Thermal Dynamics SureLok PCM-102 Instruction Manual Download | Manualshive

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INTRODUCTION & DESCRIPTION

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Manual 0-2815

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Summary of Contents for SureLok PCM-102

Page 1: ...o 0 2815 PLASMA CUTTING TORCH Instruction Manual For Use With Automated Pak Master 75XL Plus Automated Pak Master 100XL Plus CE Automated Pak Master 75XL Plus CE Automated Pak Master 100XL Plus PCM 102 For Automated Systems ...

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Page 3: ...Torch Serial _______________________________________ Plasma Cutting Torch PCM 102 For Automated Systems Instruction Manual Number 0 2815 Published by Thermal Dynamics Corporation Industrial Park No 2 West Lebanon New Hampshire USA 03784 603 298 5711 Copyright 2000 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written per mission of the pu...

Page 4: ...TALLATION PROCEDURES 3 1 3 01 Introduction 3 1 3 02 Site Location 3 1 3 03 Unpacking 3 1 3 04 Setting Up Machine Torch 3 1 3 05 Connecting Torch 3 1 3 06 Gas Connection 3 2 SECTION 4 OPERATION 4 1 4 01 Introduction 4 1 4 02 Functional Overview 4 1 4 03 Getting Started 4 1 4 04 Torch Parts Selection 4 2 4 05 Cut Quality 4 2 4 06 Operating the System 4 3 4 07 Machine Torch Operation 4 4 4 08 Recomme...

Page 5: ...cessories 6 5 6 07 Torch Spare Parts Kits 6 6 APPENDIX 1 TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM A 1 APPENDIX 2 TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS A 2 APPENDIX 3 GENERAL APPLICATION NOTES A 3 APPENDIX 4 PAK MASTER 75XL PLUS AUTOMATED SYSTEM DATA A 4 APPENDIX 5 CE AUTOMATED PAK MASTER 75XL PLUS SYSTEM DATA A 8 APPENDIX 6 AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA ...

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Page 7: ...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 of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Merc...

Page 8: ... in this manual PLASMAARC 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 your skin if you are not properly protected To protect your eyes always wear a welding hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear...

Page 9: ...rican National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilisés pour mettre en relief des informations à caractère important Ces mises en relief sont classifiées comme suit NOTE Toute opération procédure ou renseignement général sur lequel il importe d insister davantage ou qui contribue à...

Page 10: ...ser 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 soud...

Page 11: ...e les décibels le bruit ne dépassent pas les niveaux sûrs Pour des renseignements sur la manière de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles ci pour de plus amples renseignements 1 OSHA NORMES DE SÉCURITÉ DU TRAVAILET DE PROTECTION DE LA SANTÉ 29CFR 1910 disponible auprès du ...

Page 12: ...RITÉ POUR LE SOUDAGE ET LA COUPE disponible auprès de l Association des Normes Canadiennes Stan dards 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 Amé...

Page 13: ...tion 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 EN50078 applicable to plasma cutting equipment and associ ated accessories Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturi...

Page 14: ...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 fo...

Page 15: ... auto motive spark plug They consist of negative and positive sections which are separated by a center insulator Inside the torch the pilot arc is initiated in the gap between the negatively charged electrode and the positively charged tip Once the pilot arc has ionized the plasma gas the superheated column of gas flows through the small orifice in the torch tip which is focused on the metal to be...

Page 16: ...c between the electrode and the torch tip heats and ionizes the gas The main cutting arc then transfers to the workpiece through the column of plasma gas in Zone C A 00002 Workpiece Power Supply _ C B A Figure 2 3 Typical Torch Head Detail By forcing the plasma gas and electric arc through a small orifice the torch delivers a high concentration of heat to a small area The stiff constricted plasma ...

Page 17: ...interlock for the gas supply If supply pressure falls below minimum re quirements the pressure switch will open shutting off the DC power and the GAS indicator will go off When adequate gas supply pressure is available the pressure switch will close allowing power to be re sumed for cutting G Parts In Place PIP The torch head has built in contacts called Parts In Place PIP These two contacts are m...

Page 18: ...INTRODUCTION DESCRIPTION 2 4 Manual 0 2815 ...

Page 19: ...ributor and or shipping company before proceeding with system installation 3 04 Setting Up Machine Torch WARNING Disconnect primary power at the source before dis assembling the torch or torch leads The standard machine torch includes a fiberglass posi tioning tube with rack and pinch block assembly Ametal mounting tube with rack pinion assembly or the pin ion assembly only are available as option...

Page 20: ...ch Leads 9 Check the torch for proper parts assembly CAUTION The torch parts must correspond with the type of operation Refer to Section 4 04 Torch Parts Se lection 3 06 Gas Connection A Connection Connect the gas compressed air or nitrogen N2 only to the Power Supply as described in the Manual supplied with the Power Supply CAUTION Air supply must be free of oil moisture and other contaminants Ex...

Page 21: ...nforma tion as related to the Power Supply used E Power On Place the ON OFF Switch on the Power Supply to the ON position If the RUN SET LATCH switch is in SET position gas will flow If the switch is in RUN position there will be no gas flow F RUN SET or RUN SET LATCH Switch If the RUN SET or RUN SET LATCH switch is in SET position gas will flow If the switch is in RUN position there will be no ga...

Page 22: ...reads before proceeding 4 05 Cut Quality NOTES Cut quality depends heavily on set up and param eters such as torch standoff alignment with the workpiece cutting speed gas pressures and op erator ability Refer to Appendix Pages for additional informa tion as related to the Power Supply used Cut quality requirements differ depending on applica tion For instance nitride build up and bevel angle may b...

Page 23: ...e Starting For edge starts hold the torch perpendicular to the workpiece with the front of the tip near not touch ing the edge of the workpiece at the point where the cut is to start When starting at the edge of the plate do not pause at the edge and force the arc to reach for the edge of the metal Establish the cutting arc as quickly as possible D Direction of Cut In the torches the plasma gas st...

Page 24: ...lasma Standoff Distance Straight Arc Trailing Arc Leading Arc Direction of Torch Travel A 02586 Figure 4 5 Machine Torch Operation For optimum smooth surface quality the travel speed should be adjusted so that only the leading edge of the arc column produces the cut If the travel speed is too slow a rough cut will be produced as the arc moves from side to side in search of metal for trans fer Trav...

Page 25: ...torch parts The torch parts must corre spond with the type of operation Refer to Section 4 04 Torch Parts Selection WARNING Disconnect primary power to the system before disassembling the torch leads or power supply A Gouging Parameters Gouging performance depends on parameters such as torch travel speed current level lead angle the angle between the torch and workpiece and the dis tance between t...

Page 26: ...n minimal metal removal or loss of transferred main arc F Slag Build up Slag generated by gouging on materials such as car bon and stainless steels nickels and alloyed steels can be removed easily in most cases Slag does not obstruct the gouging process if it accumulates to the side of the gouge path However slag build up can cause inconsistencies and irregular metal removal if large amounts of ma...

Page 27: ...oroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air Refer to Section 5 07 Servicing Machine Torch Com ponents PCM for disassembling the Torch and Leads Assembly CAUTION Dry the torch thoroughly before reinstalling B Checking Center Insulator The center insulator separates the negative and posi tive sections of the torch If the center insulator d...

Page 28: ... Dynamics Parts 4 Short Torch Parts Life a Oil or moisture in air source b Exceeding system capability material too thick c Excessive pilot arc time d Air flow too low incorrect pressure e Improperly assembled torch f Non Genuine Thermal Dynamics Parts 5 04 Inspection and Replacement Consumable Torch Parts WARNINGS Disconnect primary power to the system before disassembling the torch or torch lead...

Page 29: ...e the most likely causes for various symptoms This guide is set up in the following manner X Symptom Bold Type Any Special Instructions Text Type 1 Cause Italic Type a Check Remedy Text Type Locate your symptom check the causes easiest listed first then remedies Repair as needed being sure to verify that unit is fully operational after any repairs A Torch will not pilot when torch activated Remote...

Page 30: ...moisture buildup do not activate torch 5 Torch tip contacts workpiece a When the tip is contacts the workpiece the amperage automatically cuts back to 35 amps E No gas flow 1 Gas not connected or pressure too low a Check source for at least 70 psi 4 8 bar 2 Faulty components in torch and leads assembly a Inspect torch assemblies and replace if neces sary Refer to Section 5 06 Torch Leads Troublesh...

Page 31: ...s by measuring the resistance between the positive pilot lead connector and the negative lead fitting If there is continuity torch leads must be re placed If no continuity infinite resistance is found proceed to paragraph C see NOTE NOTE It is possible that the Torch Head and Torch Leads will test properly with an ohmmeter The Torch Head and Torch Leads should be tested further for insulation brea...

Page 32: ...3 to confirm that the components have been prop erly assembled This completes the checks for the proper operation of the Torch Head and Torch Leads 5 07 Servicing Machine Torch PCM Components WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON A Removing Machine To...

Page 33: ...cements Section 6 06 Options Accessories Section 6 07 Spare Parts Kits NOTE Parts listed without item numbers are not shown but may be ordered by the catalog number shown B Returns If a product must be returned for service contact your authorized distributor Materials returned to without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number a...

Page 34: ...r the proper application 6 1 Assembly Torch Head PCM 102 RPT Includes items 7 9 9 8403 7 1 O Ring 8 0532 8 1 6 32 x 3 16 Phillips Pan Head Screw See Note 9 1 6 Internal Star Washer See Note 10 Shielded Lead Assembly Cable Complete 25 ft 7 6 m Length 4 7531 50 ft 15 2 m Length 4 7532 11 1 Positioning Tube With Rack Fiberglass 9 7835 12 2 Body Mounting Pinch Block Phenolic Plastic 9 4513 13 1 Pin Mo...

Page 35: ...Manual 0 2815 6 3 PARTS LISTS A 02833 1 2 3 4 5 7 6 8 9 11 14 13 12 12 15 16 17 10 18 19 Copper Shield Cup Assembly Shield Cup Body Heat Shield Copper 1a Hi Vis Shield Cup Black 1b ...

Page 36: ...ilot Return 14 AWG 1 25 ft 7 6 m Length 8 6460 1 50 ft 15 2 m Length 8 6461 5 Lead Gas Cooled Negative 5 1 25 ft 7 6 m Length 9 7665 1 50 ft 15 2 m Length 9 7796 6 Assembly Control Cable Shielded Leads 1 25 ft 7 6 m Length 8 6456 1 50 ft 15 2 m Length 8 6457 7 PVC Sleeving 1 25 ft 7 6 m Length 8 6478 1 50 ft 15 2 m Length 8 6479 8 Shield Braid 1 25 ft 7 6 m Length 8 6458 1 50 ft 15 2 m Length 8 64...

Page 37: ...vlar Sleeving 1 25 ft 7 6 m 9 7905 1 50 ft 15 2 m 9 7906 1 1 3 8 Metal Positioning Tube w Rack Pinion Assembly Kit 7 7745 1 Pinion Assembly Only 7 2827 1 1 Torch Holder Sleeve 7 2896 2 1 Pinion Gear Short 8 6074 3 1 Handwheel Torch Holder 9 4514 4 1 Low Profile Torch Holder 1 3 8 Dia w o Hardware 9 4515 5 1 Calibrated Torch Holder Bushing 9 4366 6 1 5 32 Dia x 5 8 Lg Slotted Spring Pin See Note 7 ...

Page 38: ...726 2 Gas Distributor 8 7501 1 Standard Shield Cup 8 7500 1 Shield Cup Copper 8 7496 5 O Ring 8 0532 3 Canted Coil Spring 9 7501 C For Automated Pak Master 100XL Plus Applications Qty Description Catalog VIP Spare Parts Kit Includes 5 3513 20 Electrode SureLok MaximumLife 9 8407 40 Tip Cutting Air N2 80 Amp 0 055 Orifice 9 7728 2 Gas Distributor 8 7501 1 Standard Shield Cup 8 7500 1 Shield Cup Cop...

Page 39: ...kpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power to system ACTION Close external disconnect switch RESULT Power to system ACTION RUN SET LATCH switch to SET RESULT Gas solenoid open gas flows to set pressure GAS indicator on ACTION Torch moved away from work while still activated RESULT Main arc stops...

Page 40: ...onnector To Torch Control Device Torch Control Cable Control Shield Connector Lead Shield Connector Connectors only on Shielded Leads 2 1 3 4 12 14 13 Torch Control Cable Connector Remote Pendant CNC Cable Connector Control OK To Move 3 4 12 14 13 A 02821 Torch Leads Torch Head PIP Pin PIP Pin Shield Cup Mate Lock Connectors Mate Lock Connectors Pendant Ground Shield Return Power Supply Control OK...

Page 41: ...gnificant improvement in consumable parts life Suggested Applications System General Purpose Cat 9 8402 MaximumLife Cat 9 8407 PakMaster 75XL Plus Optional Suggested PakMaster 100XL Plus Optional Suggested CE PakMaster 75XL Plus Suggested Optional CE PakMaster 100XL Plus Suggested Optional Electrode B Frequenly Asked Questions Q What Electrode can be used A Only SureLok Electrodes 9 8402 and 9 840...

Page 42: ...aterial Type of Type of Cut Thickness Material Gas Characteristics Carbon Steel Air Good Excellent Gage Nitrogen Good to Stainless Air Good Excellent 3 4 inch Nitrogen Good Aluminum Air Good Excellent Nitrogen Good Description of Cut Characteristics Excellent Minimum bevel 0 4 minimum kerf 2 x tip orifice diameter little or no dross smooth cut surface Good Slight bevel 0 10 slightly wider kerf 2 1...

Page 43: ...60 50 275 0 10 0 25 10 ga 8 7501 9 7726 8 7500 60 100 225 0 188 60 50 275 0 10 0 25 1 4 8 7501 9 7726 8 7500 60 100 90 0 188 60 50 275 0 15 0 25 1 2 8 7501 9 7726 8 7500 60 100 30 0 188 60 50 275 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With Automated Pak Master 75XL Plus Aluminum Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Distributor Ti...

Page 44: ...188 60 50 275 NR NR 1 8 7501 9 7726 8 7500 60 115 5 0 188 60 50 275 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With Automated Pak Master 75XL Plus Mild Steel Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Distributor Tip Shield Cup Amperage Output Volts Speed Standoff Plasma Pressure Flow lpm Pierce Delay Pierce Height mm Cat No Cat No Cat No ...

Page 45: ...0 50 275 NR NR 3 4 8 7501 9 7726 8 7500 60 115 8 0 188 60 50 275 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With Automated Pak Master 75XL Plus Stainless Steel Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Distributor Tip Shield Cup Amperage Output Volts Speed Standoff Plasma Pressure Flow lpm Pierce Delay Pierce Height mm Cat No Cat No Cat N...

Page 46: ...aterial Type of Type of Cut Thickness Material Gas Characteristics Carbon Steel Air Good Excellent Gage Nitrogen Good to Stainless Air Good Excellent 3 4 inch Nitrogen Good Aluminum Air Good Excellent Nitrogen Good Description of Cut Characteristics Excellent Minimum bevel 0 4 minimum kerf 2 x tip orifice diameter little or no dross smooth cut surface Good Slight bevel 0 10 slightly wider kerf 2 1...

Page 47: ...60 50 275 0 15 0 25 1 2 8 7501 9 7726 8 7500 60 100 30 0 188 60 50 275 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With CE Automated Pak Master 75XL Plus Aluminum Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Distributor Tip Shield Cup Amperage Output Volts Speed Standoff Plasma Pressure Flow lpm Pierce Delay Pierce Height mm Cat No Cat No Cat...

Page 48: ...0 105 45 0 188 60 50 275 0 25 0 250 1 2 8 7501 9 7726 8 7500 60 105 22 0 188 60 50 275 0 50 0 250 3 4 8 7501 9 7726 8 7500 60 115 10 0 188 60 50 275 NR NR 1 8 7501 9 7726 8 7500 60 115 5 0 188 60 50 275 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With CE Automated Pak Master 75XL Plus Mild Steel Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Di...

Page 49: ...60 100 25 0 188 60 50 275 0 50 0 200 1 2 8 7501 9 7726 8 7500 60 105 16 0 188 60 50 275 NR NR 5 8 8 7501 9 7726 8 7500 60 115 12 0 188 60 50 275 NR NR 3 4 8 7501 9 7726 8 7500 60 115 8 0 188 60 50 275 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With CE Automated Pak Master 75XL Plus Stainless Steel Single Gas Torch Air Plasma Air Secondary Material Thickness Gas...

Page 50: ...Material Gas Characteristics Carbon Steel Air Good Excellent Gage Nitrogen Good to Stainless Air Good Excellent 1 inch Nitrogen Good 25 4mm Aluminum Air Good Excellent Nitrogen Good Description of Cut Characteristics Excellent Minimum bevel 0 4 minimum kerf 2 x tip orifice diameter little or no dross smooth cut surface Good Slight bevel 0 10 slightly wider kerf 2 1 2 x tip orifice diameter some dr...

Page 51: ...115 0 188 70 85 365 0 00 0 20 3 8 8 7501 9 7728 8 7500 80 110 60 0 188 70 85 365 0 00 0 20 1 2 8 7501 9 7728 8 7500 80 120 30 0 188 70 85 365 NR NR 3 4 8 7501 9 7728 8 7500 80 125 10 0 188 70 85 365 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With Automated Pak Master 100XL Plus Aluminum Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Distributo...

Page 52: ... 7500 80 105 50 0 188 70 85 365 0 10 0 20 1 2 8 7501 9 7728 8 7500 80 110 30 0 188 70 85 365 0 10 0 20 3 4 8 7501 9 7728 8 7500 80 120 12 0 188 70 85 365 NR NR 1 8 7501 9 7728 8 7500 80 120 6 0 188 70 85 365 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With Automated Pak Master 100XL Plus Mild Steel Single Gas Torch Air Plasma Air Secondary Material Thickness Gas...

Page 53: ... 105 75 0 188 70 85 365 0 10 0 200 3 8 8 7501 9 7728 8 7500 80 105 40 0 188 70 85 365 0 20 0 200 1 2 8 7501 9 7728 8 7500 80 110 18 0 188 70 85 365 NR NR 3 4 8 7501 9 7728 8 7500 80 125 10 0 188 70 85 365 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With Automated Pak Master 100XL Plus Stainless Steel Single Gas Torch Air Plasma Air Secondary Material Thickness G...

Page 54: ... of Type of Cut Thickness Material Gas Characteristics Carbon Steel Air Good Excellent Gage Nitrogen Good to Stainless Air Good Excellent 1 inch Nitrogen Good 25 4mm Aluminum Air Good Excellent Nitrogen Good Description of Cut Characteristics Excellent Minimum bevel 0 4 minimum kerf 2 x tip orifice diameter little or no dross smooth cut surface Good Slight bevel 0 10 slightly wider kerf 2 1 2 x ti...

Page 55: ...115 0 188 70 85 365 0 00 0 20 3 8 8 7501 9 7728 8 7500 80 110 60 0 188 70 85 365 0 00 0 20 1 2 8 7501 9 7728 8 7500 80 120 30 0 188 70 85 365 NR NR 3 4 8 7501 9 7728 8 7500 80 125 10 0 188 70 85 365 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With CE Automated Pak Master 100XL Plus Aluminum Single Gas Torch Air Plasma Air Secondary Material Thickness Gas Distrib...

Page 56: ... 7500 80 105 50 0 188 70 85 365 0 10 0 20 1 2 8 7501 9 7728 8 7500 80 110 30 0 188 70 85 365 0 10 0 20 3 4 8 7501 9 7728 8 7500 80 120 12 0 188 70 85 365 NR NR 1 8 7501 9 7728 8 7500 80 120 6 0 188 70 85 365 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With CE Automated Pak Master 100XL Plus Mild Steel Single Gas Torch Air Plasma Air Secondary Material Thickness ...

Page 57: ... 105 75 0 188 70 85 365 0 10 0 200 3 8 8 7501 9 7728 8 7500 80 105 40 0 188 70 85 365 0 20 0 200 1 2 8 7501 9 7728 8 7500 80 110 18 0 188 70 85 365 NR NR 3 4 8 7501 9 7728 8 7500 80 125 10 0 188 70 85 365 NR NR Metric Measurements Air Plasma Cutting Data Chart PCM 102 Automated Torch With CE Automated Pak Master 100XL Plus Stainless Steel Single Gas Torch Air Plasma Air Secondary Material Thicknes...

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