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Thermal Dynamics A80 CUTMASTER Operating Manual Download Page 92

A80

  

OPERATION 

0-4985

4T-52

Stainless Steel 

100A 

Air Plasma / Air Shield

Shield Cap

Maximum Life Shield Cup

Tip

Starter Cartridge

Heavy Duty Starter 

Cartridge

Electrode

9-8239

9-8237

9-8212

9-8213

9-8277

9-8232

Material 

Thickness

Gas Pressure 

(Air)

Arc Voltage Torch Working 

Height

Travel Speed Initial Piercing 

Height

Pierce Delay

Kerf Width  

@ Rec. Speed

(GA)

(in)

inch

PSI 

(torch lead 

length)

Volts

(in)

(ipm)

(in)

(sec)

(in)

1/4

0.250

75  (25') 

 

75  (50')

114

0.16

110

0.18

0.00

0.08

3/8

0.375

116

0.16

70

0.18

0.10

0.09

1/2

0.500

119

0.16

45

0.18

0.30

0.10

5/8

0.625

130

0.19

20

0.23

2.00

0.11

3/4

0.750

135

0.19

15

0.23

2.80

0.11

1

1.000

140

0.19

10

Edge Start

0.11

Summary of Contents for A80 CUTMASTER

Page 1: ...Thermal Dynamics com 100 208 230V 460V Art A 08954_AD 600V 380 400V Operating Manual Revision AS Issue Date 10 03 2020 Manual No 0 4985 A80 AUTOMATED PLASMA CUTTING SYSTEM ...

Page 2: ... please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermal Dynamics Corporation We distinguish ourselve...

Page 3: ...ts 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 For Printing Material Specification refer to document 47x1909 Ori...

Page 4: ...hereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked periodically Malfunctioning or poorly maintained equipment should not be used Parts that are broken missing worn distorted or contami nated should be replaced immediately Should such repair or replacement ...

Page 5: ...R Cet équipement fonctionnera conformément à la description contenue dans ce manuel les étiquettes d accompagnement et ou les feuillets d information à condition d être installé utilisé entretenu et réparé selon les instructions fournies L équipement doit être contrôlé de manière périodique Ne jamais utiliser un équi pement qui ne fonctionne correctement bien ou n est pas bien entretenu Les pièces...

Page 6: ...This page intentionally blank ...

Page 7: ...USA Phone 01 800 426 1888 FAX 01 603 298 7402 The following harmonised standard in force within the EEA has been used in the design IEC EN 60974 1 2017 AMD1 2019 Arc Welding Equipment Part 1 Welding power sources IEC EN 60974 10 2014 AMD 1 2015 Published 2015 06 19 Arc Welding Equipment Part 10 Electromagnetic compatibility EMC requirements Additional Information Restrictive use Class A equipment ...

Page 8: ...ons 2 3 2 06 Power Supply Features 2 4 SECTION 2 TORCH INTRODUCTION 2T 1 2T 01 Scope of Manual 2T 1 2T 02 General Description 2T 1 2T 03 Specifications 2T 1 2T 04 Options And Accessories 2T 2 2T 05 Introduction to Plasma 2T 2 SECTION 3 SYSTEM INSTALLATION 3 1 3 01 Unpacking 3 1 3 02 Lifting Options 3 1 3 03 Power Supply location and Mounting 3 1 3 04 Opening the Contactor Cover 3 1 3 05 Primary In...

Page 9: ... 5 05 Basic Troubleshooting Guide 5 4 5 06 Power Supply Basic Parts Replacement 5 6 SECTION 5 TORCH SERVICE 5T 1 5T 01 General Maintenance 5T 1 5T 02 Inspection and Replacement of Consumable Torch Parts 5T 2 SECTION 6 PARTS LISTS 6 1 6 01 Introduction 6 1 6 02 Ordering Information 6 1 6 03 Power Supply Replacement 6 1 6 04 Replacement Power Supply Parts 6 2 6 05 Options and Accessories 6 2 6 06 To...

Page 10: ...TABLE OF CONTENTS This Page Intentionally Blank ...

Page 11: ...MES 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 ad equate 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 ...

Page 12: ...NOISE Noise can cause permanent hearing loss Plasma arc pro cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protec tive ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the deci bels sound do not exceed safe levels For...

Page 13: ... the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA StandardW117 2 CODE FOR SAFETY INWELDING AND CUTTING obtainable from the Canadian Standards Asso ciation Standards Sales 178 Rexdale Boulevard Re...

Page 14: ...uivre sélénium béryllium manganèse vanadium Lisez toujours les fiches de données sur la sécurité des matières sigleaméricain MSDS celles cidevraientêtre fournies avec le matériel que vous utilisez Les MSDS contiennentdesrenseignementsquantàlaquantitéetla naturedelafuméeetdesgazpouvantposerdesdangers de santé Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travai...

Page 15: ...ttes 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 travailcontrelesrayo...

Page 16: ...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 NATIONAL dis ponibleauprèsdelaNatio...

Page 17: ...mable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipmentthathasbeenmodifiedbyanunauthorizedparty improperlyinstalled improperlyoperatedormisused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation 1 Repair of the defective product 2 Replacement ...

Page 18: ...A80 GENERAL INFORMATION 0 4985 1 8 This page intentionally blank ...

Page 19: ...quipment identification numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Dynamics web site listed below and clicking on Thermal Dynamics and then on the Literature link www thermal dynamics com 2 02 Equipment Identification The unit s identification number specification or part number model and serial number usually appear o...

Page 20: ...e Ambient Temperature Duty Cycle Ratings 40 C 104 F Operating Range 0 50 C All Units Duty Cycle 60 80 100 Current 100 80 70 IEC IEC IEC DC Voltage 120 112 108 NOTE The duty cycle will be reduced if the primary input power AC is low or the output voltage DC is higher than shown in this chart NOTE IEC Rating is determined as specified by the International Electro Technical Commission These speci fic...

Page 21: ...15 230 60 17 9 45 36 60 6 15 380 50 18 4 28 22 32 10 6 400 50 18 7 27 22 32 10 6 460 60 23 1 29 22 30 10 6 600 60 22 8 22 17 25 12 4 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electric Code NOTE RefertoLocalandNationalCodesorlocalauthorityhavingjurisdictionforproperwiringrequirements The suggested sizes are based on flexible power ca...

Page 22: ...4 2 06 Power Supply Features Art A 08460 Mounting Rails Torch Leads Receptacle Control Panel Work Cable and Clamp Input Power Cord Automation Interface Cable Port Gas Inlet Port Filter Assembly Input Power Selection Art A 08461 ...

Page 23: ... The air flow is divided inside the torch head Single gas operation provides a smaller sized torch and inexpensive operation NOTE Refer to Section 2T 05 Introduction to Plasma on page 2T 2 for a more detailed description of plasma torch operation Refer to the Appendix Pages for additional specifications as related to the Power Sup ply used 2T 03 Specifications A Torch Configurations 1 Automation T...

Page 24: ... pressure varies with torch model operatingamperage andtorchleadslength Refertogaspressuresettingschartsforeach model H Direct Contact Hazard For standoff tip the recommended standoff is 3 16 inches 4 7 mm 2T 04 Options And Accessories For options and accessories see section 6 2T 05 Introduction to Plasma A Plasma Gas Flow Plasma is a gas which has been heated to an extremely hightemperatureandion...

Page 25: ...ter cartridge and out between the tip and shield cup around the plasma arc C Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip This pilot arc creates a path for the main arc to transfer to the work D Main Cutting Arc DC power is also used for the main cutting arc The negative output is connected to the torch electrode through the torch lead The po...

Page 26: ...A80 INTRODUCTION 0 4985 2T 4 This Page Intentionally Blank ...

Page 27: ...e mounting rails touch 3 Remove the unit and using these markings prepare holes for mounting hardware 4 Insert proper hardware If using hardware that screwsintothemountingsurface leaveallfourloose enough for the thickness of the rail to slide under the head and washer if used 5 Lower the power supply over the mounting hard wareandslideforwardorbackwarduntilthekeyway stops against the mounting hard...

Page 28: ...0 VAC and high is 460 VAC S LO HI Art A 08316 D Quick Guide to Phase Wiring The following illustration and directions are for changing phase of the power supply Art A 08493 Input Power Cable Connections Three Phase 3ø Store copper jumpers on base plate Single Phase 1ø and Jumper Settings GND L1 L2 L3 L4 GND L1 L2 L3 L4 Single and Three Phase Input Power Wiring NOTE There are two jumpers used for t...

Page 29: ...o Three Phase input power 1 Remove the Power Supply cover See A Cover Removal 2 Disconnect the original input power cable from the main input contactor and the chassis ground con nection 3 Loosen the through hole protector on the back panel of the power supply Pull the original power cable out of the power supply 4 Using a customer supplied four conductor input power cable for the voltage desired ...

Page 30: ...Supply Hose 1 4 NPT or ISO R to 1 4 6mm Fitting Air Connection to Inlet Port Installing Optional Single Stage Air Filter An optional filter kit is recommended for improved filter ing with compressed air to keep moisture and debris out of the torch 1 AttachtheSingle StageFilterHosetotheInletPort 2 Attach the Filter Assembly to the filter hose 3 Connect the air line to the Filter The illustration sh...

Page 31: ... may break off and block the small air pas sages in the torch Installing Optional Two Stage Air Filter Kit This optional two stage air line filter is also for use on compressed air shop systems Filter removes moisture and contaminants to at least 5 microns Connect the air supply as follows 1 Attach the Two Stage Filter bracket to the back of the power supply per instructions supplied with the filt...

Page 32: ...ch may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 lpm 4 Connect supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure cylinder regulator Supply hose must be at least 1 4 inch 6 mm I D For a secure seal apply thread seala...

Page 33: ...e Torch to the Power Supply 3 The system is now ready for operation Check Air Quality To test the quality of air 1 Put the ON OFF switch in the ON up posi tion 2 Put the Function Control switch in the SET position 3 Place a welding filter lens in front of the torch and turn ON the air Do not start an arc Any oil or moisture in the air will be visible on the lens 3T 02 CNC Connection 1 Locate the i...

Page 34: ... V OUT 1 on PCB1 START STOP DIVIDED ARC VOLTS W 100K IN SERIES 2 ARC VOLTS J1 J1 1 2 3 4 5 6 7 8 J3 J3 1 2 3 P10 P10 1 2 3 4 5 6 7 8 E1 E1 K1 K1 J2 J2 2 3 4 5 6 7 8 9 10 11 12 13 14 1 Art A 09819_AB WARNING This divided arc voltage output signal is positive Its common is referenced to the work lead ground Using this on a height control expecting a negative signal and whose positive input is ground...

Page 35: ... The Automation and Machine torch include a positioning tube with rack and pinch block assembly 1 Mount the torch assembly on the cutting table 2 To obtain a clean vertical cut use a square to align the torch perpendicular to the surface of the workpiece A 02585 Workpiece Square Pinch Block Assembly Automated and Machine Torch Set Up 3 The proper torch parts shield cup tip start cartridge and elec...

Page 36: ...A80 INSTALLATION 0 4985 3T 4 This Page Intentionally Blank ...

Page 37: ... power to the power supply Up is ON down is OFF 4 Air Gas Pressure Control The Pressure Control is used in the SET mode to adjust the air gas pressure Pull the knob out to adjust and push in to lock 5 AC Indicator Steady light indicates power supply is ready for op eration Blinking light indicates unit is in protective interlock mode Shut unit OFF shut OFF or disconnect inputpower correctthefault ...

Page 38: ... and turn air supply ON Connect Work Cable Clamp the work cable to the workpiece or cutting table The area must be free from oil paint and rust Connect only to the main part of the workpiece do not connect to the part to be cut off Art A 04509 Power ON Place the Power Supply ON OFF switch to the ON up position AC indicator turns ON Gas indicator turns ON if there is sufficient gas pressure for pow...

Page 39: ... the knob in the RAPID AUTO RESTART posi tion when the torch leaves the workpiece the pilot arc restarts instantly and the cutting arc restarts instantly when the pilot arc contacts the workpiece Use the Rapid Auto Restart position when cutting expanded metal or gratings or in gouging or trimming operations when an uninterrupted restart is desired And with the knob in the LATCH position the main c...

Page 40: ...A80 OPERATION 0 4985 4 4 This Page Intentionally Blank ...

Page 41: ...e output should be reduced also Refer to the appropriate Control Module Operating Manual for any Corner Slowdown adjustments that may be required Piercing With Machine or Automated Torch To pierce the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce This standoff helps avoid having molten metal blow back onto the fron...

Page 42: ...utting or gouging Torch parts Shield Cup Cutting Tip Electrode and Starter Car tridge NOTE Refer to Sections 4T 08 and following for ad ditional information on torch parts Change the torch parts for a different operation as follows WARNING Disconnect primary power at the source before assembling or disassembling torch parts or torch and leads assemblies NOTE The shield cup holds the tip and starte...

Page 43: ...g Kerf Width The width of the cut or the width of material removed during the cut Top Spatter Dross Top spatter or dross on the top of the cut caused by slow travel speed excess cutting height or cutting tip whose orifice has become elongated 4T 05 General Cutting Information WARNING Disconnect primary power at the source before disassembling the power supply torch or torch leads Frequently review...

Page 44: ... resultant cleanup can be accomplished by scraping not grinding 4T 06 Hand Torch Operation Standoff Cutting With Hand Torch NOTE For best performance and parts life al ways use the correct parts for the type of operation 1 The torch can be comfortably held in one hand or steadiedwithtwohands Positionthehandtopress the Trigger on the torch handle With the hand torch thehandmaybepositionedclosetothe...

Page 45: ... cup can be used with a non conductive straight edge to make straight cuts by hand WARNING The straight edge must be non conductive A 03539 Non Conductive Straight Edge Cutting Guide Using Drag Shield Cup With Straight Edge The crown shield cup functions best when cutting 3 16 inch 4 7mm solidmetalwithrelativelysmoothsurface Drag Cutting With a Hand Torch Drag cutting works best on metal 1 4 6 mm ...

Page 46: ...to direct blowback particles away from the torch tip and operator rather than directly back into it until the pierce is complete 3 In a portion of the unwanted metal start the pierce off the cutting line and then continue the cut onto the line Hold the torch perpendicular to the work piece after the pierce is complete 4 Hold the torch away from your body 5 Slidethetriggerreleasetowardthebackofthet...

Page 47: ...de of operation hand or machine torch and the amount of material to be removed Lead Angle The angle between the torch and workpiece depends on the output current setting and torch travel speed The recommended lead angle is 35 At a lead angle greater than 45 the molten metal will not be blown out of the gouge and may be blown back onto the torch If the lead angle is too small less than 35 less mate...

Page 48: ... Thickness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 036 70 25 75 50 101 0 14 160 0 18 0 0 0 05 16 0 060 103 0 14 140 0 18 0 0 0 05 14 0 075 105 0 14 120 0 18 0 1 0 06 12 0 105 108 0 14 80 0 18 0 2 0 06 10 0 135 110 0 14 60 0 18 0 3 0 06 3 16 0 188 111 0 14 55...

Page 49: ...eed mm Bar torch lead length Volts mm mm min mm sec mm 1 4 8 7 6m 5 2 15 2m 101 3 6 3990 4 6 0 0 1 1 2 105 3 6 2920 4 6 0 1 1 4 3 109 3 6 1810 4 6 0 3 1 5 4 110 3 6 1470 4 6 0 3 1 6 5 112 3 6 1345 4 6 0 4 1 6 6 116 3 6 1100 4 6 0 5 1 7 8 118 3 6 815 4 6 1 0 1 7 10 119 3 6 595 4 6 1 5 1 8 12 120 3 6 435 5 1 2 0 1 8 BOLD TYPE indicates maximum piercing parameters ...

Page 50: ...ch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 18 0 050 75 25 80 50 110 0 19 60 0 20 0 00 0 07 16 0 063 100 0 19 50 0 20 0 00 0 07 14 0 078 105 0 19 45 0 20 0 10 0 07 12 0 109 110 0 19 40 0 20 0 20 0 07 10 0 141 108 0 19 35 0 20 0 30 0 07 3 16 0 188 110 0 19 30 0 20 0 40 0 07 1 4 0 250 120 0 19 18 0 2...

Page 51: ...lead length Volts mm mm min mm sec mm 1 5 2 7 6 5 5 15 2 112 4 8 1670 4 8 0 0 1 7 2 105 4 8 1140 5 1 0 1 1 8 3 109 4 8 980 5 1 0 2 1 8 4 109 4 8 845 5 1 0 3 1 8 5 111 4 8 715 5 1 0 4 1 8 6 118 4 8 525 5 1 0 5 2 0 8 123 4 8 350 5 1 1 5 2 0 10 125 4 8 245 5 1 2 0 2 0 12 120 4 8 215 Edge Start 2 2 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 52: ...ir Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 040 70 25 75 50 95 0 16 300 0 16 0 0 0 06 16 0 063 97 0 16 170 0 16 0 0 0 06 12 0 097 113 0 16 100 0 16 0 2 0 07 11 0 125 115 0 16 90 0 18 0 3 0 07 9 0 160 113 0 18 85 0 18 0 4 0 07 3 16 0 188 116 0 18 75 0 18 0 5 0 07 1 4 0 250 128...

Page 53: ... lead length Volts mm mm min mm sec mm 1 0 4 8 7 6m 5 2 15 2m 95 4 1 7620 4 1 0 0 1 5 2 0 104 4 1 3500 4 1 0 2 1 6 3 0 115 4 1 2350 4 6 0 3 1 7 4 0 113 4 6 2170 4 6 0 4 1 7 5 0 118 4 6 1740 4 6 0 5 1 8 6 0 125 4 6 1015 4 6 0 8 1 9 8 0 139 4 6 500 Edge Start 2 0 10 0 153 4 6 180 Edge Start 2 2 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 54: ...rcing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 118 0 19 290 0 19 0 00 0 08 14 0 075 120 0 19 285 0 19 0 10 0 08 11 0 120 118 0 19 180 0 19 0 10 0 08 10 0 135 119 0 19 176 0 19 0 10 0 07 3 16 0 188 121 0 19 100 0 19 0 20 0 08 1 4 0 250 122 0 19 80 0 19 0 30 0 08 3 8 0 375 124 0 19 50 0 19 0 50 0 09 1 2 0 500 132 0 19 26 0 ...

Page 55: ...2 15 2m 115 4 8 7540 4 8 0 2 1 2 120 4 8 7015 4 0 0 10 1 9 3 118 4 8 4570 4 8 0 10 0 1 4 120 4 8 3650 4 8 0 20 1 9 5 121 4 8 2465 4 8 0 20 2 1 6 122 4 8 2145 4 8 0 30 2 0 8 123 4 8 1635 4 8 0 40 2 2 10 125 4 8 1180 4 8 0 60 2 4 12 130 4 8 795 4 8 0 75 2 4 15 134 4 8 530 Edge Start 2 4 20 138 4 8 325 Edge Start 2 2 25 149 4 8 165 Edge Start 2 7 BOLD TYPE indicates maximum piercing parameters BOLD I...

Page 56: ...el Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 119 0 19 350 0 20 0 00 0 05 14 0 078 116 0 19 300 0 20 0 10 0 07 11 0 125 123 0 19 150 0 20 0 10 0 07 10 0 141 118 0 19 125 0 20 0 10 0 08 3 16 0 188 122 0 19 90 0 20 0 20 0 08 1 4 0 250 123 0 19 65 0 20 0 30 0 09 3 8 0 375 130 0 19 30 0 20 0 50 0 09 1 2 0...

Page 57: ... 1 5 9 7 6m 6 2 15 2m 124 4 8 10890 5 1 0 00 0 8 2 116 4 8 7560 5 1 0 10 1 7 3 122 4 8 4365 5 1 0 10 1 7 4 119 4 8 2865 5 1 0 20 2 1 5 122 4 8 2195 5 1 0 20 2 1 6 123 4 8 1790 5 1 0 30 2 2 8 127 4 8 1190 5 1 0 40 2 2 10 130 4 8 725 5 1 0 50 2 2 12 132 4 8 580 5 1 0 90 2 1 15 132 4 8 405 Edge Start 2 6 20 136 4 8 230 Edge Start 2 5 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicat...

Page 58: ...ing Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 123 0 25 440 0 25 0 00 0 08 14 0 079 126 0 25 300 0 25 0 10 0 09 11 0 120 128 0 25 250 0 25 0 10 0 09 3 16 0 188 132 0 25 170 0 25 0 20 0 09 1 4 0 250 132 0 25 85 0 25 0 30 0 09 3 8 0 375 141 0 25 45 0 25 0 50 0 10 1 2 0 500 148 0 25 30 0 25...

Page 59: ...1 5 9 7 6m 6 2 15 2m 118 6 4 17010 6 4 0 00 1 8 2 126 6 4 7680 6 4 0 10 2 3 3 128 6 4 6410 6 4 0 10 2 3 4 130 6 4 5230 6 4 0 20 2 3 5 132 6 4 4010 6 4 0 20 2 4 6 132 6 4 2640 6 4 0 30 2 4 8 137 6 4 1630 6 4 0 40 2 4 10 142 6 4 1085 6 4 0 60 2 4 12 146 6 4 845 6 4 0 70 2 3 15 146 4 8 540 Edge Start 2 1 20 148 4 8 260 Edge Start 2 5 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicat...

Page 60: ...cing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 110 0 19 320 0 20 0 00 0 06 11 0 120 113 0 19 230 0 20 0 10 0 07 10 0 135 110 0 19 180 0 20 0 20 0 07 3 16 0 188 110 0 19 136 0 20 0 30 0 07 1 4 0 250 115 0 19 100 0 20 0 40 0 09 3 8 0 375 125 0 19 42 0 20 0 50 0 09 1 2 0 500 123 0 19 40 0 20 0 60 0 09 5 8 0 625 133 0 19 18 0 ...

Page 61: ... 15 2m 109 4 8 8915 5 1 0 00 1 5 2 111 4 8 7415 5 1 0 10 1 7 3 113 4 8 5915 5 1 0 10 1 8 4 110 4 8 4095 5 1 0 30 1 7 5 111 4 8 3325 5 1 0 30 1 8 6 114 4 8 2745 5 1 0 40 2 2 8 120 4 8 1775 5 1 0 50 2 3 10 125 4 8 1060 5 1 0 50 2 3 12 123 4 8 1025 5 1 0 60 2 3 15 130 4 8 610 5 1 0 75 2 5 20 143 6 4 395 Edge Start 2 7 25 152 6 4 210 Edge Start 3 2 BOLD TYPE indicates maximum piercing parameters BOLD ...

Page 62: ...orking Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 110 0 19 340 0 25 0 00 0 06 11 0 125 115 0 19 300 0 25 0 10 0 06 10 0 141 115 0 19 280 0 25 0 10 0 06 3 16 0 188 115 0 19 140 0 25 0 20 0 07 1 4 0 250 118 0 19 100 0 25 0 30 0 08 3 8 0 375 119 0 19 45 0 25 0 40 0 08 1 2 0 500 124 0 19 26 ...

Page 63: ... 1 5 9 7 6m 6 2 15 2m 108 4 8 9020 6 4 0 00 1 5 2 111 4 8 8380 6 4 0 00 1 5 3 114 4 8 7730 6 4 0 10 1 5 4 115 4 8 5865 6 4 0 20 1 6 5 115 4 8 3410 6 4 0 20 1 8 6 117 4 8 2765 6 4 0 30 1 9 8 119 4 8 1815 6 4 0 40 2 0 10 120 4 8 1070 6 4 0 60 2 1 12 123 4 8 765 6 4 0 80 2 3 15 131 4 8 475 Edge Start 2 5 20 137 4 8 205 Edge Start 3 0 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicat...

Page 64: ...ng Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 116 0 25 350 0 25 0 00 0 10 11 0 120 120 0 25 280 0 25 0 10 0 10 3 16 0 188 124 0 25 180 0 25 0 20 0 10 1 4 0 250 130 0 25 110 0 25 0 30 0 09 3 8 0 375 136 0 25 55 0 25 0 40 0 11 1 2 0 500 139 0 25 38 0 25 0 60 0 11 5 8 0 625 136 0 19 26 0 25...

Page 65: ... 1 5 9 7 6m 6 2 15 2m 114 6 4 8890 6 4 0 00 2 4 2 117 6 4 8420 6 4 0 00 2 5 3 120 6 4 7170 6 4 0 10 2 5 4 122 6 4 5710 6 4 0 20 2 5 5 125 6 4 4315 6 4 0 20 2 5 6 129 6 4 3190 6 4 0 30 2 4 8 133 6 4 2070 6 4 0 40 2 5 10 136 6 4 1330 6 4 0 50 2 7 12 138 6 4 1060 6 4 0 50 2 9 15 137 4 8 745 6 4 0 75 2 5 20 151 4 8 325 Edge Start 3 0 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicate...

Page 66: ... Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 1 4 0 250 75 25 75 50 110 0 18 85 0 20 0 10 0 09 3 8 0 375 112 0 18 75 0 20 0 20 0 09 1 2 0 500 115 0 18 45 0 20 0 40 0 10 5 8 0 625 118 0 18 30 0 20 0 60 0 11 3 4 0 750 120 0 18 20 0 20 1 20 0 12 1 1 000 123 0 18 15 Edge ...

Page 67: ...rch lead length Volts mm mm min mm sec mm 6 5 2 7 6m 5 2 15 2m 110 4 6 2200 5 1 0 10 2 3 8 111 4 6 2030 5 1 0 10 2 3 10 112 4 6 1790 5 1 0 20 2 3 12 114 4 6 1310 5 1 0 40 2 5 15 117 4 6 870 5 1 0 60 2 7 20 120 4 6 490 5 0 1 20 3 0 25 123 4 6 390 Edge Start 3 0 30 127 4 6 250 Edge Start 3 2 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 68: ...32 Material Thickness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 1 4 0 250 75 25 75 50 102 0 16 100 0 18 0 00 0 09 3 8 0 375 106 0 16 65 0 18 0 10 0 10 1 2 0 500 109 0 16 45 0 18 0 30 0 10 5 8 0 625 123 0 19 20 0 23 2 00 0 11 3 4 0 750 128 0 19 15 Edge Start 0 12 1 ...

Page 69: ...peed mm Bar torch lead length Volts mm mm min mm sec mm 6 5 2 7 6m 5 2 15 2m 102 4 1 2630 4 6 0 00 2 3 8 104 4 1 2080 4 6 0 10 2 4 10 106 4 1 1575 4 6 0 20 2 4 12 108 4 1 1255 4 6 0 30 2 4 15 119 4 6 685 5 7 2 00 2 7 20 129 4 8 360 Edge Start 3 1 25 135 4 8 260 Edge Start 3 2 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 70: ...Material Thickness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 1 4 0 250 75 25 75 50 110 0 19 100 0 20 0 00 0 09 3 8 0 375 124 0 19 65 0 20 0 20 0 10 1 2 0 500 128 0 19 45 0 20 0 30 0 11 5 8 0 625 132 0 19 35 0 20 0 50 0 11 3 4 0 750 135 0 19 20 0 20 2 00 0 13 1 1 00...

Page 71: ...Speed mm Bar torch lead length Volts mm mm min mm sec mm 6 5 2 7 6m 5 2 15 2m 109 4 8 2630 5 1 0 00 2 3 8 117 4 8 2080 5 1 0 10 2 5 10 125 4 8 1575 5 1 0 20 2 7 12 127 4 8 1255 5 1 0 30 2 7 15 131 4 8 960 5 1 0 50 2 8 20 136 4 8 470 6 0 2 00 3 3 25 140 4 8 270 Edge Start 3 4 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 72: ...as Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 036 75 25 80 50 107 0 16 130 0 16 0 0 0 06 16 0 060 113 0 16 120 0 16 0 0 0 06 14 0 075 108 0 16 90 0 16 0 1 0 06 12 0 105 111 0 16 75 0 16 0 2 0 06 10 0 135 114 0 16 65 0 16 0 3 0 07 3 16 0 188 115 0 16 65 0 16 0 4 0 0...

Page 73: ...Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 5 2 7 6 5 5 15 2 108 4 1 3266 4 1 0 0 1 4 2 108 4 1 2239 4 1 0 0 1 5 3 112 4 1 1794 4 1 0 1 1 7 4 114 4 1 1651 4 1 0 2 1 7 5 115 4 1 1578 4 1 0 3 1 7 6 117 4 1 1256 4 1 0 4 1 7 8 121 4 1 853 4 1 0 5 1 7 10 124 4 1 565 4 1 1 2 1 8 12 127 4 1 485 4 1 2 0 1 9 BOLD TYPE indicates maximum piercing parameters ...

Page 74: ...orking Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 18 0 050 75 25 80 50 110 0 16 60 4 1 0 0 0 06 16 0 063 108 0 16 50 4 1 0 1 0 07 14 0 078 114 0 16 45 4 1 0 1 0 07 12 0 109 113 0 16 40 4 1 0 2 0 07 10 0 141 116 0 16 35 4 1 0 3 0 07 3 16 0 188 115 0 16 30 4 1 0 4 0 07 1 4 0 250 118 0 16 20 4 1 1 2 0 07 3 8 0 ...

Page 75: ...c Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 5 2 7 6 5 5 15 2 109 4 1 1670 4 1 0 0 1 7 2 114 4 1 1140 4 1 0 1 1 8 3 114 4 1 980 4 1 0 2 1 8 4 116 4 1 845 4 1 0 3 1 8 5 115 4 1 725 4 1 0 4 1 8 6 117 4 1 565 4 1 0 5 2 0 8 122 4 1 440 4 1 1 5 2 0 10 125 4 1 360 4 1 1 8 2 0 12 127 4 1 280 4 1 2 0 2 2 BOLD TYPE indicates maximum piercing parameters ...

Page 76: ...e Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 20 0 040 75 25 80 50 110 0 19 300 0 20 0 0 0 06 16 0 063 113 0 19 170 0 20 0 1 0 07 12 0 097 120 0 19 100 0 20 0 2 0 07 11 0 125 125 0 19 90 0 20 0 3 0 07 9 0 160 126 0 19 85 0 20 0 4 0 07 3 16 0 188 128 0 19 70 0 20 0 5 0 07 1 4 0 250 137 0 19 30 0 ...

Page 77: ...h Rec Speed mm Bar torch lead length Volts mm mm min mm sec mm 1 0 5 2 7 6 5 5 15 2 110 4 8 7660 5 1 0 0 1 6 2 0 116 4 8 3490 5 1 0 2 1 8 3 0 124 4 8 2350 5 1 0 3 1 8 4 0 126 4 8 2170 5 1 0 4 1 8 5 0 129 4 8 1630 5 1 0 6 1 8 6 0 135 4 8 990 5 1 1 0 1 9 8 0 141 4 8 500 5 1 1 6 2 0 10 0 146 4 8 180 5 1 2 1 2 3 BOLD TYPE indicates maximum piercing parameters ...

Page 78: ...Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 128 0 19 250 0 20 0 00 0 09 14 0 075 129 0 19 237 0 20 0 10 0 09 11 0 120 126 0 19 200 0 20 0 10 0 08 10 0 135 128 0 19 142 0 20 0 10 0 09 3 16 0 188 132 0 19 115 0 20 0 20 0 09 1 4 0 250 134 0 19 80 0 20 0 30 0 08 3 8 0 375 132 0 19 34 0 20 0 70 0 10 1 2 0 500 144 0 19 23 0 20 0 75 0 10 ...

Page 79: ... 2 15 2m 127 4 8 6804 5 1 0 2 2 2 129 4 8 5942 5 1 0 10 2 2 3 126 4 8 5080 5 1 0 10 0 1 4 130 4 8 3316 5 1 0 20 2 3 5 132 4 8 2794 5 1 0 20 2 2 6 134 4 8 2230 5 1 0 30 2 1 8 133 4 8 1425 5 1 0 40 2 3 10 134 4 8 822 5 1 0 60 2 5 12 141 4 8 646 5 1 0 75 2 5 15 148 4 8 419 Edge Start 2 6 20 147 4 8 318 Edge Start 2 7 25 159 4 8 118 Edge Start 3 0 BOLD TYPE indicates maximum piercing parameters BOLD I...

Page 80: ...tial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 110 0 13 165 0 20 0 00 0 06 14 0 078 116 0 13 155 0 20 0 10 0 07 11 0 125 118 0 13 125 0 20 0 10 0 07 10 0 141 126 0 13 80 0 20 0 10 0 09 3 16 0 188 125 0 13 75 0 20 0 20 0 09 1 4 0 250 127 0 13 60 0 20 0 30 0 08 3 8 0 375 134 0 13 28 0 20 0 50 0 08 1 2 0 500 136 0 19...

Page 81: ... 1 5 9 7 6m 6 2 15 2m 101 3 3 4590 5 1 0 00 1 2 2 116 3 3 3925 5 1 0 10 1 7 3 118 3 3 3285 5 1 0 10 1 7 4 126 3 3 1985 5 1 0 20 2 2 5 125 3 3 1850 5 1 0 20 2 1 6 127 3 3 1605 5 1 0 30 2 1 8 131 3 3 1100 5 1 0 40 2 1 10 134 3 3 670 5 1 0 50 2 1 12 136 4 8 490 6 4 0 90 2 2 15 132 3 3 375 Edge Start 2 6 20 144 4 8 230 Edge Start 2 5 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicate...

Page 82: ...avel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 118 0 13 350 0 20 0 00 0 07 14 0 079 118 0 13 350 0 20 0 10 0 08 11 0 120 123 0 13 275 0 20 0 10 0 08 3 16 0 188 125 0 13 140 0 20 0 20 0 08 1 4 0 250 132 0 13 80 0 20 0 30 0 08 3 8 0 375 135 0 13 45 0 20 0 50 0 08 1 2 0 500 140 0 13 26 0 20 0 80 0 08 5 ...

Page 83: ...m 1 5 9 7 6m 6 2 15 2m 118 6 4 8890 6 4 0 00 2 2 118 6 4 8890 6 4 0 10 2 0 3 123 6 4 7070 6 4 0 10 2 1 4 124 6 4 5095 6 4 0 20 2 0 5 126 6 4 3335 6 4 0 20 2 0 6 130 6 4 2370 6 4 0 30 2 0 8 134 6 4 1570 6 4 0 40 2 0 10 136 6 4 1070 6 4 0 60 2 0 12 139 6 4 765 6 4 0 70 2 0 15 146 4 8 515 Edge start 2 4 20 157 4 8 260 Edge start 2 7 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicate...

Page 84: ...ce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 060 85 25 90 50 115 0 13 280 0 20 0 00 0 06 11 0 120 112 0 13 190 0 20 0 10 0 06 10 0 135 110 0 13 176 0 20 0 20 0 06 3 16 0 188 122 0 19 135 0 20 0 30 0 08 1 4 0 250 127 0 19 100 0 20 0 40 0 09 3 8 0 375 134 0 19 40 0 20 0 50 0 10 1 2 0 500 136 0 19 36 0 20 0 60 0 10 5 8 0 625 145 0 19 18 Edge Start 0 11 3 ...

Page 85: ...2 15 2m 116 3 3 7895 5 1 0 00 1 6 2 114 3 3 6395 5 1 0 10 1 6 3 112 3 3 4895 5 1 0 10 1 5 4 115 4 8 4025 5 1 0 30 1 7 5 123 4 8 3300 5 1 0 30 2 0 6 126 4 8 2735 5 1 0 40 2 2 8 131 4 8 1745 5 1 0 50 2 5 10 134 4 8 1000 5 1 0 50 2 6 12 136 4 8 935 5 1 0 60 2 6 15 143 4 8 580 5 1 0 80 2 8 20 147 4 8 325 Edge Start 2 9 25 151 4 8 210 Edge Start 3 2 BOLD TYPE indicates maximum piercing parameters BOLD ...

Page 86: ...t Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 063 85 25 90 50 114 0 125 340 0 2 0 00 0 06 11 0 125 115 0 125 260 0 2 0 10 0 06 10 0 141 116 0 125 250 0 2 0 10 0 06 3 16 0 188 115 0 125 170 0 2 0 20 0 07 1 4 0 250 118 0 125 85 0 2 0 30 0 08 3 8 0 375 127 0 19 45 0 25 0 40 0 09 1 2 0 500 136 0 19 16 0 25 0 75 0 1...

Page 87: ... 1 5 9 7 6m 6 2 15 2m 114 3 2 9410 5 1 0 00 1 5 2 114 3 2 8120 5 1 0 00 1 4 3 115 3 2 6830 5 1 0 10 1 4 4 116 3 2 5635 5 1 0 20 1 5 5 115 3 2 4010 5 1 0 20 1 8 6 117 3 2 2640 5 1 0 30 2 0 8 123 4 8 1630 6 4 0 40 2 1 10 128 4 8 1030 6 4 0 60 2 2 12 134 4 8 565 6 4 0 75 2 6 15 141 4 8 295 Edge Start 3 0 20 147 4 8 185 Edge Start 2 8 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicat...

Page 88: ...orch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 16 0 064 85 25 90 50 115 0 13 320 0 2 0 00 0 09 11 0 120 120 0 13 240 0 2 0 10 0 08 3 16 0 188 122 0 13 165 0 2 0 20 0 08 1 4 0 250 124 0 13 100 0 2 0 30 0 10 3 8 0 375 140 0 19 60 0 2 0 40 0 09 1 2 0 500 142 0 19 36 0 2 0 60 0 11 5 8 0 625 148 0 19 26 ...

Page 89: ... 1 5 9 7 6m 6 2 15 2m 113 3 3 9020 5 1 0 00 2 4 2 116 3 3 7595 5 1 0 00 2 2 3 120 3 3 6165 5 1 0 10 2 0 4 121 3 3 5045 5 1 0 20 2 1 5 122 3 3 3955 5 1 0 20 2 2 6 124 3 3 2905 5 1 0 30 2 3 8 132 4 8 2010 5 1 0 40 2 3 10 140 4 8 1430 5 1 0 50 2 3 12 142 4 8 1045 5 1 0 60 2 6 15 146 4 8 730 5 1 0 75 2 7 20 157 4 8 330 Edge Start 3 2 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicate...

Page 90: ... Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 1 4 0 250 75 25 75 50 114 0 16 85 0 18 0 00 0 08 3 8 0 375 112 0 16 70 0 18 0 20 0 09 1 2 0 500 115 0 16 40 0 18 0 30 0 10 5 8 0 625 123 0 16 30 0 18 0 40 0 10 3 4 0 750 127 0 16 20 0 18 0 80 0 11 1 1 000 133 0 16 12 Edge Start 0 12 1 ...

Page 91: ... mm Bar torch lead length Volts mm mm min mm sec mm 6 114 4 1 2210 4 6 0 00 2 0 8 113 4 1 1960 4 6 0 10 2 2 10 112 4 1 1665 4 6 0 20 2 3 12 114 4 1 1185 4 6 0 30 2 4 15 121 4 1 830 4 6 0 40 2 5 20 128 4 1 475 5 0 0 80 2 8 25 133 4 1 315 Edge Start 2 9 30 134 4 1 230 Edge Start 3 1 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 92: ...hickness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 1 4 0 250 75 25 75 50 114 0 16 110 0 18 0 00 0 08 3 8 0 375 116 0 16 70 0 18 0 10 0 09 1 2 0 500 119 0 16 45 0 18 0 30 0 10 5 8 0 625 130 0 19 20 0 23 2 00 0 11 3 4 0 750 135 0 19 15 0 23 2 80 0 11 1 1 000 140 0 19...

Page 93: ...Speed mm Bar torch lead length Volts mm mm min mm sec mm 6 5 2 7 6m 5 2 15 2m 114 4 1 2900 4 6 0 00 2 0 8 115 4 1 2265 4 6 0 10 2 2 10 116 4 1 1685 4 6 0 20 2 4 12 118 4 1 1285 4 6 0 30 2 4 15 127 4 6 685 5 7 2 00 2 7 20 136 4 8 360 5 7 2 80 2 8 25 140 4 8 260 Edge Start 2 8 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 94: ...kness Gas Pressure Air Arc Voltage Torch Working Height Travel Speed Initial Piercing Height Pierce Delay Kerf Width Rec Speed GA in inch PSI torch lead length Volts in ipm in sec in 1 4 0 250 75 25 75 50 121 0 18 110 0 19 0 00 0 10 3 8 0 375 129 0 18 60 0 19 0 20 0 10 1 2 0 500 135 0 18 45 0 19 0 30 0 11 5 8 0 625 133 0 18 32 0 19 0 60 0 11 3 4 0 750 138 0 18 25 0 19 2 00 0 11 1 1 000 143 0 18 15...

Page 95: ...Speed mm Bar torch lead length Volts mm mm min mm sec mm 6 5 2 7 6m 5 2 15 2m 120 4 6 2920 4 8 0 00 2 5 8 125 4 6 2135 4 8 0 10 2 5 10 130 4 6 1470 4 8 0 20 2 6 12 134 4 6 1230 4 8 0 30 2 7 15 134 4 6 905 4 8 0 60 2 9 20 139 4 6 595 6 0 2 00 3 0 25 143 4 6 395 Edge Start 3 6 BOLD TYPE indicates maximum piercing parameters BOLD ITALIC indicates edge starts only ...

Page 96: ...s 6774336 7145099 6933461 Other Pat s Pending 9 8231 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8211 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8212 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8253 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8233 Tip US Pat No s 6774336 7145099 6933461 Other Pat s Pending 9 8225 Tip US Pat N...

Page 97: ...US Pat No s 6914211 D505309 Other Pat s Pending 9 8245 Shield Cap US Pat No s 6914211 D496951 Other Pat s Pending The following parts are also licensed under U S Patent No 5 120 930 and 5 132 512 Catalog Description 9 8235 Shield Cap 9 8236 Shield Cap 9 8237 Shield Cup 9 8238 Shield Cap 9 8239 Shield Cap 9 8244 Shield Cap 9 8245 Shield Cap ...

Page 98: ...A80 OPERATION 0 4985 4T 58 This Page Intentionally Blank ...

Page 99: ...orch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Visually check and Carefully clean the interior Maintain more often if used under severe conditions Art A 07938_AB ...

Page 100: ...eaning Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit 5 03 Common Faults Problem Symptom Common Cause Insufficient Penetration 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Cutting current too low 6 Non Genuine Thermal Dynamics parts used 7 Incorrect gas pressure Main Arc E...

Page 101: ...Temp indicator and 76 psi indicators are ON indicating the version would be 2 3 A PSI BAR MAX MAX MIN MIN 1 2 3 4 Art A 07988 MIN MAX 0 1 2 3 4 5 6 7 5 When the Fault indicator is ON or blinking it will be accompanied by one of the pressure indicator lights depend ing on what the Fault is The following table explains each of those Faults Pressure Indicator Fault Max Over Pressure 90 Internal Error...

Page 102: ...of the unit has been exceeded 3 Failed components in unit 1 Refer to clearance information section 2 04 2 Allow unit to cool 3 Return to authorized service center for repair or replacement GAS LED OFF FAULT and MIN pressure indicators flashing 1 Gas supply not connected to unit 2 Gas supply not turned ON 3 Gas supply pressure too low 4 AIR PRESSURE CONTROL regulator set too low 5 Failed components...

Page 103: ...or faulty torch parts 4 Shorted Torch 5 Temporary Short indicated by 5 blinks per second 6 Power Supply Failure Standard rate of blinking 1 Remove shield cup from torch check upper O Ring position correct if necessary 2 Turn OFF power supply Bleed down system pressure Remove shield cup tip and starter cartridge Check starter cartridge lower end fitting for free movement Replace if fitting does not...

Page 104: ...essary 2 Place the cover onto the power supply so that slots in the bottom edges of the cover engage the lower screws 3 Tighten lower screws 4 Reinstall and tighten the upper screws C Filter Element Assembly Replacement The Filter Element Assembly is in the rear panel For better system performance the filter element should be checked per the Maintenance Schedule Subsection 5 02 and either cleaned ...

Page 105: ...r Supply shuts down automatically when the Filter Element becomes completely saturated The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter element catalog number 1 Remove power from power supply 2 Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element 3 Dis...

Page 106: ... Loosen the two bolts on the top of the Filter As semblyenoughtoallowtheFilterElementstomove freely 4 Note the location and orientation of the old Filter Elements 5 Slide out the old Filter Elements First Second Stage Cartridges as marked Art A 02942 Optional Two Stage Filter Replacement 6 Slide the replacement Filter Elements into the Filter Assembly with the same orientation as noted in Step 4 a...

Page 107: ...ough with compressed air CAUTION Dry the torch thoroughly before reinstalling O Ring Lubrication An o ring on the Torch Head and ATC Male Connector requireslubricationonascheduledbasis Thiswillallow the o rings to remain pliable and provide a proper seal The o rings will dry out becoming hard and cracked if the lubricant is not used on a regular basis This can lead to potential performance problem...

Page 108: ...O ring between the shield cup body and drag shield cap Do not lubricate the O ring Drag Shield Cap Shield Cup Body O Ring No 8 3488 Art A 03878 4 Removethetip Checkforexcessivewear indicated by an elongated or oversized orifice Clean or re place the tip if necessary Good Tip Worn Tip A 03406 Example of Tip Wear 5 Remove the starter cartridge Check for excessive wear plugged gas holes or discolorat...

Page 109: ...ation will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the power supply Address all inquiries to your authorized distributor 6 03 Power Supply Replacement The following items are included with the replacement power suppl...

Page 110: ...e Air Filter Assembly 9 7527 1 First Stage Cartridge 9 1021 1 Second Stage Cartridge 9 1022 1 Extended Work Cable 50 ft 15 2 m with Clamp 9 8529 1 Multi Purpose Cart 7 8888 1 Automation Interface Kit for Start Stop OK to move and Divided Arc Voltage 9 8311 1 Automation Harness for Start Stop and OK to move 9 9385 1 25 7 6 m CNC Cable for Automation Interface Kit 9 1008 1 35 10 7 m CNC Cable for Au...

Page 111: ...A80 0 4985 PARTS LIST 6 3 This Page Intentionally Blank ...

Page 112: ...7 1 Rack 9 9448 8 1 Mounting Tube 9 9445 9 1 End Cap Assembly 9 7044 10 2 Body Mounting Pinch Block 9 4513 11 1 Pin Mounting Pinch Block 9 4521 12 1 Torch Holder Sleeve 7 2896 13 1 Pinion Assembly does not include positioning tube 7 2827 14 1 Torch Holder Sleeve 7 2896 15 1 Pinion Gear Short 8 6074 16 1 Handwheel Torch Holder 9 4514 17 1 Low Profile Torch Holder 1 3 8 Dia w o Hardware 9 4515 18 1 ...

Page 113: ...A80 0 4985 PARTS LIST 6 5 Art A 07113 6 1 4 2 3 5 8 10 12 11 7 10 22 19 15 14 16 17 18 20 21 21 13 9 24 23 ...

Page 114: ...dy 9 8237 Shield Cup 9 8218 Shield Cap Deflector 9 8243 Shield Cup Body 9 8237 Shield Cup 9 8218 Shield Cap Machine 50 60A 9 8238 Drag Shield Cup 9 8235 Drag Shield Cup 70 100A 9 8236 Drag Shield Cup 120A 9 8258 Shield Cap Machine 70 100A 9 8239 Shield Cap Machine 120A 9 8256 Art A 08066_AG CUTTING STANDOFF 70 120A CUTTING STANDOFF 20 40A Shield Cap Deflector 9 8243 50 60A CUTTING STANDOFF Heavy D...

Page 115: ...rench 9 8062 4 1 Torch Head Assembly Replacement Kit includes items No 5 6 9 8219 5 1 Large O ring 8 3487 6 1 Small O ring 8 3486 7 Leads Assemblies with ATC connectors includes switch assemblies 1 SL100 20 foot Leads Assembly with ATC connector 4 7836 1 SL100 50 foot Leads Assembly with ATC connector 4 7837 8 1 Switch Kit 9 7031 10 1 Torch Control Cable Adapter includes item 11 7 3447 11 1 Throug...

Page 116: ...A80 PARTS LIST 0 4985 6 8 This Page Intentionally Blank ...

Page 117: ... Gas flows to set pressure ACTION RUN Rapid Auto Restart SET LATCH switch to RUN for most applications or to Rapid Auto Restart for gouging trimming or expanded metal applications or to LATCH is used for specific applications torch switch can be released after main arc transfer RESULT Gas flow stops ACTION Release Torch switch RESULT Main arc stops Gas flow stops after post flow Fans will continue...

Page 118: ...urer s test procedures Second row Rated cutting current values Third row Conventional load voltage values 4 Sections of the Data Tag may be applied to separate areas of the power supply I Art A 03288_AC Date of Mfr Output Range Amperage Voltage Type of Power Supply Note 1 Output Current Type Rated No Load Voltage Plasma Cutting Symbol Manufacturer s Name and or Logo Location Model and Revision Lev...

Page 119: ... Black PIP Negative Plasma 8 Open ATC Male Connector Front View A 03701_AB B Mechanized Machine Torch Pin Out Diagram ATC Female Receptacle Front View ATC Male Connector Front View Negative Plasma 3 White Pendant Connector 4 Black Pendant Connector 2 Orange PIP 1 Black PIP Pilot 2 PIP 1 PIP 6 Open 7 Open 5 Open 8 Ground 8 Green Pendant Connector Ground 5 White Not Used 7 Green Not Used 6 Open UNSH...

Page 120: ... 8 7 1 2 5 6 4 3 8 7 Torch Switch Green White To Power Supply Circuitry B Mechanized Torch Connection Diagram Torch Unshielded Mechanized SL100 Machine Torch Leads Leads with ATC Connector and Remote Pendant Connector Power Supply with ATC Female Receptacle Pilot Negative Plasma Power Supply To Remote Control Remote Pendant Connector PIP Switch Not Used Male ATC Leads Connector ATC Female Receptac...

Page 121: ...A80 0 4985 APPENDIX A 5 This Page Intentionally Blank ...

Page 122: ...L1 GND L3 FAN BIAS SUPPLY 12VDC BIAS SUPPLY FERRITE FILTER MTH7 MTH7 AC2 AC2 J9 J9 J2 J2 1 2 AC3 AC3 TP3 TP3 MTH4 MTH4 SOL 1 SOL 1 C3 C4 C7 C8 C3 C4 C7 C8 MOT3 MOT3 SW2 SW2 J14 J14 MTH6 MTH6 PMTH2 PMTH2 80A_AC3 80A_AC3 PRI 3 PRI 3 J13 J13 1 2 3 4 5 6 80A_AC2 80A_AC2 PRI 2 PRI 2 J1 J1 1 2 3 K1 K1 K5 K5 PRI 2 PRI 2 AC1 AC1 J4 J4 1 2 3 4 5 MTH8 MTH8 C16 17 C16 17 K1 K1 PRI 4 PRI 4 K6 K6 SW1 SW1 1 3 2...

Page 123: ...MAND TIP DRAG SENSE TEST POINTS A120 ONLY J2 J1 CNC PINOUT 1 3 4 7 8 11 12 14 OK TO MOVE PIP START 24VAC RETURN 24VAC SUPPLY OVERTEMP TEMP CIRCUIT PRESSURE TRANSDUCER AIR INLET FILTER REGULATOR SOLENOID VALVE ATC GAS CONTROL 0 100PSI 0 4 5VDC OVERTEMP D3 5A 250VAC 30VDC 1TORCH AUTOMATION TORCH SOLENOID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 29 34 35 36 37 38 39 V_OUT_...

Page 124: ...m A80 C7 C10 may not be installed MTH4 MTH4 TP3 TP3 AC3 AC3 J2 J2 1 2 J9 J9 AC2 AC2 MTH7 MTH7 MOT3 MOT3 C3 C4 C7 C8 C3 C4 C7 C8 SOL 1 SOL 1 MTH6 MTH6 J14 J14 PRI 2 PRI 2 80A_AC2 80A_AC2 J13 J13 1 2 3 4 5 6 PRI 3 PRI 3 80A_AC3 80A_AC3 PMTH2 PMTH2 C16 17 C16 17 MTH8 MTH8 J4 J4 1 2 3 4 5 AC1 AC1 PRI 2 PRI 2 K1 K1 PRI 4 PRI 4 J7 J7 1 2 T1 T1 MTH2 MTH2 SW1 SW1 1 3 2 4 MOT1 MOT1 PMTH1 PMTH1 PRI 1 PRI 1 ...

Page 125: ...DMD_1 TIP_SEN COMMON COMMON 12 VDC SUPPLY 48 VDC SUPPLY CURRENT DEMAND TIP DRAG SENSE TEST POINTS J2 J1 CNC PINOUT 1 3 4 7 8 11 12 14 OK TO MOVE PIP START 24VAC RETURN 24VAC SUPPLY OVERTEMP TEMP CIRCUIT PRESSURE TRANSDUCER AIR INLET FILTER REGULATOR SOLENOID VALVE ATC GAS CONTROL 0 100PSI 0 4 5VDC OVERTEMP D3 5A 250VAC 30VDC 1TORCH AUTOMATION TORCH SOLENOID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1...

Page 126: ...al codes 1 Disconnect the power from the power supply 2 Remove the screws that attach the power supply cover to the chassis Remove the cover 3 Route the cable through the customer supplied strain relief at the rear of the power supply Art A 10286 Cut out for cable 4 On the main board use insulated type 1 4 inch ring lug terminal ends to connect to Vout1 polarity and WORK 1 polarity WARNING The raw...

Page 127: ...A80 0 4985 APPENDIX A 11 V_out2 Polarity Work2 Polarity Art A 10288_AB 5 Tighten the strain relief 6 Replace the cover 7 Connect the cable to negative and positive of Torch Height Control ...

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Page 130: ...46801 Email EUCustomerService thermal dynamics com ASIA PACIFIC Cikarang Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fax 61 3 9474 7391 International Ph 61 3 9474 7508 Fax 61 3 9474 7488 Shanghai China Sales Office Ph 86 21 6407262...

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