January 28, 2003 Manual No. 0-2848
PLASMA
CUTTING TORCH
Instruction Manual
For Use With:
• Firepower FP-55 Power Supply
•Model PCH-62 Torch
Read and understand this entire Instruction Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this instruction manual represents our best judgement, Thermal Dynamics Corporation assumes no liability for its use.
Firepower PCH-62 Torch
Instruction Manual Number 0-2848 www.firepoweronline.com
Published by
Thermal Dynamics Corporation 82 Benning Street
West Lebanon, New Hampshire, USA 03784 (603) 298-5711
Copyright 2001 by
Thermal 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 to any party for any loss or damage caused by errors or omissions in the PCH-62 Torch Instruction Manual, whether such errors result from neg- ligence, accident, or any other cause.
Printed in the United States of America January 28, 2003
Record the following information for Warranty purposes:
Where Purchased:_____________________________________
Purchase Date:________________________________________
Power Supply Serial #:_________________________________
Torch Serial #:________________________________________
WARNING
WARNING
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ... 1-1 1.01 Notes, Cautions and Warnings ... 1-1 1.02 Important Safety Precautions ... 1-1 1.03 Publications ... 1-2 1.04 Note, Attention et Avertissement ... 1-3 1.05 Precautions De Securite Importantes ... 1-3 1.06 Documents De Reference ... 1-5 1.07 Declaration of Conformity ... 1-7 1.08 Statement of Warranty ... 1-8 SECTION 2:
INTRODUCTION & DESCRIPTION ... 2-1 2.01 Scope of Manual ... 2-1 2.02 General Description ... 2-1 2.03 Optional Equipment ... 2-1 2.04 Specifications & Design Features ... 2-1 2.05 Introduction to Plasma ... 2-2 SECTION 3:
INSTALLATION PROCEDURES ... 3-1 3.01 Introduction ... 3-1 3.02 Site Location ... 3-1 3.03 Unpacking ... 3-1 3.04 Setting Up Torch ... 3-1 3.05 Connecting Torch ... 3-1 3.06 Gas Connection ... 3-3 SECTION 4:
OPERATION ... 4-1 4.01 Introduction ... 4-1 4.02 Functional Overview ... 4-1 4.03 Getting Started ... 4-1 4.04 Torch Parts Selection ... 4-2 4.05 Cut Quality ... 4-2 4.06 General Cutting Information ... 4-3 4.07 Torch Operation ... 4-4 4.08 Recommended Cutting Speeds ... 4-5
TABLE OF CONTENTS (continued)
SECTION 5:
CUSTOMER/OPERATOR SERVICE ... 5-1 5.01 Introduction ... 5-1 5.02 General Torch Maintenance ... 5-1 5.03 Common Operating Faults ... 5-2 5.04 Inspection and Replacement of Consumable Torch Parts ... 5-2 5.05 Troubleshooting Guide ... 5-3 5.06 Torch & Leads Troubleshooting ... 5-4 5.07 Servicing Torch Components ... 5-6 SECTION 6:
PARTS LISTS ... 6-1 6.01 Introduction ... 6-1 6.02 Ordering Information ... 6-1 6.03 Replacement Torch Parts ... 6-2 6.04 Complete Torch & Leads Assembly Replacement ... 6-2 APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM ... A-1
APPENDIX 2: GENERAL APPLICATION NOTES ... A-2
APPENDIX 3: FirePower 55 SYSTEM DATA ... A-3
Date: 5/1/00 (Special) 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These high- lights are categorized as follows:
NOTE
An operation, procedure, or background informa- tion which requires additional emphasis or is help- ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the oper- ating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN- GEROUS AND HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Per- sons who work near plasma arc cutting applica- tions should consult their medical health profes- sional and the manufacturer of the health equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and follow all warnings, safety precautions and in- structions before using the equipment. Call 1-603- 298-5711 or your local distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any met- als which may contain one or more of the follow- ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the in- formation regarding the kind and amount of fumes and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where com- bustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth de- fects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the op- erator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
GENERAL INFORMATION 1-2 Date 5/1/00 (Special)
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publica- tions.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operat- ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable ma- terial in the workplace. Any material that cannot be removed must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut under- water or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dis- sipated. Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc pro- cesses can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent per- manent loss of hearing.
• To protect your hearing from loud noise, wear pro- tective ear plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the deci- bels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.
• To protect your eyes, always wear a welding hel- met or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro- tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Minimum Protective Suggested Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELD- ING AND GAS WELDING AND CUTTING, ob- tainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
Date: 5/1/00 (Special) 1-3 GENERAL INFORMATION 5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PRO- CESSES, obtainable from American National Stan- dards Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS- TIBLES, obtainable from American Welding Soci- ety, 550 N.W. LeJeune Rd, Miami, FL 33126 8. NFPA Standard 51, OXYGEN-FUEL GAS SYS-
TEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protec- tion Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM- PRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA- PHY obtainable from the National Welding Sup- ply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA- TORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non- respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au person- nel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous
GENERAL INFORMATION 1-4 Date 5/1/00 (Special) les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respi- ration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’ état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres par- ties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de tra- vail est humide ou moite.
• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page 5, article 9.)
• Débranchez l’alimentation électrique avant tout tra- vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières com- bustibles ou provoquer l’explosion de fumées inflammables.
• Soyez certain qu’aucune matière combustible ou in- flammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.
Date: 5/1/00 (Special) 1-5 GENERAL INFORMATION RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-vio- lets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lu- nettes de protection ou une autre sorte de protec- tion oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protec- tion en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protec- tions auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.
• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Docu- ments, U.S. Government Printing Office, Washing- ton, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Super- intendent of Documents, U.S. Government Print- ing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Pro- tection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
GENERAL INFORMATION 1-6 Date 5/1/00 (Special) 9. Norme 70 de la NFPA, CODE ELECTRIQUE
NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Associa- tion), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Bou- levard, Rexdale, Ontario, Canada, M9W 1R3 13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103 14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRA- TIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W.
LeJeune Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC- TION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018
Date: 5/1/00 (Special) 1-7 GENERAL INFORMATION
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation Address: Industrial Park #2
West Lebanon, New Hampshire 03784 USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc- tive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ- ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: Giorgio Bassi Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano (BO) Italy
GENERAL INFORMATION 1-8 Date 5/1/00 (Special)
1.08 Statement of Warranty
LIMITED WARRANTY: Firepower® (hereinafter “Firepower”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Firepower products as stated below, Firepower shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Firepower’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 Firepower’s sole option, of any components or parts of the product determined by Firepower to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Firepower shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Firepower with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Firepower whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY FIREPOWER PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Firepower products shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the following further limitations on such three (3) year period.
FP-55, POWER SUPPLIES PARTS LABOR
MAIN POWER MAGNETICS ... 3 YEARS ... 1 YEAR ORIGINAL MAIN POWER RECTIFIER ... 3 YEARS ... 1 YEAR CONTROL PC BOARD ... 3 YEARS ... 1 YEAR ALL OTHER CIRCUITS AND COMPONENTS ... 1 YEAR ... 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS, POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT... 1 YEAR ... 1 YEAR EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS... 1 YEAR ... 1 YEAR REPAIR/REPLACEMENT PARTS... 90 DAYS ... NONE
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Firepower repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Firepower warranties.
Effective May 5, 2000
Manual 0-2848 2-1 INTRODUCTION
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions and maintenance procedures for the PCH-62 Torch. Ser- vice of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understand- ing of the characteristics and capabilities of this equip- ment will assure the dependable operation for which it was designed.
2.02 General Description
NOTE
Refer to Section 2.05, Introduction to Plasma, for a more detailed description on plasma theory.
The Torch provides cutting capacity of up to 1/2 inch (12.7 mm) at 40 amperes drawn at the power supply.
In the torch, a single torch lead provides compressed air from a single source to be used as both the plasma and secondary gas. The air flow is divided inside the torch head. Single-gas operation allows for a smaller sized torch and inexpensive operation.
Plasma torches are similar in design to the common au- tomotive spark plug. They consist of negative and posi- tive sections which are separated by a center insulator.
Inside the torch, the pilot arc is initiated in the gap be- tween the negatively charged electrode and the positively charged tip. Once the pilot arc has ionized the plasma gas, the superheated column of gas flows through the small orifice in the torch tip, which is focused on the metal to be cut.
2.03 Optional Equipment
A. Stand-off Cutting Guide
Simple, push-on guide attachment to allow for torch dragging without risk of touching tip. See Section 6 for catalog number.
2.04 Specifications & Design Features
Refer to Appendix Pages for additional specifications.
A. Torch Configuration and Dimensions
The torch head is at 70° to the torch handle. The torch includes an ergonomic torch handle and torch trigger assembly.
3.0 in (76.2 mm) 10.5 in
(267 mm)
A-02956
1.1in (28 mm)
Figure 2-1 Torch Dimensions
B. Torch Leads Length
Hand Torch: 20 ft (6.1m)
C. Torch Parts
Gas Distributor, Electrode, Tip, Shield Cup
D. Parts-In-Place (PIP)
Torch Head has built-in contacts. 12vdc circuit rating.
E. Type of Cooling
Combination of ambient air and gas stream through torch
F. Torch Ratings
Ambient Temperature
104° F (40° C)
Duty Cycle 100% @ 60 Amps @ 375 scfh
Maximum Current 60 Amps
Voltage (Vpeak) 500V Arc Striking Voltage 12 kV
Torch Ratings
G. Plasma Power Supply Used With
• Firepower FP-55 Power Supply
H. Direct Contact Hazard
For exposed tip the recommended standoff is 1/8" - 3/8" (3 -9.5 mm)
INTRODUCTION 2-2 Manual 0-2848
2.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes elec- trically conductive. The plasma arc cutting and goug- ing processes use this plasma to transfer an electrical arc to the workpiece. The metal to be cut or removed is melted by the heat of the arc and then blown away.
While the goal of plasma arc cutting is separation of the material, plasma arc gouging is used to remove metals to a controlled depth and width.
In a Plasma Cutting Torch a cool gas enters Zone B (refer to Figure 2-2), where a pilot arc between the electrode and the torch tip heats and ionizes the gas.
The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C.
;;
;;
;;
;
;
;
;
;
;;
;;
A-00002
Workpiece Power
Supply + _
C
B A
Figure 2-2 Typical Torch Head Detail
By forcing the plasma gas and electric arc through a small orifice, the torch delivers a high concentration of heat to a small area. The stiff, constricted plasma arc is shown in Zone C (Figure 2-2). Direct current (DC) straight polarity is used for plasma cutting, as shown in the illustration.
Zone A (Figure 2-2) is used as a secondary gas that cools the torch. This gas assists the high velocity plasma gas in blowing 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 secondary gases.
The plasma gas flows into the torch through the nega- tive lead, through the gas distributor, around the elec- trode, and out through the tip orifice.
The secondary gas flows down around the outside of the torch gas distributor, and out between the tip and shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established be- tween the electrode and cutting tip. This pilot arc cre- ates a path for the main arc to transfer to the work.
D. Capacitive Discharge (CD)
Because direct current (DC) alone is not sufficient to strike and maintain the pilot arc, capacitive discharge is also used. The high voltage jumps between the tip and electrode with the DC following.
E. Main Cutting Arc
DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead. The positive output is con- nected to the workpiece via the work cable and to the torch through a pilot wire.
F. Interlocks
One pressure switch acts as an interlock for the gas supply. If supply pressure falls below minimum re- quirements the pressure switch will open, shutting off the DC power, and the GAS Indicator will go off.
When adequate gas supply pressure is available the pressure switch will close, allowing power to be re- sumed for cutting.
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 inside the shield cup when the shield cup is in- stalled. The torch will fail to operate if these contacts are not made.
A-03540
Torch Trigger
PIP Pins Shield Cup To Control
Cable Wiring
Torch Switch
Figure 2-3 Parts-In-Place (PIP) Diagram
Manual 0-2848 3-1 INSTALLATION
SECTION 3:
INSTALLATION
3.01 Introduction
This section describes installation of the Torch. These instructions apply to the Torch and Leads Assemblies only.
Installation procedures for the Power Supply, Options and Accessories are provided in Manuals specifically pro- vided for those products.
The complete installation consists of:
• Site Selection
• Unpacking
• Setting Up Torch
• Connecting Torch
• 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 manual to be sure that the location meets all safety requirements.
3.03 Unpacking
Each component of the system is packaged and protected with a carton and packing material to prevent damage during shipping.
1. Unpack each item and remove any packing material.
2. Locate the packing list(s) and use the list to identify and account for each item.
3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping company before proceeding with system installation.
3.04 Setting Up Torch
The torch is factory assembled to the Power Supply and requires no special set up. The proper torch parts (shield cup, tip, gas distributor, and electrode) must be installed for the type of operation. Refer to Section 4.04, Torch Parts Selection for more information.
3.05 Connecting Torch
NOTE
Equipment ordered as a system will have the Torch factory connected to the Power Supply.
The Torch Leads must be properly installed to the Power Supply for proper operation. If the torch leads were not factory-installed, make all torch connections to the Torch Bulkhead Panel.
WARNING
Disconnect primary power at the source before dis- assembling the torch or torch leads.
A. Cover Removal
1. Remove the upper screws which fasten the cover to the main assembly.
A-02776
Lower screws
Upper screws
Ground wire
Figure 3-1 Cover Removal NOTE
There is a ground wire connection to the inside of the unit. There is no need to disconnect the ground wire, unless there is a need for more room to work.
INSTALLATION 3-2 Manual 0-2848 2. Loosen, but do not remove, the four lower screws,
then carefully pull the Cover up and away from the unit to gain access to the inside of the unit.
3. To reinstall the cover, complete the following:
a. Reconnect the ground wire, if necessary.
b. Place the cover onto the frame so that it rests on the four lower screws.
c. Tighten lower screws.
d. Reinstall and tighten the four upper screws.
B. Torch Connection
1. Remove the retaining nut from the Strain Relief.
Strain Relief Nut Strain Relief Torch Leads
Assembly
A-03529
Negative / Plasma Lead
Pilot Lead
Figure 3-2 Retaining Nut Removal
2. Feed the torch lead ends and the Strain Relief into the hole in the unit.
3. Secure the Strain Relief with the retaining nut re- moved earlier.
4. Connect the torch Negative/Plasma Lead to the bulkhead connection inside the Power Supply.
Adapter Plug
Pilot Lead Torch Lead
Assembly
Negative/Plasma Lead Adapter
Connector Pilot Lead Stud
Negative/Plasma Lead Connection
A-03527
Control Circuit Connectors Note: Actual Bulkhead configuration may differ from that shown.
Figure 3-3 Torch Lead Connections
5. Connect the PIP Cables to the mating connectors on the Adapter supplied on the Power Supply.
6. Remove the top nut and washer from the Pilot Stud.
7. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed in the above Step.
8. Tighten the Strain Relief onto the Torch Leads.
9. Check the torch for proper parts assembly.
CAUTION
The torch parts must correspond with the type of operation. Refer to Section 4.04, Torch Parts Se- lection.
10. Re-install the Power Supply cover.
Manual 0-2848 3-3 INSTALLATION
3.06 Gas Connection
A. Connection
Connect the gas, compressed air only, to the Power Supply as described in the Manual provided with the Power Supply.
CAUTION
Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause double-arcing, rapid tip wear, or even com- plete torch failure. Contaminants may cause poor cutting performance and rapid electrode wear.
B. Checking Air Quality
To test the quality of air, place a welding filter lens in front of the torch and turn on the gas. Any oil or mois- ture in the air will be visible on the lens. Do not ini- tiate an arc!
C. Filtering
An in-line pneumatic dryer/evaporator type air fil- ter, capable of filtering to at least 5 microns, is required when using air from a compressor. This type filter will insure that moisture, oil, dirt, chips, rust particles, and other contaminants from the supply hose do not enter the torch. For highly automated applications, a refrigerated drier may be used.
INSTALLATION 3-4 Manual 0-2848
Manual 0-2848 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 Firepower FP-55 Power Supply to provide a plasma cutting sys- tem which can cut most metals from gauge thickness up to 1/2 inch (12.7 mm). Refer to Appendix Pages for additional information.
4.03 Getting Started
This procedure should be followed at the beginning of each shift:
WARNING
Disconnect primary power at the source before as- sembling or disassembling power supply, torch parts, or torch and leads assemblies.
A. Torch Parts
Check that torch is properly connected and assembled.
Install proper torch parts for the desired application (refer to Section 4.04, Torch Parts Selection).
B. Input Power
Check the power source for proper input voltage.
Close main disconnect or plug the unit in to supply primary power to the system.
C. Work Cable
Check for a solid work cable connection to the workpiece.
D. Gas Supply
Select desired single gas supply. Make sure gas sources meet requirements (see Note). Check connec- tions and turn gas supply on.
NOTE
Refer to Appendix Pages for additional informa- tion.
E. Power On
Place the ON/OFF Switch on the Power Supply to the ON position. If the RUN/SET switch is in SET position, gas will flow. If the switch is in RUN posi- tion there will be no gas flow.
F. RUN/SET Switch
If the RUN/SET switch is in SET position, gas will flow. If the switch is in RUN position there will be no gas flow.
G. Current Output Level
At the Power Supply, set the desired current output level between 20 - 40 amps for cutting or gouging.
H. Pressure Setting
Place the RUN/SET switch to the SET position. Ad- just the gas pressure control on the Power Supply for the proper gas pressure (see Note).
NOTE
Refer to Appendix Pages for additional informa- tion.
I. Ready for Operation
Return the RUN/SET switch to RUN position.
NOTES
For general cutting, use the RUN position which provides normal torch operation where the torch switch must be held throughout the main arc trans- fer.
Refer to Appendix 1 for a typical detailed block dia- gram of Sequence of Operations.
The system is now ready for operation.
Press the Torch Trigger to initiate the pilot arc. There is a 2 second pre-flow before the arc starts.
OPERATION 4-2 Manual 0-2848
4.04 Torch Parts Selection
The type of power supply and the type of operation to be performed determine the torch parts to be used:
Type of operation:
Drag cutting or standoff cutting Torch parts:
Shield Cup, Cutting Tip, Electrode and Gas Dis- tributor
NOTE
Refer to Appendix Pages for additional informa- tion.
To change the torch parts use the following procedure:
NOTE
The tip and gas distributor are held in place by the shield cup. Position the torch with the Shield cup facing upward to prevent these parts from falling out when the cup is removed.
1. Unscrew and remove the shield cup from the torch head.
Torch Head Assembly
Shield Cup DistributorGas
Tip Electrode
A-03006
O-ring
Canted Spring
Figure 4-1 Torch Parts
2. Tilt the torch head to remove the tip and gas distribu- tor.
3. Remove the SureLok Electrode by pulling it straight out of the Torch Head.
4. Install the desired SureLok Electrode by pushing it straight into the torch head until it clicks.
5. Install the desired gas distributor and tip for the op- eration into the torch head.
6. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.
4.05 Cut Quality
NOTES
Cut quality depends heavily on set-up and param- eters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and op- erator ability.
Refer to Appendix Pages for additional informa- tion.
Cut quality requirements differ depending on applica- tion. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning opera- tion. The following cut quality characteristics are illus- trated in the following figure.
Kerf Width
Cut Surface Bevel Angle
Top Edge Rounding
Cut Surface Drag Lines Dross
Build-Up Top Spatter
A-00007
Figure 4-2 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 cut when nitrogen is present in the plasma gas stream.
These build-ups may create difficulties if the material is to be welded after the cutting process.
C. Bevel Angle
The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A per- fectly perpendicular cut would result in a 0° bevel angle.
D. Top-Edge Rounding
Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the work- piece.
Manual 0-2848 4-3 OPERATION
E. Bottom Dross Build-up
Molten material which is not blown out of the cut area and re-solidifies on the plate. Excessive dross may require secondary clean-up operations after cutting.
F. Kerf Width
The width of the cut (or the width of material removed during the cut).
G. Top Spatter (Dross)
Top spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose orifice has become elongated.
4.06 General Cutting Information
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, eye and ear protection. Make sure no part of the operator’s body comes into contact with the work- piece while the torch is activated.
Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.
Handle torch leads with care and protect them from damage.
A. Piloting
Piloting is harder on parts life than actual cutting be- cause the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever pos- sible, avoid excessive pilot arc time to improve parts life.
B. Torch Standoff
Improper standoff (the distance between the torch tip and workpiece) can adversely affect tip life as well as shield cup life. Standoff may also significantly affect the bevel angle. Reducing standoff will generally re- sult in a more square cut.
C. Edge Starting
For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touch- ing) the edge of the workpiece at the point where the
cut 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 as quickly as possible.
D. Direction of Cut
Inside the torch, the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas.
This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.
Right Side Cut Angle Left Side
Cut Angle
A-00512
Figure 4-3 Side Characteristics of Cut
To make a square-edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clock- wise direction.
E. Dross
When dross is present on carbon steel, it is commonly referred to as either “high speed dross", "slow speed dross", or "top dross”. Dross present on top of the plate is normally caused by too great a torch-to-plate distance. "Top dross" is normally very easy to remove and can often be 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 not adhere tightly to the cut edge, and can be easily scraped off. "High speed dross" usually forms a narrow bead along the bottom of the cut edge and is very difficult to remove. When cutting a troublesome steel, it is sometimes useful to reduce the cutting speed to produce "slow speed dross". Any resultant cleanup can be accomplished by scraping, not grinding.
OPERATION 4-4 Manual 0-2848
4.07 Torch Operation
A. Standoff Cutting
NOTE
For best performance and parts life, always use the correct parts for the type of operation.
1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows 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 the following:
a. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip on the edge of the workpiece at the point where the cut is to start.
b. For standoff cutting, hold the torch 1/8 - 3/8 in (3-9 mm) from the workpiece as shown be- low.
A-00024
Shield Cup Torch
Standoff Distance 1/8" - 3/8"
Figure 4-4 Standoff Distance
3. With the torch in starting position, press and hold the Torch Trigger. After an initial two second pre- flow, the pilot arc will come on and remain on until the cutting arc starts.
4. Once on, the main arc remains on as long as the Torch 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 comes back on automatically.
5. To shut off the torch simply release the Torch Trig- ger. When the trigger is released a gas post-flow will occur. If the Torch Trigger is pushed during the post-flow, the cutting arc will restart immedi- ately when the torch is brought within range of the workpiece.
B. Standoff Cutting Guide With Straight Edge
The Standoff Cutting Guide (option with some sys- tems) can be used with a non-conductive straight edge to make straight cuts by hand.WARNING
The straight edge must be non-conductive.
Non-Conductive Straight Edge Cutting Guide Standoff Cutting Guide
Torch
A-02792
Shield Cup
Figure 4-5 Using Standoff Cutting Guide With Straight Edge
The guide functions best when cutting 3/16 inch (4.7 mm) or greater solid metal with relatively smooth surfaces. Use drag cutting for thinner metal.
C. Drag Cutting
Drag cutting works best on metal 3/16" (4.7 mm) thick or less.
NOTE
For best parts performance and life, always use the correct parts for the type of operation.
Manual 0-2848 4-5 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 or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the holding technique that feels most comfortable and allows 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 second pre-flow, the pilot arc will come on and remain on until the cutting arc starts.
5. Once on, the main arc remains on as long as the Torch Trigger is held down, unless the torch is withdrawn from the work or torch motion is too slow. If the cutting arc is interrupted, the pilot arc comes back on automatically.
6. To shut off the torch simply release the Torch Trig- ger. When the Trigger is released a gas post-flow will occur. If the Torch Trigger is pushed during the post-flow, the cutting arc will restart immedi- ately when the torch is brought within range of the workpiece.
D. Piercing
1. The torch can be comfortably held in one hand or steadied with two hands. Position the hand to press the Trigger on the torch handle. With the hand torch, the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection. Choose the technique that feels most comfortable and al- lows good 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) rather than directly back into it until the pierce is com- plete.
3. In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line. Hold the torch perpendicular to the work- piece after the pierce is complete.
4. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying the shield cup in anti-spatter compound will minimize the amount of scale which adheres to it.
4.08 Recommended Cutting Speeds
Cutting speed depends on material, thickness, and the operator’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 NOTES
This information represents realistic expectations using recommended practices and well-maintained systems. Actual speeds may vary up to 50% from those shown.
Refer to Appendix Pages for cutting speed chart information as related to the Power Supply used.
OPERATION 4-6 Manual 0-2848
Manual 0-2848 5-1 SERVICE
SECTION 5:
SERVICE
5.01 Introduction
This section describes basic maintenance procedures per- formable by operating personnel. No other adjustments or repairs are to be attempted by other than properly trained personnel.
WARNINGS
Disconnect primary power at the source before dis- assembling the torch or torch leads.
Frequently review the Important Safety Precau- tions (Section 1). Be sure the operator is equipped with proper gloves, clothing, eye and ear protec- tion. Make sure no part of the operator’s body comes into contact with the workpiece while the torch is activated.
Sparks from the cutting process can cause damage to coated, painted, and other surfaces such as glass, plastic and metal.
Handle torch leads with care and protect them from damage.
5.02 General Torch Maintenance
A. Cleaning Torch
Even if precautions are taken to use only clean air with a torch, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch.
WARNINGS
Disconnect primary power to the system before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
The inside of the torch should be cleaned with electri- cal contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air.
Refer to Section 5.07 for disassembling the Torch and Leads Assembly.
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 does not provide adequate resistance, current which is in- tended for the pilot arc may be dissipated into the torch head, resulting in torch failure.
WARNINGS
Disconnect primary power to the system before disassembling the torch or torch leads.
DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON.
1. Remove the shield cup, tip, gas distributor, and electrode from the torch. Disconnect the torch leads from the power supply to isolate the torch from power supply circuits.
2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch fittings. Infinite resistance (no continuity) should be found. If continuity is found, refer to subsection 5.06, Torch and Leads Troubleshooting.
C. O-Ring Lubrication
The external o-ring on the Torch Head Assembly (shield cup) requires lubrication on a scheduled ba- sis. This will allow the o-ring to remain pliable and provide a proper seal. The o-ring will dry out, be- coming hard and cracked, if the o-ring lubricant is not used on a regular basis. This can lead to potential leaks of the secondary gas around the end of the shield cup.
It is recommended to apply a very light film of o-ring lubricant (Catalog # 8-4025) to the o-ring on a weekly basis.
NOTE
DO NOT use other lubricants or grease, they may not be designed to operate within high tempera- tures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.
SERVICE 5-2 Manual 0-2848
5.03 Common Operating Faults
These 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 Firepower Parts used 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
f. Non-Genuine Firepower Parts used 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 Firepower Parts used 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
f. Non-Genuine Firepower Parts used
5.04 Inspection and Replacement of Consumable Torch Parts
WARNINGS
Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while primary power is connected.
Remove the consumable torch parts per the following procedure:
NOTE
The tip and gas distributor are held in place by the shield cup. Position the torch with the shield cup facing upward to prevent these parts 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 be re- moved may affect the performance of the system.
2. Inspect the cup for damage. Wipe it clean or replace if damaged.
Torch Head Assembly
Shield Cup DistributorGas
Tip Electrode
A-03006
O-ring
Canted Spring
Figure 5-1 Front End Torch Parts Assembly 3. Remove the tip. Check for excessive wear (indicated
by an elongated or oversized orifice). Clean or re- place the tip if necessary.
Manual 0-2848 5-3 SERVICE
Good Tip Worn Tip
A-00942
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 SureLok Electrode by pulling it straight out of the torch head. Refer to the following figure and check the face of the electrode for excessive wear.
Worn Electrode New Electrode
A-02794
Figure 5-3 Electrode Wear
6. Reinstall the SureLok electrode into the torch head by pushing it straight into the torch head until it clicks.
7. Reinstall the gas distributor and tip into the torch head.
8. Hand tighten the shield cup until it is seated on the torch head. If resistance is felt when installing the cup, check the threads before proceeding.
5.05 Troubleshooting Guide
This subsection covers troubleshooting that requires dis- assembly and electronic measurements. It is helpful for solving many of the common problems that can arise with this torch assembly.
How to Use This Guide
The following information is a guide to help the Cus- tomer/Operator determine the most likely causes for various 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 unit is fully operational after any repairs.
Troubleshooting
A. Torch will not pilot when torch switch is activated
1. Power Supply RUN/SET switch in SET position a. Place switch to RUN position.
2. Parts-In-Place (PIP) not satisfied
a. Check canted coil spring inside shield cup.
3. Faulty torch switch a. Check continuity.
4. Faulty torch parts
a. Inspect torch parts and replace if necessary. Re- fer to subsection 5.04, Inspection and Replace- ment Consumable Torch Parts.
5. Gas pressure too high
a. Set proper operating gas pressure 6. Faulty components in torch and leads assembly.
a. Inspect torch assemblies and replace if neces- sary. Refer to subsection 5.06, Torch and Leads Troubleshooting.
7. Faulty components in power supply system compo- nents
a. Return for repair or have qualified technician repair per Service Manual.
B. No cutting output
1. Torch not properly connected to power supply a. Check that torch leads are properly attached to
power supply.
2. Shield cup not properly installed on torch
a. Check that shield cup is fully seated against torch head (do not overtighten).
3. Parts-In-Place (PIP) not satisfied
a. Check canted coil spring inside shield cup.
SERVICE 5-4 Manual 0-2848 4. Faulty components in torch and leads assembly
a. Inspect torch assemblies and replace if neces- sary. Refer to subsection 5.06, Torch and Leads Troubleshooting.
5. Faulty components in power supply system
a. Return for repair or have qualified technician repair per Service Manual.
C. Limited cutting output with no control
1. Poor input or output connections to power supply a. Check all input and output connections.
2. Faulty components in torch and leads assembly a. Inspect torch assemblies and replace if neces-
sary. Refer to subsection 5.06, Torch & Leads Troubleshooting.
3. Faulty components in power supply system
a. Return for repair or have qualified technician repair per Power Supply Service Manual.
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 for
suggested cutting speeds).
4. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not activate torch)
E. No gas flow
1. Gas not connected or pressure too low
a. Check source for proper operating gas pressure (refer to Appendix Page for proper gas pres- sure setting).
2. Faulty components in torch and leads assembly a. Inspect torch assemblies and replace if neces-
sary. Refer to subsection 5.06, Torch and Leads Troubleshooting.
3. Faulty components in power supply system
a. Return for repair or have qualified technician repair per Power Supply 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 Page
for the Power Supply being used).
3. Excessive oil or moisture in torch
a. Hold torch 1/8 inch (3 mm) from clean surface while purging and observe oil or moisture buildup (do not activate torch).
5.06 Torch & Leads Troubleshooting
A. General Information
Failures in the Torch & Leads can be isolated to the Torch Head or Torch Lead components. To properly isolate the failed part requires the use of an ohmmeter and a Hi-Pot Tester.
WARNING
The use of a Hi-Pot Tester should be performed only by 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 dissipated into the torch head, resulting in torch failure.
In the Torch Leads the negative and positive leads are isolated 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 the Torch Head or Torch Lead components using an ohm- meter.
The actual assembly and consumables may vary for dif- ferent torches but the basic procedure is the same for all torches. Make the quick check on the Torch Head and Leads per the following procedure: