut is to start. The transferredcutting arc will then be established at the plate edgewhen the torch is activated.

3. The machine torch can be activated by the remoteoperator control panel, remote control pendant, or byremote interface device such as CNC. After a twosecond gas purge, the pilot arc will start. The pilot arcwill stay on as long as the torch is activated.

4. With the pilot arc on the main cutting arc is establishedas soon as the torch is brought within 1/8 - 3/8 in (3 -10 mm) of the workpiece. If the cutting arc is inter-rupted and the torch is still activated, as when cuttingexpanded metal, the pilot arc will automatically restart(see Auto-Restart Options, page 3-13). De-activatingthe torch will shut off either the pilot or main arc(depending on the mode of operation).

Figure 3-I Machine Torch Set-up


Cutting with aMachine Torch

(continued)

5. Cut with a standoff of 1/8 - 3/8 in (3 - 10 mm) from thework. The torch should be held perpendicular to theworkpiece while cutting. Start cutting slowly andadjust cutting speed for optimum cutting performance.Cutting Speeds (page 3-26) contains typical cuttingspeeds for various materials and material thicknesses.

A standard shield cup is recommended for most machinecutting applications. The touch cup (short shield cup) isdesigned for light gage cutting where arc voltage measure-ment is needed for a standoff control. Do not allow anexposed torch tip to contact the workpiece.

The arc characteristics vary with gases used, cutting speed,material, and thickness. Air plasma normally produces astraight arc (on stainless or aluminum), while nitrogenplasma generally creates a 5 trailing arc (see Figure 3-J).

Figure 3-J Machine Torch Operation


The corner slowdown feature provides an output currentreduction in to correspond with the reduction in torchtravel speed as a mechanized torch moves through acorner. When activated by CNC or other control device,the corner slowdown eliminates excessive metal removalin corners.

Normally open (NO) contacts (supplied by the controldevice) close when the torch travel speed decreasesthrough a corner. When the contacts close, power supplyoutput drops to a pre-set current level.

A two-pole DIP switch in the remote operator controlpanel PC board allows the corner slowdown to operatewith normally closed (NC) contacts in the control device ifdesired.

Corner slowdown adjustment is located on the remoteoperator control panel (see Operating Controls, page 3-3).

The control is factory set fully counter-clockwise forminimum 50 amps output during corner slowdown. Turnthe control clockwise to increase corner slowdown output.When the control is turned fully clockwise, corner slow-down output is increased to a maximum 150 amps.

To view the corner slowdown setting, press and hold thestop control. The expected CSD output level will be dis-played on the ammeter.

In the PAK 15XC, the corner slowdown setting is inde-pendent (not a percentage) of the main current setting. Forexample, if CSD current is set to 100 amps, and maincutting current is set to the minimum 50 amps, the actualcurrent level would actually increase through the CSDcycle.

For electrical connections, refer to the CNC InterfaceSchematic (page 6-4.)

Corner Slowdown (CSD)

NOTE

Corner Slowdown Settings

NOTE


Figure 3-K Piercing with a Hand Torch

3.8 PIERCING

In some cutting operations, it may be desirable to start thecut within the plate area rather than at the plate edge.Piercing the plate is not recommended on plates having athickness greater than 3/4 in (19 mm). Blowback from thepiercing operation can shorten the life of torch parts. Allpiercing should therefore be done as quickly as possibleand at maximum amperage (150 amps) and maximumstandoff.

When piercing with a hand torch, tip the torch slightly sothat blowback particles blow away from the torch tip (andoperator) rather than directly back into it (see Figure 3-K).

Pierce off the cutting line and then continue the cut asshown in Figure 3-K. Clean spatter and scale from theshield cup and the tip as soon as possible. Spraying ordipping the shield cup in anti-spatter compound willminimize the amount of scale which adheres to it.

A method called running start is recommended whenpiercing with a machine mounted torch. The torch shouldbe positioned far enough off the cutting line to allow thepierce to be complete before the cutting line is reached.This allowance depends on the thickness of the materialand the torch travel speed.

Piercing with a Hand Torch

Merlin Pak 15XC European Instruction Manual

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