Thermal Dynamics SIGNATURE PAK 1250XRTM Owner'S Manual Download

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April 4, 2001 Manual No. 0-2377

PLASMA ARC

CUTTING SYSTEM

SIGNATURE

PAK

1250XR

• PAK 1250 XR POWER SUPPLY
• PCH/M-52 TORCH WITH WITH LEADS
• WORK CABLE WITH CLAMP
• TORCH SPARE PARTS KIT
• RUNNING GEAR WITH HANDLE
• AIR LINE FILTER AND REGULATOR

Summary of Contents for SIGNATURE PAK 1250XRTM

Page 1: ...al No 0 2377 PLASMA ARC CUTTING SYSTEM SIGNATURE PAK 1250XRTM PAK 1250 XR POWER SUPPLY PCH M 52 TORCH WITH WITH LEADS WORK CABLE WITH CLAMP TORCH SPARE PARTS KIT RUNNING GEAR WITH HANDLE AIR LINE FILT...

Page 2: ......

Page 3: ...is Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date April 4 2001 Record the following information for Warranty pur...

Page 4: ...N 15 3 1 OPERATING CONTROLS 15 3 2 PRE OPERATION SET UP 16 3 3 CUTTING OPERATION 17 3 4 GOUGING OPERATION 21 3 5 GENERAL OPERATING NOTES 23 3 7 CUTTING SPEEDS 24 3 8 SEQUENCE OF OPERATION 26 SECTION 4...

Page 5: ...our 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 o...

Page 6: ...ual PLASMA ARC RAYS PlasmaArc 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 yo...

Page 7: ...dway New York NY 10018 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en rel...

Page 8: ...produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez...

Page 9: ...visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAILET DE PROTECTION DE LA SANT 29CFR 1910 disponible aupr s du Superintendent of D...

Page 10: ...Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philad...

Page 11: ...ion standard C22 2 number 60 forArc 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 EN...

Page 12: ...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 o...

Page 13: ...50 ft 15 2 m Torch Leads PCH M 52 Spare Parts Kit 25 ft 7 6 m Work Cable and Clamp Running Gear and Handle Air Line Filter and Regulator Assembly or High Pressure Gas Regulators Figure 1 A The Signat...

Page 14: ...ormation on power input current ratings circuit protection and wire sizes Range I 35 amps Range II 70 amps Range III 105 amps Duty Cycle 80 Approximate Shipping Weight 275 lbs 125 kg Voltage Frequency...

Page 15: ...eads Approx 1 0 lb 45 kg Most materials up to 1 25 in 32 mm Current Rating Cutting Range Weight Gas Requirements Pressure Hot Flow Plasma Gas Compressed Air 40 psi For Cutting Argon Hydrogen 2 8 bar 2...

Page 16: ...kages Available in 25 ft 7 6 m or 50 ft 15 2 m lengths For extending leads up to a maximum of 100 ft 30 5 m See page 37 for ordering information Power Supply Accessories Torch Accessories Plasma Gas F...

Page 17: ...nsfer to the work 1 5 THEORY OF OPERATION continued GENERAL INFORMATION Plasma Gas Flow continued Gas Distribution Figure 1 D Theory of Operation Because DC current alone is not sufficient to initiate...

Page 18: ...heated the appropriate switch will open causing the temperature light to go out and shutting off power to the main contactor When the overheated component cools down the switch will close again and al...

Page 19: ...g gear includes rear wheels with mount ing hardware factory installed front casters and handle The optional cylinder rack running gear see page 8 is designed for mounting and transporting two gas cyli...

Page 20: ...set it onto a platform to install the cylinder rack 3 Attach the base extensions to the base of the unit 4 Attach the cylinder tray to the base extensions 5 Feed the axle through the large holes in t...

Page 21: ...secure the wheel assembly 8 Follow the same procedure to install the second wheel assembly 9 Mount the cylinder support bracket to the back of the power supply as shown 10 Attach the handle to the fr...

Page 22: ...r Flow 470 SCFH 221 lpm For Cutting or Gouging Systems that are set up for shop air operation include the following parts for air line connections 2 Air Line Regulators with Brackets 1 Air Line Filter...

Page 23: ...adequate air flow Multi gas systems require high pressure gas regulators on the gas cylinders 1 Install regulators on the cylinders see manufacturer s specifications for recommended procedures 2 Conne...

Page 24: ...n the main transformers T1 T2 and T3 The low voltage leads are color coded yellow c Remove the tie wraps securing the insulated sleeving on the low voltage taps d Remove the high voltage transformer t...

Page 25: ...ch for proper assembly see page 27 2 3 INSTALLATION continued Input Power Supply continued INSTALLATION Work Cable Connection Table 2 A Line Voltages Circuit Protection and Recommended Wire Size Based...

Page 26: ...ecommended method for lifting the power supply is to use a forklift see Figure 2 G Approach from either side of the unit Lifting from the front or rear may damage protruding fittings Place the forks b...

Page 27: ...e switch is satisfied Light goes out in RUN mode and comes on only when gas is flowing to the torch Red light indicates main contactor closure supplying current to the main bridge rectifier and that c...

Page 28: ...utting or Gouging 9 5619 Multi Gas Cutting or Gouging 9 5711 Air electrodes are for use with air only Do not use air electrodes for multi gas nitrogen or argon hydrogen operation Multi gas electrodes...

Page 29: ...switch is pressed WARNING CAUTION Plasma Cutting Operation Hand Torch OPERATION WARNING Disconnect primary power to the system before disassembling the torch leads or power supply 1 The hand torch sho...

Page 30: ...ressed as when cutting expanded metal the pilot arc will automatically restart If the switch is set to DELAYED closed position there is always a two second pre flow delay before restarting Releasing t...

Page 31: ...terial thicknesses To start a cut at the plate edge line up the center of the torch along the edge of the plate and press the control switch The transferred cutting arc will then be established at the...

Page 32: ...piercing with a hand torch tip the torch slightly so that blowback particles blow away from the torch tip and operator rather than directly back into it see Figure 3 F Pierce off the cutting line and...

Page 33: ...ARNING Disconnect primary power to the system before disassembling the torch leads or power supply Gouging performance depends on the torch travel speed the current level the angle at which the torch...

Page 34: ...6 mm may result in minimal metal removal or loss of transferred main arc Slag generated by gouging on materials such as carbon and stainless steels nickels and alloyed steels can be removed easily in...

Page 35: ...the ON OFF switch on the unit to OFF p osition when cutting operations have been completed Always open the power supply discon nect switch five minutes after the last cut is made NOTE WARNING 3 6 COMM...

Page 36: ...r Minute 50 100 150 200 250 300 350 400 Meters per Minute 1 27 2 54 3 81 5 08 6 35 7 62 8 89 10 16 mm gage in 1 00 0 75 0 50 0 25 0 125 0 62 MATERIAL THICKNESS 25 20 15 10 5 4 8 12 16 CUTTING SPEED AI...

Page 37: ...00 250 300 350 400 Meters per Minute 1 27 2 54 3 81 5 08 6 35 7 62 8 89 10 16 mm gage in 1 00 0 75 0 50 0 25 0 125 0 62 MATERIAL THICKNESS 25 20 15 10 5 4 8 12 16 N2 CO2 ON ALUMINUM Range III Range II...

Page 38: ...26 Figure 3 J Sequence of Operation 3 8 SEQUENCE OF OPERATION OPERATION...

Page 39: ...electrode see CAUTION below Check the torch for proper assembly Tip and electrode selection must correspond with the type of operation cutting or gouging air or multi gas See Torch Parts Selection pa...

Page 40: ...t of Consumable Parts Figure 4 C Hand Torch Leads Replacement 4 2 TORCH LEADS REPLACEMENT Figure 4 B Electrode Deterioration Disconnect primary power to the system before disassembling the torch leads...

Page 41: ...ce the handle on the torch head and reconnect the torch switch leads connectors Secure the connec tors with electrical tape 10 Pull the leads sleeving up inside the handle and secure to the leads with...

Page 42: ...necessary solvents for cleaning electrical apparatus may be used While the side panels are off inspect the wiring in the unit Look for any frayed wires or loose connections that should be corrected Wh...

Page 43: ...on C TEMP indicator is not lit 1 Blown fuse or open circuit breaker at discon nect panel 2 Blown fuse 1FU 3 Rear panel wiring harness plug not properly con nected 4 ON OFF switch SW1 faulty 5 Auxiliar...

Page 44: ...fol lowed by the closing of the high frequency relay HF indicator lit At this time the pilot arc should be established If this does not happen check to see if 1 there is any light visible inside the t...

Page 45: ...gap points K Spark in torch but no pilot L No spark can be seen in torch but spark is present at spark gap points TROUBLE POSSIBLE CAUSE REMEDY M No cutting arc 1 Faulty time delay circuit 2 High freq...

Page 46: ...tch SW3 1 Allow unit to cool 2 Check and correct 3 Check primary power source 4 Replace fuses 1 Check diode See E page 35 2 Check contactors and replace if necessary 3 Check switch and replace if nece...

Page 47: ...ints should be bright blue If the spark appears to be weak or nonexistent disconnect the wire between the spark gap and the capacitor and try to start the torch again If the spark is stronger with thi...

Page 48: ...heatsink compound this is a white grease is present between the diode and heat sink Check to be sure that air passages in and out of the unit are not obstructed 5 Diodes that are faulty at the time o...

Page 49: ...tification of the correct choice for each system configuration Parts listed without item numbers are not illustrated but may be ordered by the catalog number shown Order replacement parts by catalog n...

Page 50: ...D 5 1 12 2 7 3128 Front Caster 5 1 1 7 3117 Cylinder Rack Running Gear 5 1 1 7 3139 Air Line Filter Assembly Includes All Fittings 5 1 2 9 1020 Air Line Filter Assembly Filter Only 5 1 1 9 1021 Repla...

Page 51: ...PARTS LIST 39 5 1 SYSTEM COMPONENTS ACCESSORIES continued Figure 5 1 PAK 1250 XR System Components R R 1 2 3 12 9 11 8 11 10 6 4 5 7 13 14 A 01464...

Page 52: ...ontrol Panel Overlay International 5 2 3 1 9 4210 Torch Leads Boot 5 2 4 1 8 1119 Top Panel 5 2 7 1 9 5607 ON OFF Switch Kit 3PST SW1 5 2 8 1 9 3405 RUN SET Switch DPDT SW2 5 2 9 1 9 4188 LED Control...

Page 53: ...ohm 100 W R5 5 3 6 2 9 4337 Solenoid Assembly Includes All Fittings SOL1 2 5 3 7 2 9 4078 Reducing Bulkhead Fitting 5 3 8 4 8 0354 Close Nipple Fitting 5 3 9 2 8 0312 Female Tee Fitting 5 3 10 2 8 02...

Page 54: ...V 3 phase 50 Hz 9 5686 575V 3 phase 60 Hz 5 4 3 1 9 2391 Strain Relief Input Power Cable 5 4 4 3 9 5586 Main Contactor 24 VAC W1 W2 W3 5 4 5 1 8 1127 Fan Motor Mounting Bracket 5 4 6 1 8 1125 Fan Moto...

Page 55: ...PARTS LIST 43 5 4 BASE COMPONENTS continued Figure 5 4 Base Components A 01467...

Page 56: ...uxiliary Transformer For 50 Hz and 50 60 Hz T4 5 5 1 8 4235 Auxiliary Transformer Socket 5 5 1 9 5171 Auxiliary Transformer Receptacle 5 5 11 1 8 0367 Fuse 5 amp 250V For 200 220V units 1FU 5 5 11 1 8...

Page 57: ...PARTS LIST 45 5 5 UPPER EQUIPMENT PANEL COMPONENTS continued Figure 5 5 Upper Equipment Panel Components 11 12 8 18 10 7 17 13 14 15 15 4 3 2 1 6 5 16 11 9 A 01468...

Page 58: ...C Board Main Bridge 5 6 5 1 8 1129 Negative Heatsink 5 6 6 1 8 1130 Positive Heatsink 5 6 7 1 8 1131 Suppression Coil L1 5 6 8 2 8 1163 Internal Gas Hose 5 6 9 9 9 5466 Diode Reverse Polarity 40A 1000...

Page 59: ...Range I 35 amps 5 7 1 9 5707 Cutting Tip 047 in Orifice For Range II 70 amps 5 7 1 9 5708 Cutting Tip 059 in Orifice For Range III 105 amps 5 7 7a 1 8 5128 Gouging Cup 5 7 7b 1 9 5617 Standard Shield...

Page 60: ...9 5662 Negative Torch Lead 25 ft 7 6 m 5 8 1 9 5663 Negative Torch Lead 50 ft 15 2 m 5 8 1 9 5664 Plasma Gas Hose 25 ft 7 6 m 5 8 1 9 5665 Plasma Gas Hose 50 ft 15 2 m 5 8 1 9 4279 Positive Pilot Wir...

Page 61: ...PARTS LIST 49 5 8 TORCH ACCESSORIES continued Figure 5 8 Torch Accessories 1 2 3 7 A 01484 10 11 13 12 16 15 14 5 8 6 4 9...

Page 62: ...PARTS LIST 50 5 9 TROUBLESHOOTING DIAGRAM...

Page 63: ...t Stop CSR Ready to Move Ground CSD Corner Slowdown Customer Supplied CNC SIGNAL INTERFACE CABLE POWER SUPPLY 49 50 54 55 GND 45 59 CSD RED BLACK WHITE BROWN GREEN BLUE ORANGE W CSR GND 24 VAC W1 W2 4...

Page 64: ...PARTS LIST 52 A 01583 5 11 SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC SHEET 1...

Page 65: ...PARTS LIST 53 A 01583...

Page 66: ...PARTS LIST 54 SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC SHEET 2 A 01584...

Page 67: ...PARTS LIST 55 A 01584...

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