Download - PLASMA CUTTING TORCH

November 15, 2004 Manual No. 0-2751

PLASMACUTTING TORCH

• Model PCH-40 Hand Torch• Model PCM-40 Machine Torch

Instruction Manual

For Use With:PakMaster 50XL Plus Power Supply

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, theManufacturer assumes no liability for its use.

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

Plasma Cutting TorchModel PCH-40 & PCM-40Instruction Manual Number 0-2751

Published by:Thermal Dynamics Corporation82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermal-dynamics.com

Copyright 1999 byThermal Dynamics Corporation

All rights reserved.

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 toany party for any loss or damage caused by any error or omission inthis Manual, whether such error results from negligence, accident, orany other cause.

Printed in the United States of America

Publication Date: November 15, 2004

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION................................................................................................. 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 1-11.02 Important Safety Precautions ........................................................................ 1-11.03 Publications .................................................................................................. 1-21.04 Note, Attention et Avertissement ................................................................... 1-31.05 Precautions De Securite Importantes ............................................................ 1-31.06 Documents De Reference ............................................................................. 1-51.07 Declaration of Conformity .............................................................................. 1-71.08 Statement of Warranty .................................................................................. 1-8

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

2.01 Scope of Manual ........................................................................................... 2-12.02 General Description ...................................................................................... 2-12.03 Specifications & Design Features ................................................................. 2-12.04 Options And Accessories .............................................................................. 2-22.05 Introduction to Plasma .................................................................................. 2-3

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

3.01 Introduction ................................................................................................... 3-13.02 Site Location ................................................................................................ 3-13.03 Unpacking .................................................................................................... 3-13.04 Setting Up the Hand Torch ............................................................................ 3-13.05 Setting Up the Machine Torch ....................................................................... 3-13.06 Connecting the Torch .................................................................................... 3-23.07 Gas Connection ............................................................................................ 3-3

SECTION 4:OPERATION ...................................................................................................................... 4-1

4.01 Introduction ................................................................................................... 4-14.02 Functional Overview ...................................................................................... 4-14.03 Getting Started ............................................................................................. 4-14.04 Torch Parts Selection.................................................................................... 4-14.05 Cut Quality ................................................................................................... 4-24.06 Operating the System ................................................................................... 4-34.07 Hand Torch Operation ................................................................................... 4-44.08 Machine Torch Operation .............................................................................. 4-64.09 Recommended Cutting Speeds ..................................................................... 4-74.10 Gouging ........................................................................................................ 4-7

TABLE OF CONTENTS (continued)

SECTION 5:SERVICE .......................................................................................................................... 5-1

5.01 Introduction ................................................................................................... 5-15.02 General Torch Maintenance .......................................................................... 5-15.03 Common Operating Faults ............................................................................ 5-25.04 Inspection and Replacement Consumable Torch Parts .................................. 5-25.05 Troubleshooting Guide .................................................................................. 5-35.06 Torch & Leads Troubleshooting ..................................................................... 5-45.07 Servicing Hand Torch (PCH) Components ..................................................... 5-65.08 Servicing Machine Torch (PCM) Components ...............................................5-10

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

6.01 Introduction ................................................................................................... 6-16.02 Ordering Information ...................................................................................... 6-16.03 Replacement Hand Torch Parts ..................................................................... 6-26.04 Replacement Machine Torch Parts ............................................................... 6-46.05 Complete Torch & Leads Assembly Replacement ......................................... 6-66.06 Options and Accessories .............................................................................. 6-76.07 Spare Parts Kit ............................................................................................. 6-8

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

APPENDIX 2: CUTTING SPEED CHARTS ................................................................................ A-2

Date: January 27, 2004 1-1 GENERAL INFORMATION

SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OFPLASMA ARC EQUIPMENT CAN BE DAN-GEROUS AND HAZARDOUS TO 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 materialyou are using. These MSDSs will give you the in-formation regarding the kind and amount of fumesand gases that may be dangerous to your health.

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

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

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

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

• This product, when used for welding or cutting,produces fumes or gases which contain chemicalsknown to the State of California to cause birth de-fects and, in some cases, cancer. (California Health& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

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

• Never touch any parts that are electrically “live”or “hot.”

GENERAL INFORMATION 1-2 Date: January 27, 2004

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

• Repair or replace all worn or damaged parts.

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

• Install and maintain equipment according to NECcode, refer to item 9 in Subsection 1.03, Publica-tions.

• Disconnect power source before performing anyservice or repairs.

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

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors fromthe workplace.

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

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

• Hydrogen gas may be formed and trapped 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 1.03, Publications, in this manual.

PLASMA ARC RAYS

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

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

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

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

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

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

Minimum Protective SuggestedArc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

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

1.03 Publications

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

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

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

3. NIOSH, SAFETY AND HEALTH IN ARC WELDINGAND GAS WELDING AND CUTTING, obtainablefrom the Superintendent of Documents, U.S. Govern-ment Printing Office, Washington, D.C. 20402

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

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


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

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

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

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

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

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

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

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

14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARA-TION FOR WELDING AND CUTTING OF CONTAIN-ERS AND PIPING THAT HAVE HELD HAZARDOUSSUBSTANCES, obtainable from the American WeldingSociety, 550 N.W. LeJeune Rd, Miami, FL 33126

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

1.04 Note, Attention etAvertissement

Dans ce manuel, les mots “note,” “attention,” et“avertissement” sont utilisés pour mettre en relief desinformations à caractère important. Ces mises en reliefsont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignementgénéral sur lequel il importe d’insister davantageou qui contribue à l’efficacité de fonctionnementdu système.

ATTENTION

Toute procédure pouvant résulterl’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessuresde l’opérateur ou des autres personnes se trouvantdans la zone de travail en cas de non-respect de laprocédure en question.

1.05 Precautions De SecuriteImportantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DUMATÉRIEL DE SOUDAGE À L’ARC AU JETDE PLASMA PEUVENT PRÉSENTER DESRISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergieélectrique haute tension et des émissionsmagnétique qui peuvent interférer la fonctionpropre d’un “pacemaker” cardiaque, les appareilsauditif, ou autre matériel de santé electronique.Ceux qui travail près d’une application à l’arc aujet de plasma devrait consulter leur membreprofessionel de médication et le manufacturier dematériel de santé pour déterminer s’il existe desrisques de santé.

Il faut communiquer aux opérateurs et au person-nel TOUS les dangers possibles. Afin d’éviter lesblessures possibles, lisez, comprenez et suivez tousles avertissements, toutes les précautions de sécuritéet toutes les consignes avant d’utiliser le matériel.Composez le + 603-298-5711 ou votre distributeurlocal si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet deplasma peuvent présenter des risques et des dangers desanté.


• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fuméeprovenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en airsi l’aération fournie ne permet pas d’éliminer la fuméeet les gaz.

• Les sortes de gaz et de fumée provenant de l’arc deplasma dépendent du genre de métal utilisé, desrevêtements se trouvant sur le métal et des différentsprocédés. Vous devez prendre soin lorsque vouscoupez ou soudez tout métal pouvant contenir un ouplusieurs des éléments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécuritédes matières (sigle américain “MSDS”); celles-cidevraient être fournies avec le matériel que vousutilisez. Les MSDS contiennent des renseignementsquant à la quantité et la nature de la fumée et des gazpouvant poser des dangers de santé.

• Pour des informations sur la manière de tester lafumée et les gaz de votre lieu de travail, consultezl’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables decoupe à débit d’eau ou à courant descendant pourcapter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans unezone où se trouvent des matières ou des gaz combus-tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fuméeprovenant des solvants et des produits de nettoyagechlorés. 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 deséléments reconnu dans L’état de la Californie, quipeuvent causer des défauts de naissance et le cancer.(La sécurité de santé en Californie et la code sécuritéSec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Leprocédé au jet de plasma requiert et produit de l’énergieélectrique haute tension. Cette énergie électrique peutproduire des chocs graves, voire mortels, pour l’opérateuret 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-vousde la pièce de travail ou des autres parties du circuitde soudage.

• Réparez ou remplacez toute pièce usée ouendommagée.

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

• Montez et maintenez le matériel conformément auCode électrique national des Etats-Unis. (Voir la page5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel deconsignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scorieschaudes, des étincelles ou de l’arc de plasma. Le procédéà l’arc de plasma produit du métal, des étincelles, desscories chaudes pouvant mettre le feu aux matières com-bustibles ou provoquer l’explosion de fuméesinflammables.

• Soyez certain qu’aucune matière combustible ou in-flammable ne se trouve sur le lieu de travail. Protégeztoute telle matière qu’il est impossible de retirer de lazone de travail.

• Procurez une bonne aération de toutes les fuméesinflammables ou explosives.

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

• Prévoyez une veille d’incendie lors de tout travail dansune zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sousles pièces de travail en aluminium lorsqu’elles sontcoupées sous l’eau ou sur une table d’eau. NE PAScouper les alliages en aluminium sous l’eau ou surune table d’eau à moins que le gas hydrogène peuts’échapper ou se dissiper. Le gas hydrogène accumuléexplosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesservos yeux et brûler votre peau. Le procédé à l’arc deplasma produit une lumière infra-rouge et des rayons


ultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous protégezpas correctement.

• Pour protéger vos yeux, portez toujours un casque ouun écran de soudeur. Portez toujours des lunettes desécurité munies de parois latérales ou des lunettes deprotection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteurapproprié pour protéger votre peau contre lesétincelles et les rayons de l’arc.

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

• Protégez les autres personnes se trouvant sur la zonede travail contre les rayons de l’arc en fournissant descabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans lerecommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance SuggeréeCourant 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 observéclairement. L’experience a démontrer que les filtresmoins foncés peuvent être utilisés quand l’arc estcaché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.Les procédés de soudage à l’arc de plasma peuventprovoquer des niveaux sonores supérieurs aux limitesnormalement acceptables. Vous dú4ez vous protéger lesoreilles contre les bruits forts afin d’éviter une pertepermanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portezdes tampons protecteurs et/ou des protectionsauriculaires. Protégez également les autres personnesse trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer queles décibels (le bruit) ne dépassent pas les niveauxsûrs.

• Pour des renseignements sur la manière de tester lebruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plusrécentes ayant été faites à celles-ci pour de plus amplesrenseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DEPROTECTION 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 DESOPÉRATIONS DE COUPE ET DE SOUDAGE,disponible auprès de la Société Américaine deSoudage (American Welding Society), 550 N.W.LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DESOPÉRATIONS DE COUPE ET DE SOUDAGE ÀL’ARC ET AU GAZ, disponible auprès du Superin-tendent of Documents, U.S. Government PrintingOffice, Washington, D.C. 20402

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

5. Norme ANSI Z41.1, NORMES POUR LESCHAUSSURES PROTECTRICES, disponible auprèsde l’American National Standards Institute, 1430Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIESLORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ETDE 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 DECONTENEURS AYANT RENFERMÉ DES PRODUITSCOMBUSTIBLES, disponible auprès de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL33126

8. Norme 51 de l’Association Américaine pour la Pro-tection contre les Incendies (NFPA), LES SYSTEMESÀ GAZ AVEC ALIMENTATION EN OXYGENEPOUR LE SOUDAGE, LA COUPE ET LESPROCÉDÉS ASSOCIÉS, disponible auprès de la Na-tional Fire Protection Association, Batterymarch Park,Quincy, MA 02269


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

10. Norme 51B de la NFPA, LES PROCÉDÉS DECOUPE ET DE SOUDAGE, disponible auprès de laNational Fire Protection Association, BatterymarchPark, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANSRISQUE DES GAZ COMPRIMÉS EN CYLINDRES,disponible auprès de l’Association des GazComprimés (Compressed Gas Association), 1235Jefferson Davis Highway, Suite 501, Arlington, VA22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POURLE SOUDAGE ET LA COUPE, disponible auprèsde l’Association des Normes Canadiennes, Stan-dards Sales, 178 Rexdale Boulevard, Rexdale,Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LASÉCURITÉ DU SOUDAGE, disponible auprès del’Association Nationale de Fournitures de Soudage(National Welding Supply Association), 1900 ArchStreet, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine deSoudage, RECOMMANDATIONS DE PRATIQUESSURES POUR LA PRÉPARATION À LA COUPE ETAU SOUDAGE DE CONTENEURS ET TUYAUXAYANT RENFERMÉ DES PRODUITSDANGEREUX , disponible auprès de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTIONRESPIRATOIRE, disponible auprès de l’AmericanNational Standards Institute, 1430 Broadway, NewYork, NY 10018


1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation forthe enforcement of this Directive.

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

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

National Standard and Technical Specifications

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

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

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment 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 relatedindustry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensurethe 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 WardOperations DirectorThermadyne EuropeEuropa BuildingChorley N Industrial ParkChorley, Lancashire,England PR6 7BX


1.08 Statement of Warranty

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

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

Parts

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

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

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

Control PC Board 3 Years 1 Year 2 Years 1 Year

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

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

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

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

Effective: November 15, 2001

Manual 0-2751 2-1 INTRODUCTION

SECTION 2:INTRODUCTION

2.01 Scope of Manual

This manual contains descriptions, operating instructionsand maintenance procedures for the PCH/M-40 Torch.Service of this equipment is restricted to Thermal Dynam-ics trained personnel; unqualified personnel are strictlycautioned against attempting repairs or adjustments notcovered in this manual, at the risk of voiding the War-ranty.

Read this manual thoroughly. A complete understand-ing of the characteristics and capabilities of this equip-ment will assure the dependable operation for which itwas designed.

2.02 General Description

NOTE

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

The PCH/M-40 Torch provides cutting capacity of up to1/2 inch (12.7 mm) at 40 amperes. In the torch, a singletorch lead provides compressed air from a single sourceto be used as both the plasma and secondary gas. The airflow is divided inside the torch head. Single-gas opera-tion provides a smaller sized torch and inexpensive op-eration.

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 positivelycharged tip. Once the pilot arc has ionized the plasmagas, the superheated column of gas flows through thesmall orifice in the torch tip, which is focused on the metalto be cut.

2.03 Specifications & DesignFeatures

A. Torch Configurations and Dimensions

14.1 in.

1.1 in.

1.4 in.

5.1in.

0.62 in. dia.

3.4 in.

10.0 in.

1.1 in.

1.1in.

3.0 in.

10.5 in.

A-02736

(129.5 mm)

(35.6 mm)

(15.2 mm)(358.1 mm)

(28 mm)

(267 mm)

(76.2 mm)

(28 mm)

(254 mm)

(86.4 mm)

(28 mm)

0.75 sleeve(19.0 mm)

Figure 2-1 Torch Dimensions & Configurations

INTRODUCTION 2-2 Manual 0-2751

1. Hand Torch PCH-40

PCH-40 is available with torch head at 70° or 90° to thetorch handle. The hand torches include a torch handleand torch trigger assembly.

2. Machine Torch PCM-40

The standard machine torch has a 180° torch head anda fiberglass positioning tube with rack & pinch blockassembly.

Available options include a kit with metal mounting tubewith rack & pinion assembly and a kit with the pinionassembly by itself.

B. Torch Leads Lengths

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

C. Current Rating

40 Amps Max., DC, Straight Polarity

D. Duty Cycle (Cutting)

100% on 1/2 inch (12.7 mm) material

E. Cutting Range

Mild steel up to 1/2 inch at 10 IPM (inches per minute) (12.7mm at 0.25 MPM (meters per minute))

F. Pierce Rating

1/4 inch (6.3 mm) on mild steel

G. Transfer Distance

3/8 in (9.5 mm)

H. Gouging Capacity

0.125 " / 3.2 mm

0.125 " / 3.2 mm

20 inches / minute0.5 m / minute

Art # A-04282

I. Bevel Cut Capability

0° to 45° on 1/4 inch (6.3 mm) material

J. Torch Parts

Gas Distributor, Electrode, Tip, Shield Cup

K. Parts-In-Place (PIP)

Torch Head has built-in contacts.

L. Gas Requirement

Gas Type Compressed Air (Only)Gas Pressure 70 psi (4.8 bar)

Total Gas Flow Cutting: Gouging:

200 scfh (94.4 lpm)230 scfh (108.5 lpm)

PCH-40 & PCM-40 TorchGas Requirements

CAUTION: Maximum input gas pressure must not exceed 125 psi (8.6 bar)

M. Direct Contact Hazard

For exposed tip the recommended standoff is 1/8" to 3/8" (3- 9.5 mm).

2.04 Options And Accessories

These items can be used to customize a standard system for aparticular application or to further enhance performance.

• Spare Parts Kit - Contains replacement front-end torchparts.

• Circle Cutting Guide Kit - Easy add-on attachments toallow for straight line, circle cutting, and beveling with ahand torch. The guide fits both the 70° and 90° handtorches.

• Standoff Cutting Guide - Simple push-on attachment toallow for torch dragging without risk of touching tip.

• 1-3/8" Metal Mounting Tube with Rack & Pinion Assem-bly

• Pinion Assembly

• Computer Control (CNC) Cable 25 foot (7.6 m) or 50 foot(15.2 m)

• Hand Pendant Control Assembly - Used for machine ap-plications. Hand Pendant Control has 20 foot (6.1 m)cable which provides ON/OFF signals to the Power Sup-ply.

• Extension Cable for Hand Pendant Control - 25 foot(7.6 m) cable which can be added to the Hand PendantControl cable to provide a total control cable lengthof 50 foot (15.2 m).

Manual 0-2751 2-3 INTRODUCTION

2.05 Introduction to Plasma

A. Plasma Gas Flow

Plasma is a gas which has been heated to an extremely hightemperature and ionized so that it becomes electrically con-ductive. The plasma arc cutting and gouging process usethis plasma to transfer an electrical arc to the workpiece.The metal to be cut or removed is melted by the heat of thearc and then blown away.

While the goal of plasma arc cutting is separation of thematerial, plasma arc gouging is used to remove metals to acontrolled depth and width.

In a Plasma Cutting Torch a cool gas enters Zone B (refer toFigure 2-2), where a pilot arc between the electrode and thetorch tip heats and ionizes the gas. The main cutting arcthen transfers to the workpiece through the column of plasmagas in Zone C.

��

��

��

��

A-00002

Workpiece

PowerSupply

+

_

C

B

A

Figure 2-2 Typical Torch Head Detail

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

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

B. Gas Distribution

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

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

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

C. Pilot Arc

When the torch is started a pilot arc is established betweenthe electrode and cutting tip. This pilot arc creates a pathfor the main arc to transfer to the work.

D. Capacitive Discharge (CD)

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

E. Main Cutting Arc

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

F. Interlocks

One pressure switch acts as an interlock for the gas supply.If supply pressure falls below minimum requirements thepressure switch will open, shutting off the DC power, andthe GAS indicator will go off. When adequate gas supplypressure is available the pressure switch will close, allow-ing power to be resumed for cutting.

INTRODUCTION 2-4 Manual 0-2751

G. Parts-In-Place (PIP)

The torch head has built-in contacts called Parts-In-Place(PIP). These two contacts are made through the ring insidethe shield cup when the shield cup is installed. The torchwill fail to operate if these contacts are not made.

A-00458

Torch Switch

PIP Pin

PIP PinShield CupTo Control

Cable Wiring

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

A-03761

Torch Trigger

PIP Switch Shield Cup

To ControlCable Wiring

Torch Switch

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

Manual 0-2751 3-1 INSTALLATION

SECTION 3:INSTALLATION

3.01 Introduction

This section describes installation of the Torch. Theseinstructions apply to the Torch and Leads Assemblies only.Installation procedures for the Power Supply, Options,and Accessories are given in Manuals specifically pro-vided for those units.

The complete installation consists of:

1. Site Selection

2. Unpacking

3. Setting Up Torch

4. Connecting Torch

5. Gas Connection

3.02 Site Location

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

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

3.03 Unpacking

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identifyand account for each item.

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

3.04 Setting Up the Hand Torch

The hand torch (PCH) is factory connected to the PowerSupply and requires no special set up. The proper torchparts (shield cup, tip, gas distributor, and electrode) mustbe installed for the type of operation. Refer to Section4.04, Torch Parts Selection for more information.

3.05 Setting Up the Machine Torch

WARNING

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

The standard machine torch (PCM) is factory connectedto the Power Supply and includes a fiberglass position-ing tube with rack and pinch block assembly. A metalmounting tube with rack & pinion assembly or the pin-ion assembly only are available as options.

1. Mount the torch assembly on the cutting table.

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

A-02591

Pinch BlockAssembly

Workpiece

Square

Figure 3-1 Machine Torch Set-Up

3. The proper torch parts (shield cup, tip, gas dis-tributor, and electrode) must be installed for thetype of operation. Refer to Section 4.04, Torch PartsSelection for more information.

INSTALLATION 3-2 Manual 0-2751

3.06 Connecting the Torch

WARNING

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

1. If the torch leads were not factory-installed, con-nect the torch lead connections to the Power Sup-ply as described in the manual supplied with thePower Supply.

Pilot Lead

Torch LeadAssembly

Negative/PlasmaLead

A-03762Control CableConnector

Figure 3-2 Hand Torch Lead Connections

2. Check the torch for proper parts assembly.

CAUTION

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

3. In machine type operations the Machine Torch hastwo cable connectors supplied at the console endof the torch. One connector plugs into the powersupply and the other plugs into the remote pen-dant lead. The remote pendant lead connector al-lows connection to a remote pendant or CNC cablewhile using PIP connections in the Torch Assem-bly.

Connect the remote pendant control cable to thelead connector provided on the Torch leads.

Remote Pig-TailAssembly

A-03588Closed End Splice

Strain Relief

Strain ReliefNut

NegativeLead

Pilot ReturnLead

Figure 3-3 Machine Torch Connections

2

3

4

12

14

13

Torch ControlCable Connector

Remote Pendant/CNCCable Connector

PIPCircuitControl

OK-To-Move

3

4

12

14

13

A-01366

Figure 3-4 Remote Pendant Connector Diagram

Manual 0-2751 3-3 INSTALLATION

3.07 Gas Connection

A. Connection

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

CAUTION

Air supply must be free of oil, moisture, and othercontaminants. Excessive oil and moisture maycause double-arcing, rapid tip wear, or even com-plete torch failure. Contaminants may cause poorcutting performance and rapid electrode wear.

B. Checking Air Quality

To test the quality of air, place a welding filter lens infront of the torch and turn on the gas. Any oil or mois-ture in the air will be visible on the lens. Do not ini-tiate an arc!

C. Filtering

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

INSTALLATION 3-4 Manual 0-2751

Manual 0-2751 4-1 OPERATION

SECTION 4:OPERATION

4.01 Introduction

This section provides a description of the Torch Assem-bly followed by operating procedures.

4.02 Functional Overview

The Torch is designed to operate with the Pak Master 50XLPlus Cutting System to provide a plasma cutting systemwhich can cut most metals from gauge thickness up to a1/2 inch (12.7 mm). With a quick change of torch partsthe torch can be used for plasma arc gouging.

4.03 Getting Started

This procedure should be followed at the beginning ofeach shift:

WARNING

Disconnect primary power at the source before as-sembling or disassembling power supply, torchparts, or torch and leads assemblies.

A. Torch Parts

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

B. Input Power

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

C. Work Cable

Check for a solid work cable connection to the work-piece.

D. Gas Supply

Select desired single gas supply. Make sure gas sourcesmeet requirements (refer to Section 2.03-L, Gas Re-quirements). Check connections and turn gas supplyon.

E. Power On

On the Power Supply place the ON/OFF switch tothe ON position.

F. Current Output Level

At the Power Supply, set the desired current outputlevel to a maximum of 40 amperes.

G. Pressure Settings

Place the RUN/SET/LATCH switch to the SET posi-tion. Gas will flow. Adjust gas pressure control to 70psi ±5 (5 bar).

H. Ready for Operation

Return the RUN/SET/LATCH switch to RUN orLATCH position. Gas will not flow until the TorchTrigger is pressed.

NOTES

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

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

The system is now ready for operation. Push the TorchTrigger to initiate the arc. There is a 2 second pre-flowbefore the arc starts.

NOTES

Refer to Appendix 1 for a detailed block diagram ofthe Sequence of Operation.

4.04 Torch Parts Selection

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

Type of operation:

Drag cutting, standoff cutting or gouging

Torch parts:

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

The torch parts installed from the factory are as follows:

• Shield Cup (Catalog # 9-6003)

• Cutting Tip (Catalog # 9-6501)

• Electrode (Catalog # 9-6506)

• Gas Distributor (Catalog # 9-6507)Refer to Figure 4-2 for the various torch parts.

OPERATION 4-2 Manual 0-2751

A-01367

Copper Shield CupCatalog No. 9-6503

StandoffCutting Tip (.031 in)Catalog No. 9-6500

DragCutting Tip (.031 in)Catalog No. 9-6501

ElectrodeCatalog No. 9-6506

Gas DistributorCatalog No. 9-6507

Standard Shield CupCatalog No. 9-6003

Crown Shield CupCatalog No. 9-6004

Gouging TipCatalog No. 9-6502

Figure 4-2 Torch Parts Selection

To change the torch parts for a different operation usethe following procedure:

NOTE

The tip, gas distributor, and electrode are held inplace by the shield cup. Position the torch with theshield cup facing upward to prevent these partsfrom falling out when the cup is removed.

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

Torch Head

StandardShield Cup

GasDistributor

TipElectrodeCrown

Shield Cup

A-02471

Figure 4-3 PCH-40 Torch Parts (70° Head)

2. Remove the tip, gas distributor and electrode.

3. Install the desired electrode, gas distributor and tipfor the operation into the torch head.

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

4.05 Cut Quality

NOTE

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

Cut quality requirements differ depending on applica-tion. For instance, nitride build-up and bevel angle maybe major factors when the surface will be welded aftercutting. Dross-free cutting is important when finish cutquality is desired to avoid a secondary cleaning opera-tion. The following cut quality characteristics are illus-trated in Figure 4-4:

Kerf WidthCut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007

Figure 4-4 Cut Quality Characteristics

A. Cut Surface

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

B. Nitride Build-Up

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


C. Bevel Angle

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

D. Top-Edge Rounding

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

E. Bottom Dross Build-up

Molten material which is not blown out of the cut areaand re-solidifies on the plate. Excessive dross mayrequire secondary clean-up operations after cutting.

F. Kerf Width

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

G. Top Spatter (Dross)

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

H. Various Materials and Thicknesses

The following table defines the cut quality on variousmaterials and thicknesses:

Table 4-A Cut Quality on Various Materials

Material Type of Type of Cut

Thickness Material Gas Characteristics

Gageto

1/2 inch

Good - Excellent

Good - Excellent

Good - Excellent

Air

Air

Air

Carbon Steel

Stainless

Aluminum

Description of Cut Characteristics:

Excellent - Minimum bevel (0 - 4°), minimum kerf (2 xtip orifice diameter), little or no dross, smoothcut surface.

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 xtip orifice diameter), some dross (easily removed),medium-smooth cut surface, slight top edgerounding.

4.06 Operating the System

WARNINGS

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

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

CAUTION

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

NOTE

Handle torch leads with care and protect them fromdamage.

A. Piloting

Piloting is harder on parts life than actual cutting be-cause the pilot arc is directed from the electrode tothe tip rather than to a workpiece. Whenever pos-sible, avoid excessive pilot arc time to improve partslife.

B. Torch Standoff

Improper standoff (the distance between the torch tipand workpiece) can adversely affect tip life as well asshield cup life. Standoff may also significantly affectthe bevel angle. Reducing standoff will generally re-sult in a more square cut.

C. Edge Starting

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

D. Direction of Cut

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


travel, the right side of the cut is more square than theleft (Refer to Figure 4-5). To make a square-edged cutalong an inside diameter of a circle, the torch shouldmove counterclockwise around the circle. To keep thesquare edge along an outside diameter cut, the torchshould travel in a clockwise direction.

Right SideCut Angle

Left SideCut Angle

A-00512Figure 4-5 Side Characteristics of Cut

E. Dross

When dross is present on carbon steel, it is commonlyreferred to as either “high speed, slow speed, or topdross”. Dross present on top of the plate is normallycaused by too great a torch to plate distance. "Topdross" is normally very easy to remove and can oftenbe wiped off with a welding glove. "Slow speed dross"is normally present on the bottom edge of the plate.It can vary from a light to heavy bead, but does notadhere tightly to the cut edge, and can be easilyscraped off. "High speed dross" usually forms a nar-row bead along the bottom of the cut edge and is verydifficult to remove. When cutting a troublesome steel,it is sometimes useful to reduce the cutting speed toproduce "slow speed dross". Any resultant cleanupcan be accomplished by scraping, not grinding.

4.07 Hand Torch Operation

A. Standoff Cutting With Hand Torch

NOTE

For best performance and parts life, always use thecorrect parts for the type of operation.

1. The torch can be comfortably held in one hand orsteadied with two hands. Position the hand topress the Trigger on the torch handle. With thePCH-40, the hand may be positioned close to thetorch head for maximum control or near the backend for maximum heat protection. Choose theholding technique that feels most comfortable andallows good control and movement.

NOTE

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

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

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

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

A-00024

Shield Cup

Torch

StandoffDistance 1/8" - 3/8"

Figure 4-6 Standoff Distance

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

4. Once on, the main arc remains on as long as theTorch Trigger is held down, unless the torch is with-drawn from the work or torch motion is too slow.If the cutting arc is interrupted, the pilot arc comesback on automatically.

NOTE

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

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


B. Crown Shield Cup With Straight Edge

The Crown Shield Cup can be used with a non-con-ductive straight edge to make straight cuts by hand(refer to Figure 4-7). The Crown Shield Cup func-tions best when cutting 3/16" metal (4.7 mm) that isrelatively smooth metal surfaces that are solid. (Usedrag cutting for thinner metal).

WARNING

The straight edge must be non-conductive.

Non-ConductiveStraight EdgeCutting Guide

Crown ShieldCup

Torch

A-02600

Figure 4-7 Using Crown Shield Cup With StraightEdge

C. Drag Cutting With a Hand Torch

Drag cutting works best on metal 3/16" (4.7 mm) thickor less.

NOTE

For best parts performance and life, always use thecorrect parts for the type of operation.

1. Install the drag cutting tip and set the output cur-rent to 35 amps or less.

2. The torch can be comfortably held in one hand orsteadied with two hands. Position the hand topress the Trigger on the torch handle. With thePCH-40, the hand may be positioned close to thetorch head for maximum control or near the backend for maximum heat protection. Choose theholding technique that feels most comfortable andallows good control and movement.

3. Keep the torch in contact with the workpiece dur-ing the cutting cycle.

4. Press the Torch Trigger, and after an initial two sec-ond pre-flow, the pilot arc will come on and re-main on until the cutting arc starts.

5. Once on, the main arc remains on as long as theTorch Trigger is held down, unless the torch is with-drawn from the work or torch motion is too slow.If the cutting arc is interrupted, the pilot arc comesback on automatically.

NOTES

Most cutting is performed with the power supplyin the RUN position. For specific applications, theLATCH position may be preferred where the TorchTrigger can be released after the main arc transfer.In the LATCH position, the torch remains activateduntil the main arc breaks from the workpiece.

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

D. Piercing With Hand Torch

1. The torch can be comfortably held in one hand orsteadied with two hands. Position the hand topress the Trigger on the torch handle. With thePCH-40, the hand may be positioned close to thetorch head for maximum control or near the backend for maximum heat protection. Choose thetechnique that feels most comfortable and allowsgood control and movement.

NOTE

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

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

3. In a portion of the unwanted metal start the pierceoff the cutting line and then continue the cut ontothe line. Hold the torch perpendicular to the work-piece after the pierce is complete.

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


4.08 Machine Torch Operation

A. Cutting With Machine Torch

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

1. Use a square to check that the torch is perpendicu-lar to the workpiece to obtain a clean, vertical cut.

A-02591

Pinch BlockAssembly

Workpiece

Square

Figure 4-8 Checking Alignment

2. To start a cut at the plate edge, position the centerof the torch along the edge of the plate (refer toFigure 4-8).

B. Travel Speed

Proper travel speed is indicated by the trail of the arcwhich is seen below the plate ( Figure 4-9). The arccan be one of the following:

1. Straight Arc

A straight arc is perpendicular to the workpiecesurface. This arc is generally recommended forthe best cut using air plasma on stainless or alu-minum.

2. Leading Arc

The leading arc is directed in the same directionas torch travel. A five degree leading arc is gener-ally recommended for air plasma on mild steel.

3. Trailing Arc

The trailing arc is directed in the opposite direc-tion as torch travel.

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

A-02590

Figure 4-9 Machine Torch Operation

For optimum smooth surface quality, the travel speedshould be adjusted so that only the leading edge ofthe arc column produces the cut. If the travel speed istoo slow, a rough cut will be produced as the arc movesfrom side to side in search of metal for transfer.

Travel speed also affects the bevel angle of a cut. Whencutting in a circle or around a corner, slowing downthe travel speed will result in a squarer cut. The powersource output should be reduced also. Refer to theappropriate Control Module Operating Manual forany Corner Slowdown (CSD) adjustments that maybe required.


C. Piercing With Machine Torch

To pierce with a machine torch, the arc should bestarted with the torch positioned as high as possibleabove the plate while allowing the arc to transfer andpierce. This standoff helps avoid having molten metalblow back onto the front end of the torch.

When operating with a cutting machine, a pierce ordwell time is required. Torch travel should not beenabled until the arc penetrates the bottom of the plate.As motion begins, torch standoff should be reducedto the recommended 1/8 - 1/4 inch (3-6 mm) distancefor optimum speed and cut quality. Clean spatter andscale from the shield cup and the tip as soon as pos-sible. Spraying or dipping the shield cup in anti-spat-ter compound will minimize the amount of scalewhich adheres to it.

4.09 Recommended Cutting Speeds

Cutting speed depends on material, thickness, and theoperator’s ability to accurately follow the desired cut line.The following factors may have an impact on system per-formance:

• Torch parts wear

• Air quality

• Line voltage fluctuations

• Torch standoff height

• Proper work cable connection

NOTE

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

Refer to Appendix 2, Cutting Speed Charts, for completechart data.

4.10 Gouging

WARNINGS

Be sure the operator is equipped with proper gloves,clothing, eye and ear protection and that all safetyprecautions at the front of this manual have beenfollowed. Make sure no part of the operator’s bodycomes in contact with the workpiece when the torchis activated.

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

CAUTIONS

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

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

A. Gouging Parameters

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

B. Torch Travel Speed

Optimum torch travel speed for gouging is 20 inchesper minute (0.5 meters per minute). Travel speed isdependent on current setting, and lead angle, andmode of operation (hand or machine torch).

C. Current Setting

Current settings depend on torch travel speed, modeof operation (hand or machine torch), and the amountof material to be removed.


D. Lead Angle

The angle between the torch and workpiece dependson the output current setting and torch travel speed.At 40 amps, the recommended lead angle is 35° (referto below). At a lead angle greater than 45° the moltenmetal will not be blown out of the gouge and may beblown back onto the torch. If the lead angle is toosmall (less than 35°), less material may be removed,requiring more passes. In some applications, such asremoving welds or working with light metal, this maybe desirable.

A-00025

35˚

Workpiece

Torch Head

Standoff Height1/8 - 1/4"

Direction of Travel

Figure 4-10 Gouging Angle and Standoff Distance

E. Standoff Distance

The tip to work distance affects gouge quality anddepth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm)allows for smooth, consistent metal removal. Smallerstandoff distances may result in a severance cut ratherthan a gouge. Standoff distances greater than 1/4 inch(6 mm) may result in minimal metal removal or lossof transferred main arc.

F. Slag Build-up

Slag generated by gouging on materials such as car-bon and stainless steels, nickels, and alloyed steels,can be removed easily in most cases. Slag does notobstruct the gouging process if it accumulates to theside of the gouge path. However, slag build-up cancause inconsistencies and irregular metal removal iflarge amounts of material build up in front of the arc.The build-up is most often a result of improper travelspeed, lead angle, or standoff height.

Manual 0-2751 5-1 SERVICE

SECTION 5:SERVICE

5.01 Introduction

This section describes basic maintenance procedures perform-able by operating personnel. No other adjustments or repairsare to be attempted by other than Thermal Dynamics Trainedpersonnel.

WARNINGS

Disconnect primary power at the source beforedisassembling the torch or torch leads.

Frequently review the Important Safety Precau-tions (page 1). Be sure the operator is equippedwith proper gloves, clothing, eye and ear protec-tion. Make sure no part of the operator’s bodycomes into contact with the workpiece while thetorch is activated.

CAUTION

Sparks from the cutting process can cause dam-age to coated, painted, and other surfaces suchas glass, plastic and metal.

NOTE

Handle torch leads with care and protect themfrom damage.

5.02 General Torch Maintenance

A. Cleaning Torch

Even if precautions are taken to use only clean air with atorch, eventually the inside of the torch becomes coatedwith residue. This buildup can affect the pilot arc initiationand the overall cut quality of the torch.

WARNINGS

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

DO NOT touch any internal torch parts while theAC indicator light on the front panel of the PowerSupply is ON.

The inside of the torch should be cleaned with electricalcontact cleaner using a cotton swab or soft wet rag. Insevere cases, remove the torch from the leads and clean itby pouring electrical contact cleaner into the torch and blow-ing it through with compressed air.

NOTE

Refer to Section 5.06, Servicing Hand Torch Com-ponents.

CAUTION

Dry the torch thoroughly before reinstalling.

B. Checking Center Insulator

The center insulator separates the negative and posi-tive sections of the torch. If the center insulator doesnot provide adequate resistance, current which is in-tended for the pilot arc may be dissipated into thetorch head, resulting in torch failure.

WARNINGS



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

2. Using an ohmmeter (set to 10K or higher), checkfor continuity between the positive and negativetorch fittings. Infinite resistance (no continuity)should be found. If continuity is found, refer toSection 5.07, Torch and Leads Troubleshooting.

SERVICE 5-2 Manual 0-2751

5.03 Common Operating Faults

The following are the more common cutting faults and the pos-sible causes:

1. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

e. Cutting current too low

f. Non-Genuine Thermal Dynamics Parts

2. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Cutting current too high

d. Work cable disconnected

e. Worn torch parts


3. Excessive Dross Formation

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Worn torch parts

d. Improper cutting current

e. Non-Genuine Thermal Dynamics Parts

4. Short Torch Parts Life

a. Oil or moisture in air source

b. Exceeding system capability (material too thick)

c. Excessive pilot arc time

d. Air flow too low (incorrect pressure)

e. Improperly assembled torch


5.04 Inspection and ReplacementConsumable Torch Parts

WARNINGS



Remove the consumable torch parts as follows:

NOTE

The torch tip, gas distributor, and electrode areheld in place by the shield cup. Hold the torchwith the shield cup facing upward to keep theseparts from falling out when the cup is removed.

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

NOTE

Slag built up on the shield cup that cannot beremoved may effect the performance of the system.

Torch Head

StandardShield Cup

GasDistributor

TipElectrodeCrown

Shield Cup

A-02471

Figure 5-1 Torch Consumable Parts

2. Inspect the cup for damage. Wipe it clean or replace ifdamaged.

3. Remove the tip. Check for excessive wear (indicated by anelongated or oversized orifice). Clean or replace the tip ifnecessary.

Good Tip Worn Tip

A-00323

Figure 5-2 Tip Wear


4. Remove the gas distributor and check for excessive wear,plugged gas holes, or discoloration. Replace if necessary.

5. Remove the electrode and check the face of the electrode.It should not be worn more than 0.062 inch (1.5 mm). If it isworn beyond this point it must be replaced.

A-00022

Worn Electrode

New Electrode

.062 in(1.5 mm)

Figure 5-3 Electrode Wear

6. Reinstall the electrode, gas distributor and tip into the torchhead.

NOTE

Be careful not to overtighten the electrode whenreinstalling.

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

5.05 Troubleshooting Guide

A. Troubleshooting

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

B. How to use this Guide

The following information is a guide to help the Cus-tomer/Operator determine the most likely causes forvarious symptoms.

This guide is set up in the following manner:

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

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

A. Torch will not pilot when torch switch is activated

1. Power Supply RUN/SET/LATCH switch in SET posi-tion

a. Place RUN/SET/LATCH switch to RUN position.

2. Parts-In-Place (PIP) pins missing or damaged

a. Check pins, and replace missing ones or damagedones if necessary.

3. Faulty torch switch

a. Check continuity

4. Faulty torch parts

a. Inspect torch parts and replace if necessary. Referto Section 5.04, Inspection and Replacement Con-sumable Torch Parts

5. Gas pressure too high

a. Set pressure to maximum of 70 psi (4.8 bar).

6. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if necessary.Refer to Section 5.09, Torch and Leads Troubleshoot-ing.

7. Faulty components in power supply system compo-nents

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

B. No cutting output

1. Torch not properly connected to power supply

a. Check that torch leads are properly attached topower supply

2. Shield cup not properly installed on torch

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

3. Parts-In-Place (PIP) pins not installed, or damaged.

a. Check PIP pins - if missing or damaged, replacepins.






C. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.


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



D. Erratic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

3. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix 2, CuttingSpeed Charts).

4. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface whilepurging and observe oil or moisture buildup (do notactivate torch)

5. Torch tip is being dragged across workpiece

a. Whenever the tip is dragged across the workpiece,the amperage automatically folds back to 35 amps.

E. No gas flow

1. Gas not connected or pressure too low

a. Check source for at least 70 psi (4.8 bar).




a. Return for repair or have qualified technician repairper Service Manual.

F. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix 2, CuttingSpeed Charts).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3 mm) from clean surface whilepurging and observe oil or moisture buildup (do notactivate torch).

5.06 Torch & LeadsTroubleshooting

A. General Information

Failures in the Torch and Leads can be isolated to the TorchHead or Torch Lead components. To properly isolate thefailed part requires the use of an ohmmeter and a Hi-PotTester.

WARNING

The use of a Hi-Pot Tester should be performed onlyby a qualified electronic technician.

In the Torch Head the center insulator separates the nega-tive and positive charged sections of the torch. If the cen-ter insulator does not provide adequate resistance, cur-rent which is intended for the pilot arc may be dissipatedinto the torch head, resulting in torch failure.

In the Torch Leads the negative and positive leads areisolated from each other. If there is not adequate resis-tance between the leads then torch failure may occur.


B. Quick Check Procedure

This quick check will identify major isolation failures in theTorch Head or Torch Lead components using an ohmmeter.

The actual assembly and consumables may vary for differenttorches but the basic procedure is the same for all torches.Make the quick check on the Torch Head and Leads as follows:

WARNINGS


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

1. Remove the consumables from the torch.

2. Disconnect the torch leads from the power supplyto isolate the torch from power supply circuits.

3. Using an ohmmeter (set to 10K or higher), checkfor continuity between the positive and negativetorch fittings.

• If there is continuity between the two torch fit-tings proceed to Step 4.

• If no continuity (infinite resistance) is foundbetween the two torch fittings proceed to para-graph C.

4. Remove the torch head from the leads (refer to theproper Section on servicing the Torch Compo-nents).

5. With the torch head disconnected from the leads,measure the resistance between negative fitting orcathode body of the torch head and the positivefitting or anode body of the torch head.

No continuity (infinite resistance) should be measuredbetween negative and positive sections of the torchhead.

• If there is continuity, torch head must be replaced.

• If no continuity (infinite resistance) is found pro-ceed to Step 6.

6. Check the torch leads by measuring the resistance be-tween the positive pilot lead connector and the nega-tive lead fitting.

• If there is continuity, torch leads must be replaced.

• If no continuity (infinite resistance) is found pro-ceed to paragraph ‘C’ (see NOTE).

NOTE

It is possible that the Torch Head and Torch Leadswill test properly with an ohmmeter. The TorchHead and Torch Leads should be tested further forinsulation breakdown if no other fault can be found.

C. Checking Proper Isolation ResistanceProcedure

The Torch Head and Torch Leads should be tested fur-ther for insulation breakdown if no other fault has beenfound. This procedure requires the use of a Hi-Pot Tester.

WARNING

This procedure should be performed only by a quali-fied electronic technician.

1. To test the Torch Head center insulator for insula-tion breakdown use the following procedure:

a. Remove the Torch Head Assembly from theTorch Leads if not already done.

b. Remove the consumables from the Torch HeadAssembly if not already done.

c. Connect a Hi-Pot Tester capable of producing2500VAC between the positive pilot lead andthe negative lead fittings.

d. Increase the output of the Hi-Pot Tester to amaximum of 2500VAC.

• If the voltage drops to 0VAC or leakage currentis detected, then the Torch Head center insula-tor is breaking down and the Torch Head mustbe replaced.

• If the Torch Head center insulator passes thetest, then proceed to Step 2.


2. Test the Torch Leads for insulation breakdown as fol-lows:

a. Connect the Hi-Pot Tester between the positive pi-lot lead and the negative lead fittings. The fittingon the other end of the Torch Leads must be sepa-rated (isolated) from each other.

b. Increase the output of the Hi-Pot Tester to a maxi-mum of 2500VAC.

• If the voltage drops to 0VAC or leakage currentis detected, then the insulation between the TorchLeads is breaking down and the Torch Leadsmust be replaced.

• If the Torch Leads passes the test, then proceedto Step 3.

3. Visually check that the PIP wires, torch switch wires,pilot lead connection, and negative lead connectionsare properly connected and in good condition (no shortsor arcing).

A-00458

Torch Switch

PIP Pin

PIP PinShield CupTo Control

Cable Wiring

Figure 5-4A Torch Switch and PIP Schematic (MachineTorch)

A-03761

Torch Trigger

PIP Switch Shield Cup

To ControlCable Wiring

Torch Switch

Figure 5-4B Torch Switch and PIP Schematic (HandTorch)

• If problems are evident, repair or replace as required.

• If there are no visual problems, then proceed to Step4.

4. Check the pilot lead, negative lead and switch controlwires for opens from one end of the torch leads to theother.

• If open, replace leads or open component of theTorch Leads Assembly.

• If not open, then proceed to Step 5.

5. Check the pilot and switch control wires for shorts toother components in the Torch Leads.

• If shorted, then replace Torch Leads.

• If not shorted, then proceed to Step 6.

6. Carefully reassemble the components and recheck thecompleted assembly per paragraph ‘B’, Step 3 to con-firm that the components have been properly assembled.

This completes the checks for the proper operation of the TorchHead and Torch Leads.

5.07 Servicing Hand Torch (PCH)Components

WARNING

Disconnect primary power to the system before dis-assembling the torch, leads, or power supply.

NEVER touch any internal torch parts while theAC indicator light on the Power Supply is ON.

A. Removing the Hand Torch Head Assembly

The removal of the torch head assembly requires dis-assembly of the torch handle and leads as follows:

1. Remove the five screws from the torch handle as-sembly. Pull the halves apart and set aside.

A-02823

Handle Screws(Five Places)

Handle Half

Figure 5-5 Torch Handle Screw Removal

2. Disconnect both PIP connectors.

3. Slide the insulation sleeve on the Pilot Lead backtowards the Lead.

4. Remove the screw and star washer securing thePilot Lead to the head assembly.


5. Slide the insulation sleeving on the Negative/PlasmaLead back towards the Lead.

NOTE

Some units may have shrink on tubing instead ofinsulation sleeving. If this is the case, remove theshrink on tubing from the Negative/Plasma Lead,being careful not to damage the lead under theshrink on tubing.

Handle Shell

Handle Shell

Spring

Trigger

Torch Switch

Negative / Plasma LeadInsulation Sleeving Pilot Lead

Insulation Sleeving

A-03544

Figure 5-6 Hand Torch Assembly

6. Disconnect the Negative/Plasma Lead from the torchhead.

7. Remove the defective torch head.

B. Reassembling the Hand Torch HeadAssembly

WARNING

Disconnect primary power to the system before dis-assembling the torch, leads, or power supply.

Install the Torch Head Assembly as follows:

IMPORTANT

The insulation sleeves are critical for safety. Besure both are properly installed and not damagedduring reassembly.

1. Slide the replacement insulator sleeving over theNegative/Plasma Lead.

2. Connect the Negative/Plasma Lead to the replacementTorch Head Assembly.

3. Carefully position the insulation sleeving over the con-nectors, as shown below.

A-03545

Negative/PlasmaLead Insulation Sleeving

Figure 5-7 Insulation Sleeving Position for Negative/Plasma Lead

4. Insert the screw through the Pilot Lead lug and theninstall the star washer before securing it to the TorchHead Assembly.

5. Carefully position the Insulation Sleeving over the Pilotconnection.


A-03546

Pilot Lead Insulation Sleeving

Figure 5-8 Insulation Sleeving Position for PilotConnection

6. Reconnect the two PIP wires to the mating connectorsin the leads assembly.

7. Place the Torch Head Assembly in the handle shellhalves keeping in mind the following:

• Place the torch head assembly switch leads sothat no connectors or wires extend beyond theedge of the handle.

• Allow sufficient slack in the leads to avoid pull-ing the leads tightly around the edge of thehandle.

• Position Pilot Lead under the Negative/PlasmaLead.

• Position the Pilot Lead so that the screw willnot penetrate the Insulation Sleeving when thehandle halves are reassembled.

NOTE

For safety reasons, it is critical that the sleevingnot be used if it is damaged during reassembly.Replace sleeving if damaged.

8. Place the torch handle halves together and install thefive assembly screws as follows:

a. Insert the two screws at the Torch Head end of theHandle and torque to 15 in-lbs.

b. Insert the two screws at the Torch Lead end of theHandle and torque to 15 in-lbs.

c. Insert the center screw and torque to 15 in-lbs.

d. Check the Torch Trigger for proper operation. Itshould move freely and not bind. If the trigger binds,loosen the center screw only until the Trigger movesfreely.

A-02824

Handle Half

#1

#2

#3

Install Screws InSequence Shown

Figure 5-9 Torch Handle Screw Installation

9. Install the front end torch parts.

C. Removing Hand Torch Control Switch

To remove the Torch Control Switch Assembly requiresgaining access to the switch wiring and requires par-tial disassembly of the torch handle as follows:

1. Remove the five screws from the torch handle as-sembly. Pull the halves apart and set aside.

A-02823

Handle Screws(Five Places)

Handle Half

Figure 5-10 Torch Handle Screw Removal


2. Cut the Torch Switch leads between the butt splicesand the torch leads, and as close as possible to thesplices.

Handle Shell

Handle Shell

Spring

Trigger

Torch Switch

Negative / Plasma LeadInsulation Sleeving Pilot Lead

Insulation Sleeving

A-03544

Figure 5-11 Hand Torch Assembly

3. Remove the defective Torch Switch from the handle.

D. Reassembling Torch Switch Assembly

1. Strip back the insulation from the Torch Switch leadsapproximately 3/16". Install heat-shrink insulation onthe Torch Switch leads. Use butt splices to connect thetwo Torch Switch leads to the switch leads in the Torchleads assembly. Slide the heat-shrink insulator over thebutt splices. Use a heat gun to shrink the heat-shrinkinsulation into position on the butt splices.

2. Position Torch Head and Torch Control Switch in handle,making sure all connectors and leads do not extendbeyond the edge of the handle.

3. Position Pilot Lead under the Negative/Plasma Lead.

4. Position the Pilot Lead so that the screw will not pen-etrate the Insulation Sleeving when the handle halvesare reassembled.

NOTE

For safety reasons, it is critical that the sleevingnot be used if it is damaged during reassembly.Replace sleeving if damaged.

5. Replace the handle and secure with five screws as fol-lows:

a. Insert the two screws at the Torch Head end of theHandle and torque to 15 in-lbs.

b. Insert the two screws at the Torch Lead end of theHandle and torque to 15 in-lbs.

c. Insert the center screw and torque to 15 in-lbs.

d. Check the Torch Trigger for proper operation. Itshould move freely and not bind. If the trigger binds,loosen the center screw only until the Trigger movesfreely.

A-02824

Handle Half

#1

#2

#3

Install Screws InSequence Shown

Figure 5-12 Torch Handle Screw Installation


5.08 Servicing Machine Torch(PCM) Components

WARNINGS


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

A. Removing Machine Torch Head

1. Unscrew the positioning tube from the Torch Head.

2. Slide the positioning tube back over the leads toexpose the Negative/Plasma Lead connection,Pilot Lead connection, and two PIP (parts-in-placecircuit) connectors.

PositioningTube

Pinch BlockAssembly

Machine Torch Head Art A-04283

Figure 5-13 Torch Mounting Assembly

3. Disconnect the Negative/Plasma and Pilot Leads andthe PIP connectors to allow removal of the Torch HeadAssembly.

Pilot LeadConnection

Parts-in-PlaceWires

Negative/PlasmaLead Connection

Art # A-04284

Figure 5-14 Machine Torch Head Removal

C. Reassembling Machine Torch Assembly

1. Connect the two PIP lead connectors, the Negative/Plasma and Pilot leads.

NOTE

Tape the PIP lead connectors to the leads cover-ing.

2. Screw the positioning tube tightly onto the Torch HeadAssembly.

Manual 0-2751 6-1 PARTS LISTS

SECTION 6:PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceablecomponents. Torch Assemblies are field serviceable, so acomplete breakdown of parts is provided. The parts listsare arranged as follows:

Section 6.03 Replacement Hand Torch Parts

Section 6.04 Torch Options And Accessories

Section 6.05 Complete Assembly Replacements

Section 6.06 Spare Parts Kits

NOTE

Parts listed without item numbers are not illus-trated, but may be ordered by the catalog numbersshown.

B. Returns

If a product must be returned for service, contact yourauthorized distributor. Materials returned to the Manu-facturer without proper authorization will not be ac-cepted.

6.02 Ordering Information

Order replacement parts by catalog number and completedescription of the part or assembly, as listed in the de-scription column of the Parts List. Also include the modeland serial number of the torch. Address all inquiries toyour authorized distributor.

PARTS LISTS 6-2 Manual 0-2751

6.03 Replacement Hand Torch Parts

Item # Qty Description Catalog #

1 1 Assembly, Basic Head, PCH-40, 70° 9-8055

1 Assembly, Basic Head, PCH-40, 90° 9-8054

2 2 Parts-In-Place (PIP) Pins 9-5723

3 1 Electrode, (Air / N2) 9-6506

4 1 Distributor, Gas 9-6507

5 1 Tip, Air, 0.031" Orifice, 40 Amp 9-6500

1 Tip, Air, 0.031" Orifice, Drag Cutting 9-6501

1 Tip, Air, 0.046",Orifice, Gouging 9-6502

6 1 Shield Cup, Standard 9-6003

6a 1 Copper Heat Shield Cup, optional (use with 9-6003) 9-6503

6b 1 Crown Shield Cup, optional (use with 9-6003) 9-6004

7 1 #6-32 x 3/16" Phillips Pan Head Screw Purchase Locally

8 1 #6 Internal Star Washer Purchase Locally

1 Handle, Split, with Trigger (includes items 9-13) 9-8058

9 1 Trigger, Lexan, Orange 9-8059

10 1 Handle, PCH-40 9-8060

11 1 Spring, 0.390 O.D. x 0.750 9-8061

12 1 Torch Handle Socket Head Cap Screw Kit (5 pcs, 6-32 x 1/2" ) 9-8062

13 1 Assembly, Torch Switch 9-8063

14 1 Negative Lead Insulation Sleeving 9-8056

15 1 Pilot Wire Insulation Sleeving 9-8057

16 3 Pin Housing, PIP, Switch 9-8111

17 3 Pin 9-8101

18 3 Socket Housing, PIP 9-8112

19 3 Socket 9-8102

20 1 Lead Assembly, Composite Cable (includes items 10, 12, 13, 21, 22)

Unshielded Leads, Complete

25 ft (7.6 m) Length 4-0815

50 ft (15.2 m) Length 4-0816

21 1 Through - Hole Protector (includes nut) (included in item #22) 9-8103

22 1 Torch Adapter (includes item #21) 7-3447


10

1

9

11

12

13

14

7

8

10

15

Art # A-03557

2

4

3

5

6

Heat Shield(Copper)

Crown ShieldCup

6a

6b

Optional

20

22

21

18 & 19

16 & 17


6.04 Replacement Machine Torch Parts

Item # Qty Description Catalog #

1 1 Standard Shield Cup Assembly 9-6003

1a 1 Heat Shield (Copper), optional 9-6503

2 1 Tip, Cutting, Air / N2, 0.031" Orifice, 40 Amps 9-6500

1 Tip, Drag, Air / N2, 0.031" Orifice, 35 Amps 9-6501

1 Tip, Gouging, Air, 0.046" Orifice 9-6502

3 1 Distributor, Gas 9-6507

4 1 Electrode, Air / N2 9-6506

5 1 Parts-in-Place (PIP)Pins 9-5723

6 1 Assembly, Basic Head, PCH-40 180° (includes #7 and #8) 9-8053

7 1 #6 Internal Star Washer Purchase Locally

8 1 #6-32 x 1/16 Phillips Pan Head Screw Purchase Locally

9 1 Lead Assembly, Cable

Unshielded Leads, Complete

25 ft (7.6m) Length 4-2897

50 ft (15.2m) Length 4-2898

10 1 Fiberglass Positioning Tube with Rack 9-7835

11 2 Body, Mounting, Pinch Block 9-4513

12 1 Pin, Mounting, Pinch Block 9-4521

13 1 Torch Holder Sleeve 7-2896

14 3 #10-32 x 5/8" Phillips Pan Head Screw Purchase Locally

15 2 #10-32 x 32 x 1 1/4 Lg Phillips Pan Head Screw Purchase Locally

16 2 #10-32 Regular Nylon Lock Nut Purchase Locally

17 2 Pin Housing 9-5577

18 2 Pin 9-5170

19 1 Remote Pendant Adapter 7-3452

20 1 Leads Strain Relief (includes nut) 9-8103

21 1 Splice, Closed End - PCM-40 Only 9-7572

1 Plug 9-3294

1 Strain Relief 9-3295

22 2 Socket Housing 9-5578

23 2 Socket 9-4650

24 1 Pinch Block Mounting Kit (includes items 11 - 16) 7-3252

25 1 Power Supply Adapter 7-3452


1

2

3

4

5

6

7

8

10

13

1216

14

15

11

11

Heat Shield(Copper)

1a

Optional

17 & 18

22 & 23

24

920

19

25


6.05 Complete Torch & Leads Assembly Replacement

Description Catalog #

Unshielded Leads

PCH-40 70° Hand Torch, 25 ft (7.6 m) Leads with Torch Adapter 2-5035



PCH-40 90° Hand Torch, 50 ft (15.2 m)Leads with Torch Adapter 2-5038

PCM-40 180° Machine Torch, 25 ft (7.6 m) Leads 2-5039

PCM-40 180° Machine Torch, 50 ft (15.2 m) Leads 2-5040

Suggested Replacement Assemblies

Hand Torches with Two Piece Ergonomic Handle:

RPT-28ER 70° Hand Torch, 20 ft (6.1 m) Leads 7-3550-2




Replacement Hand Torch (PCH) requires Torch Control Cable Adapter 7-3447

Machine Torches with Unshielded Leads (Metal Mounting Tube with Rack & Pinion Assembly):

RPT-28R Machine Torch, 20 ft (6.1 m) Leads 7-3552

RPT-28R Machine Torch, 50 ft (15.2 m) Leads 7-3555

Replacement Machine Torch (PCM) requires Torch Control Cable Adapter 7-3448

Machine Torches with Unshielded Leads (Fiberglass Mounting Tube with Pinch Block Assembly):

RPT-28ER Machine Torch, 20 ft (6.1 m) Leads 7-3556

RPT-28ER Machine Torch, 50 ft (15.2 m) Leads 7-3557

Replacement Machine Torch (PCM) requires Torch Control Cable Adapter 7-3448


6.06 Options and Accessories

Item Qty Description Catalog #

1 Circle Cutting Guide 7-8910

1 Remote Hand Pendant Control with 20 ft. Cable 7-3460

1 Hand Pendant Extension - 25 ft 7-7744

1 Computer Control (CNC) Cable

25 Ft (7.6 m) 8-5557

50 Ft (15.2 m) 8-5558

1 1-3/8" Metal Positioning Tube w/Rack & Pinion Assembly Kit 7-7745

Pinion Assembly

1 Pinion Assembly Only 7-2827

1 1 Torch Holder Sleeve 7-2896

2 1 Pinion Gear-Short 8-6074

3 1 Handwheel (Torch Holder) 9-4514

4 1 Low Profile Torch Holder (1 3/8" Dia) without Hardware 9-4515

5 1 Calibrated Torch Holder Bushing 9-4366

6 1 5/32 Dia x 5/8 Lg Slotted Spring Pin Purchase Locally

7 1 3/8-24 x 3/8Socket Head Set Screw, Cup Point Purchase Locally

8 2 1/4-20 x 5/8 Hex Socket Head Screw Purchase Locally

9 1 #10-24 x 3/8 Hex Socket Set Screw, Cup Point Purchase Locally

1

2

3

4

5

6

7 8

8

9A-02737


6.07 Spare Parts Kit

Qty Description Catalog #

Cutting, Spare Parts Kit , PCH-40, Includes: 5-5055

5 Tip, Air, 0.031" Orifice, Standoff 9-6500

3 Tip, Air, 0.031" Orifice, Drag 9-6501

3 Electrode, Air 9-6506

1 Box, Utility 8-3141

1 Fuse, (0.8 amp, 600V) 9-7526

1 Adapter Fitting 1/4" Hose to 1/4 NPT 8-4264

Manual 0-2751 A-1 APPENDIX

APPENDIX 1: TYPICAL SYSTEM SEQUENCE OFOPERATION BLOCK DIAGRAM

ACTION

ON/OFF switchto OFF

RESULT

All indicators off.Power supply fans off.

ACTION

RUN/SET/LATCHswitch to RUN.

RESULT

Gas flow stops. GAS indicator off.

ACTION

Torch moved within transfer distance of workpiece.

RESULT

Main arc transfer.Pilot arc off.

ACTION

Torch deactivated (by torch switch release or by remote device).

RESULT

Main arc stops.(Power supply enable signal removed.)

Gas flows (15 seconds)

NOTE - If torch is activated duringpost-flow, pilot arc will immediately restart. If torch is within transfer distance (3/8 in) of

workpiece, main arc will transfer.

After post-flow:

Gas solenoid closes, gas flow stops. GAS indicator off.

ACTION

Open external disconnect.

RESULT

No power to system.

ACTION

Close externaldisconnect switch.

RESULT

Power to system.

ACTION

RUN/SET/LATCH switch to SET.

RESULT

Gas solenoid open, gas flows to set pressure.

GAS indicator on.

ACTION

Torch moved away from work (while

still activated).

RESULT

Main arc stops.Pilot arc automatically

restarts.PILOT ARC

ACTION

ON/OFF switchto ON.

RESULT

AC indicator blinks for 8seconds then steady on.

Fans on. Power circuit ready.

ACTION

Protect eyes and activate torch

RESULT

Gas flows (2 seconds).

After gas pre-flow:

DC indicator on. Pilot relay closes.

Pilot arc established

A-02461

LATCH

ACTIONTorch Switch

can be released.

RESULTTransfer will continue until torch is removed

from workpiece.

APPENDIX A-2 Manual 0-2751

APPENDIX 2: CUTTING SPEED CHARTS

Air Plasma Cutting Speed Data ChartType Torch: PCH/M-40 Type Material: AluminumType Plasma Gas: Air Type Secondary Gas: Single Gas Torch

Thickness Tip Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height

Inches mm (Cat. No.) (vdc) (Amps) Inches Meters Inches mm psi bar Plasma Total Delay (Sec) Inches mm

1/16 1.59 9-6500 100 40 280 7.11 0.125 3.18 70 4.8 40 190 0.0 0.188 4.78

1/8 3.18 9-6500 118 40 125 3.18 0.125 3.18 70 4.8 40 190 0.0 0.188 4.78

1/4 6.35 9-6500 124 40 40 1.02 0.125 3.18 70 4.8 40 190 0.5 0.188 4.78

3/8 9.53 9-6500 130 40 20 0.51 0.125 3.18 70 4.8 40 190 1.0 0.250 6.35

1/2 12.70 9-6500 136 40 9 0.23 0.125 3.18 70 4.8 40 190 1.5 0.250 6.35

Air Plasma Cutting Speed Data ChartType Torch: PCH/M-40 Type Material: Mild SteelType Plasma Gas: Air Type Secondary Gas: Single Gas Torch



1/16 1.59 9-6500 110 40 275 6.99 0.125 3.18 70 4.8 40 190 0.0 0.188 4.78

1/8 3.18 9-6500 112 40 75 1.91 0.125 3.18 70 4.8 40 190 0.0 0.188 4.78

1/4 6.35 9-6500 115 40 35 0.89 0.125 3.18 70 4.8 40 190 0.5 0.188 4.78

3/8 9.53 9-6500 117 40 18 0.46 0.125 3.18 70 4.8 40 190 1.0 0.250 6.35

1/2 12.70 9-6500 124 40 10 0.25 0.125 3.18 70 4.8 40 190 1.5 0.250 6.35

Air Plasma Cutting Speed Data ChartType Torch: PCH/M-40 Type Material: Stainless SteelType Plasma Gas: Air Type Secondary Gas: Single Gas Torch



1/16 1.59 9-6500 110 40 275 6.99 0.125 3.18 70 4.8 40 190 0.0 0.188 4.78

1/8 3.18 9-6500 112 40 75 1.91 0.125 3.18 70 4.8 40 190 0.0 0.188 4.78

1/4 6.35 9-6500 114 40 35 0.89 0.125 3.18 70 4.8 40 190 0.5 0.188 4.78

3/8 9.53 9-6500 117 40 18 0.46 0.125 3.18 70 4.8 40 190 1.0 0.250 6.35

1/2 12.70 9-6500 124 40 10 0.25 0.125 3.18 70 4.8 40 190 1.5 0.250 6.35