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SERVICE

Manual 0-2583

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

D. Limited output with no control

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Incorrect setting of current control on power supply

a. Check and adjusted to proper setting.

2. Faulty components in torch and leads assembly

a. Inspect torch assemblies and replace if neces-

sary. Refer to Section 5.08, Torch and Leads
Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

E. Erractic or improper cutting output

1. Poor input or output connections to power supply

a. Check all input and output connections.

2. Current set too low at power supply

a. Increase current setting.

3. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix I, Cut-

ting Speed Charts).

4. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.18 mm) from clean sur-

face while purging and observe oil or moisture
buildup (do not activate torch)

F. 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 5.08, Torch and Leads
Troubleshooting.

3. Faulty components in power supply system components

a. Return for repair or have qualified technician

repair per Service Manual.

G. Torch cuts but not adequately

1. Current set too low at power supply

a. Increase current setting

2. Torch is being moved too fast across workpiece

a. Reduce cutting speed (refer to Appendix I, Cut-

ting Speed Charts).

3. Excessive oil or moisture in torch

a. Hold torch 1/8 inch (3.18 mm) from clean sur-

face while purging and observe oil or moisture
buildup (do not activate torch)

5.06 Servicing Machine Torch

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 Torch Head

1. Unscrew the retaining nut from the mounting tube

and slide the mounting assembly up over the leads.

2. Pull the mounting adaptor from the torch head as-

sembly. Slide the positioning tube, adaptor, and
retaining nut back over the leads to expose the
negative/plasma lead connection, pilot lead con-
nection, and two PIP (parts-in-place circuit) con-
nectors.

Machine

Torch Head

Retaining Nut

Mounting Adaptor

Positioning Tube

Bushing

Pinion Assembly

A-00944

Figure 5-4 Torch Mounting Assembly (PCM-100XL)

3. Disconnect the negative/plasma and pilot leads

and the PIP connectors to allow removal of the
torch head.

Содержание PCH-100XL

Страница 1: ...January 15 2001 Manual No 0 2583 PLASMA CUTTING TORCH Instruction Manual Model PCH 100XL Hand Torch Model PCM 100XL Machine Torch...

Страница 2: ......

Страница 3: ...t the Manufacturer assumes no liability for its use Plasma Cutting Torch Model PCH 100XL PCM 100XL Instruction Manual Number 0 2583 Published by Thermal Dynamics Corporation Industrial Park No 2 West...

Страница 4: ...9 2 03 Specifications Design Features 9 2 04 Options And Accessories 10 2 05 Introduction to Plasma 10 SECTION 3 INSTALLATION PROCEDURES 13 3 01 Introduction 13 3 02 Site Location 13 3 03 Unpacking 1...

Страница 5: ...Machine Torch Components 28 5 07 Servicing Hand Torch Components 29 5 08 Torch And Leads Troubleshooting 30 SECTION 6 PARTS LISTS 33 6 01 Introduction 33 6 02 Ordering Information 33 6 03 Replacement...

Страница 6: ......

Страница 7: ...r 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...

Страница 8: ...n 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 an...

Страница 9: ...from American 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 utilis s pour mettre en re...

Страница 10: ...u m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres person...

Страница 11: ...les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivante...

Страница 12: ...RIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S CU...

Страница 13: ...on 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 EN5...

Страница 14: ...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 s...

Страница 15: ...operation provides a smaller sized torch and inexpensive operation Plasma torches are similar in design to the common au tomotive spark plug They consist of negative and posi tive sections which are s...

Страница 16: ...rch Dimensions 2 04 Options And Accessories These items can be used to customize a standard system for a particular application or to further enhance perfor mance refer to Section 6 for ordering infor...

Страница 17: ...the torch is started a pilot arc is established be tween the electrode and cutting tip This pilot arc cre ates a path for the main arc to transfer to the work D High Frequency Because direct current D...

Страница 18: ...INTRODUCTION DESCRIPTION 12 Manual 0 2583...

Страница 19: ...XLhand torches include a handle assembly with torch switch PCM 100XL machine torches include a metal mounting tube with rack and pinion assembly with remote pendant PCH M 100XL Spare Parts Kit includi...

Страница 20: ...n extra cable connector sup plied at the control cable connector This connec tor allows connection to a remote pendant or CNC cable while using PIP connections in the TorchAs sembly Connect the remote...

Страница 21: ...east 5 microns is required when using air from a compressor This type filter will insure that moisture oil dirt chips rust particles and other contminants from the supply hose do not enter the torch F...

Страница 22: ...INSTALLATION PROCEDURES 16 Manual 0 2583...

Страница 23: ...et requirements refer to Secton 2 03 K Gas Re quirements Check connections and turn gas supply on E Purge System On the Power Supply place the ON OFF switch to the ON position An automatic gas purge p...

Страница 24: ...orch Shown Shield Cup Gas Distributor Tip Electrode A 00937 Figure 4 2 PCH M 100XL Torch Parts 2 Tilt the torch head to remove the tip and gas distribu tor 3 Using a 7 32 inch 5 5 mm nut driver remove...

Страница 25: ...peed excess cutting height or cutting tip whose orifice has become elongated H Various Materials and Thicknesses The following table defines the cut quality on various materials and thicknesses Table...

Страница 26: ...dross is present on carbon steel it is commonly referred to as either high speed slow speed or top dross Dross present on top of the plate is normally caused by too great a torch to plate distance Top...

Страница 27: ...d operator rather than directly back into it until the pierce is com plete 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 t...

Страница 28: ...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...

Страница 29: ...eck torch parts The torch parts must correspond with the type of operation Refer to Section 4 04 Torch Parts Selection WARNING Disconnect primary power to the system before disassembling the torch lea...

Страница 30: ...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 mo...

Страница 31: ...upply is ON The inside of the torch should be cleaned with electri cal contact cleaner using a cotton swab or soft wet rag In severe cases the torch can be removed from the leads refer to Section 5 06...

Страница 32: ...ng the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Remove the consumable torch parts per the following procedure NOTE The tip and...

Страница 33: ...activating switch again 3 Parts In Place PIP not satisfied a Check canted coiled spring inside shield cup 4 Faulty torch parts a Inspect torch parts and replace if necessary Re fer to Section 5 04 Ins...

Страница 34: ...bly a Inspect torch assemblies and replace if neces sary Refer to Section 5 08 Torch and Leads Troubleshooting 3 Faulty components in power supply system components a Return for repair or have qualifi...

Страница 35: ...torch switch sheath back over the handle to expose the heat shrink covering the torch switch connectors Sheath Connectors From Torch Switch Torch Handle Torch Control Switch A 00947 Figure 5 6 Removi...

Страница 36: ...rol Cable Wiring Figure 5 8 Torch Switch and PIP Schematic 7 Tape the two control cable connector leads together 8 Pull the leads sheathing over the three connectors and secure with electrical tape to...

Страница 37: ...be tween the torch leads is breaking down and the leads must be replaced Carefully reassemble the components and recheck the completed assembly per paragraph A Step 3 to confirm that the components ha...

Страница 38: ...SERVICE 32 Manual 0 2583...

Страница 39: ...ries Section 6 06 Complete Assembly Replacements 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 produc...

Страница 40: ...Cutting Air N2 0 047 Orifice 55 Amps 8 7504 1 Tip Drag Air N2 0 039 Orifice 35 Amps 8 7503 1 Tip Gouging Air 0 073 Orifice 8 7506 5 1 Distributor Gas 8 7501 1 Distributor Gas Gouging 8 7508 6 1 Elect...

Страница 41: ...35 PARTS LISTS 11 8 1 2 4 10 7 9 13 14 12 5 6 3 A 00948 Castle Shield Cup Assembly Shield Cup Body Heat Shield Copper Copper Shield Cup Assembly Shield Cup Body Heat Shield Copper 1a 1b Hi Vis Shield...

Страница 42: ...Head Screw See Note 10 1 6 Internal Star Washer See Note 11 1 Lead Assembly Cable Unshielded Leads Complete 25 ft 7 6m Length 4 0012 50 ft 15 2m Length 4 0013 Shielded Leads For EMC Power Supplies On...

Страница 43: ...Manual 0 2583 37 PARTS LISTS 11 12 13 23 23 22 16 19 20 21 18 24 9 1 2 4 8 10 7 14 15 3 5 6 17 A 00949 Copper Shield Cup Assembly Shield Cup Body Heat Shield Copper 1a Hi Vis Shield Cup Black 1b...

Страница 44: ...alog 1 Remote Pendant Control includes 7 3114 1 Switch Handle 8 1662 1 Switch Plate 8 1712 1 Eyebolt 1 4 20 x 1 2 Long 9 3096 1 Paddle Switch 9 4229 1 Cord Grip 9 4428 1 23 5 AWG Coil Cord 8 4246 1 Pl...

Страница 45: ...th EMC Power Supplies Only PCH 100XL 70 Hand Torch 25 ft 7 6 m Leads 2 0801 PCH 100XL 70 Hand Torch 50 ft 15 2 m Leads 2 0802 PCH 100XL 90 Hand Torch 25 ft 7 6 m Leads 2 0803 PCH 100XL 90 Hand Torch 5...

Страница 46: ...Cutting Air Spare Parts Kit Includes 5 0001 1 Lubricant 8 4025 1 Box Utility 8 3141 1 Nut Driver 7 32 8 4220 3 Electrode Air N2 8 7502 5 Cutting Tip Air N2 0 052 Orifice 70 Amp 8 7505 2 Tip Drag Air...

Страница 47: ...ckness Tip Output Volts Amperage Speed Per Minute Standoff Plasma Gas Press Flow SCFH Pierce Pierce Height Inches mm Cat No VDC Amps Inches Meters Inches mm PSI BAR Plasma Total Delay Sec Inches mm 1...

Страница 48: ...rt If torch is within transfer distance 3 8 in of workpiece main arc will transfer After post flow Gas solenoid closes gas flow stops GAS indicator off ACTION Open external disconnect RESULT No power...

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