Miller | JJ518269 | Owner Manual | Miller QUICK CUT 5000 User manual

Miller QUICK CUT 5000 User manual
AUTO ARC)~
January
1989
FORM:OM.143 527
Effe ctlve Witii Seria
No. JJ5I 8269
MODEL: QUICK CUTTM
OWNERS.
MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with
special emphasis on the safety material throughout the manual, before
installing, operating, or maintaining this equipment. This unit and these
instructions
only by persons trained and experienced in the safe
operation of welding equipment. Do not allow untrained persons to install,
operate, or maintain this unit. Contact your distributor if you do not fully
are
for
use
5000
MILLER ELECTRIC
A Miller
Mfg. Co.
Group Ltd., Company
P0 Box 1079
Appleton,
WI 54912 USA
Tel. 414-734-9821
understand these instructions.
TC-125 647
PRINTED IN U.S.A.
ERRATA SHEET
After this manual
to data
was
printed, refinements
appearing
equipment design occurred. This
ot Sections 2-4 and 3-2, and also before
beginning
Add the following CAUTION at the
A~
In
CAUTION: INCORRECT PLASMA GAS
Use
only
Do not
air
use
or
can cause
any other gas
Step
torch and power source
2 of Section 5-1.
damage.
-
combination of gases.
or
INTRODUCTION
Specifications
Table 2-1.
SpecifIcations
input At
Rated Output
At 40%
Duty Cycle
Maximum
Open-
~
Rated Load Output
50/60 HZ Sin~–hase
Amperes
115V
30 Amperes
At
120 Volts DC
Add Section 2-5.
exceptions
nitrogen for the plasma gas supply.
AMENDMENT TO SECTION 2
Amend Table 2-1.
sheet lists
later In this manual.
I
Plasma Gas
Air Or Nitrogen Onl~
At
KVA
230V
KW
Flow/Pressure
I
370 Volts
DC
Weight
Net
Ship
2.8 CFM
33
38
7.6
4.6
(79 L/min.)
52 lbs.
56 lbs.
At 50 PSI
(24 kg)
(25 kg)
(345 kPa)
Cutting Speed (Chart 2-1)
cutting speed chart enables the operator to determine the maximum cutting speed for various thickness of mrld
capabilities of the power source. The curve indicates the proper speeds at which cutting may be dcne.
indicated may not be achieved instantaneously. Cutting may have to begin at a slower speed w~trt
the
speeds
although
an increase in speed until the optimum speed is reached. Cutting at speeds above the proper speeds shown by the
curve will cause rapid erosion of the tip and electrode and should be avoided.
The
steel within the
CAUTION: EXCEEDING RECOMMENDED CUTTING SPEEDS will
electrode.
cause
rapid erosion of the tip
Do not exceed indicated cutting speeds.
Add Chart 2-1.
Cutting Speed
Chart 2-1.
CuttIng Speed
90
z
(2.31
z
80
(1.5)
z
d
LU
0,
0
30
(0.8)
I
I,
I
I
20
12
3/18
(CAGe)
I
~
.I0(2.~1
PLATE
1/4
3/8
ll~ ~
.20(~.I)
.30(7.61
THIC~(NESS. IN. (MM)
.i.0(I0.2)
SB.lr
~
and
AMENDMENT TO SECTION 6- MAINTENANCE & TROUBLESHOOTING
Amend Section 6-5C. OVERLOAD PROTECTION: Air Pressure Switch
Air Pressure Switch
C.
To prevent damage to the torch due to insufficient air pressure, this unit is protected by air pressure switch S5 located in
pressure/regulator. Should air pressure drop below a preset value, S5 would close, the READY light would turn
the air
ott, and the unit would be completely inoperative. Should the READY light be turned on, check airfilterlregulator and air
compressor (see Table 6-2. Troubleshooting).
Add Section 6-9. SHIELD CUP DETECTOR PIN INSPECTION
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn off power source, and
remove
input power plug from receptacle before inspecting, maintaining.
servicing.
or
HOT SURFACES
Allow
can cause severe
burns.
cooling period before servicing.
Each time the shield cup is removed from the torch, check that the shield cup detector pins move freely. If there is diii
around the pins, clean pins with electrical contact cleaner, and recheck lorfree movement, lilt becomes necessary to
replace the torch body or pin assembly, contact the nearest Factory Authorized Service Station.
AMENDMENT TO SECTION 7- ELECTRICAL DIAGRAMS
Amend
Diagram
7-1. Circuit
Diagram (see Page
3
on
this Errata
Sheet)
Add
Diagram
7-2. Circuit
Diagram
For Driver Board PC2 (see
Add
Diagram
7-3. Circuit
Diagram
For Transformer Control Board PC3 (see
Add
Diagram
7-4. Circuit
Diagram For Filter Board PC4 (see Page 5
Add
Diagram 7-5. Circuit Diagram
For
Page
4 on this Errata
on
Page
5
Sheet)
on
this Errata Sheet)
this Errata Sheet)
High Frequency Board PC5 (see Page
6 on this Errata
Sheet)
AMENDMENT TO SECTION 9- PARTS LIST
Amend Parts List
Dia.
Mkgs
as
follows:
Part
No.
Replaced
With
Description
25-31
125 125
Deleted
Item not available as an
25-35
125 126
125 114
125 123
Deleted
Deleted
Deleted
Deleted
126 797
125 175
125 056
125181
130 286
130 285
130 031
130032
Item not available as an
Item not available as an
Item not available as an
25-36
25-38
25-39
2527-1
27-3
iT
27-13
Torch
Work
31-4
First
125 121
125 030
125 175
125 056
125181
125 068
Item not available as an
TORCH. APT-3000
assembly
assembly
assembly
assembly
assembly
TERMINAL, (addeddiamkg)
FITTING. (added dia mkg)
.
TERMINAL,(addeddiamkg)
TORCH BODY, (consisting of) (Eff w/JK634462)
DETECTIVE PIN KIT, (consisting of)
INSULATING COVER
SCREW
digit represents page no digits following dash represent item no.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS
OM-296
-
Page
2
OU3r~V
063-B
~1 D~
9
PS ,
-.0
IT
SC125
No.
Diagram
Circuit
i~i~
~
~
~
ii
~
!
~
A
TMI
PS
!f!
~
Diagr m
Circuit
7-1.
Diagr m
644
29
SC-i
No.
Diagram
Circuit
PC2
Board
Driver
For
Diagram
Circuit
7-2.
DIagr m
0
-o lQ
CN6 -3
CN2 -3
CNI -f
CN9- I
CN3 -3
CN4 -3
CNI -3
CN5-3
CN8- I
CN2- I
CN8-2
CN3- I
CN7- I
CN4- I
CN7-3
CN5- I
CN6- I
Circuit
Diagram
No. SA-1 29 636
Diagram 7-3. CircuIt Diagram For Power Distribution Board PC3
3<
Ri
L2
C2
>2
C3
Cl
4
CN I
CNS
7
5
3
3
CN3
L7
L8
Circuit
Diagram
7-4. CircuIt
Diagram
Diagram
No. SA-129 638
For Filter Board PC4
OM Y~...
~e 5
4
c~
C6
EI(
OTB?
ct4I
3
1B2
Circuit
DIagram
OM-296
Page
6
7-5. CircuIt
Diagram
For
High Frequency
Diagram
Board PC5
No. SA1
29 639
TABLE OF CONTENTS
Page
Section No.
SECTION 1
-
No.
SAFETY RULES
1
1-1.
Introduction
1-2.
General Precautions
1-3.
Arc
1-4.
Standards Booklet Index
1
4
Welding
5
SECTION 2-INTRODUCTION
7
2-1.
Duty Cycle
2-2.
General Information And
2-3.
2-4.
7
Safety
8
Receiving-Handling
Description
8
SECTION 3INSTALLATION
3-1.
Location
8
3-2.
Air
Filter/Regulator Installation And Connections
Input Voltage Changeover Switch
Electrical Input Connections
8
3-3.
3-4.
9
9
SECTION 4- OPERATOR CONTROLS
4-1.
Power Switch/Breaker And Power On
4-2.
Ready Light
11
4-3.
Metal Switch
11
4-4.
Thickness Control
11
4-5.
Gas/Air Switch
11
4-6.
Trigger
Light
Hold Switch
11
11
SECTION 5- SEQUENCE OF OPERATION
5-1.
5-2.
5-3.
Plasma Arc Cutting (PAC)
Cutting Problems And Recommendations
Shutting Down
12
13
13
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
Routine Maintenance
13
6-2.
Shield
14
6-3.
Torch And
6-4.
Spark Gap
16
6-5.
Overload Protection
16
6-6.
Safety
6-7.
Circuit Board
6-8.
Cup. Tip,
And Electrode
Inspection And Replacement
Work Lead Inspection And Connections
Shutdown Devices
Handling
Troubleshooting
Precautions
15
16
17
17
SECTION 7- ELECTRICAL DIAGRAMS
Diagram
7-1. Circuit
Diagram
19
28
27
26
24
Section No.
Page
SECTION 8- PLASMA ARC CUTTING
8-1.
General
8-2.
Definitions
(PAC) INSTALLATION GUIDELINES
20
20
Radiation
8-3.
High-Frequency
8-4.
Location
8-5.
General Installation Procedures
8-6.
Guidelines For Installation Of Plasma Arc
Power Sources
8-7.
Installation Guidelines Checklist
SECTION 9
21
21
21
Cutting (PAC)
22
23
PARTS LIST
Figure
9-1. Main
Figure
Figure
Figure
Figure
Figure
Figure
9-2.
9-3.
9-4.
Assembly
Capacitor Assembly
Terminal Assembly, Output
Front Panel Assembly
.
9-5. Pilot Unit
9-6. Rectifier
29
Assembly
9-7. Torch, Model APT-3000
30
31
LIST OF CHARTS AND TABLES
Table 2-1.
Specifications
7
Table 6-1. Maintenance Schedule
13
Table 6-2.
18
Troubleshooting
No.
SECTION 1
INTRODUCTION
1-1.
by experience. Learning safety through per
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of
others teach you.
We learn
Safe practices developed from experience in the use of
and cutting are described in this manual. Re
search, development, and field experience have
evolved reliable equipment and safe installation, opera
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The rea
son for the safe practices may not always be given.
welding
Some
are
based
on common sense,
technical volumes to
explain.
others may
require
It is wiser to follow the
SAFETY RULES
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1 -3A.2.
Avoid
oily
or
greasy
clothing.
A
spark may ignite
Hot metal such as electrode stubs and
should never be handled without gloves.
them.
workpieces
Medical first aid and eye treatment. First aid facilities
and a qualified first aid person should be available for
each shift unless medical facilities are close by for im
mediate treatment of flash burns of the eyes and skin
burns.
should be worn when working on overhead or
confined space. A hard hat should be worn when
others work overhead.
Ear
in
plugs
a
rules.
Flammable hair preparations should not be used by per
Read and understand these safe practices before at
tempting to install, operate, or service the equipment.
sons
Comply with these procedures as applicable to the par
ticular equipment used and their instruction manuals, for
personal safety and for the safety of others.
Failure to observe these safe practices may cause seri
injury or death. When safety becomes a habit, the
equipment can be used with confidence.
ous
B.
intending
to weld or cut.
Toxic Fume Prevention
Severe discomfort, illness
or
death
can
result from
fumes, vapors, heat,
oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent them
with adequate ventilation as described in ANSI Stan
dard Z49.1 listed in Standards index. NEVER ventilate
or
with oxygen.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut
ting; and 2-Arc Welding (and Cutting) (only).
Lead -, cadmium -, zinc -, mercury-, and beryllium-bear
ing and similar materials, when welded (or cut) may pro
duce harmful concentrations of toxic fumes. Adequate
Reference standards: Published Standards on safety
are also available for additional and more complete pro
cedures than those given in this manual. They are listed
local exhaust ventilation must be used, or each person
in the area as well as the operator must wear an air-sup
in the Standards Index in this manual. ANSI Z49.1 is the
Metals coated with or containing materials that emit
toxic fumes should not be heated unless coating is re
moved from the work surface, the area is well ventilated
and, if necessary, while wearing an air-supplied respira
most
complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements
also
provide
a
basis for
equip
use, and service.
ment
installation,
1-2.
GENERAL PRECAUTIONS
plied respirator. For beryllium, both
must be used.
tor.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira
tor.
DIfferent arc welding processes, electrode alloys,
and fluxes can produce dIfferent fumes, gases, and
radiatIon levels. in addItion to the Information In
this manual, be sure to consult flux and electrode
Material
manufacturers
Safety Data Sheets
(MSDSs)
for
specific technical data and precautIon
concerning their material.
ary
measures
A.
Burn PreventIon
protective clothing-gauntlet gloves designed for
welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffiess trousers
to avoid entry of sparks and slag.
Wear
use
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving
confined space, shut OFF gas supply at source
possible accumulation of gases in the space if
downstream valves have been accidentally opened or
left open. Check to be sure that the space is safe before
to prevent
re-entering it.
in
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod
ucts. The ultraviolet (radiant) energy of the arc can also
decompose tnchloroethylene and perchioroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
OM-296
Page
1
atmosphere or where the radiant energy can penetrate
atmospheres containing even minute amounts of
to
trichioroethylene
C.
Fire and
or
perchioroethylene.
Explosion
ment as recommended in A6.O.
level may substitute for
working
Watertilling just below
inerting.
A container with unknown contents should be cleaned
Prevention
(see preceding paragraph). Do NOT depend on sense
or sight to determine if it is safe to weld or cut.
of smell
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate
rial; misuse of
short circuits.
compressed
gases and
cylinders;
and
BE AWARE ThAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
(in electrical parts) of metallic particles that can
and
short circuits.
cause
Hollow
welding
castings or containers must be vented before
or cutting. They can explode.
Explosive atmospheres. Neverweld orcut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
0.
Compressed
Gas
EquIpment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-i, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN
DERS, listed 11 in Standards Index.
1.
Pressure
Regulators
relief valve is
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, venti
fators. if the work cannot be moved, move combustibles
at least 35 feet away out of reach of sparks and heat; or
protect against ignition with suitable and snug-fitting,
fire-resistant covers or shields.
Walls
touching combustibles
on
opposite
sides should
(or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
not be welded on
shields.
Fire watcher must be standing by with suitable fire extin
guishing equipment during and for some time afterweid
ing or cutting if:
a.
appreciable
construction)
b.
c.
combustibles (including
are within 35 feet
appreciable
combustibles
feet but
be
can
are
building
further than 35
ignited by sparks
openings (concealed or visible) in floors orwalls
sparks
combustibles
or
metal
adjacent
partitions can
walls, ceilings, roofs,
to
be
ignited by
with
one or more
Never connect
a
relief devices.
regulator
cylinder containing gas
regulator was designed.
to a
other than that for which the
Remove
faulty regulator from service immediately for
repair (first close cylinder valve). The following symp
toms indicate a faulty regulator:
Leaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop
pin when pressurized, nor returns to stop pin after pres
sure release.
Do NOT attempt to repair. Send faulty regula
repair to manufacturers designated repair cen
ter, where special techniques and tools are used by
trained personnel.
Repair.
tors for
within 35 feet may expose combustibles to
d.
Regulator
designed to protect only the
from
regulator
overpressure; it is not intended to protect
downstream
equipment. Provide such protection
any
radiant
or
2.
Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders
third rails, electrical wires, or welding circuits.
produce short circuit
(See 1-3C.)
conducted heat.
arcs that
may lead to
a
including
They can
serious
ac
cident.
permit should be obtained before operation to
supervisors approval that adequate precautions
Hot work
ensure
ICC
or
DOT
assurance
have been taken.
marking must be on each cylinder. It is an
safety when the cylinder is properly han
of
dled.
After work is done, check that
glowing embers, and flames.
An
area
is free of
sparks,
empty container that held combustibles, or that can
or toxic vapors when heated, must
produce flammable
never be welded on or Cut, unless container has first
been cleaned as described in AWS Standard A6.O,
listed 7 in Standards Index.
a thorough steam or caustic cleaning (or
solvent or water washing, depending on the combusti
bles solubility) followed by purging and inerting with ni
trogen or carbon dioxide, and using protective equip-
This includes:
a
OM-296
Page
2
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or alter name, number, or other markings on a cylinder.
It is
illegal
and hazardous.
Empties: Keep valves closed, replace caps securely;
keep them separate from FULLS and return
promptly.
mark MT;
Prohibited
use.
Never
use a
cylinder
or
other than its intended use, NEVER
roller.
its contents for
as a
support
or
Locate
or secure
cylinders
so
they
cannot be knocked
Passageways and work areas. Keep cylinders
where they may be struck.
clear of
areas
Transporting cylinders. With a crane, use a secure sup
port such as a platform or cradle. Do NOT lift cylinders
off the ground by their valves or caps, or by chains,
slings, or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not al
low contents to exceed 130F.
ignition. Wipe
Protect
cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT
hammer or wrench to open a
valve that can not be opened by hand. Notify
use a
cylinder
your supplier.
gas
Never refill any
try
to mix any gases in a
cylinder.
gases to
cylinder containing any other gas.
a
connections. When
assembling threaded
con
nections, clean and smooth seats where necessary.
Tighten. If connection leaks, disassemble, clean, and
retighten using properly fitting
wrench.
Adapters. Use a CGA adapter (available from your sup
plier) between cylinder and regulator, if one is required.
use two wrenches to tighten adapter marked RIGHT
and LEFT HAND threads.
Regulatoroutlet (or hose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex
shank) for fuel gas.
on nut or
Pressurizing Steps:
Drain
regulator of residual gas through suitable vent be
opening cylinder (or manifold valve) by turning ad
justing screw in (clockwise). Draining prevents exces
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
fore
cylinder.
Cylinder fittings
changed.
or
Tighten
5.
gases. Never
Mixing
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
that the regulator inlet and cylinder outlet match.
NEVER CONNECT a regulator designed for a particular
Cool with water spray
where such exposure exists.
3.
outlet away from people and sources of
a clean tintless cloth.
with
over.
should
never
be
modified
or
ex
Hose
Stand to side of regulator while
Prohibited use. Never use hose other than that de
signed for the specified gas. A general hose identifica
tion rule is: red for fuel gas, green for oxygen, and black
to connect
Open cylinder valve slowly so that regulator pressure in
slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol
lowing position: For oxygen, and inert gases, open fully
to seal stem against possible leak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
standard brass f it
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
for inert gases.
Use ferrules
or
clamps designed
nary wire or other
hoses to fittings.
substitute)
No copper
tings
tubing splices.
splice hose.
to
Avoid
Use
for the hose
as a
only
binding
(not
ordi
creases
regulators.
long runs to prevent kinks and abuse. Suspend
ground to keep it from being run over, stepped
otherwise damaged.
hose off
on, or
opening cylinder valve.
Check for leaks
on
first
pressurization and regularly
there-after. Brush with soap solution (capfull of ivory
Liquid*
or
equivalent per gallon of water). Bubbles indi
cate leak. Clean off soapy water after test; dried soap is
Coil
excess
prevent kinks and tangles.
hose to
Protect hose from
sparks, slag,
damage by sharp edges,
combustible.
and
by
E.
User
ResponsibIlities
and open flame.
Remove leaky
regularly for leaks, wear, and loose con
nections. Immerse pressured hose in water; bubbles in
Examine hose
mediately
in
for
equipment
defective equipment from service im
repair. See User Responsibility statement
or
manual.
dicate leaks.
F.
Repair leaky
ing (1-2D3). Do
or worn
hose
by culling
area
out and
splic
NOT tape.
Close gas supply at
G.
4.
Proper
Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except
for
hydrogen,
crack valve
momentarily, pointing
Leaving Equipment Unattended
source
and drain gas.
Rope Staging-Support
Rope staging-support should not be
cutting operation; rope may bum.
used
forwelding or
*Trademrk of Proctor & Gamble.
OM-296
Page
3
ARC WELDING
1-3.
Comply with precautions in 1-1, 1 -2, and this section.
Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in
Arc
frared energy radiates, weidments are hot, and com
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan
dards referenced in index.
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in
flash goggles.
area.
Before starting to weld,
bay doors are closed.
B.
are
make sure that screen
wearing
flaps
Comply
with
precautions
in 1 -2B.
Generatorengine exhaust must be vented to the outside
can
kill.
Burn Protection
C.
Comply
with
The welding
precautions
FIre and
ExplosIon Prevention
in 1-2.
Comply
with
precautions
in 1 -2C.
is intense and
visibly bright. Its radiation
can damage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Equipments rated capacity. Do not overload arc
ing equipment. It may overheat cables and cause
Skin burns resemble acute sunburn, those from gasshielded arcs are more severe and painful. DONT GET
BURNED; COMPLY WITH PRECAUTIONS.
cause a
1.
arc
Protective
Clothing
long-sleeve clothing (particularly for gas-shielded
gloves, hat, and shoes (1 -2A). As nec
essary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-re
sistant leggings. Avoid outer garments of untreated cot
in addition to
ton.
Bare skin protection. Wear dark, substantial clothing.
Button collar to protect chest and neck and button pock
ets to prevent
2.
Eye
weld
a
fire.
Loose cable connections may overheat or flash and
lire.
Never strike
an arc on a
sel. It creates
Wear
arc)
or
Toxic Fume PreventIon
air. Carbon monoxide
A.
See that all persons
cylinder or other pressure
ves
brittle area that can cause a violent rup
ture or lead to such a rupture under rough handling.
D.
Compressed
Comply
E.
a
with
Gas
EquIpment
precautions
in 1 -2D.
Shock Prevention
Exposed hot conductors or other bare metal in the weld
ing circuit, or in ungrounded, electrically-HOT equip
ment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
entry of sparks.
and Head Protection
protection.
Protect eyes from exposure to
electric arc without protection.
arc.
NEVER look at
an
To protect
against shock:
Wear
containing a filter plate shade
no. 12 ordenser must be used when welding. Place over
face before striking arc.
dry insulating gloves and body protection. Keep
body and clothing dry. Never work in damp area without
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
Protect filter plate with
can not
Welding
helmet
or
shield
a
clear
cover
plate.
tween
Cracked
or
broken helmet
worn; radiation can pass
Cracked, broken,
or
shield should NOT be
or
through
loose filter
plates
IMMEDIATELY. Replace clear
ken, pitted,
or
to cause burns.
replaced
plate when bro
spattered.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should
the helmet not be lowered over the face before an arc is
struck. Looking at an arc momentanly with unprotected
eyes
(particularly
a
high intensity gas-shielded arc)
retinal burn that may leave
in the field of vision.
cause a
area
3.
Protection of
Nearby
a
can
at floor level.
OM-296 Page 4
through
the
body.
A
voltage will exist between the electrode and any con
ducting object in the work circuit. Examples of conduct
ing objects include, but are not limited to, buildings, elec
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source Is off.
1.
Grounding
the
Equipment
permanent dark
Personnel
Enclosed welding area. For production welding, a sepa
rate room or enclosed bay is best. In open areas, sur
round the operation with low-reflective, non-combusti
ble screens or panels. Allow for free air circulation, par
ticularly
metal reduces the electrical resistance, and could en
dangerous and possibly lethal currents to flow
able
must be
cover
be avoided. Sweat, sea water, or moisture be
and an electrically HOT part or grounded
body
Arc
welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 Safety In Welding
And Cutting.
When installing, connect the frames of each unit such as
welding power source, control, work table, and water cir
culatorto the building ground. Conductors must be ade
quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly fa
tally. Do NOT GROUND to electrical conduit, orto a pipe
carrying ANY gas or flammable liquid such as oil or fuel.
b.
Equipment without output
welding,
conductors
are
check
ground for continuity. Be sure
touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. if a three-prong
plug is added for connection to a grounded mating re
ceptacle, the ground lead must be connected to the
ground prong only. If the line cord comes with a threeprong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground prong.
Fully
NOT
insulated electrode holders should be used. Do
holders with protruding screws.
use
Fully insulated lock-type connectors
join welding cable lengths.
should be used to
Cables
4.
Frequently inspect cables for wear,
cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or
damaged insulation
to avoid
possibly-lethal shock
damaged areas may be
equivalent to original cable.
from bared cable. Cables with
give
taped
to
Keep
cable
resistance
dry,
7.
free of oil and grease, and protected
Terminals And Other
Exposed
Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or
red-tag switches) to prevent accidental turning ON of
power. Disconnect all cables from welding power
source, and pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld
ing. If, in an emergency, it must be disconnected, guard
against shock bums, or flash from switch arcing.
Power disconnect switch must be available
welding power
Protection For Wearers of Electronic LIfe
For more information, refer to the
their latest revisions and comply
following standards or
as applicable:
1.
ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
2.
NIOSH,SAFETYAND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING obtainable
from the
ernment
a.
3.
Superintendent of Documents, U.S. Gov
Printing Office, Washington, D.C. 20402.
OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the
Documents, U.S. Government
Washington, D.C. 20402.
Equipment with output on/off control (contactor)
of
Welding power
sources
for
use
Sup
STANDARDS BOOKLET INDEX
1-4.
exposed parts of electrical units
insulating covers secured before opera
Electrode
the
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
tion.
6.
near
source.
port Devices (Pacemakers)
Parts
Terminals and other
should have
Devices
such as interlocks and circuit breakers
should not be disconnected or shunted out.
from hot metal and sparks.
5.
Safety
Safety devices
F.
Connectors
3.
power switch is turned ON. Never touch the
electrode unless the welding power source is
of f.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Electrode Holders
2.
(no
Welding power sources used with shielded
metal arc welding (SMAW) and similar proc
esses may not be equipped with welding power
output on-off control devices. With such equip
ment the electrode is electrically HOT when the
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip
ment ground lead to the third (live) wire, or the equip
ment will become electrically HOT-a dangerous condi
tion that can shock, possibly fatally.
Before
on/off control
contactor)
with the gas
Superintendent
Printing Office,
metal arc
welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor
mally are equipped with devices that permit onoff control of the welding power output. When
so equipped the electrode wire becomes elec
trically HOT when the power
switch is
ON and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob
ject in contact with the electrode circuit unless
the welding power source is off.
4.
ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable from the Ameri
National Standards Institute, 1430
New York, NY 10018.
can
source
5.
Broadway,
ANSI Standard Z41.1. STANDARD FOR MENS
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430
Broadway,
New York, NY 10018.
OM-296
Page
5
6.
7.
8.
ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES
obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS
TIBLES obtainable from the American Welding So
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126.
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.
from the Compressed Gas Association, 1235 Jef
ferson Davis Highway, Suite 501, Arlington, VA
22202.
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable from the Ca
nadian Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
M9W 1R3.
13. NWSA booklet, WELDING SAFETY BIBLiOGRA
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA
19103.
Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR ThE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING ThAT HAVE
H ELD HAZARDOUS SUBSTANCES, obtainable
14. American
9.
Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
NFPA
Association,
Batterymarch
Park,
Quincy,
MA
02269.
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126.
Batterymarch Park, Quincy,
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA
TORY PROTECTION, obtainable from the Amen
can National Standards Institute, 1430 Broadway,
Protection Association,
MA 02269.
11. CGA
Pamphlet P-i,
PRESSED GASES
OM-296
Page
6
SAFE HANDLING OF COM
IN CYLINDERS obtainable
New York, NY 10018.
SECTION 2
Table 2-1.
Rated Output
At 40%
Duty Cycle
30 Amperes
At 120 Volts
DC
Maximum
OpenCircuit
voltage
INTRODUCTION
SpecificatIons
input At
Rated Load Output
50/60 Hz Single-Phase
Plasma
Weight
Gas
Amperes At
200V
230V
KVA
KW
Air
38
33
7.6
4 6
(79 Llmin.)
52 lbs.
56 lbs.
At 50 PSI
(24 kg)
(25 kg)
Net
Ship
2.8 CFM
370 Volts
DC
~
(345 kPa)
~
8-1/8 In.
(206 mm)
18-1/2 In.
(470 mm)
17-3/8 In.
(440 mm)
TC-125 647
Figure
2-1.
2-1. Overall Dimensions
DUTY CYCLE
This power source and torch are rated at 40 percent duty
cycle. The duty cycle is the percentage of a ten minute
period that the power source and torch can be operated
at a given output without causing overheating and dam
age to the power source and torch. Since this unit is
rated at 40 percent duty cycle, it can be operated at
rated load for four minutes Out often. During the remain
ing six minutes,
cooling.
the unit should idle to
permit proper
4A
CAUTION: EXCEEDING THE DUTY CYCLE
RATINGS will damage the power source and
torch.
Do not exceed indicated
2-2.
A.
duty cycles.
GENERAL INFORMATION AND SAFETY
General
Information presented in this manual and on various la
on this unit pertains to
bels, tags, and plates provided
equipment design, installation, operation, maintenance,
OM-296 Page 7
and troubleshooting which should be read, understood,
and followed for the safe and effective use of this equip
ment.
The nameplate of this unit uses international symbols
for labeling the front panel controls. The symbols also
appear at the appropnate section in the text.
2-3.
unpacking equipment, check carton for any dam
age that may have occurred during shipment. File any
claims for loss or damage wIth the deliverIng carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manufactur
Before
ers
B.
Safety
RECEIVING-HANDLING
Transportation Department.
requesting information about this equipment, al
ways provide the Model Description and Serial Number.
When
installation, operation, maintenance, and trou
bleshooting of this equipment requires practices and
procedures which ensure personal safety and the safety
of others. Therefore, this equipment is to be installed,
operated, and maintained only by qualified persons in
accordance with this manual and all applicable codes
The
such as, but not limited to, those listed at the end of Sec
tion 1
Safety Rules.
2-4.
DESCRIPTION
This unit is a direct current, straight polarity (electrode
negative) Plasma Arc Cutting (PAC) power source re
quiring single-phase electrical input. The unit will cut
metals through 1/4 in. (6.35 mm) thick using the Plasma
Arc Cutting (PAC) process.
-
Safety instructions specifically pertaining to this unit ap
pear throughout this manual highlighted by the signal
words WARNING and CAUTION which identify differ
ent levels of hazard.
This unit is designed to be used with the supplied model
APT-3000 curved-nozzle torch. An optional model
APT-3000M straight-nozzle torch is also available.
Rated output is 30 amperes at 120 volts dc, 40 percent
duty cycle.
WARNING statements include installation, operation,
and maintenance procedures or practices which if not
carefully followed could
or
result in serious
personal injury
loss of life.
CAUTION statements include installation, operation,
and maintenance
procedures
practices which if not
minor personal injury or
or
carefully followed could result in
damage to this equipment.
A third signal word, IMPORTANT highlights instruc
tions which need special emphasis to obtain the most ef
ficient operation of this equipment.
Plasma is air which has been heated to an extremely
high temperature and ionized so that the air becomes
electrically conductive. The electrode is located inside
the tip of the torch. The torch tip has a small opening (ori
fice) which constricts the arc. The compressed air flows
through the arc where it is heated to the plasma tem
perature range. Since the air cannot expand due to the
constriction of the tip, air is forced through the orifice and
emerges in the form of a highly compressed airstream.
The heat formed by the arc and the plasma melts the
metal, and the airstream forces the molten metal from
the cut.
SECTION 3INSTALLATION
A~
WARNING: ELECTRIC SHOCK
can
kill.
Do not place any filtering device over the in
take air passages of this power source.
Do not touch live electrical parts.
Warranty
Turn off power source, and remove input
power plug from receptacle before moving unit.
Figure
IMPORTANT:
Read entire Section 8
frequency equipment location
lines before installing this unit.
3-1.
LOCATION
a
and
regarding highinstallation guide
8
overall
The service life and
dimensions
of
the
power
efficiency
of this unit
are
reduced
3-2. AIR
FILTER/REGULATOR
INSTALLATION
AND CONNECTIONS (Figure 3-1 And Figure 3-2)
IMPORTANT:
Be
sure
that this unit is
supplied by
a
clean, dry air supply (see Table 2-1. Specifications for
pressure and flow rate
1.
Page
gives
specifications).
combustible surfaces.
Maintain at least 10 inches (254 mm) of unre
stricted space on all sides of unit, and keep un
derside free of obstructions.
OM-296
2-1
source.
moisture, corrosive vapors, and extreme heat.
WARNING: FIRE OR EXPLOSION can result
from placing unit on or over combustible
surfaces; RESTRICTED AIR FLOW causes
overheating and possible damage to inter
nal parts.
over
type of air filtering device
when the unit is subjected to high levels of dust, dirt,
(Figure 2-1)
Do not locate unit
is void if any
is used.
Remove the two air filter/regulator mounting
bracket screws from rear of unit, and install air filter/
regulator mounting bracket onto rear of unit (see
Figure
3-1 and
Figure 3-2).
2.
This unit is equipped with an Input Voltage Change
switch to allow operation from different line volt
ages. To change the switch position, proceed as fol
lows:
Remove retaining nrig from air lifter/regulator, and
insert top of air litter/regulator through bottom of
mounting bracket.
ply.
over
IMPORTANT: Check air filter/regulator for proper flow
direction. Position air filter/regulator so that air will flow
in direction indicated on filter body (see Figure 3-1), or
install with plugged port toward rear of unit.
3.
Secure air filter/regulatorto mounting bracket by
installing and tightening retaining nng.
4.
Coat threads with teflon tape, and install and tighten
end of supplied 12 in. (305 mm) long air hose with
1/2 in. (12.7mm) fitting to Out port of airfilter/regula
tor
5.
re
3-3.
VOLTAGE
Place Input Voltage Changeover switch in either the
200 or 230 volts position to match the available in
panel
access cover
input power
(see Figure 3-2).
Close and
secure rear
panel
access cover.
ELECTRICAL INPUT CONNECTIONS
(4.6 m) cord with a NEMA 6-50 plug attached is
provided on this unit. Connect the plug to a properly
grounded and protected (fuses or circuit breakers) sin
gle-phase 200/230 volts ac receptacle.
A 15 ft.
CHANGEOVER
The National Electrical Code (Article 630B., 1987 Edi
tion) provides standards for amperage carrying capabil
ity of supply conductors based on the duty cycle of the
power source. This unit has a 40 percent duty cycle and
can be operated at rated load for four minutes out of ten;
therefore, the cord and plug supplied with this unit com
ply with these standards. Be sure. that the building sup
ply and receptacle comply with NEC standards and any
SWITCH
(Figure 3-2)
ELECTRIC SHOCK
can
3.
rear
remove
(Figure 3-2)
Connect air line hose from air compressor to In port
of air filter/regulator (see Figure 3-1).
VOLTAGE
Open
3-4.
Coat threads with teflon tape, and install and tighten
remaining end of air hose to air input fitting on rear of
unit located directly below input power cord (see
a
2.
4.
(see Figure 3-1).
INPUT
Turn off power source, and
plug from receptacle.
put voltage.
Figure 3-2).
6.
1.
can
damage
kill; INCORRECT
unIt.
Do not touch live electrical parts.
additional state and local codes.
Turn off power source, and remove input
power plug from receptacle before inspecting or
changing switch positions.
Do not operate unit with
IMPORTANT: The supply wiring for the power source
must be capable of carrying a 38 ampere load for 200
volts operation or a 33 ampere load for 230 volts opera
tion. The power source must be the only load connected
to the supply Circuit. Poor unit performance or frequently
opening line fuses or circuit breakers can result from an
access cover open or
missing.
This power source is designed to be operated from a
200 or 230 volts, single-phase, 50/60 Hz, ac power sup-
inadequate
or
improper supply.
Ret&rilng
1/2 in.
Connect To Air
Fitting
(12.7 mm)
Hose Fitting
(to Out Port)
input
On Power Source
Mounting
Bracket
Locking
Screw
Air Filter!
Arrow indicates
Regulator
Adlustment
Direction Of Air Flow
Knob
Air Pressure ~
In Port
Gauge
TC-126 828
Figure
3-1. Air
Filter/Regulator Components
And Information
OM-296 Page 9
Rear Panel Access Cover
(Shown
in
Open Position)
Locking
Screw
Location
Input
Power Cord
Air
FIIter/Reguiator
Air Pressure
Gauge
Air
input
Fitting
Out Port
TB.125 648
Figure
3-2. Rear Panel View With
Component
Locations
SECTION 4- OPERATOR CONTROLS
GaelAIr Switch
Metai Switch
Fuse Fl
Thickness Control
Input Power
Plasma Cutting
Torch
Power On
Light
Light
Work Clamp
TC-125 647
Figure
OM-296
Page
10
4-1.
Operator Controls
POWER SWITCH/BREAKER AND POWER ON
LIGHT (Figure 4-1)
4-1.
ing cutting. The METAL switch should be placed in the
BARE position whenever possible to get the longest
possible life from the torch electrode and tip.
4-4.
POWER
Placing the POWER switch/breaker in the ON position
energizes the power source. The POWER ON light and
fan motor come on whenever the POWER switch/break
er is placed in the ON position and indicate that the unit
is receiving input power. Placing the POWER switch/
breaker in the OFF position turns off the power source,
POWER ON light, and fan motor.
CAUTION: RESElliNG TRIPPED POWER
without
SWITCH/BREAKER
correcting
damage to this unit.
not reset tripped POWER switch/breaker.
problem
Do
can cause
See Table 6-2.
4-2.
READY LIGHT
Troubleshooting in Section
6.
(FIgure 4-1)
When the READY light comes on, all of the safety shut
down devices within the control circuitry have been
monitored, and the unit is ready for operation. If the
READY light does not come on when the POWER
switch/breaker is placed in the ON
safety devices (see Section 6-6).
4-3.
(FIgure 4-1)
The THICKNESS control provides a means for selecting
the cutting capacity of the power source. Rotating the
control clockwise increases the cutting capacity of the
power source. The scale surrounding the control is cali
brated in gauge thickness for mild steel. Increase gauge
setting by four gauges when cutting aluminum. Proper
adjustment of the THICKNESS control will provide the
longest possible life from the torch electrode and tip.
4-5.
4A
THICKNESS CONTROL
00
METAL SWITCH
position,
check the
(Figure 4-1)
The METAL switch provides a means for cutting bare or
painted metal. When the METAL switch is placed in the
position, the unit provides a pilot arc and high
frequency for arc starting and during cutting. When the
METAL switch is placed in the BARE position, the unit
provides only high frequency for arc starting and not dur
PAINTED
GAS/AIR SWITCH
(FIgure 4.1)
provides a means for adjusting the
filter/regulator without energizing the cutting circuit.
Placing the GAS/AIR switch in the SET position ener
gizes the air solenoid thereby allowing the air filter/regu
latorto be properly set to 50 PSI (3.4 bars). Placing the
GAS/AIR switch in the CUT position provides air to the
cutting torch.
The GAS/Al R switch
air
4-6.
TRIGGER HOLD SWITCH
(Figure 4-1)
The TRIGGER hold switch provides the capability of
torch switch self-hold for long cutting operations. When
the TRIGGER hold switch is placed in the HOLD posi
tion, the torch switch can be released while cutting, and
the cutting circuit will continue to operate until the torch
switch is pressed again. When the TRIGGER hold
switch is placed in the NORMAL position, the torch
switch must be held closed while cutting and released at
the end of the cutting operation. The TRIGGER hold
switch should be placed in the NORMAL position for
short cutting operations and placed in the HOLD posi
tion for long cutting operations.
SECTION 5- SEQUENCE OF OPERATION
a
WARNING: PLASMA ARC CUTTING can be
hazardous; FIRE OR EXPLOSION can result
from placing unIt on
surfaces.
or near
combustible
Only qualified persons are to operate this
equipment according to all codes and employ
ers safety practices.
Do not locate unit over combustible surfaces.
Use
torch(es) specified
in Owners
Manual.
Keep children away.
CUTTING CONTAINERS, such
as
barrels,
tanks, and pIpes, can result In explosions,
fire, or poisonous fumes.
Cut containers only after they have been
and prepared.
Wear
tion.
Do not
sulation.
use
cables
or
Warranty is void if the power source is operated
portion of the outer enclosure removed.
FUMES AND GASES
your health.
in
Keep all covers, panels,
place.
and guards
Keep
securely
damaged in
Do not place any filtering device over the in
take air passages of this power source.
ELECTRIC SHOCK can kill; IMPROPER AIR
FLOW AND EXPOSURE TO ENVIRONMENT
damage Internal parts.
torch with
Ma/nt aTh at least 10 inches (254 mm) of unre
stricted space on al/sides of power source, and
keep underside free of obstructions.
with any
Do not touch live electrical parts.
body protec
Turn off power source, and remove input
power plug from receptacle before cleaning slag
from torch tip or replacing any torch parts.
properly cleaned
can
and
dry insulating gloves
can
seriously
harm
your head out of any fumes.
Ventilate area,
vice.
or use
approved breathing de
OM-296
Page
11
Read Material Safety Data Sheets (MSDSs)
and manufacturers instructions for any materi
als used.
3.
Place the POWER switch/breaker in the ON
tion. The POWER ON light will come on.
4.
Turn on air supply, and adjust air filter/regulator to
50 PSI (3.4 bars) while observing air pressure
gauge on rear of unit. For proper regulation, the rec
ommended output from the air supply should pro
vide a minimum of 80 PSI (5.4 bars) and a maximum
When possible cut over a water table or work
fable designed to minimize fumes, gases, and
sparks.
Cutting aluminum plate on a water fable may
cause
hydrogen detonation beneath the
workpiece. Contact equipment manufacturer for
recommended practices for cutting aluminum.
FLYING SPARKS AND
cause fire and burns.
Do not cut where
mable material.
HOT
METAL
according
can
flying sparks can strike flam
Protect yourself and others from
and hot metal.
Watch for fire, and keep
a
fire
5.
6.
ARC RAYS
7.
Wear safety goggles with correct filter shade.
Wear
Cover skin.
Protect
8.
ears.
PILOT ARC
can cause
when
9.
pressed.
CUTTING WORKPIECE ON
FLOOR can cause concrete to
Do not
floor.
setting.
screw.
Place the METAL switch in the desired
Section 4-3).
position (see
Rotate the THICKNESS control to the desired posi
(see Section 4-4).
Place the GAS/AIR switch in the CUT position. The
READY light will come on indicating that the unit is
for
operation.
Place the TRIGGER hold switch in the NORMAL
position (see Section 4-6 for long cutting opera
tions).
burns.
Keep torch tip away from personnel
switch is
Tighten locking
ready
face shield.
a
Turn air filter/regulator adjustment knob clock
wise to increase pressure setting or counter
tion
can burn eyes and skin; NOISE
damage hearing.
adjustment
b.
clockwise to decrease pressure
extinguisher
nearby.
Make pressure
as follows:
Loosen locking screw in center of air filter/regu
lator adjustment knob.
c.
dling.
(10.2 bars).
Figure 3-1
to
a.
flying sparks
Allow work and equipment to cool before han
can
of 150 PSI
posi
ANSI Z49.1.
CONCRETE
explode.
place workpiece directly on concrete
dry insulating gloves and clothing, and wear
safety goggles with correct filter shade according to
Wear
10. Connect work
clamp
to
clean,
glass
metal
at
workpiece.
tip of torch at edge of metal
tip just over metal edge.
11. Place
HOT METAL SPARKS will mark
bare
and
in
to be cut with hole
burn trim.
Remove, cover,
or
protect any glass
or
trim.
seconds of
can damage vehicle
and other electronic compo
CUTTING CURRENT
computer(s)
nents.
Disconnect both battery cables before
on a vehicle.
12. Press torch switch. There will be
2
material away from torch tip. Proper
being used when sparks go out bot
rected
through
cutting
speed is
tom of cut.
briefly at end of cut to allow metal bridge to
be Cut, and then release torch switch. Postflow air
will flow for approximately 10 seconds to cool the
14. Pause
Be sure torch to power scurce as well as lead
connections to work clamp are clean and tight.
To be 100 percent free of risk, disconnect the
computer(s) from the vehicle.
See Section 1 Safety Rules for basic safety in
approximately
air before arc starts.
13. Once arc starts, drag tip slowly and smoothly across
material. Adjust torch speed so that sparks are di
cutting
Place work clamp as close to the cut as possi
ble to avoid long electrical paths.
pref low
torch. If another cut is started before
the arc will start
postf low ends,
immediately.
-
5-1.
PLASMA ARC CUTTING
a
This unit
material to start
a cut away from the metal edge. On
WARNING: Read and follow safety informa
beginning of entire Section 5 before
tion at
proceeding.
2.
Place the GAS/AIR switch in the SET
12
pierce the
light
wear
will increase
slight gap
or
angle
accordingly. Always pierce using
a
to the material so that molten metal
will be blown
Install and connect unit according to Section 3.
Page
can
gauge material, there will be little or no additional wear
on torch parts, but as the material becomes thicker, the
(PAC)
1.
OM-296
also be used to
IMPORTANT:
formation.
position.
ing
a way from the torch tip. Molten metal b/ow
back onto the torch tip will further reduce the tip life.
Wear a face shield if any piercing is to be part of the op
eration.
CUTTING PROBLEMS AND RECOMMENDA
TIONS
5-2.
If arc goes on/off while
3.
The torch is
a.
1.
If
sparks
cut or cut is not clean:
b.
2.
workpiece being
cut is too thick.
The
c.
Tip or electrode worn; replace tip
(see Section 6-2).
If arc goes out while
5-3.
The torch was lifted too far from workpiece;
place torch on workpiece while cutting.
a.
clamp disconnected; connect work clamp
clean, bare metal at workpiece.
Work
b.
to
Check READY
c.
light;
see
See Table
remedies.
4.
andelectrode
cutting:
Section 4-2.
moved too
slowly; increase
Tip or electrode worn; replace tip and
(see Section 6-2).
travel.
b.
being
torch travel.
moved too fast; slow torch
being
The torch is
a.
top of
come out
cutling:
6-2.
Troubleshooting
for
electrode
additional
SHUTTING DOWN
1.
Stop cutting.
2.
Allow unit to idle for 1 to 2 minutes.
3.
Place the POWER switch/breaker.in the OFF
tion.
4.
Turn oft air
posi
supply.
SECTION 6- MAINTENANCE & TROUBLESHOOTING
6-1.
Torch Cable And Leads
B.
ROUTINE MAINTENANCE
IMPORTANT: Every six months inspect the labels on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See Parts List for part number of
precautionary labels.
WARNING: Read and follow safety Informa
tion at beginnIng of entIre Section 6-1 before
a
proceeding.
Every three months inspect cable, leads, and torch for
breaks in insulation. Repair or replace cable, leads, and
torch if insulation breaks are present. Clean and tighten
connections at each
4~
WARNING: ELECTRIC SHOCK can kIll; SIG
NIFICANT DC VOLTAGE exIsts after removal
of Input power.
Do not touch live electrical parts.
Turn off power source, remove input power
plug from receptacle, and WAIT before inspect
ing, maintaining,
or
servicing.
Internal voltage will decrease to 50 volts or
less within 60 seconds after removal of input
power. Lesser voltages may remain for up to two
minutes.
Measure
touching
voltage
input capacitors
HOT SURFACES
CleanIng
WARNING: Read and follow safety Informa
tion at beginning of entIre Section 6-1 before
a
proceeding.
Every six
months
dust and dirt from the inside of
Remove the outer enclosure, and use
vacuum
the power
source.
a vacuum
suction for the
dirty conditions
are
cleaning operation. If dusty
present, clean the unit monthly.
serious
Injury.
moving parts.
can cause severe
or
Table 6-1. MaIntenance Schedule
Frequency*
can cause
away from
Internal
before
any parts.
MOVING PARTS
Keep
on
C.
inspection.
Maintenance
Every Week
required
trode
Every
Units in heavy service environ
or as
Month
Inspect shield cup, tip, and elec
(see Section 6-2).
ments:
burns.
Check labels, leads, torch; clean
Allow
A.
cooling period before servicing.
Fan Motor
This power source is equipped with an exhaust fan and
relies on forced draft for adequate cooling. The fan mo
tons manufactured with lifetime sealed bearings and re
quires
no
maintenance.
internal parts.
Every
3 Months
Check cables, leads, torch (see
Section 6-1 B).
Every
6 Months
Check all labels (see IMPORTAN
block, Section 6-1). Clean internal
parts (see Section 6-iC).
Frequency of service is based on units operated
40 hours per week. Increase frequency of maint
enance if usage exceeds 40 hours per week.
OM-296
Page
13
6-2. SHIELD CUP, TIP, AND ELECTRODE INSPEC
And
TION AND REPLACEMENT (Figure 6-1
6.
Inspect end of electrode (see Figure 6-1). If erosion
depth of electrode exceeds 0.039 in. (1.0 mm), re
move and replace electrode using supplied wrench.
7.
Reinstall
8.
Reinstall input power plug into 200/230 volts
ceptacle, and resume operation.
Figure 6-2)
a
WARNING: ELECTRIC SHOCK
can
kill.
Do not touch live electrical parts.
Turn off power source, and remove input
plug from receptacle before inspecting,
tip and
shield cup.
Contact Surface
power
maintaining,
or
servicing.
HOT SURFACES
Allow
ac re
can cause severe burns.
cooling period
before
Shield
Cup
servicing.
EXCESSIVE TIP AND ELECTRODE WEAR
damage torch.
can
Oversized
Hole
Inspect shield cup, tip, and electrode weekly
or whenever cutting speed or thickness has
been significantly reduced.
Worn
rip
or electrode replacement becomes
replace both at the same time. Be sure to
only genuine replacement parts.
IMPORTANT: If tip
necessary,
use
To
replace
torch parts,
proceed
as
1.
Turn off power source, and
plug from receptacle.
2.
Remove shield cup.
3.
Using
a
5.
0ll00.059 ln.(I.5
Remove
Electrode
on
Figure 6-1).
tip using supplied
S.OO93
wrench.
If hole in tip is deformed or 50 per
replace tip (see Figure 6-1).
inspect hole in tip.
cent oversize,
mm)
input power
clean, dry cloth, wipe off contact surface
shield cup (see
4.
remove
Ullllm
(LII
follows:
Figure
Cup, Tip,
InspectIon
6-1. ShIeld
And Electrode
Torch
Plasma
Cutting
Pilot Arc/
Torch
Air/Torch ()
Detector
Connector
Lead I
Tip And
~2Iectrode Wrench
Figure
OM-296 Page 14
6-2. Torch Parts
Replacement
ShIeld
Cup
Leads 3
Detector
And 4
Lead 2
TORCH AND WORK LEAD INSPECTION AND
CONNECTIONS (Figure 6-3)
6-3.
4.
5.
a
WARNING: ELECTRIC SHOCK can kill; SIG
NIFICANT DC VOLTAGE exists after removal
of Input power.
Do not touch live electrical parts.
Turn off power source, remove input power
plug from receptacle, and WAIT be fore inspect
ing, maintaining,
or
servicing.
Internal voltage will decrease to 50 volts or
less within 60 seconds after removal of input
power. Lesser voltages may remain for up to two
minutes.
can cause severe
Disconnect torch switch leads 3 and 4 from terminal
strip iT.
6.
Disconnectwork leadfromwork
7.
Remove torch cable and leads from unit.
B.
Relnstallatlon Of Torch And Work Lead
1.
Route
2.
Route
a.
c.
Connect torch cable to air/torch
If it should become necessary to replace the torch
work lead and clamp, proceed as follows:
1.
Turn off power source, and
plug from receptacle.
2.
3.
Open
lower front
Loosen cable
from air/torch
panel
remove
access
re
(-) output
con
Connect pilot arc/shield cup detector lead 1 to
terminal 1 on iT.
Connect shield cup detector lead 2 to terminal 2
on
Removal Of Torch And Work Lead
strain
burns.
cooling period before servicing.
A.
through
connect cable and leads as follows:
nector.
b.
Allow
through strain relief, and con
(+) output terminal.
torch cable and leads
new
lief, and
(+) outputterminal.
work lead
new
nect to work
Measure voltage on input capacitors before
touching any parts.
HOT SURFACES
Disconnect pilot arc/shield cup detector lead 1 and
shield cup detector lead 2 from terminal strip IT.
IT.
or
d.
Connect torch switch PB1 lead 3 to terminal 3
on ii.
e.
Connect torch switch PB1 lead 4 to terminal 4
input power
door.
clamp, and disconnect torch cable
(-) output connector.
on
iT.
3.
Secure torch cable and leads in strain relief.
4.
Close and
5.
Reinstall
ceptacle,
secure
lower front
panel
access
door.
input
power plug into 200/230 volts ac
and resume operation.
re
Terminals 3 And 4: Torch 5witch Lead Connections
Terminal 2: ShIeld
Terminal 1:
Cup Detector Lead Connection
Pilot Arc/Shield
Cup Detector
Lead Connection
Air/Torch ()
Connector
Torch Switch
Torch Terminal
Work
Strip iT
(+) Output
Terminal
Plasma
Cutting
Torch And Cable
Relief
Work
Clamp
And Lead
18-t25 646
Figure
6-3. Lower Front Panel VIew With Access Door
Open
OM-296
Page
15
SPARK GAP
6-4.
6-5.
(Figure 6-4)
OVERLOAD PROTECTION
(Figure 4-1)
WARNING: ELECTRIC SHOCK
AA
WARNING: ELECTRIC SHOCK can kill; SIGNIFICANT DC VOLTAGE exists after removal
of
~.
Input power.
power
maintaining,
Turn off power source, remove input power
plug from receptacle, and WAIT be fore inspect-
maintaining,
or
MOVING PARTS
Keep
on
input capacitors
serious
Injury.
moving parts.
HOT SURFACES can cause severe burns.
Allow
a
can
damage unit.
Use only replacement fuse of same size,
type, and rating (see Parts List).
Fuse Fl protects the control circuit of the power source
from overload. Should Fl open, the READY tight PL2
would be off, and the unit would be completely inopera
To replace fuse Fl correct the
follows:
,
1.
cooling period before servicing,
Troubleshooting
servicing.
tive.
can cause
away from
before
or
INCORRECT FUSE
servicing.
Internal voltage will decrease to 50 volts or
less within 60 seconds after removal of input
power. Lesser voltages mayre main forup to two
minutes.
Measure voltage
touching any parts.
Do not touch live electrical parts.
Turn off power source, and remove input
plug from receptacle before inspecting,
Do not touch live electrical parts.
ing,
kilt.
can
to be
performed only by quaIl-
2.
and
problem,
Turn off power source, and remove
plug from receptacle.
Depress
proceed as
input power
and rotate fuse holder cover couriterclock
wise.
fied persons.
3.
Pull out fuse with
cover
when fuse holder
cover
is
free.
provided with a spark gap assembly located
behind the front panel. The spark gap was set at the factory, and readjustment is not recommended. Normal
spark gap setting is 0.047 in. (1.2 mm). If it should be
come necessary to adjust the spark gap, proceed as folThis unit is
Insert
5.
Install fuse with fuse holder
6.
new
Depress and
Turn off power source, and
plug from receptacle.
remove
input power
7.
Reinstall
ceptacle,
6-6.
2.
Remove left half of wrapper from unit.
3.
Loosen screw A.
4.
Place feeler gauge of proper thickness between
point C.
5.
Apply slight pressure against point
gauge is held firmly in gap.
A.
cover
Tighten
7.
Reinstall left half of wrapper onto unit,
screw
Reinstall
ceptacle,
B so feeler
un
input power plug
and
resume
into 200/230 volts ac re
operation.
SAFETY SHUTDOWN DEVICES
Shield
Cup
Detector CIrcuit
input power plug into 200/230
and resume operation.
volts ac
re-
~
TA124 812
Page
16
6-4.
not
properly
in-
on
light be turned off, check that shield cup is clean
properly installed according to Section 6-2. Weekly
check the shield cup detector circuit for proper operation
by loosening the shield cup and observing the READY
light. If READY light turns off, the detector circuit is oper
ating properly. If READY light remains on, turnoff power
source and contact the nearest Factory Authorized
Service Station immediately.
READY
B.
Figure
or
the torch,the READY light would turn off, and
the unit would be completely inoperative. Should the
stalled
and
A.
6.
OM-296
back into unit.
rotate fuse holder cover clockwise
Should the shield cup be removed
8.
cover.
til cover is secure.
lows:
1.
fuse into fuse holder
4.
Spark Gap Adjustment
Tip Leakage
Detector CircuIt
TO prevent injury from electric shock caused
READY
by
the tip
in contact with each other, the
would turn off, and the unit would be com
and electrode
coming
light
pletely inoperative. Should the READY light be turned
off, check and replace the tip and electrode according to
Section 6-2, if necessary.
C.
AIr Pressure Switch
To prevent damage to the torch due to insufficient air
pressure, this unit is protected by normally closed air
pressure switch S5 located in the air pressure/regulator.
Should air pressure drop below a preset value, S5 would
open, the READY light would turnoff, and the unit would
be completely inoperative. Should the READY light be
turned oft, check air filter/regulator and air compressor
(see Table
D.
6-2.
INCORRECT INSTALLATION or misaligned
can damage cIrcuIt board.
plugs
Be
Troubleshooting).
sure
properly installed and
that plugs are
aligned.
EXCESSIVE PRESSURE
Thermal ProtectIon
can
break cIrcuit
board.
This unit is protected by normally closed thermostats
TP1 and TP2 located in the power supply circuit. Should
TP1
The fan motor FM would continue to
Should the READY light be turned off due to a ther
pletely inoperative.
mal shutdown, a cooling
minutes will be required.
6-7.
only minimal pressure and gentle move
disconnecting or connecting board
plugs and removing or installing board.
TP2 open, thermal shutdown would occur, the
light would turn off, and the unit would be com
or
READY
run.
Use
ment when
period of approximately five
6-8.
TROUBLESHOOTING (Table 6-2)
AA
WARNING: ELECTRIC SHOCK can kill; SIG
NIFICANT DC VOLTAGE exIsts after removal
of input power.
Do not touch live electrical parts.
CIRCUIT BOARD HANDLING PRECAUTIONS
Turn off power source, remove
A~
Internal voltage will decrease to 50 volts or
less within 60 seconds after removal of input
power. Lesser voltages may remain for up to two
minutes.
Do not touch live electrical parts.
Turn off power source, remove input power
plug from receptacle, and WAiTbefore inspect
ing, maintaining, or servicing.
Measure voltage
touching any parts.
Internal voltage will decrease to 50 volts or
less within 60 seconds after removal of input
power. Lesser voltages may remain for up to two
minutes.
Measure
voltage
on
input capacitors
MOVING PARTS
Keep
Allow
Keep
away from
HOT SURFACES
Allow
can cause
a
serious
4A
(ESD)
can
burns.
Perform work
can cause severe
burns.
It is assumed that the unit was
properly installed accord
to Section 3 of this
manual, the operator is familiar
with the function of controls, and the power source was
ELECTROSTATIC DISCHARGE
damage circuit boards.
Transport circuit boards in
shielding carriers or packages.
moving parts.
performed only by quali
ing
servicing.
Put on properly grounded
BEFORE handling circuit boards.
injury.
to be
working properly
CAUTION:
serious
fied persons.
can cause severe
before
input capacitors before
cooling period before servicing.
Troubleshooting
Injury.
moving parts.
cooling period
a
on
can cause
away from
HOT SURFACES
before
touching any parts.
MOVING PARTS
input power
plug from receptacle, and WAIT before inspect
ing, maintaining, or servicing.
WARNING: ELECTRIC SHOCK can kIll; SIG
NIFICANT DC VOLTAGE exists after removal
of input power.
wrist
strap
proper static-
only at a static-safe
The
following
remedies for
until trouble
table is
some
designed
to
diagnose
and
provide
of the troubles that may develop in
Use this table in conjunction with the
this power source.
circuit diagram while
performing troubleshooting proce
dures. If the trouble is not remedied after performing
these procedures, contact the nearest Factory Author
ized Service Station. In all
work area.
developed.
cases
of
equipment malfunc
procedures and
tion, strictly follow the manufacturers
instructions.
OM-296
Page
17
Table 6-2.
Troubleshooting
CAUSE
TROUBLE
REMEDY
Authonzed Service Station.
Unit completely moperative; POWER ON light
PL1 and READY light
PL2 both oft.
POWER switch/breaker CB1 tnpped.
POWER ON light PL1
off; fan motor FM does
Line disconnect switch in the OFF
Place line disconnect switch in the ON
position.
position.
Contact
Factory
.
not run.
Line fuse
or
Power cord
circuit breaker open.
plug
not secure in power
Check and
breaker.
replace
Secure power cord
line fuse or reset circuit
plug.
receptacle.
Does not
FM runs;
light PL1
light PL2
cut; fan motor
POWER ON
and READY
both on.
Work clamp not connected.
Connect work clamp to clean, bare metal at
workpiece.
Torch switch PBI lead connections.
Check, clean, and tighten torch switch lead
(see Section 6-3).
connections
No
high frequency.
READY light PL2 off;
POWER ON light
Torch switch PB1 lead connections.
Check, clean, and tighten torch switch lead
connections (see Section 6-3).
Fuse Fl open.
Check and
6-5.
Shield cup not tight or shield cup
contact surface dirty.
Check, clean, and tighten shield cup on torch
(see Section 6-2).
Shield cup detector lead connections.
Check, clean, and tighten shield cup detector
lead connections (see Section 6-3).
Electrode touching tip inside torch.
Check and
replace
Fl
according
to Section
PL1 on.
tighten
electrode (see Section
6-2).
Thermostats TP1 and/or TP2 open
(thermal shutdown).
Allow
a cooling penod of approximately five
minutes (see Section 6-6).
Insufficient air pressure (see Table 2-1.
Specifications for requirements).
Repair
Incorrect air pressure
Adjust
Dirty
air
adjustment.
filter/regulator.
or
replace
air filter/regulator (see
Section 5-1).
both
OM-296
on.
Page
18
Fan motor FM.
Step
4 in
Clean air filter/regulator according to
manufacturers instructions (supplied with
unit).
Fan does not run;
POWER ON light PU
and READY light PL2
air compressor.
Replace FM.
m r ii C, -I
U) ii C, -l 0 z -.1
C,
C)
I a
U)
TIP
~-IELD I~TECOR
TORCH SWITCH
.
PILOT ARC
I
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SECTION 8- PLASMA ARC CUTTING
8-1.
GENERAL
The following information is necessary to make a proper
installation of the high-frequency plasma arc cutting
(PAC) equipment described in this instruction manual.
The importance of
emphasized since
case
histories of interference due to
cutting (PAC) equipment
most cases, an inadequate installa
arc
have shown that, in
tion was at fault. In the event that interference with
authorized FCC services occurs, the user is required to
take suitable steps to clear the situation. In such cases,
these instructions could serve as a guide in minimizing
might be caused by the high-frequency
plasma arc cutting (PAC) equipment. The Factory Serv
ice Department personnel will assist the user by supply
ing technical information.
interference that
Many processes and applications of processes require
open-circuit voltages sufficient to jump from the elec
trode to the work without making direct contact. The
maximum open-circuit voltage (OCV) of a plasma arc
cutting (FAG) power source is not sufficient for this. It
takes several thousand volts to cause an electrical
spark to jump the gap between the torch electrode and
the pilot, creating an initial path of ionization, that the arc
current can follow without the hazards that would be pre
frequencies.
provide these higher voltages, it is common
superimpose a high open-circuit voltage on
practice
the output of a plasma arc cutting (PAC) power source
by using high-frequency techniques. The resulting highfrequency voltage can be a source of interference and
to
will be discussed in this section.
High-Frequency AssIsted
(PAC) Power Sources
Plasma Arc
Cutting
In the plasma arc cutting (PAC) process, high frequency
may be used for initiating the cutting arc and, in the case
of an arc outage, reinitiating the cutting arc.
mustflowto
energyfromthe high-frequency
the torch electrode via a good quality, low impedance,
and well insulated connecting cable.
The
source
Cutting CIrcuIt
The circuit consists of all attachments connected to the
electrode, pilot arc, and work terminals.
C.
Output Terminals
Output
cutting
D.
terminals are the terminals which
current and pilot arc.
provide
the
The electrode terminal is the terminal to which the elec
trode lead or cutting torch is connected.
Page
20
pilot
terminal is the terminal to which the
arc
pilot
lead is connected.
F.
Work Terminal
The work terminal is the terminal to which the
is connected.
cutting
workpiece
G.
Torch
Cutting
A device used in the
plasma arc cutting (PAC) process
position of the electrode, to transfer cur
arc, and to direct the flow of plasma gas.
to control the
rent to the
H.
Cutting
Zone
The
cutting zone is the space within 50 ft. (15 m) in all
directions from the midpoint between the power source
and the cutting arc (see Figure 8-6).
I.
Bonding
Bonding
refers to
connecting metallic objects together
objects to be at the same potential regard
less of any current flow between them (see Figure 8-3
and Figure 8-4).
to cause the
Grounding (Earthing)
J.
Depending
tion,
on
the
practices
within
jurisdictions,
one
of
or
commonly used to indicate the connec
bonding, of parts of the apparatus to the
earth .The terms may be used
K.
interchangeabiy.
Receiver
A receiver is any device normally used for receiving
electromagnetic energy and converting it to useful com
L.
Conduction
Conduction is the transmission of high-frequency en
ergy via an electrical conductor or conducting medium.
M.
HIgh Frequency
High frequency is radio frequency energy, either
or pulsed, used to start a plasma arc.
con
tinuous
N. High-Frequency
(PAC)
Assisted Plasma Arc
High-frequency assisted plasma arc
fers to any of the plasma arc cutting
Cutting
culling (PAC)
(PAC)
re
processes
requiring high frequency.
0.
Electrode Terminal
OM-296
The
munications purposes.
DEFINITIONS
A.
B.
Pilot Arc Terminal
these terms is
In order to
8-2.
INSTALLATION GUIDELINES
E.
correct installation cannot be over
a
high-frequency plasma
sent at low power
(PAC)
Interference
Interference is the unwanted and problematic
of
P.
high-frequency
reception
energy.
Radiation
Radiation is the transmission of
through space.
high-frequency
energy
HIGH-FREQUENCY RADIATION
8-3.
Installations using high frequency as an integral part of
the power source will produce some high-frequency ra
diation. Such radiation, if the signal strength is sufficient
at the receiving device, can cause an inconvenience or
disruption of communications
or can cause
malfunction
in sensitive electronic controls and systems. The four
major causes of high-frequency radiation are as follows:
Direct Radiation From The Power Source
A.
Direct radiation is that radiation emanating directly from
the power source. Radiation from the power line is not
considered to be direct radiation from the power source.
Plasma Arc
,
Cutting (PAC)
Direct Radiation From The
B.
Power Source
Cutting Circuit
Ground
~
S.0084
Keep
all unshielded and ungrounded
wires out of the weldIng zone.
Any attachment to the output terminals of the power
source is capable of acting as an antenna and radiating
high-frequency energy. Since direct radiation
cutting circuit is the major source of radiation, it
tant to have only the proper torch attached.
is
impor
GENERAL INSTALLATION PROCEDURES
8-5.
Conduction And Radiation From The Power
C.
Figure 8-1. Requirements To Minimize Reradla
tion Pickup in The Vicinity Of The Cutting Zone
from the
A.
Torch And Work Cables Or Leads
Line
Position the torch and work cables or leads as close to
gether and as close to the floor orground plane as possi
Most power lines are capable of conducting high-fre
quency energy which may cause interference directly or
ble.
from these power lines. Normally, such
radiation is small when compared to that caused by ra
diation from the torch and work cables or leads.
by reradiation
Reradiatlon
D.
cutting circuit can be picked up by un
objects or unshielded wiring in the im
Radiation from the
grounded
mediate
metal
vicinity, conducted
radiated. This
can
be
a
some
troublesome
distance, and
source
re
of interfer
B.
High-Frequency
Cutting
When the
plasma arc cutting (PAC) power source is in
operation, all service doors and covers must be closed,
securely fastened, and adequately bonded to ensure
good contact around the entire perimeter of the open
ing. Except for changes and adjustments allowed by the
manufacturer, the power source should not be modified.
Plasma Arc Cutting (PAC)
Power Source
Place leads
\
ence.
on
floor
or
boards, and keep them
to I in. (19-25 mm) apart.
on
3/4
8-4.
Assisted Plasma Arc
(PAC) Power Sources
LOCATION
Locate the power source as close to the cutting process
as possible. Also consider the nearness of a suitable
ground connection when selecting a
tion of the power source. Ideally,
should be iocated in
an area
amount of miscellaneous
site forthe installa
the power source
a limited
where there is
wiring (lighting, power,
tele
phone, communications, and other unshielded conduc
tors) located within the cutting zone. Ungrounded, me
tallic conductors in the cutting zone can act as antennas
which will pick up, conduct, or reradiate the high-f re
quency energy transmitted by the cutting circuit. All mis
cellaneous wiring in the cutting zone should be enclosed
metallic conduit, copper braid, or
some other material having an equivalent shielding eff i
ciency, and grounded at 50 ft. (15 m) intervals (see
in
grounded, rigid
Figure 8-1).
Electrical
Input
Supply
Figure
C.
It
S-0085
8-2.
General Rules For Torch And Work
Cables Or Leads
Grounding (Earthing)
is
recommended
that
grounded. This ground
The
Workpiece
the
workpiece be firmly
by grounding the
must be made
workpiece with No. 12 AWG or smaller wire to a driven
ground rod or to a water pipe which enters the earth
within 10 ft. (3 m) of the workpiece.
OM-296
Page
21
D.
Metal
Buildings
Installation of a plasma arc cutting (PAC) power source
within a suitably bonded and grounded (earthed) metal
building can be an effective means of reducing high-fre
quency radiation. Wherever possible, install power
sources in such places.
Grounded
rigid metallic conduit, copper braid, or some other mate
rial having an equivalent shielding capability (spirally
wound, flexible, metallic conduit is not suitable). Shield
ing of the miscellaneous wiring in the cutting zone must
be grounded at 50 ft. (15 m) intervals. Good low resis
tance electrical connections must be maintained be
tween conduit sections
Copper
(see Figure 8-4).
Copper Strap
Coupling
Figure
F.
8-4.
Bonding
Method For Conduit Sections
Power Service
The plasma arc cutting (PAC) power source should be
connected to the line input power supply as instructed in
this manual, If the unit is equipped with a power cord, the
Metal
Panels
Bonding
FIgure
8-3.
Of Metal Panels
sooig
Grounding And Bonding
Building
Panels Of Metal
is installed within a
metal building, precautions must be taken to be sure
that the building is properly bonded and grounded
However, when the power
E.
ting
more
Plasma Arc Cutting (PAC)
Power Source
source
(earthed). This can be accomplished by placing several
good electrical ground rods around the periphery of the
building. During the construction of a new building of
any type having metal in the structure, be sure that all
the reinforcing and structural steel is bonded together
(as by welding each piece of metal to all other adlacent
pieces). For metal buildings, adjacent metal panels
should be bolted or welded together at frequent inter
vals. All windows and doorways should be covered with
grounded copper screen or galvanized hardware cloth
of not
supply conductors serving the power source should be
completely enclosed in solid, metallic conduit, or in
equivalent shielding, up to the point of connection with
the power cord. The solid metallic conduit, or equivalent
shielding, should extend the entire distance from the
power entrance location in the building to the power
source. Shielding should be electrically continuous
throughout its length and should be connected so that
good electrical contact is provided between the shield
ing and the power source.
Is
Line Fuse
And Switch
in The Cut
Zone
______
________
Figure
Ground
8-5.
Installation Of Plasma Arc
S -002 1
Cutting
(PAC) Power Source
8-6.
GUIDELINES
FOR
INSTALLATION
OF
PLASMA ARC CUTTING (PAC) POWER SOURCES
1.
metallic conductors in the cutting zone
antennas which will pick up, conduct, and/or
telephone, communications, and other conductors
within the cutting zone must be enclosed in grounded,
22
Locate the
equipment so that the ground lead, when
workpiece, can be kept as short as
connected to the
possible.
high-frequency
energy transmitted by the
cutting circuit. This means that all ungrounded water
pipes must be grounded, and that all lighting, power,
reradiate the
Page
c
Conduit
~
Receptacle
Ungrounded,
OM-296
eta
,o
than 1/4 in. (6.4 mm) mesh.
ShIeldIng Of MIscellaneous Wiring
can act as
5Oft.(15m)
Line Input
Power Suppivi
2.
Shield the line input power leads up to the point of
connection of the
plasma arc cutting (PAC) power
specified by the manufactures require
(see Section 8-5F).
source as
ments
3.
Be sure that the conduit system is continuous to a
point at least 50 ft. (15 m) from the power source,
and that the conduit system is one complete run
within the cutting zone. If rigid, metallic conduit is
not used, be sure that the shielding used has
Plasma Arc
Power
equivalent shielding efficiency. Copper sleeving,
lead covered cable, or the equivalent, is satisfac
tory. Spirally wound, flexible metallic conduit is not
suitable.
4.
Keep torch and work cables or leads as close to
gether and as close to the ground plane as possible.
5.
Adjust spark gap setting
given
6.
to the minimum
setting
in this manual.
~-
Center Point
Secure all service and
access
Figure
doors before operat
ing.
S.0022
9.
Be sure that all
8-6.
CuttIng
Zone
ground connections
are
clean and
tight.
7.
Visualize the
cutting
zone as a
sphere with
a
50 ft.
radius centered on a point between the
power source and the cutting torch (see Figure 8-1
and Figure 8-6), and proceed as follows:
(15 m)
a.
Have all unshielded power, lighting, and com
munication wires within the cutting zone placed
in grounded shields or relocated outside the
cutting
10. If the power source is operated within a metal build
ing, be sure that the building is properly grounded.
All items may not be necessary or practical for each in
stallation. Complete the necessary items to eliminate in
terference with authorized FCC services.
1.
zone.
INSTALLATION GUIDELINES CHECKLIST
8-7.
Is
equipment properly
located
(see Sections 8-4,
8-5D, 8-5E, and 8-6.1)?
b.
Ground all large metallic objects, long guy
wires,
c.
Be
or
sure
phone
support wires within the cutting
that there
are no
wires within the
2.
Are ac
3.
Are torch and work cables
zone.
external power ortele
cutting
properly
Use driven
ground
installed
or
leads and
(see Sections 8-5A
equipment
8-6.4)?
and
zone.
4.
8.
input power connections properly made (see
Sections 8-5B, 8-6.2, and 8-6.3)?
rods which enter the
ground
10 ft. (3 m) or less from the ground connection, or
cold water pipes as the ground for the workpiece.
5.
Are ground connections properly made (see Sec
tions 8-5C, 8-6.1, 8-6.4, 8-6.10, and 8-6.11)?
Is
equipment properly set up and adjusted (see Sec
tions 8-6.5 and
8-6.6)?
OM-296
Page
23
SECTION 9- PARTS LIST
0
N
I-
.c,)
E
C)
(n
4
I
I-
C)
0
1~
a)
C)
C.,
L.
LI.
C.,
LI.
\
\
0)
OM-296
Page
24
Dia.
Item
No.
Mkqs.
Part
No.
Main
9-1
Figure
1
2
3
4
5
6
7
8
DCV1
9
10
T2
11
12
13
14
15
16
17
AS1
18
19
20
21
S4
22
23
24
25
26
27
28
S5
FM
TI
29
30
31
32
33
34
35
36
37
38
39
40
Zi
125134
125135
+125 113
125133
125130
125111
125106
125110
125109
125105
125115
125108
125276
125107
125128
125092
+125 117
125021
125293
125118
125137
125119
125120
125132
125131
125093
125091
125122
125083
125124
124729
125125
125136
125084
125127
125126
125114
125129
125123
125121
+125 116
125045
125042
125043
125044
125145
125030
Quantity
Description
Assembly
SCREW
NUT
CASE
GROMMET
SUPPORT
CIRCUIT CARD ASSEMBLY
DC POWER SOURCE, 2 amp 15 volts
CIRCUIT CARD ASSEMBLY
CIRCUIT CARD ASSEMBLY
2
2
2
1
20
1
1
1
1
TRANSFORMER, control
TERMINAL, 15 amp 2 pole
1
1
CIRCUIT CARD ASSEMBLY
LABEL, warning electric shock
1
can
kill etc
2
CIRCUIT CARD ASSEMBLY
1
HOSE, air
VALVE, 88 volts dc 2 way
PANEL, rear
LABEL, warning primary changeover 200-230 volts
1
SCREW
COVER
SCREW
2
1
1
1
1
SWITCH, toggle SPDT 15 amp 250 volts
BUSHING, strain relief
13
1
1
ac
-
FITTING
1
FITTING, pipe brass tee
PRESSURE SWITCH, air
FAN MOTOR, 200 volts ac 3100 rpm
BRACKET, mtg fan motor
TRANSFORMER, power main
1
BASE
1
-
1
1
1
-
1
-
LABEL, warning general precautionary
CAPACITOR ASSEMBLY (Figure 9-2)
SCREW
STABILIZER
LEG, rubber
TERMINAL ASSEMBLY, output (Figure 9-3)
FRONT PANEL ASSEMBLY (Figure 9-4)
HOSE CLAMP
PILOT UNIT (Figure 9-5)
RECTIFIER ASSEMLBY (Figure 9-6)
BRACKET
REGULATOR/FILTER ASSEMBLY
REGULATOR/FILTER
1
10
1
4
1
1
1
1
1
1
(consisting of)
1
1
HOSE, air
BRACKET, mtg air filter/regulator
GAUGE, air 0-1 60 PST
TORCH, model APT-3000 (Figure 9-7)
1
1
-
1
1
ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
+When
OM-296
Page
25
2
1
5
Figure
item
No.
Figure
Dia.
Mkgs.
9-2
1
2
RI
3
4
5
C1,13
6
R2
7
8
9-2.
Part
No.
CapacItor Assembly
Description
125 125
CapacItor Assembly (Fig
125 167
BRACKET, mtg
125 169
125170
125171
125 172
125 174
RESISTOR
BUS BAR
BUS BAR
125 173
125168
-
Quantity
9-1 Item 31)
capacitor
1
1
1
1
CAPACITOR, electrolytic 1800 uf 400 volts
RESiSTOR, cement 20 watt 8.2K ohm
BRACKET, mtg component
ac
-
INSULATOR
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-296 Page 26
2
1
1
1
2
8
9
10
11
12
FIgure
Item
No.
Dia.
Mkgs.
9-3. TermInal
Part
No.
Assembly, Output
Descnption
Quantity
125 126
Terminal
TERMINAL, 15 amp 4 pole
BRACKET, mtg component
FITTING, pipe brass 9/16-18 UNF
RESISTOR, cement 40 watt 6.8K ohm
RESISTOR, cement 20 watt 8.2K ohm
TERMINAL, 15 amp 2 pole
TERMINAL, 6 amp 4 pole
CAPACITOR, metanzed film 0.047 uf 630 volts dc
CAPACITOR, ceramic 0.01 uf 400 volts ac
RESISTOR,46OvoItsO.6watt
FASTON TERMINAL, receptacle
14
125 175
125 176
125 056
125 177
125 174
125 115
125 179
125 180
125 152
125186
125 187
125 188
125 181
125183
15
125182
16
17
125184
Figure 9-3
1
2
3
4
5
R13
~R12
6
7
8
C14
9
C15,16,17
10
RV1
11
12
13
125185
Assembly, Output (Fig
9-1 Item
35)
1
1
-
1
-
FASTON
TERMINAL,
1
1
1
1
I
3
1
1
tab
TERMINAL, 30 amp 600 volts
1
ac 1
pole
1
STOPPER
BINDER
INSULATOR
SUPPORT
1
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-296
Page
27
4
I
1
3
6
7
3
8
2
9
iT
16
1
FIgure
Item
No.
Dia.
Mkgs.
1
Fl
2
3
4
5
6
7
S1,2,3
8
CB1
R15
9
10
11
12
13
14
15
16
17
18
Part
No.
125 114
FIgure 9-4
PL1
LED1
9-4. Front Panel
*125 138
106 172
125 275
125 140
125141
125 142
125 143
125 112
125283
125 147
125148
125 144
125284
125 146
125280
125281
125282
097922
Assembly
Descnption
Front Panel
Assembly (FIg
Quantity
9-1 Item
36)
FUSE, 5 amp 250 volts ac
HOLDER, fuse 250 volts ac
NAMEPLATE
PANEL, front
1
INSULATOR
RESISTOR, carbon 0.3 watt 5K ohm
SWITCH, toggle SPST3 amp 30 volts dc
CIRCUIT PROTECTOR, 2P.50 amp 250 volts
ac
.
.
NUT
SHAFT
DOOR,access-front
LAMP, indicator 220 vofts
ac, red lens
SCREW
LAMP, indicator 15 mamp dc, green lens
NUT
WASHER
RiNG
KNOB
.
.
Re~mmended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
-,
OM-296 Page 28
3
2
.3
.4
5
Figure
Item
No.
FIgure
2
3
Dia.
Mkgs.
9-5
05
C18
CR1
4
5
R10,11
6
13
7
8
R9
9
RB
Part
No.
9-5. Pilot Unit
Descnption
(Fig 9-1
Quantity
38)
125 123
PIlot Unft
125 166
125 164
125 165
125 115
125 162
125 085
125 163
125161
125103
DIODE, high speed 2.5 amp 600 volts
CAPACITOR, film 20 uf 400 volts dc
1
RELAY, enclosed 24 volts dc SPST
I
TERMINAL, 15 amp 2P
RESISTOR, WW 60 watt 12 ohm
2
COUPLING COIL
1
BRACKET
1
RESISTOR, cement 5 watt 100 ohm
RESISTOR, cement 20 watt. 3.3K ohm
1
Item
-
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-296
Page
29
5
4
.7
8
1
18
13
3
5
17
16
FIgure
Item
No.
Figure
1
2
3
Dia.
Mkgs.
9-6
R5
R7
C2-10
4
5
D3,4
6
CT2
7
8
TMI
9
SR2
10
C11,12
11
.
12
R6
13
14
15
TP1
16
17
SRi
18
R3,4
Part
No.
9-6. RectIfier
Assembly
Description
125 121
RectIfier Assembly (Ag 9-1 Item 39)
125 149
125 150
125 152
125159
125 089
125 090
125160
125 086
125 088
125 153
125154
125 155
125 156
125157
125158
125 095
125 087
125 151
RESISTOR, cement 40 watt 400 ohm
RESISTOR, WW 53 watt 10 ohm
CAPACITOR, ceramic 0.01 Ut 400 volts
Page
30
1
1
9
ac
BUSBAR
DIODE, high
2
-
speed
12 amp 600 volts
2
CURRENT TRANSFORMER
BUSBAR
TRANSISTOR MODULE, 100 amp 600 volts
DIODE MODULE, 50 amp 1200 volts
CAPACITOR, film 0.047 uf~1000 vofts dc.~
BINDER
1
2
1
1
2
1
SUPPORT,mtg-capacitor
1
RESISTOR, cement 10 watt 10 ohm
I
SUPPORT
1
HEATSINK
1
THERMOSTAT, NC
DIODE MODULE, 75 amp,8U0 vo1ts~
RESISTOR,WW53watt3.3 ohm
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN
OM-296
Quantity
1
.
.
1
.:~
2
ORDERiN~G R~PLACEMENT PARTS.
-.
.
2
3
4
14-~
.6
7
8
.9
1~
10
Figure
Dia.
Rem
No.
Mkgs.
9-7
Figure
9-7.
Part
No.
125 030
Torch, Model APT-3000
Description
Quantity
Torch, Model APT-3000
1
125071
CUP
1
2
125070
125 069
125 068
125 294
125 075
125 074
125 076
125 080
125 078
125 079
125 077
125 073
125 072
TIP
1
ELECTRODE
TORCH BODY
1
INSULATING TUBE
SWITCH COVER
TORCH SWITCH
HEAT SHRINKABLE TUBE
HOSE SHEATH
PILOT AND DETECTIVE LEAD
TORCH SWITCH LEAD
POWER CABLE ASSEMBLY
TORCH HANDLE
WRENCH
1
3
4
5
6
7
8
9
10
11
12
13
14
1
1
1
1
1
1
1
1
1
1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-296
Page
31
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