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Plasma Cutting
System
Thermal Arc TA 500
August 7, 2001
Instruction Manual
Manual No. 0-0470
WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the
Manufacturer assumes no liability for its use.
Plasma Cutting System TA 500
Instruction Manual Number 0-0470
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1984 by
Thermal Dynamics Corporation www.thermal-dynamics.com
All rights reserved.
Reproduction of this work, in whole or in part, without written permission 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 any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: August 7, 2001
Record the following information for Warranty purposes:
Where Purchased:_________________________________________
Purchase Date:____________________________________________
Power Supply Serial #:_____________________________________
Torch Serial #:_____________________________________________
Contents
4.3 HE 200 Coolant Recirculator Maintenance .................................................... 4-3
TA500 Power Supply
HE200 Coolant
Recirculator
Supply Console
Operator Control Panel
M200 Torch with Arc Starter
GENERAL INFORMATION
GASES AND FUMES
Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful 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 operating area.
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. Persons who work near plasma arc cutting applications should consult their medical health professional 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 instructions before using the equipment. Call 1-603-
298-5711 or your local distributor if you have any questions.
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 metals which may contain one or more of the following:
Antimony
Arsenic
Barium
Beryllium
Cadmium
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
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 information 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 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 combustible 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 defects 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 operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
Date: May 1, 2000 (SPECIAL) i General Information
• 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 Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating 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 material 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 underwater 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 dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Publications in this manual.
General Information
PLASMA ARC RAYS ii
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 helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect 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:
Arc Current
Minimum Protective
Shade No.
Suggested
Shade No.
Less Than 300*
300 - 400*
400 - 800*
8
9
10
9
12
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.
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 WELDING
AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-
PATION AND EDUCATIONAL EYE AND FACE PRO-
TECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
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
Date: May 1, 2000 (SPECIAL)
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-
ING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARA-
TION FOR WELDING AND CUTTING OF CONTAIN-
ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Note, Attention et Avertissement
ATTENTION
Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect 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.
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 personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.
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.
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 respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.
Date: May 1, 2000 (SPECIAL) iii General Information
• 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 argent arsenic baryum béryllium cadmium chrome cobalt cuivre manganèse mercure nickel plomb sélénium 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.
• 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.)
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir l'article 9.)
• Débranchez l’alimentation électrique avant tout travail 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 combustibles ou provoquer l’explosion de fumées inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable 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.
CHOC ELECTRIQUE
RAYONS D’ARC DE PLASMA
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
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-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.
General Information iv Date: May 1, 2000 (SPECIAL)
• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc
Moins de 300*
300 - 400*
400 - 800*
Nuance Minimum Nuance Suggerée
Protective Numéro Numéro
8
9
10
9
12
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.
sûrs.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux
• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page v.
Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRA-
VAIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American 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 Protection 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
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL, 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
Date: May 1, 2000 (SPECIAL) v General Information
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
General Information vi Date: May 1, 2000 (SPECIAL)
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 Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated 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
Date: May 1, 2000 (SPECIAL) vii General Information
Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics ® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
PAK Units, Power Supplies
Parts
XL Plus &
CutMaster Series
Parts
Cougar/Drag-Gun
Parts
All Others Labor
Main Power Magnetics
Original Main Power Rectifier
Control PC Board
All Other Circuits And Components Including,
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat
Exchanges, And Accessory Equipment
3 Years
3 Years
3 Years
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
2 Years
2 Years
2 Years
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
Torch And Leads
Maximizer 300 Torch
PCH/M-62 & PCH/M-102 Torches
All Other Torches
1 Year
180 Days 180 Days
1 Year
180 Days
1 Year
1 Year
180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 1, 2000
General Information viii Date: May 1, 2000 (SPECIAL)
SECTION 1: DESCRIPTION
1.1
OF EQUIPMENT
General Information
A. 500 Amp System
A complete 500 amp TA500 system includes:
• M200 machine mounted torch with either 15, 25, 35 or 50 foot (4.6, 7.6, 10.7 or 15.2 meter) leads.
• Introductory spare parts kit for torch.
• Thermal Arc TAC 500 Power Supply.
• Pilot Arc Starter.
• Supply Console for gas and water connections and power manifolding.
• Operator Control Panel (with or without enclosure) that contains all switches, controls and indicator lights necessary to direct system functions.
• HE 200 Coolant Recirculator, a closed loop system that recirculates, deionizes and cools the torch coolant.
• Gas Regulators for assuring constant working pressure regardless of variation in inlet pressure.
• Supply hoses and cables to interconnect all components in lengths required for the particular installation. This must be decided prior to ordering the system. Refer to CC65 catalog C500 for ordering details.
B. 1000 Amp System
A complete 1000 amp TA500 system consists of the same components as the 500 amp system plus an additional TAC
500 Power Supply (connected in parallel with another TAC
500), an 8 foot long parallel control cable, two negative power cables and two positive work cables.
C. Options
• A Hi-Flow Water Shield Assembly to reduce smoke, noise and glare.
• Torch Standoff Control that automatically sets and maintains the torch a fixed distance above the metal being cut.
1.2
Specifications
A. M200 Torch
• Current Rating: 1000 amperes maximum, General Purpose, DCSP; 750 amperes maximum, Water Shield,
DCSP.
• General Purpose: Cutting of most metals up to a maximum thickness of 4” (100 mm), piercing up to 2” (50 mm).
• Water Shielding: Cutting of most metals up to a maximum thickness of 3” (76 mm), piercing up to 1-1/2” (38 mm).
• Weight: 7.5 lbs (3.4 kg), without leads.
0.937" Ø
13.625" Max.
6.525" Min.
16.0"
M200 Torch Dimensions
• Gas Requirements:
2.25"
O.D.
Plasma Gas: N2
Secondary Gas: CO 2 ,
Ar/H 2 , or Comp. Air
Secondary Gas: H 2 O
Setting Consumption
60 psi
(4.1 bar)
110 scfh
(52 lpm)
60 psi
(4.1 bar)
350 scfh
(165 lpm)
15 gph
(56 lph)
15 gph
(56 lph)
B. Thermal Arc 500 Power Supply
• Power Input: 150 KVA, 50/60 Hertz, 3 phase in one of the following standard voltage/amperage combinations:
1-230/460 volts, 360/180 amps
2-460/575 volts, 180/145 amps
3-220/380 volts, 375/215 amps
• Rated Output: 500 amperes DC straight polarity at 200 volts
• Current Control: 150 to 500 amps continuously adjusted by a feedback circuit
• Control Circuit: 24 volt
• Weight: 1500 lbs. (680 kg)
Manual No 0-0470 1-1 General Information
47"
(119.4 cm)
D. HE 200 Coolant Recirculator
• Power Input: 50 or 60 Hz, 3 phase in one of the following standard voltage/amperage combinations:
1- 230 volts, 60 Hz, 5.5 amps
2- 460 volts, 60 Hz, 2.75 amps
3- 575 volts, 60 Hz, 2.2 amps
• Pump Capacity: 5.2 gpm (23.6 lpm)
• Capacity: 80,000 BTU/hr
• Weight: 263 lbs. (119.4 kg)
42"
(106.7 cm)
32"
(81.3 cm)
38-1/2"
(98 cm)
28"
(71 cm)
TAC 500 Dimensions
C. Supply Console
• Power Input: From 500 Power Supply
• Plasma and Secondary Gas Pressure: Controlled by pressure regulator at gas supply
• Secondary Water Flow: Controlled by a flow meter on front panel
• Torch Coolant: From HE 200 Coolant Recirculator
• Weight: 50 lbs. (22.7 kg)
HE 200 Dimensions
E. Control Panel
• Power Input: from 500 Power Supply
• Weight: 15 lbs (6.8 kg)
9-5/8"
(24.4 cm)
9-3/4"
(25 cm)
26"
(66 cm)
19"
(48 cm)
16-5/8"
(42.2 cm)
8-1/4"
(21 cm)
Supply Console Dimensions
Control Panel Dimensions
General Information 1-2 Manual No 0-0470
1.3
Plasma 1.4
Theory of Operation
Plasma is a gas which has been heated to an extremely high temperature and ionized so that the gas becomes electrically conductive. The plasma cutting process uses this plasma to transfer an electric arc to the workpiece.
The metal to be cut is melted by the heat of the arc and then blown away.
In a plasma torch, a cool gas such as nitrogen (N2) enters in
Zone A. In Zone B a pilot arc between the electrode and the front of the torch heats and ionizes the gas. An arc transfers to the workpiece through a column of plasma gas in Zone C.
_
Power
Supply
+
C
Plasma Torch
Workpiece
A-00002
B
A
By forcing the plasma gas and electric arc through a small orifice, torches deliver a high concentration of heat to a very small area. The stiff, constricted plasma arc is shown in Zone
C. Direct current straight polarity is used for plasma cutting, as shown in the illustration.
The exclusive Dual-Flow design of cutting torches uses a secondary gas. The secondary gas assists the high velocity plasma in blowing the molten metal out of the cut, resulting in fast clean, dross (slag)-free cuts. CO
2
, supplied from cylinders, or water, from the plant water system, is normally used as the secondary. Compressed air may be used as the secondary gas for some applications.
The main components of the TA500 cutting system are illustrated in the block diagram and their function is summarized below.
Plasma and Secondary Gases
Plasma and secondary gases flow through the Control
Console to the cutting torch at pressures set at the external regulators. The pressure of each gas is indicated on the gages mounted on the front of the Supply Console. Solenoid valves in the Supply Console turn the gases on and off and receive their signals from the
Power Supply relay logic P.C. Board. The gas pressure interlocks shut the system down if the plasma gas pressure falls below 40 psi.
The plasma gas flows to the torch through the black lead, around the electrode and out through the tip orifice.
The secondary gas (or water) flows to the torch through the yellow lead, through the outer insulator, inner tip retainer and end piece and out around the plasma arc.
Pilot Arc/Arc Starter
When the START button is pressed the main contactor is activated. After two seconds the pilot contactor closes. The pilot bridge rectifier converts single-phase
AC power from the main transformer Arc Starter winding to DC for the pilot arc. At the same time the arc starter circuit starts a series of high-voltage pulses.
These pulses jump the gap between the electrode and the tip in the torch, which starts the pilot arc. The pilot arc then runs for half a cycle (1/120 sec) when the voltage drops and the pilot goes out until another pulse from the arc starter circuit starts it again. The arc starter circuit provides 15 pulses per second which results in a rapid-fire ‘pop pop pop’ pilot arc. This pilot arc makes a path for transferring the main arc to the work.
Cutting Arc
The main bridge rectifier converts the 3-phase AC power to DC for the main cutting arc. The negative output is connected to the electrode through the green torch lead. The positive output is connected to the workpiece (through the work cable).
Manual No 0-0470 1-3 General Information
Current Control
The desired cutting current is set with the control knob, located to the left of the ammeter, on the Control panel. A control circuit in the Power Supply stabilizes the cutting current against fluctuations due to changes in line voltages, material thickness, torch standoff and travel speed. Changing the saturating current in the reactor changes the amount of AC power supplied to the main bridge rectifier. The saturating current is controlled by SCR’s which are in turn controlled by a printed circuit card which compares the actual cutting current to the current selector potentiometer setting.
Coolant Recirculator
When the Power Supply is turned on the Coolant
Recirculator starts circulating coolant through the torch and back to the Recirculator through the radiators, reservoir, filter and pump. The Recirculator is a closed loop system and includes a deionizer assembly which maintains the resistivity of the coolant.
General Information 1-4 Manual No 0-0470
Manual No 0-0470
System Block Diagram
1-5 General Information
General Information 1-6 Manual No 0-0470
SECTION 2:
INSTALLATION
2.1
Unpacking New Equipment
The TA-500 is skid mounted and protected with a carton and padding material to prevent damage in shipment. The other components are packed separately. Make sure all items on the packing list are identified and accounted for. Inspect components for possible shipping damage.
One copy of the TA-500 Instruction Manual, in a transparent plastic envelope, is packed in with the TA-500 unit.
2.2
Equipment Installation
Select a clean, dry location with adequate working space around all components. The power supply is air cooled and must be located where there is free circulation of air through the machine. At least two feet of clearance should be provided on all sides of the power supply to allow for circulation of air and any maintenance that may be required. A source of 3-phase power and a source of gases with pressure regulators are required.
Review PRECAUTIONS in the front of the manual to be sure that the location selected meets all safety requirements.
When cutting material under 3 inches thick most users prefer Nitrogen (N2) as the plasma gas and water as the secondary, since it is economical and easy to obtain good cut quality with this combination. However, CO
2 is sometimes preferred as the secondary.
For material over 3 inches thick Nitrogen (N2) as the plasma gas and a mixture of 65% Argon/35% Hydrogen (Ar/H
2
) as the secondary gas is preferred.
To connect the units, follow these step by step procedures:
Thermal Arc Power Supply
1. Remove the cover and both side panels.
2. Remove the paper band (Fig. 2-A) stapled around the left motor strut.
3. Check for possible loose connections and damage that may have occurred during shipment.
Paper Band
Figure 2-A Voltage Connection Tag
4. Check the transformer (Fig. 2-A) to be sure that it is set up for the available power. Section 4.8
describes the connections for the various voltages. Find the one that corresponds to the available power and compare it to the terminal board on the transformer. Correct the connections if necessary.
CAUTION
Input voltage of the available three phase power source must correspond to one of the three operating voltages of the TA-500 transformer supplied. If not properly connected, damage to the equipment may result.
5. Check the three-phase power service to be used.
Recommended maximum fuse or circuit breaker sizes are given in Table 2-A.
6. With the primary power disconnect switch open and fuses removed, feed the primary power cables through the Input fitting in the rear panel
(Fig. 2-C) of the Power Supply. Connect the electrical ground wire to the ground lug (Fig. 2-D).
A proper ground connection must be made to the brass stud. The other leads are attached to terminals L1, L2 and L3 (Fig. 2-E). Recommended wire sizes are given in Table 2-A.
Manual No 0-0470 2-1 Installation
Ground Lug
Input
Strain
Relief
Figure 2-C Power Supply Rear Panel. Input of
Primary Power Cables
Power
Transformer
(T1)
1
2
3
Line
Voltages
Accepted
230
460
460
575
220
380
Fuse or
Circuit
Breaker
Amperages
450
225
225
170
450
250
Recommended
Minimum
Primary Wire
400 MCM
2/0
2/0
1
400 MCM
3/0
Table 2-A Line Voltages, Circuit Protection and
Recommended Wire Size.
NOTE:
This information is based on the 1978 National
Electrical Code, Table 310-16. Larger sizes may be required if the length exceeds 25 feet.
Figure 2-D Ground Lug
WARNING
Do Not Turn On Power Until Step 37.
7. On the right-hand side of the power supply base, about half-way back, are the connection lugs for the output cables. Feed the two positive (RED) Work cables, (end with large hole in lug), through the large plastic bushing on the lower right hand side of the front panel. Connect the cables to the positive (RED) output connections. The other end of these cables are connected to the work table.
8. Feed the two negative (GREEN) cables, (end with large hole in lug), through the same plastic bushing as the positive cables. Connect to the negative (GREEN) output connection in the
Power Supply. The other end of these cables will be connected to the Supply Console.
9. Replace the side panels and cover.
Installation 2-2 Manual No 0-0470
L2
L1
L3
Figure 2-E Input Power Connections
Supply Console
10. Place the Supply Console in the desired location and remove the cover.
Negative
Plastic
Bushing
Figure 2-F Cable Connections
Power
Manifold
Feed Negative Cable Through Here
Figure 2-G Supply Console Rear Panel
11. Feed the two negative (GREEN) cables through the smaller plastic bushing on the back of the
Console and connect to the bottom terminals of the power manifold (Fig. 2-F).
12. Replace the cover temporarily.
13. Connect one of the coolant hoses to the fitting marked COOLANT RETURN on the console and the other to the fitting marked RETURN on the HE200 Coolant Recirculator. Connect the other coolant hose to the fitting marked
COOLANT SUPPLY on the Console and SUP-
PLY on the HE200.
CAUTION
Do not use other hose or pipe for this purpose. If any additional fittings or connectors are used in the coolant system they MUST be made of brass or stainless steel.
14. Connect the Arc Starter Control cable (OR-
ANGE) to the rear panel of the Supply console marked as such. Connect the other end to the
Power Supply receptacle color-coded OR-
ANGE.
15. The Supply Console Control cable (GREEN/
ORANGE) is keyed by the connectors on each end. Find the end that mates with the receptacle on the rear of the Supply Console marked
CONTROL and connect. The other end connects to the Power Supply receptacle colored
GREEN/ORANGE.
NOTE
The other connections to the Supply Console will be made later.
Manual No 0-0470 2-3 Installation
HE 200
CAUTION
Do not attempt to run the HE 200 until the torch leads are connected to the Control Console (steps
28-33). Refer to step 38.
NOTE
Refer to the instruction manual packed with the
HE 200 for installation instructions.
16. Add coolant supplied to the reservoir of the HE
200. Fill to the crosswires in the bottom of the round neck.
17. The Supply and Return hoses should already be connected per step 13. If not, connect hoses to the correct fittings.
18. Connect 3-phase power source to the starter box on the outside of the unit per the HE 200 instruction manual.
19. Connect the starter cable to the Power
Supply receptacle marked COOLANT
RECIRCULATOR.
CAUTION
The 115 VAC power from the TA-500 Power
Supply is to operate the starter of the
Recirculator only, it will not operate the motor.
Control Panel - TA-500
20. Mount the Control Panel in a convenient spot.
21. Connect the Control Panel cable (YELLOW/
ORANGE) to the upper receptacle (color-coded
YELLOW/ORANGE) on the rear of the Control Panel. The connections are keyed on each end. Connect the other end to the Power Supply receptacle marked REMOTE PANEL CON-
TROL.
Computer Interface Option
22. To interface the Control Panel with a Computer
Control connect the Computer Interface Cable
(BLUE/ORANGE) to the middle receptacle
(color-coded the same) on the rear of the Control Panel. Figure 2-H shows the direct relationship of the Computer Interface Cable with the Control Panel. The dotted lines indicate input and output signals required from a computer to operate the TA500 System. The Control Panel Station Select signal is optional and must be jumpered if not used.
NOTE
Refer to the Interface diagram at the back of this manual for a more detailed description of the inter-connections and functions.
Control
Panel
Line
No.
SW2 START
42
125
SW3 STOP
118
138
ON/OFF
SW1
119
G
P29
Pin No.
2
5
8
3
6
9
7
Figure 2-H
CNC Signals
(input)
WARNING
Start
Stop
Station Select
Ground
NOTE: When signals marked are not used the lines must be jumpered .
Standoff Control
The Standoff Control Panel is shipped separately. Refer to Instruction Manual for Standoff Control Installation.
Gas Connections
Do Not Stand In Front of the Valve Outlet When
Executing Step 23.
23. Examine the cylinder valve and ensure that it is clean and free of oil, grease and other foreign matter. Momentarily open the cylinder valve to blow out any dust which may be present.
24. Connect the appropriate regulator on the cylinder valve. The gas supplies must be equipped with adjustable pressure regulators capable of being set between 0 and 60 psi (0-4.1 bar) and of delivering 150 Standard Cubic Feet per Hour
(SCFH) of N2 and 400 SCFH of CO
2
or compressed air.
Pressure regulators for use with TDC units and specifically calibrated for use with nitrogen
(Cat. No. 9-2722) and carbon dioxide (Cat. No.
9-2759) are supplied when a TA-500 System is ordered. They are also available from Thermal Dynamics as accessories, as are regulators for argon/hydrogen (Cat. No. 9-3053) and compressed air (Cat.
No. 9-3022).
Installation 2-4 Manual No 0-0470
25. Connect the plasma gas supply hose (BLACK) to the plasma gas cylinder and the fitting on the rear panel of the Control Console marked PLASMA GAS.
26. Connect the secondary gas (if used) supply hose
(YELLOW) to the secondary gas cylinder and the fitting on the rear panel of the Control Console marked SECONDARY GAS.
NOTE
A typical 50-lb CO2 cylinder is capable of delivering 35 SCFH on a continuous basis. Therefore, it may be necessary to manifold several cylinders to obtain the required torch flow rate, depending on the application and duty cycle.
27. If water shield will be used as the secondary, connect secondary water supply hose (YEL-
LOW) to the water source and the rear panel of the Supply Console marked SECONDARY WA-
TER SHIELD.
NOTE:
The water source must be capable of delivering a minimum water pressure of 20 psi. This water does not need to be deionized, but in water systems with an extremely high mineral content a water softener is recommended.
Arc Starter
A box housing some of the Arc Starter components is shipped separately. It must be mounted close to the torch (usually on the torch lifter frame) and connected to the torch leads. The 16-pin connector protruding from the torch leads covering is connected to the end of the box marked WHITE/YELLOW. The wire lead color-coded RED is connected to the end of the box marked RED. The wire lead color-coded GREEN is connected to the end of the one marked GREEN.
M200 Torch
28. Check the torch to see that it is properly assembled (refer to Section 4-1).
WARNING
Underwater cutting requires special insulated torch parts. See Figure 5-10.
29. The torch is normally shipped attached to the gas and water leads. If this is not the case, refer to Section 4-1.
30. Remove the cover from the Supply Console.
31. Pass the torch leads and arc starter connector through the larger plastic bushing on the rear panel of the
Supply Console.
32. The torch leads are color-coded. Attach them to the appropriate (color-coded) fittings on the bulkhead board. Connect the arc starter plug to the receptacle marked ARC STARTER.
33. Replace the cover on the Supply Console and secure.
Hi-flow Water Shield (Optional)
NOTE:
Refer to the instruction manual packed with the
Hi-Flow Water Shield for installation instructions.
34. Connect the Hi-Flow starter control cable to the receptacle marked HI-FLOW WATER SHIELD on the front panel of the Power Supply.
CAUTION
The 115 VAC power from the TA-500 Power
Supply is to operate the contactor of the Hi-
Flow Water Shield pump only. It will not operate the motor.
1000 Amp System (Two TA-500 Power
Supplies)
To connect two (2) TA-500 Power Supplies together for a
1000 amp system the first (master) unit is connected as described in step 1 through 36. The second (slave) unit is connected per steps 1 through 11 with the additional interconnecting step.
35. Connect the end of the Parallel Control cable colorcoded WHITE to the receptacle marked PARALLEL
RELAY on the front panel of the first (master) Power
Supply. Connect the end color-coded YELLOW/
ORANGE to the receptacle REMOTE PANEL CON-
TROL on the second (slave) unit.
NOTE:
There should be 2 negative (GREEN) cables from each of the two Power Supplies to the Supply Console and 2 positive (RED) work cables from each of the two Power Supplies to the workpiece.
36. Inspect all connections to ensure that they are securely made and tightened. Check that all covers and panels are replaced and secured.
Manual No 0-0470 2-5 Installation
CAUTION
Do not attempt to operate this system unless all parts of all enclosures are in place. This is important for proper cooling as well as for safety.
WARNING
Care should be taken when working around the unit when the power is turned on. No changes of electrical connections or torch parts should be attempted unless the primary power is first turned off.
37. Turn on the primary power and verify the direction of rotation of the fan motor. It should blow air out the back of the unit. If air is not blown out the back of the unit, the rotation is incorrect and any two motor leads (lines 44, 45, or 46) on the transformer terminal board should be switched.
38. When the ON-OFF switch on the Control Console is moved to ON the HE 200 should come on. Run the Coolant Recirculator for several minutes to remove air trapped in the lines. After running for a few minutes, turn the
Recirculator OFF and remove the reservoir cap.
Bring the coolant up to the level of the crosswires and install the Reservoir Cap/Cartridge Assembly supplied with the unit. Replace the cover and secure.
39. The System is now ready for operation.
Installation 2-6 Manual No 0-0470
SECTION 3: OPERATION
3.1
Operating Controls
1
2
AC POWER
3
READY
ON
4
OFF
5
0 200 400 600 800 1000
D.C. AMPERES
5 6
3
4 7
8
2 9
1 10
CURRENT CONTROL
9
START
NORMAL
SOFT
START
PIERCE
8
6
STOP
RUN
PURGE
SET
7
Red STOP button is pressed to stop the cutting cycle and turn off the power to the torch.
7. RUN/PURGE/SET Switch (SW6)
Move to the PURGE (center) position to purge the plasma gas in the torch. SET (down) position is used to set the plasma and secondary flow rates.
The Power Supply cannot be actuated in either the
PURGE or SET position but will operate normally in the RUN (up) position.
8. NORMAL/SOFT START/PIERCE Switch (SW2)
This three-way switch is used to set the mode of operation of the Power Supply. Most cutting will be done in the NORMAL (up) position. For rapid piercing the PIERCE (down) position gives a current surge when the torch is first started. The SOFT
START (center) position is a low power start which is useful in prolonging the orifice life of small tips.
9. START Switch (SW2)
Green START button is pushed to initiate the cutting cycle.
Figure 3-A Operator Control Panel
1. Ammeter (AM)
Indicates amperage supplied to torch.
2. AC POWER Indicator (LT3)
Red light indicates that Primary AC power is being supplied to the system.
NOTE: Fan is on when light is on.
3. “Ready” Indicator (LT4)
Amber light indicates that the ON/OFF switch is in the ON position and that all system requirements are met.
4. ON/OFF Switch (SW1)
Move up to ON position to turn on HE 200 and activate control circuits. Move down to OFF position to deactivate control circuits.
5. CURRENT CONTROL Knob
Adjust knob while cutting until desired current is read on Ammeter.
6. STOP Switch (SW3)
Manual No 0-0470 3-1 Operation
11 10
12 13 14
1FU
2FU
3FU
4FU
AC POWER
DC POWER
PILOT
AUTO
MAN
SURFACE
UNDERWATER
DO NOT SWITCH
UNDER LOAD
ON
HI-FLOW
WATER SHIELD
OFF
100
200 300 400
AMPERES
D.C.
500
100
200 300 400
VOLTS
D.C.
500
14. HI-FLOW WATER SHIELD ON/OFF Switch (SW8)
The ON position activates the circuitry for the hi-Flow
Water shield (optional) control. The OFF position deactivates the circuit.
15. Voltmeter
Indicates the voltage between the torch electrode and the workpiece (voltage on main bridge rectifier). Useful in troubleshooting.
16. Ammeter
Indicates amount of cutting current being supplied from the Power Supply to the torch.
19 21 17
PLASMA
18
SECONDARY
COOLANT
16 15
Figure 3-B TA-500 Power Supply Front Panel
GAS
WATER
SHIELD
10. AC POWER Indicator
Red light indicates that Primary AC power is being supplied to the Power Supply.
NOTE: Fan should be running when this light is on.
11. DC POWER Indicator
Red light indicates that main contactor (W) has closed to supply current to the main bridge rectifier and that cutting current is available.
12. PILOT AUTO/MAN Switch (SW9)
With the switch in the MAN position the pilot arc will start two seconds after the green START button is pressed and will stay on for 2 seconds only.
The main cutting arc must transfer in this time. If the pilot arc goes out press the red STOP button, and the green START button to recycle the torch.
The torch must be recycled after each cut to start the pilot arc again. In the AUTO position the pilot arc will remain on until the cutting arc is transferred and will restart when the cutting arc goes out.
13. SURFACE/UNDERWATER Switch (SW8)
Selects the proper resistance value of the pilot resistor for the type of cutting operation.
NOTE: Do not switch under load.
20
Figure 3-C Supply Console Front Panel
17. PLASMA Gauge
Indicates pressure at which plasma gas is being supplied to the torch.
18. SECONDARY Gauge
Indicates pressure at which secondary gas is being supplied to the torch.
19. SECONDARY Flowmeter
Indicates flow rate at which secondary water is being supplied to torch.
20. GAS/WATER SHIELD Switch (SW7)
Used to select either gas or water as a secondary.
21. COOLANT Gauge
Indicates pressure at which coolant is supplied to the torch.
Operation 3-2 Manual No 0-0470
3.2
Pre-Operation Set-up
This procedure should be followed at the beginning of each shift:
WARNING
Check to be sure main disconnect switch is open.
1. Check the coolant level in the Coolant
Recirculator and fill to proper level if necessary.
2. Check the torch to be sure it has the proper components and is assembled and adjusted correctly.
3. Close the main disconnects supplying 3-phase power to the Power Supply, Coolant
Recirculator and Hi-Flow Water Shield (if used).
4. Turn the ON/OFF switch on the Control Panel to ON. The Coolant Recirculator will come on.
The amber READY light will come on. (If the gas supply is on, the gases will flow for 2 seconds).
5. Select the plasma gas pressure for the type of cutting to be done from Table 3-B. Move the
RUN/SET/PURGE switch to the SET position.
Open the plasma gas supply valve at the source.
Adjust the pressure regulator on the gas supply until the plasma pressure selected from the
Table is obtained.
6. Move the switch to PURGE for approximately
3 minutes (this allows the plasma gas to run).
This will remove any condensation or moisture that may have accumulated in the torch while it was shut down. If there is any sign of moisture after purging, determine the cause and correct it before operating the system.
NOTE:
Only the plasma gas needs to be purged.
7. Return the RUN/SET/PURGE switch to the
SET position and open the secondary supply valve at the source. Adjust the pressure regulator at the gas supply until pressure reads 60 psi (4.1 bar) or turn on the secondary water if water shield cutting and set at about 12 gph.
8. Return the RUN/SET/PURGE switch to the
RUN position.
9. Set the CURRENT ADJUST knob on the Control Panel for desired amperage level.
10. Check the position of the HI-FLOW WATER SHIELD
ON/OFF switch and the PILOT AUTO/MAN switch on the Power Supply for desired operating mode.
Surface or Underwater Cutting
11. The two cutting modes, Surface and Underwater, require a different pilot resistance. This is easily selected using the SURFACE/UNDERWATER switch on the TA500. The M200 torch also requires different parts for underwater operation. Refer to Section
4.1 for details.
Bevel Cutting
12. Bevel cutting requires a greater standoff distance due to the angle of the torch. The pilot resistance therefore must be changed to ensure that the main arc will transfer and that proper standoff will be found when using an SC504 Standoff Control. The proper resistance for surface bevel cutting is obtained by moving the SURFACE/UNDERWATER switch to the
UNDERWATER position.
When bevel cutting, underwater resistance value of the pilot resistor (R2) must be adjusted. Consult the
Thermal Dynamics Customer Service Department for assistance in obtaining the correct resistance value.
The system is now ready for operation.
3.3
Operation
WARNING
Be sure the operator is equipped with proper eye and ear protection and that all precautions in the front of this manual have been followed.
1. The M200 torch must be at right angles to the plate to obtain a clean, vertical cut. Use a square, as shown in Figure 3-F, to align the torch.
Manual No 0-0470 3-3 Operation
3. Adjust the cutting speed for good cutting performance, as indicated by a trailing arc of approximately
5 degrees (Fig. 3-G).
5 o Approx.
Figure 3-F Using a Square to set up the M200 Torch
2. To start a cut at the edge of the plate, line up the torch away from the plate and press the START button on the Control Panel. The pilot arc characteristics will depend on which PILOT mode is selected (see 3.1.12) and the position of the
SURFACE/UNDERWATER Switch (3.1.13).
The cutting arc will be established at the plate edge as the torch approaches the plate.
Figure 3-G Proper Cutting Speed Produces a Trailing
Arc of Approximately 5 Degrees
4. In some cutting operations, it may be desirable to start the cut within the plate area rather than at the plate edge. Piercing is not recommended in over 2inch (50 mm) thick material when using Water Shield.
When a lot of piercing is required, a special tip (Cat.
No. 8-6047) and end cap (Cat. No. 8-6057) should be used. To pierce, set the NORMAL/SOFT START/
PIERCE switch to the PIERCE position (see 3.1.8).
NOTE:
The suggestions listed below should be followed in all cutting operations:
1. At shut down wait five minutes before moving the ON/OFF switch to OFF and opening the main disconnect switch. This allows the Power
Supply and torch to cool down.
2. For maximum parts life, do not operate the pilot arc any longer than necessary.
3. Remember that cutting current can be adjusted at any time (see Instruction Manual for Standoff Control). Learn to change the current output to provide a comfortable working speed for the particular material being cut.
4. Use care in handling torch leads and protect them from damage.
Operation 3-4 Manual No 0-0470
5. In continuous cutting applications, it is often necessary to manifold 4 to 6 CO
2 maintain pressure.
cylinders together to
6. Because of the swirl of the plasma gas in the torch, the right-hand side of the cut (in relation to the torch travel, as shown in Fig. 3-H) is normally of better quality. A reverse swirl electrode is available for applications requiring the better quality be on the left side of the cut (in relation to the torch travel).
Scrap
(Beveled)
Side
Better
(Square)
Side
Torch Travel
Figure 3-H Direction of Gas Flow Using Standard Gas
Distributor
3.4
Cutting and Speed Selection
The desired cutting current and the speed at which the torch is moved along the line of the cut depends on the thickness and composition of the workpiece. Use Table 3-B as a starting guide to establish the proper cutting speed for the material being cut.
COMMON CUTTING FAULTS
Listed below are common cutting problems followed by probable causes of each. If problems are caused by the TA-500 system, refer to the trouble shooting section (Section 4).
1. Insufficient Penetration a. Cutting speed too high b. Current too low
2. Main Arc Extinguishes a. Cutting speed too slow b. Standoff too high
3. Dross Formation a. Improper gas pressure or mixture b. Improper cutting speed c. Faulty electrode or tip d. Current too high e. Stand-off too low
4. Burned-Out Tips a. High cutting current b. Damaged or loose cutting tip c. Contact with work d. Heavy spatter e. Low plasma gas pressure f.
Improper selection of SOFT/NORM/PIERCE
WARNINGS
FREQUENTLY REVIEW THE SAFETY PRECAU-
TIONS GIVEN AT THE FRONT OF THIS
MANUAL.
It is not enough to simply move the ON/OFF switch on the Control Panel to its OFF position when cutting operations have been completed.
Always open all power disconnect switches 5 minutes after the last cut is made.
Manual No 0-0470 3-5 Operation
Table 3-B Recommended Cutting Speeds
The following charts are intended as a guide in determining approximate conditions for making good quality cuts in various thicknesses of material. Slower speeds may generally be obtained by reducing the current.
250 Amperes
The speeds below are typical for cutting at 250 amperes using the 8-6042 tip and the 8-6006 end piece.
GENERAL PURPOSE
Plasma gas: N2 at 60 psi (4.1 bar) (85 scfh)
Secondary gas: CO
2
at 60 psi (4.1 bar) (85 scfh)
WATER SHIELD
Plasma Gas: N2 at 60 psi (4.1 bar) (85 scfh)
Secondary: Water - 12 gph
THICKNESS:
INCHES/MINUTE (METERS/MINUTE)
1/4" (6 mm)
BEST MAX
Stainless Steel 140 (3.56) 250 (6.35)
1/2" (12.7 mm)
BEST
85 (2.16)
MAX
125 (3.18)
Aluminum
Carbon Steel
135 (3.43) 250 (6.35)
100 (2.54) 200 (5.08)
100 (2.54)
60 (1.52)
135 (3.43)
80 (2.03)
500 Amperes
The speeds below are typical for cutting at 500 amperes using the 8-6044 tip and the 8-6006 end piece.
GENERAL PURPOSE WATER SHIELD
Plasma gas: N2 at 60 psi (4.1 bar) (95 scfh)
Secondary gas: CO
2
at 60 psi (4.1 bar) (350 scfh)
Plasma Gas: N2 at 60 psi (4.1 bar) (95 scfh)
Secondary: Water - 12 gph
THICKNESS:
Stainless Steel
Aluminum
Carbon Steel
INCHES/MINUTE (METERS/MINUTE)
1/2" (12.7 mm) 3/4" (19 mm)
BEST MAX BEST
150 (3.81) See Note B 90 (2.29)
MAX
125 (3.18)
180 (4.57) See Note B 110 (2.79) 140 (3.56)
75 (1.9) 125 (3.18) 55 (1.4) 75 (1.9)
THICKNESS:
Stainless Steel
Aluminum
Carbon Steel
INCHES/MINUTE (METERS/MINUTE)
1" (25.4 mm) 1-1/2" (38 mm)
BEST
60 (1.52)
80 (2.03)
35 (0.89)
MAX
80 (2.03)
100 (2.54)
50 (1.27)
BEST
40 (1.02)
50 (1.27)
20 (0.51)
MAX
50 (1.27)
60 (1.52)
30 (0.76)
THICKNESS:
Stainless Steel
Aluminum
Carbon Steel
INCHES/MINUTE (METERS/MINUTE)
2" (50.8 mm)
BEST
25 (0.64)
35 (0.89)
15 (0.38)
MAX
30 (0.76)
45 (1.14)
25 (0.64)
Operation 3-6 Manual No 0-0470
750 Amperes
The speeds below are typical for cutting at 750 amperes using the 8-6045 tip and the 8-6006 end piece.
GENERAL PURPOSE
Plasma gas: N2 at 60 psi (4.1 bar) (100 scfh)
WATER SHIELD
Plasma Gas: N2 at 60 psi (4.1 bar) (100 scfh)
Secondary gas: CO
2
at 60 psi (4.1 bar) (350 scfh)
THICKNESS:
Stainless Steel
Aluminum
Carbon Steel
Secondary: Water - 12 gph
INCHES/MINUTE (METERS/MINUTE)
1/2" (12.7 mm) 3/4" (19 mm)
BEST MAX BEST MAX
180 (4.57) See Note B 120 (3.05) 150 (3.81)
200 (5.08) See Note B 160 (4.06) 180 (4.57)
140 (3.56) See Note B 75 (1.9) 95 (2.41)
THICKNESS:
Stainless Steel
Aluminum
Carbon Steel
INCHES/MINUTE (METERS/MINUTE)
1" (25.4 mm) 1-1/2" (38 mm)
BEST
80 (2.03)
100 (2.54)
50 (1.27)
MAX
100 (2.54)
130 (3.3)
65 (1.65)
BEST
50 (1.27)
80 (2.03)
30 (0.76)
MAX
60 (1.52)
100 (2.54)
40 (1.02)
1000 Amperes
The speeds below are typical for cutting at 1000 amperes using the 8-6046 tip and the 8-6006 end piece.
For material under 3” (76 mm) thick:
GENERAL PURPOSE
Plasma gas: N2 at 60 psi (4.1 bar) (110 scfh)
Secondary gas: CO
2
at 60 psi (4.1 bar) (350 scfh)
For material over 3” (76 mm) thick:
GENERAL PURPOSE
Plasma Gas: N2 at 60 psi (4.1 bar) (110 scfh)
Secondary: Ar/H
2
at 25 psi (1.7 bar) (250 scfh)
THICKNESS:
Stainless Steel
Aluminum
INCHES/MINUTE (METERS/MINUTE)
2" (51 mm) 2-1/2" (64 mm)
BEST
50 (1.27)
60 (1.52)
MAX
65 (1.65)
75 (1.9)
BEST
35 (0.89)
55 (1.4)
MAX
50 (1.27)
70 (1.78)
THICKNESS:
Stainless Steel
Aluminum
INCHES/MINUTE (METERS/MINUTE)
3" (76 mm)
BEST MAX
20 (0.51)
40 (1.02)
30 (0.76)
60 (1.52)
4" (102 mm)
BEST
10 (0.25)
20 (0.51)
MAX
Note A: This information represents our best judgement but Thermal Dynamics Corporation assumes no liability for its use.
Note B: Exceeds maximum speed of most motorized torch carriers.
Manual No 0-0470 3-7 Operation
Operation 3-8 Manual No 0-0470
SECTION 4: SERVICE
The Service Section is divided into nine parts:
4.1 Torch Maintenance
4.2 TAC 500 Power Supply Maintenance
4.3 HE 200 Coolant Recirculator Maintenance
4.4 Gas Pressure Regulators
4.5 Troubleshooting Guide
4.6 Returns
4.7 Primary Voltage Selection
4.8 Trouble-Shooting
4.9 Test Procedures
WARNING
Disconnect the primary power before disassembling the torch.
4.1
Torch Maintenance
Disassembly
1. Unscrew the collar (19) and pull the end cap
(17) off. The end piece (16) and O-ring (15) will remain in the end cap when it is removed.
2. Remove the coolant baffle (20) from the front of the inner tip retainer (9).
3. Pull the outer insulator (13) off.
4. Unscrew the inner tip retainer (9). The cutting tip will remain in the inner tip retainer. If additional leverage is needed to remove this part insert a 5/32 inch diameter rod in one of the large holes.
5. Remove the tip (6) from the inner tip retainer by pressing back on the front of the tip. Considerable pressure may be needed to push the tip past the O-ring seals.
6. Remove the electrode (5) from the torch by unscrewing it from the electrode seat (4). The electrode seat does not need to be removed from the torch unless it has been damaged.
7. Remove the water tube (2) by lifting it out of the torch.
Manual No 0-0470 4-1
18
18
1
3
21
2
12
20
15
16
14
10
11
12
13
14
17
4
3
5
7
6
8
9
19
Figure 4-A M200 Torch
Service
For routine disassembly of the torch, no other parts need to be removed. The electrode seat (4) does not require replacement unless it has been damaged by a severe electrode failure. This part unscrews from the center post of the torch and should be gripped with a piece of emery cloth. If necessary, pliers may be used very gently to remove this part.
Torch Assembly
CAUTION
There are several O-ring seals in this torch to prevent leakage of the coolant. It is important to observe the following precautions for all O-rings:
A. Make sure that the O-ring groove and the surface that the O-ring will seal against are clean and free of nicks and scratches.
B. Make sure that the O-ring is not cut or cracked.
C. Lubricate all O-rings with a light coating of Cat.
No. 8-4025 O-ring lubricant. This should be used sparingly, just enough to make the O-ring slippery but not enough to accumulate in the torch.
If a new electrode seat (4) is installed in the torch, the
O-ring (3) in the center post of the torch should be replaced before installing the new one. The new electrode seat may be gripped with emery cloth and screwed into the center post of the torch. It is not necessary to use pliers.
When assembling the torch, proper orientation of the coolant baffle (20) relative to the M200 basic head assembly (1) is important. The basic head assembly has two projections on the sides of the plastic body that are called ‘marks’ in step 8 below.
Assemble the torch as follows:
1. Install a new O-ring in the electrode seat. This
O-ring is included with each new electrode. The
O-ring is installed in the groove located about
3/8” (9.5 mm) back from the front of the electrode seat.
2. Install the water tube (2) in the center of the torch, small end first.
3. Install the electrode (5). Make sure it screws in all the way.
4. Install new O-rings in the inner tip retainer (9).
These O-rings (7 and 8) are supplied with each new cutting tip. The should be lubricated lightly with Cat. No. 8-4025 O-ring lubricant and placed in the proper groove in the tip retainer.
Service 4-2
18
18
1
3
21
2
12
20
15
16
14
10
11
12
13
14
17
4
3
5
7
6
8
9
19
Figure 4-B M200 Torch
Manual No 0-0470
5. Install the new tip (6) in the inner tip retainer.
This is installed by pressing it in from the back.
If the O-rings are properly lubricated, thumb pressure is adequate (with a slight twisting motion of the thumb).
6. Install the inner tip retainer with the tip in place on the front end of the torch. The tip retainer must be screwed completely into place. It is essential that the ceramic O-ring on the tip be firmly in contact with the electrode.
7. Install the outer insulator (13) on the torch.
Before pushing this into place, make sure that the O-rings on the inside diameter are in good condition and properly lubricated. The insulator must be pushed onto the torch as far as it will go.
8. Install the coolant baffle (20) on the front of the inner tip retainer. The triangular projections go into the holes in the inner tip retainer that are aligned with the marks on the plastic torch body.
If the holes do not align exactly, use the closest ones. DO NOT loosen the inner tip retainer to improve the alignment.
9. Install the end piece (16) in the front of the end cap, small end forward.
10. Install O-ring (15) in the end cap against the back of the ceramic end piece. A light coating of O-ring lubricant will help hold this O-ring in place until the end cap is installed.
11. Press the end cap (17), complete with end piece
(16) and O-ring (15) in place, onto the outer insulator (13). Install the collar (19) over the end cap (17) and screw it onto the torch body.
This completes the torch assembly. There is a chance that water may get in the plasma gas passages in the torch during assembly. All water must be removed before operation.
To remove all traces of water:
1. Turn the Console RUN/SET switch to SET.
2. Turn on the coolant.
3. Turn on the plasma gas (nitrogen). Do not turn on the shield water (water shield cutting). The shield gas may be on or off (dual flow cutting).
4. With plasma gas flowing, look for traces of moisture in the gas stream.
WARNING
Do not operate the torch unless the plasma gas stream is completely free of moisture.
Be sure to turn on the secondary gas or shield water before starting to cut.
4.2
The only routine maintenance the TAC 500 Power Supply requires is an occasional removal of the cover and side panel and a thorough blowing out of dust with an air hose.
4.3
TAC 500 Power Supply
Maintenance
HE 200 Coolant Recirculator
Maintenance
Parts in the HE 200 Coolant Recirculator require routine maintenance. The coolant level should be checked daily and Thermal Arc coolant added to keep the level at the crosswires in the cylindrical section. If Thermal
Arc coolant is not available, distilled or deionized water may be used if the temperature does not go below freezing. The resistivity of the water must measure above .1 megohm cm.
CAUTION
Do not use tap water. It could cause severe damage to the torch.
The reservoir contains a cap/cartridge assembly which includes a small cartridge of deionizing resin to maintain the resistivity of the coolant. The cartridge must be replaced when it changes from gray to straw color.
A coolant filter with a reusable screen is located above the pump. The screen should be removed and cleaned once every six months or at any time the coolant pressure drops. To remove the filter screen, remove the top of the HE 200 unit and unscrew the hex nut on the bottom of the filter housing.
The coolant recirculator has a pressure relief valve that is factory set at 150 psi (10.3 bar) and should not require adjustment. Normal operating pressure is approximately 110 psi (7.6 bar). If the pressure relief valve must be adjusted see the HE-200 manual.
Manual No 0-0470 4-3 Service
The pump is pre-greased at the factory and should only require lubrication every two years. To lubricate, remove screws from the two grease fittings on top of the pump and apply grease supplied with the HE 200 unit.
CAUTION
Do not over-lubricate the pump; it will cause pump failure.
The fan belt may become loose due to usage. The belt tension should be such that moderate finger pressure
(about mid-distance from pulley to pulley) gives about
1/4 inch (6 mm) deflection. The belt tension may be adjusted by changing the width of the gap on the large adjustable pulley. Using a 5/32 hex key wrench loosen the two set screws 180 degrees apart on side of pulley.
Remove key and rotate by half turns until desired gap is obtained. Replace the square key and tighten set screws again.
1
A-01894
2 3
6
4
5
4.4
Gas Pressure Regulators
The Thermal Arc gas pressure regulators provide a means of conveniently selecting and maintaining the required working pressures of the gases. The regulator will hold this pressure constant. Inlet pressure is reduced in one step to the working pressure by means of a pressure balanced poppet valve controlled by a spring loaded piston in a low pressure chamber. A large adjusting spring knob (6, Figure 4-C) provides for adjusting spring pressure against its piston. A sintered stainless steel filter, in the inlet connector (1), prevents dirt from entering the regulator mechanism.
No regular maintenance of the gas pressure regulators is required, except an occasional lubrication of the adjusting screw thread and on its end, where it contacts the adjusting spring. Lubricant is available from Thermal Dynamics for this purpose (Catalog No. 9-2781).
Replacement parts in the regulator include the pressure gauges, the O-ring seals on the piston and above the poppet valve, and the poppet valve. (See Assembly Parts List Fig. 5-12 for replacement parts).
1. Inlet connection
2. Inlet pressure gage
3. Safety valve
4. Working pressure gage
5. Hose connection
6. Adjusting knob
Figure 4-C Components of Gas Pressure
Regulator
Do not attempt to remove the sintered metal filter in the inlet connection. This is not a serviceable item.
CAUTION
Service 4-4 Manual No 0-0470
Manual No 0-0470 4-5 Service
4.5
If the TA-500 System malfunctions the troubleshooting guide will be helpful in correcting the problem. Since the malfunction may be due to a faulty connection rather than a faulty component, be sure to check all connections to a component that appears to be malfunctioning.
The troubleshooting guide is arranged in the normal operating sequence of the system for easy reference. Each problem has listed next to it the possible causes and the remedy.
In some cases the remedy is too complex to fit the table, in which case there is a reference to one of the “Test Procedures”.
4.6
Returns
If a product must be returned for service, contact your distributor. Material returned without proper authorization will not be accepted.
4.7
The TA500 transformers are manufactured for two voltage ranges. These ranges are specified on the Serial
Number Tag attached to the front of the unit. If the voltage ranges must be changed, the proper connections are shown on the transformer terminal board.
4.8
Troubleshooting Guide
Primary Voltage Selection
Trouble-Shooting
Some of the circuitry of the Standoff Control can affect the characteristics of the Power Supply and Torch, therefore it should be disconnected at the connection marked
POWER SUPPLY on the bottom left hand side of the
SC electronic unit inside the Power Supply. The jumper connector, mounted to the wiring harness, should be connected to the wiring harness connector. This will avoid any interference of the Standoff Control while troubleshooting the Power Supply. (See SC 504 instruction manual for trouble-shooting the Standoff Control).
A. No AC POWER Light on TAC 500.
1. Blown fuse or open circuit breaker at primary.
1. Replace fuse or reset breaker.
B. No AC POWER Light on Control Panel.
1. Supply Console cover interlock switch (SW5) not actuated or bad.
a. Check cover for proper installation. Replace
SW5 if bad.
2. Blown fuse (4Fu) in TAC 500.
a. Replace fuse.
C. No READY Light (Control Panel).
1. Coolant pressure switch PS2 in Supply Console open
(pressure below 75 psi/5.2 bar).
a. Check coolant level in HE200. Clean pump filter screen. Adjust pump. Replace pump.
2. Pressure switch PS2 in Supply Console not satisfied.
a. Adjust (75 psi/5.2 bar) or replace PS2. (See
A, Section 4.8).
D. Gases do not flow when “ready” Light comes on.
1. Gas supply not on.
a. Open valve.
2. Faulty post flow time delay (TD1).
a. Check TD1 (See B, Section 4.8).
E. Gases flow more than 2 seconds.
1. RUN/SET/PURGE switch in set.
a. Move to RUN.
2. Faulty post flow time delay (TD1).
a. Check TD1 (See B, Section 4.8).
F. Cannot set desired gas pressures.
1. Empty gas cylinders.
a. Replace.
2. Faulty gas regulator.
a. Repair or replace.
3. Faulty Solenoid Valve.
a. Replace.
When the START button is pressed, the gases and red
DC POWER Light should come on. If this does not happen, check as follows:
G. Gas does not flow when START button is pressed.
1. Faulty control relay 4CR.
a. Check relay (See C, Section 4.8).
2. START switch SW9 not closing.
a. Check for continuity when pressed.
3. No 24 volt power.
a. Check transformer T2.
Service 4-6 Manual No 0-0470
H. No red DC POWER Light.
1. Pressure switch PS3 in Supply Console not satisfied.
a. Check gas pressure setting (Plasma 60 psi/
4.1 bar).
2. Pressure switch out of adjustment.
a. Reset (See A, Section 4.8).
3. Main transformer overheated.
a. Allow to cool down.
4. Faulty main contactor (W).
a. Check contactor (See D, Section 4.8).
The Pilot Arc should start 2 seconds after the red DC
POWER Light comes on. If it does not, check the torch parts to make sure they are in good condition and properly assembled. Next, check the Arc Starter unit for loose connections and components for obvious failures.
Check to see if:
1) There is any “click” inside the Power Supply at the time the Pilot Arc should start (2 seconds after pushing
START button).
I. No “click” inside the Power Supply 2 seconds after the START button is pushed.
1. Faulty time delay TD2.
a. Check TD2 (See B, Section 4.8).
2. Faulty pilot control relay (PCR) a. Check PCR
J. No Pilot Arc (or intermittent).
1. Damaged (defective) Torch parts.
a. Replace.
2. Dirty (wet) Plasma gas.
a. Purge.
b. Check for leaks on hoses and fittings.
c. Replace gas cylinders.
K. No Pilot Arc at all.
1. Blown pilot fuse (1Fu or 2Fu) a. Replace.
2. Pilot contactor (PCR) not closing a. Check PCR
3. Broken conductor in lead a. Replace lead.
4. Loose connection a. Repair.
5. Gas purge relay (TD2) not closing a. Replace TD2.
6. CSR activating prematurely.
a. Check for shorted toroid (See E, Section 4.8) or bad relay P.C. board.
7. Pilot Bridge diodes (D17, 18, 19, 20) failed.
a. Check diodes (see G, Section 4.8, and Q, Section 4.8).
8. Arc Starter transformer (T3) failed.
a. Check (See F, Section 4.8) and replace.
9. Diodes in Arc Starter Box shorted or open.
a. Check (See G, Section 4.8).
10. Arc Starter failed.
a. Replace.
L. Weak Pilot Arc.
1. Faulty Arc Starter/Shunt PC Board a. Check PC Board (See N, Section 4.8). Replace if needed.
2. Dirty coolant in HE200 a. Check HE200 deionizer cartridge (Section
4.3)
The Cutting Arc should start as soon as the torch, with
Pilot Arc running, is brought to within about 1/2 inch
(12 mm) of the workpiece. If it does not, check:
M. No Cutting Arc.
1. Work Cable not connected.
a. Connect.
2. One leg of 3 phase primary power out.
a. Check all 3 input phases for voltage.
3. One leg of main contactor (W) not closing.
a. Check voltage at diodes.
4. Main contactor (W) fails to operate.
a. Check relay (1CR); replace if needed.
b. Check thermal protection switch (TP1, 2, 3); replace if needed.
c. Replace contactor.
Manual No 0-0470 4-7 Service
d. Check jumper wire in J8 connector; replace if faulty.
5. Reactor and/or transformer overheated due to exceeding the amperage rating of the Power Supply or air flow restricted.
a. Reduce amperage to recommended ratings. Clear air passages.
Once the Cutting Arc is established, the cutting current reading on the Control Panel ammeter should be adjustable by turning the CURRENT CONTROL knob. If it is not, there is a problem in the current regulating circuit as follows:
N. Unit only puts out minimum current (125 A).
1. Fuse 3Fu blown.
a. Replace.
2. Fuse blows again.
a. Check diodes and SCRs in control bridge (See
J & Q, Section 4.8).
3. Potentiometer failed.
a. Check (See K, Section 4.8).
4. Reactor disconnected.
a. Check (See L, Section 4.8).
5. Current Control P.C. board failed.
a. Check (See I, Section 4.8).
6. Relay CSR not closing.
a. Bad CSR. Replace (See M, Section 4.8).
b. Loose wire on toroid (T4). Correct.
c. Bad toroid (T4). (See E, Section 4.8).
d. Check Arc Starter PC Board (See N., Section
4.8).
O. Unit only puts out maximum current (500+ A).
1. Arc Starter/Shunt P.C. board failed.
a. Check P.C. board (See N, Section 4.8). Replace if faulty.
2. Current Control PC Board failed.
a. Check PC Board (See I, Section 4.8). Replace if faulty.
P. Unit can only put out about 375 amps maximum.
1. Current Control P.C. board failed.
a. Check P.C. board (See I, Section 4.8).
2. One SCR failed.
a. Check SCRs (See O, Section 4.8).
Cut quality begins okay but deteriorates during the cutting process.
Q. Deteriorating cut quality.
1 Frozen CO2 regulator.
a. Add heater.
b. Replace with high flow regulator.
2. Cylinder not delivering.
a. Manifold several cylinders together.
If the Torch parts life is short, check:
R. Short torch parts life.
1. Pilot arc remains on during cut.
a. Check CSR (See M, Section 4.8).
2. No prepurge gas flow.
a. Check time delay relay.
3. No post purge gas flow.
a. Check time delay relay.
4. Misuse of torch.
a. Use torch with ratings for current and work thickness.
5. Incorrect gas pressure.
a. Check and correct.
6. Inadequate coolant flow.
a. Clean filter in HE200.
b. Adjust or replace pump in HE200.
7. Restricted coolant hose or lead.
a. Remove restriction or replace hose.
S. Discolored Electrode.
1. Contaminated gas.
a. Check plasma gas system for leaks.
2. No pre or post purge.
a. Check TD1 and TD2 (See B, Section 4.8).
3. Gas hoses switched.
a. Check.
Service 4-8 Manual No 0-0470
4.9
Test Procedures
The following tests are suggested for specific problems listed in the preceding trouble shooting chart. The letter designation corresponds to those listed in the “Remedy” section of the chart.
WARNING
Several of these tests involve voltage measurements that must be made with power on. In order to make these measurements, the Supply
Console cover interlock switch must be propped closed or bypassed. Use extreme care when making these tests and be sure to return the interlock switch to proper operation after work is completed.
Test requiring voltage measurements are marked with the warning symbol: at the connections from the reactor. (220 volt 3 phase power should always be present at lines 105, 106 and
107 when the primary power is turned on).
E. To check the toroid coil, measure the resistance from
J400-5 to J400-6. It should be 22 ohms.
F. The Arc Starter transformer (T3) has two different voltage outputs to check to verify its status. Using a voltmeter, place the probes between J400-19 and 20. This voltage should measure
280-330 VAC. Measure the voltage between J400-15 and 17. This should read 10-15VAC. Both voltages must check out or the transformer is faulty.
G. A “quick check” can be made on the main diodes without removing them from the circuit as follows:
Using an ohmmeter with the RX1 or RX10 scale, measure the resistance of each diode in both directions. The readings should differ by at least a factor of 10. If they do not differ (both high or both low) the diode has failed and must be replaced.
All other tests are to be made with the primary power to the system turned off.
A. Pressure switches are located in the Supply Console on the PLASMA GAS line just inside of the solenoid valve on the inlet fitting and on the line running from the power manifold to the
NEG connection on the bulkhead board. The switches are normally open. The pressure at which the switches will close may be adjusted by turning the knurled wheel just under the plastic part of the switch. Turn clockwise to increase the pressure at which switch is actuated.
B. The two time delay relays, TD1 and TD2, are interchangeable and can normally be checked by swapping them. They are the “delay on operate” type with a 2 second delay.
C. The relay can be tested by removing it from the relay socket and with the power on, measure the voltage between pins A and B on the socket.
The voltage should read close to the voltage specified for the relay. If it is, then the relay is bad. If not, then the trouble lies in the circuitry.
D. To check the main contactor remove the left side panel of the machine. The contactor should close when 115 volt AC is applied to lines 1 and
80 (when the START button is pressed). At this time, 220 volt 3 phase power should be present
Manual No 0-0470 4-9
H. The 3-phase AC input to the main bridge rectifier is
220 volts. This can be measured at the top of the main bridge rectifier where the diode pigtails are joined with the reactor leads (see Fig. 5-8) at any time that the DC power light is on.
I. The best way to check the P.C. board is to replace it with one known to be good. The current control PC board in the PAK 10, 22, 44, and 350 can be used.
J. Locate the control bridge (see Fig. 5-8). Disconnect the multi-conductor plug next to this component.
Using an ohmmeter with the RX10 scale, all diodes should be checked for high resistance in one direction and low resistance in the other direction. The
SCRs should read a high resistance in both directions. If diode D16 is shorted, see ‘R’ below.
K. Remove the current regulating printed circuit card
(see illustration below) from the power supply. With the CURRENT CONTROL knob set at MIN measure the resistance between the 3rd (pin 20) and 7th (pin
16) pins, counting from the top (see below). This should read 0 ohms and increase smoothly to 10,000 ohms as the CONTROL knob is rotated to MAX.
Now measure the resistance between the 3rd (pin 19) and 4th (pin 20) pins. This should read 10,000 ohms.
Service
22
19
16
20
L. With the control bridge connected to the circuit, measure the resistance across the diode on the center heat sink in both directions. It should read about 5 ohms both ways.
M. The coil of relay CSR should read about 3K ohms measured from pin A to pin B on bottoms of relay.
N. The easiest way to check the PC Board is to replace it with one known to be good.
1. An in-rush current surge is the most probable cause of main diode failure. The in-rush surge is prevented by capacitor C4 and resistor R6,10 in series with each other across the output of the bridge rectifier. The capacity and resistor, as well as the wires connecting them to the circuit, should be completely checked in any case of diode problems. The capacitor is a polarized capacitor, and it is important to be sure that the side marked + is connected to the positive side of the circuit.
2. High frequency protection for the diodes is provided by capacitors C5, C6 and C7 which are installed between each side of the bridge rectifier. These capacitors and their connections should be checked.
3. Overheating of the diode can occur if air flow over the heat sink is inadequate or if the diode is not properly fastened to the heat sink. Check to see that the diodes are torqued to 25 foot pounds
(34 Nm) and that electrically conductive heat sink compound (this is a white grease) is present between the diode and heat sink. Also check for normal operation of the fan and be sure that the air passages into and out of the unit are not obstructed.
4. The diode that was faulty at the time of manufacture is difficult to diagnose. This usually fails during the first few hours of operation. Before deciding that this was the case, be sure to check out the other three possibilities.
This concludes the trouble-shooting procedures.
O. With a soldering pencil, disconnect the ‘pigtail’ lead to the SCRs one at a time. When more than one wire is connected to the pigtail, the two wires should be connected to each other. Operate the unit with one and then the other SCR disconnected and note the maximum amperage.
The output will remain unchanged when the bad SCR is disconnected and will drop to minimum when the good SCR is disconnected.
P. Transformer T1 in the Standoff Control electronics chassis can be checked by placing the probe of a voltmeter in pins J23-18 and J23-20 of the PC board connector. This voltage should read close to 25 VAC.
Q. A bad varistor (VR) is difficult to detect by itself.
However, it will cause the D16 diode on the control bridge to short and burn out. If this happens or if the varistor looks burnt, replace both.
Service 4-10 Manual No 0-0470
SECTION 5: PARTS
LISTS
Assembly Parts List
The Assembly Parts List illustrates the parts of the
Thermal Arc 500 Cutting System and gives the catalog number for replacement parts.
An item number in parentheses indicates the item is located behind the item pointed to. An asterisk beside the item number indicates the part is a main assembly, not a component. Parts listed without item numbers are not illustrated, but may be ordered by the catalog number shown.
Oredering Information
When ordering replacements parts, order by catalog number and complete description of the part or assembly, as given in the description column of the Assembly Parts List. In addition, give the model number of the machine, the machine serial number and its operating voltages, as given on the plate attached to the unit in question. Address all inquires to your authorized distributor.
Manual No 0-0470 5-1 Parts Lists
6
7
4
5
5.1
System Components
Item No.
1
2
3
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
TA500 Power Supply
Supply Console
Operator Control Panel (Without Enclosure)
Operator Control Panel (With Enclosure)
Control Panel Enclosure (Optional)
M200 Torch with Mounting Tube
Arc Starter
HE200 Coolant Recirculator
Hi-Flow Water Shield Assembly (Optional)
15' M200 Torch Leads Package
25' M200 Torch Leads Package
35' M200 Torch Leads Package
50' M200 Torch Leads Package
15' Negative Water Cooled Lead
25' Negative Water Cooled Lead
35' Negative Water Cooled Lead
50' Negative Water Cooled Lead
15' Plasma Gas Hose
25' Plasma Gas Hose
35' Plasma Gas Hose
50' Plasma Gas Hose
15' Secondary Gas Hose
25' Secondary Gas Hose
35' Secondary Gas Hose
50' Secondary Gas Hose
15' Coolant Return Hose
25' Coolant Return Hose
35' Coolant Return Hose
50' Coolant Return Hose
15' Arc Starter Cable
25' Arc Starter Cable
35' Arc Starter Cable
50' Arc Starter Cable
15' Lead Sleeving
25' Lead Sleeving
35' Lead Sleeving
50' Lead Sleeving
* The length is shown as a suffix to the 5 digit catalog number. To order
non-standard lengths, simply specify the desired length as a suffix to the 5 digits of the catalog number for the next longer length lead.
EXAMPLE: To order a 28' Torch Leads Package, include -28 as a suffix to the first 5 digits of the catalog number for the 35' Torch Leads Package. The 28'
Torch Leads Package would then be ordered with catalog number 4-5007-28.
NOTE: Refer to Sales Catalog for complete details on System Specifications.
Ref.
Cat. No.
*9-5049-50
*9-5032-15
*9-5038-25
*9-5044-35
*9-5050-50
*9-5033-15
*9-5039-25
*9-5045-35
*9-5051-50
*9-5034-15
*9-5040-25
*9-5046-35
*9-5052-50
*9-5035-15
*9-5041-25
*9-5047-35
*9-5053-50
*9-5036-15
*9-5042-25
*9-5048-35
*9-5054-50
3-5001
3-5002
3-5007
3-5008
3-5009
2-2766
3-5003
7-3008
7-2962
*4-5005-15
*4-5006-25
*4-5007-35
*4-5008-50
*9-5031-15
*9-5037-25
*9-5043-35
Parts Lists 5-2 Manual No 0-0470
TA500 Power Supply
HE200 Coolant
Recirculator
Supply Console
Operator Control Panel
M200 Torch with Arc Starter
Manual No 0-0470
Hi-Flow Water Shield
Figure 5-1 Thermal Arc 500 Cutting System
5-3 Parts Lists
5.2
Front Panel Components
Item No.
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
Qty.
2
1
2
2
1
1
1
1
1
1
1
A/R
1
2
1
2
2
1
2
2
Description
Fuse Holder
Fuse- 20 amp
Fuse Holder
Fuse- 20 amp
Fuse- 5 amp
Toggle Switch- SPST, 2 pos.
Toggle Switch- SPDT, 2 pos.
Panel Indicator (red)
Ammeter
Voltmeter
Plastic Bushing
2" Locknut
Twistloc Base
Receptacle- 32 Pin
Receptacle- 14 Pin
Left Corner Support
Right Corner Support
Bottom Front Panel
Top Front
Socket
Ref.
1FU, 2FU
1FU, 2FU
3FU, 4FU
3FU
4FU
SW8, SW10
SW9
LT1, LT2
A
V
J8, J9
J10, J11
Cat. No.
9-2937
8-1339
9-2936
8-1335
8-1025
9-3325
9-3426
8-1885
9-5159
9-5158
8-0241
8-0242
9-3290
9-5172
9-3293
9-5306
9-5307
9-5304
9-5305
9-3297
Parts Lists 5-4 Manual No 0-0470
16
19
13
14, 20
15, 20
HI-FLOW
WATER SHIELD
COOLANT
RECIRCULATOR
CONTROL
REMOTE
PANEL
CONTROL
SUPPLY
CONSOLE
PARALLEL
RELAY
ARC
STARTER
8 1, 2 3, 4 3, 5
1FU 2FU
3FU
4FU
AC POWER
AUTO
DC POWER
PILOT
MAN
SURFACE
UNDERWATER
DO NOT SWITCH
UNDER LOAD
ON
OFF
HI-FLOW
WATER SHIELD
100
200 300 400
AMPERES
D.C.
500
100
200 300 400
VOLTS
D.C.
500
7
6
6
10
9
17
18
11, 12
Manual No 0-0470
Figure 5-2 TA 500 Front View
5-5 Parts Lists
5.3
Rear Panel Components
Item No.
7
8
5
6
3
4
1
2
Qty.
1
1
1
1
3
1
1
3
Description
Input Strain Relief
Fuse Holder
Fuse- 8amp
Left Corner Support
Right Corner Support
Bottom Rear Panel
Top Rear Panel
Fan Guard
7 8
4
6
Ref.
5FU, 6FU, 7FU
5FU, 6FU, 7FU
Cat. No.
9-3291
9-2937
9-3641
9-5306
9-5307
9-5310
9-5308
9-5309
2,3
1
5
Parts Lists
Figure 5-3 TAC 500 Rear View
5-6 Manual No 0-0470
5.4
Right Side Components
Item No.
5
6
7
3
4
1
2
Qty.
1
1
1
1
1
2
1
Description
Resistor 8.5 ohm, 1000w
Fastener
Output Terminal Board
Bridge Assembly
Side Channel
Cable- Bridge (-) to output terminal board
Cable- Bridge (+) to output terminal board
1
Ref.
R2
Cat. No.
9-5488
9-3995
9-5322
9-5323
9-5324
9-5325
2
4
5
6
Manual No 0-0470
3 7
Figure 5-4 TA500 Right Side View
5-7 Parts Lists
5.5
Left Side Components
10
11
12
13
8
9
10
10
14
15
Item No.
7
7
5
6
3
4
1
2
2
1
1
1
1
1
1
1
1
1
Qty.
1
1
1
1
1
1
2
2
Description
Motor Mounting Bracket
Motor Bracket Strut
Main Contactor Bracket (left)
Main Contactor Bracket (right)
Fan Blade
Side Channel
Contactor Coil
Contactor
Contactor Rebuilding Kit
Resistor-100 ohm, 100w
Reactor
Transformer (230/460V)
Transformer (460/575V)
Transformer (220/380V)
Motor
Thermostat
Cable- W to main trans. output, 18-1/2”
Cable- W to main trans. output, 24”
Cable- W to main trans. output, 36”
1 11
Ref.
W
W
R16
Cat. No.
9-5312
9-5311
9-2750
9-5314
9-5315
9-5316
8-1987
8-1304
5-2865
9-3568
9-5160
9-5467
9-5415
9-5489
8-1357
9-3615
Parts Lists
12
10
2
5
6
13
9
14
15
4
12 8 3
Figure 5-5 TAC 500 Left Side View
5-8
7
Manual No 0-0470
5.6
Equipment Board Assembly
Item No.
9
10
11
12
13
14
15
16
(17)
7
8
(5)
6
1
(2)
(3)
4
Qty.
2
1
1
1
1
1
1
1
1
1
1
1
2
1
3
1
1
Description
Printed Circuit Board Cover
Printed Circuit Board-Current Regulating
Transformer
Relay- 2 sec Time Delay
Resistor- 1K ohm, 25w
Resistor- 25 ohm, 50w
Transformer- 12V
Relay- DPDT, 120VAC
Transformer- 12V
Contactor
Relay- 3PDT, 24VAC
Printed Circuit Board- 5 Relay
Wiring Harness
Printed Circuit Board- 3 Relay
Relay- 3PDT, 12vdc
Relay- 3PDT, 120VAC
Printed Circuit Board- Arc Starter
Ref.
T3
TD1, TD2, TD3
R7
R8, R9
T1
5CR
T2
PCR
4CR
CSR1, CSR2
2CR
Cat. No.
9-5350
9-5186
9-5168
9-2694
9-5162
9-5351
9-3515
9-2906
9-5352
9-7554
9-5165
9-5174
9-5353
9-5167
9-5163
9-5257
(5)
6 7 8 9 10
4
(3)
(17)
1
(2)
Manual No 0-0470
16
15 14
Figure 5-6 TA 500 Equipment Board Assembly
5-9
11
12
13
Parts Lists
5.7
Bridge Assemblies
Item No.
7
8
5
6
3
4
1
2
9
10
11
12
13
Qty.
1
2
1
2
1
4
1
7
4
1
2
1
1
Description
Bridge Assembly
Capacitor- .25 mfd
Varistor Assembly
Lug Terminal
Pilot Bridge Assembly
Capacitor- 4 mfd
Resistor- 2 ohm
Resistor- 2.5k ohm
Resistor- 5 ohm
Resistor- 27k ohm
Resistor- 1 megohm
Capacitor- 2100 mfd, 450V
Heat Sink Separator
4 11 2 5 2 11 4
Ref.
C1, 2, 5, 6, 7, 8, 9
VR
Cat. No.
8-1951
9-4028
C3, 10
R14
R3, 4
R6, 10
R5
R11, 12, 13, 15
C4
9-3210
8-1957
9-2390
8-1299
9-2537
9-5187
9-5287
9-5154
1
2
9
12
4
10
8
7
2
2
3
11
6
13
Parts Lists
Figure 5-7 TA 500 Bridge Assemblies
5-10 Manual No 0-0470
5.8
Bridge Assemblies
Item No.
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
2
2
1
3
2
2
1
Qty.
1
1
2
1
1
1
3
3
1
1
Description
Heat Sink (neg)
Heat Sink (pos)
Diode- 300 amp (str)
Diode- 300 amp (rev)
Diode- 40 amp (str)
Diode- 40 amp (rev)
Diode- 40 amp (str)
Toroid Assembly
Thermostat
Toroid Bracket
Resistor- 100 ohm
Heat Sink
Heat Sink
Diode- 40 amp (str)
Silicon Control Rectifier
Inductor
Zener Diode- 1w
Control Bridge Assembly
Ref.
D1, 3, 5
D2, 4, 6
D17, 19
D18
D20
T4
R1
D11, 12, 16
D9, 10
L1, 2
D13, 14
Cat. No.
9-5156
9-5357
9-2246
9-2247
8-1562
8-1558
9-5260
9-2967
9-2967
9-5358
9-3120
9-3121
8-1562
9-2686
9-5189
9-5188
9-5359
12 13
5
11
2
7
Manual No 0-0470
9
1
10
8
4
Figure 5-8 TA 500 Bridge Assemblies
5-11
3
12
18
15
(16)
17
16
6
Parts Lists
5.9
Supply Console Components
Item No.
29
30
31
25
26
27
28
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
Qty.
1
2
3
1
1
2
1
2
1
1
1
1
1
1
2
1
1
2
2
1
3
1
1
1
1
4
1
1
A/R
A/R
1
Description
Connecting Bolt
Power Connection Block
Power Block Base
Power Block Sub-base
Spill Tray
Pressure Switch
Interlock Switch
Solenoid Valve
Solenoid Valve
Flow Control Valve
Flowmeter
Capacitor- .25 mfd
Pressure Gauge
Pressure Gauge
Insulated Bushing
Nut
Insulated Bushing
Receptacle- 14 Pin
Receptable- 37 Pin
Straight Adapter
R.H. Hose Adapter
Straight Adapter
Straight Adapter
O2B Fitting
Base
Front Panel
Rear Panel
Bulkhead
Flow Switch
Socket
Pin
Cover
Ref.
Cat. No.
9-3278
9-5191
PS3
SW5
9-2903
8-1741
8-1741
SOL1, SOL2, SOL3 8-1786
SOL4, SOL5 9-5193
8-1787
C11
COOLANT
8-1877
8-1951
9-2850
PLASMA, SECONDARY 9-2851
9-5326
J14, J15
J13
FS1
9-5327
9-3293
9-5331
8-0319
8-0330
8-0259
8-1251
8-0260
9-5328
9-5204
9-5329
9-5330
9-5476
9-3297
9-3296
9-5202
Parts Lists 5-12 Manual No 0-0470
13 11 14 26 14
1
24
28
18, 30
5
23
22
27
25 15, 16 7 17
21
19, 31
21
18, 30
20
Figure 5-9 Supply Console
12
2, 3, 4
6
29
10
8
(9)
21
Manual No 0-0470 5-13 Parts Lists
11
12
13
14
7
8
9
10
15
16
20
21
22
23
24
25
5.10 M200 Torch Components
Item No.
3
4
1
2
5
6
17
18
19
Qty.
4
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
3
1
1
Description
M200 Head Assembly
Water Tube
O-Ring
Electrode Seat
Electrode (For N2/CO
2
operation up to 100KW)
Electrode (For operation above 100KW)
0.081 Tip- 150 amps
0.109 Tip- 250 amps
0.125 Tip- 350 amps
0.141 Tip- 500 amps
0.172 Tip- 750 amps
0.201 Tip- 1000 amps
0.250 Tip- 500 amps (gouging)
0.218 Tip- 1000 amps
O-Ring
O-Ring
Inner Tip Retainer
O-Ring
O-Ring
O-Ring
Outer Insulator
O-Ring (Red)
O-Ring
End Piece
End Piece (Piercing)
End Piece (For Water Shield and most other applications)
End Piece (For Ar/H
2
as secondary)
End Cap
End Cap- Underwater
End Cap- For Extensive Piercing
O-Ring
Collar
Collar- Underwater
Coolant Baffle
Adapter
Arc Starter
Mounting Tube with Rack
Pinion Assembly
Bushing
M200 Torch with Mounting Tube
Ref.
Cat. No.
9-2210
8-0553
8-0547
8-0542
8-6060
9-3720
8-0563
8-0607
8-0610
8-6006
8-6029
8-6056
8-6077
8-6057
8-0527
8-6059
8-6054
9-1640
8-0530
9-1642
9-1641
9-1662
8-6041
8-6042
8-6043
8-6044
8-6045
8-6046
8-6047
8-6067
8-0538
8-0554
8-6078
9-2451
8-6058
3-5003
9-1720
7-2828
8-6522
2-2766
Parts Lists 5-14 Manual No 0-0470
18
Manual No 0-0470
18
25
1
3
21
2
12
20
15
16
14
10
11
12
13
14
17
4
3
5
7
6
8
9
19
24
23
Figure 5-10 M200 Torch
5-15
22
Parts Lists
5.11 Operator Control Panel
Item No.
13
14
15
16
9
10
11
12
17
18
19
7
8
5
6
3
4
1
2
Qty.
1
1
1
A/R
1
1
1
1
1
1
1
1
1
1
1
2
A/R
1
A/R
Description
Toggle Switch- SPST
Toggle Switch- DPDT
Push Button Switch (Green)
Push Button Switch (Red)
Contact Block N/C
Contact Block N/O
Panel Indicator (Red)
Panel Indicator (Amber)
Meter
Potentiometer- Dual, 10K
Receptacle- 37 Pin, Std. Sex
Knob
Control Panel
Connector Bracket
Receptacle- 37 Pin, Rev. Sex
Pin
Socket
Receptacle- 16 Pin
Socket
14 11,17 6
18,19
Parts Lists
Ref.
SW1
SW4, SW6
SW2, LT5
SW3
SW3
SW2
LT3
LT4
M
POT1, POT2
J12
J29
P24
Cat. No.
9-3325
8-1777
9-5227
9-5228
9-5229
9-5230
8-1885
8-1886
9-5231
9-5232
9-5331
9-5221
9-5172
9-3296
9-3297
9-3258
5
4
2
9
15,16 10
1
7
8
13
Figure 5-11 Operator Control Panel
5-16
12
3
9
Manual No 0-0470
7
7
5
6
3
4
1
2
8
8
9
10
11
5.12 Gas Pressure Regulators
Item No.
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Lubricant
Regulator, CO
2
Regulator, Compressed Air
Regulator, Nitrogen
Regulator, Argon/Hydrogen
Gauge, Inlet Pressure (0-315 KG/CM)
Gauge, Outlet Pressure (0-16 KG/CM)
Adjusting Screw, with Knob
Seal, O-Ring
Valve
Seal, O-Ring
Nipple for use with N2 Regulator
Nipple for use with CO
2
Regulator
Nut for use with N2 Regulator
Nut for use with CO
2
Regulator
Washer for use with CO
2
Regulator
Hose Adapter for use with N2 and CO Regulators
Inlet Adapter
Ref.
Cat. No.
9-2871
9-2759
9-3022
9-2722
9-3053
9-2821
9-2820
9-2825
9-2823
9-2822
9-2824
9-3010
9-3012
9-3011
9-3014
9-3013
9-3009
9-3518
1
8
9 7
11
5
A-01911
2
4
10
3
6
Manual No 0-0470
Figure 5-14 Gas Pressure Regulators
5-17 Parts Lists
APPENDIX 1
Manual No. 0-0470
Art # A-04077
A-1 Appendix
APPENDIX 2
Appendix A-2
Art #A-04078
Manual No. 0-0470
APPENDIX 3
Manual No. 0-0470 A-3 Appendix
Appendix
1
BLK
2
BLK
APPENDIX 4
5
RED
6
R-BLU
7
R-YEL
8
R-BLU
RED
BRN
9
3
4
BRN
GRN
10
11
GRN-YEL
12
GRN
ARC STARTER TRANSFORMER
PHASING DIAGRAM
42A519 10/18/78
Art # A-04079
A-4 Manual No. 0-0470
APPENDIX 5
Manual No. 0-0470 A-5 Appendix
1
APPENDIX 6
2 3 4 5
Appendix
Art # A-03982
A-6 Manual No. 0-0470
6 7 8 9 10
Manual No. 0-0470 A-7
Art # A-03982
Appendix
2
APPENDIX 7
3 1 4 5
A
F
B
C
D
E
Art # A-03981 1
Coolant
Recirculator
4CR
J3-5
J3-4
J7-14 J7-29
J8-1
J8-24
TA500
115VAC
5A
4FU
J8-8
J12-8
R
LT3
Operator Control
Panel
TP3
CSR2
TP1
J2-12
TP2
J7-12
24VAC T2
J12-7 J8-7
J7-8
J9-13
J9-11
J7-9
J9-10
J9-12
J8-23
J8-15
J8-14
HCR2
J103-5
J101-8
J7-16
J7-15
J107-12
Up
Down
J107-16
J107-15
Pilot 2
J101-1
CSRH
CSRH
J101-7
J101-9
J103-14
J101-3 Pilot 2
Down
J102-14
J102-12
Up
Sample Pilot 1
J102-16
J102-2
J101-2
J2-6
I45
J1-6
2CR
J1-5 J7-11
J107-11
+12v
R266
18
PC102
+12v Unreg
From Logic Board
J102-13 J102-15
Sample
2
PC101
SC504 Chassis
2 3 4 5
Appendix A-8 Manual No. 0-0470
6 7 8
J104-5
J104-11
J104-10
J104-15
J104-32
J104-31
J104-29
J104-30
J104-24
J104-25
J104-26
J104-27
J104-20
J104-21
J104-28
J104-16
J29
TA500 Control Panel
J12-1
J12-24
Sw2
Start
2
3
6
J12-23
Sw3 Stop
5
7
J12-15
J12-14
Sw1
On / Off
J106-5
J106-11
Find Height Sw102
J106-10
J106-15
J106-32
Sw101
R
On / Off
5A
1FU
J106-31
J106-29
J106-30
J106-24
J106-25
J106-26
J106-27
J106-20
J106-21
J106-28
Sw105
J106-16
Hold Height
J124 / P24-1
J124 / P24-2
8
9
11
12
J124 / P24-4
14
J124 / P24-5
15
J124 / P24-12
17
J124 / P24-3
18
J124 / P24-13
21
J124 / P24-14
22
J124 / P24-6
24
J124 / P24-7
25
J124 / P24-8
26
J124 / P24-9
27
J124 / P24-11
28
J124 / P24-10
29
J124 / P24-15
30
J124 / P24-16
31
6
SC504 Control Panel
7 8
9
Computer Signals
Input / Output
Start
Stop *
Ground
Control Panel
Station Select *
Find Height (Momentary Closure)
SC504 Control Panel
Station Select *
Main Arc Transfer (OK to Move) Signal
Height Found
(Momentary Closure)
Up / Down Signals to
Torch Lifter Motor
10
Disable Standoff Control, Regulate to Original Arc Voltage (Height) *
Disable Standoff Control, Resample
New Arc Voltage (Height)
NOTES:
1. * Indicates signal lines that must be tied together when not utilized
by the computer.
9
3/29/82 42B620
Rev 'A' 4/8/82
10 Art # A-03981
F
E
A
B
C
D
Manual No. 0-0470 A-9 Appendix
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