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OTC CTPWM-0802 Owner's Manual

Plasma cutting torch
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MANUAL NO: 80A Torch
OWNER'S
MANUAL
FOR
PLASMA CUTTING TORCH
MODEL: CT(P•Z)W(M•L)-0802
DO NOT DESTROY
IMPORTANT:
Read and understand the entire contents of this
manual, with special emphasis on the safety material throughout
the manual, before installing, operating, or maintaining this
equipment. This equipment and this manual are for use only by
persons trained and experienced in the safety operation of cutting
equipment. Do not allow untrained persons to install, operate or
maintain this equipment. Contact your distributor if you do not
fully understand this manual.
OTC DAIHEN Inc.
WELDING & MECHATRONICS DIVISION
Last Modified: December, 2006

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Summary of Contents for OTC CTPWM-0802

  • Page 1 Do not allow untrained persons to install, operate or maintain this equipment. Contact your distributor if you do not fully understand this manual. OTC DAIHEN Inc. WELDING & MECHATRONICS DIVISION Last Modified: December, 2006...

  • Page 2: Table Of Contents

    CONTENTS 1. SAFETY INFORMATION ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 2 2. PLASMA ARC CUTTING SAFETY PRECAUTIONS ‥‥‥‥‥‥‥‥‥‥‥ 2 3. ACCESSORIES ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 4. TORCH DRAWING ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 9 5. NOTICE AT OPERATION 6. MAINTENANCE AND TROUBLESHOOTING ‥‥‥‥‥‥‥‥‥‥‥‥‥ 12 ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 16 7. PARTS LIST 8. SPECIFICATIONS ‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥‥ 17...

  • Page 3: Safety Information

    P. 2 / 17 1. SAFETY INFORMATION The following safety alert symbols and signal words are used throughout this manual to identify various hazards and special instructions. WARNING gives information regarding possible personal WARNING injury or loss of life. CAUTION refers to minor personal injury or possible CAUTION equipment damage.
  • Page 4 P. 3 / 17 ELECTRIC SHOCK can kill. Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuits are electrically live whenever the output is on. The power line and internal circuits of this equipment are also live when the line disconnect switch is on. When plasma cutting all metal components in the torch and work circuits are electrically live.
  • Page 5 P. 4 / 17 FUMES AND GASES can be hazardous to your health. Cutting produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 1. Keep your head out of the fumes. Do not breathe the fumes. 2.
  • Page 6 6. Do not press the torch switch other than when ready to start the arc. 7. When electromagnetic trouble occurs, take the measures shown in this instruction manual until trouble is corrected. Please contact OTC-DAIHEN , when necessary. 8. Pacemaker wearers must not come near this equipment during operation until consulting your doctor.
  • Page 7 P. 6 / 17 Rotating parts may cause injuries. Be sure to observe the following. If hands, fingers, hair or clothes are put near the fan’s rotating parts, injuries may occur. 1. Do not use this equipment if the case and the cover are removed. 2.
  • Page 8 P. 7 / 17 PRINCIPAL SAFETY STANDARDS Arc welding equipment – Installation and use, Technical Specification IEC 62081, from International Electrotechnical Commission Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society. Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office.
  • Page 9 Confirming Torch Package Contents Please confirm the following components were shipped with your torch package Plasma Cutting Torch Included Items Electrode Wrench Torch Switch Only included with Vinyl Cap CTPW(M)(L)-0801 (Remove before using) Part Names Torch Switch Protective Cover Short Handle Torch Torch Switch Torch Body Handle...
  • Page 10 Operation Precaution CAUTION Observe the followings to prevent the electrical shock. • Do not touch live electrical parts. • When power source is on, do not touch the tip. If you push the torch switch, the voltage increases, which may lead to electrical shock. CAUTION If you touch plasma arc or pilot arc, you will be burned.
  • Page 11 Operation Precaution (cont’d) (2) During Cutting • The best distance from tip to the base mate- Metal Guage rial is 4mm; the maximum distance should not exceed 5mm. • When using for gas cutting and using a metal type gauge, the guage use insulator (Part No. H775L00) is used to insulate between the base material and guage.
  • Page 12 Precautions for Cutting Operation (Continued) (3) End of Cutting Do not cut down with touching tip to base metal. Strong arc generates, and the hole of tip can be deformed. At cutting terminal, keep tip away from base metal for 1～3mm, then cut it down.
  • Page 13 Precautions for Cutting Operation (Continued) Long Handle Torch (CTZW(M・L)-0801) (3) Straight Torch (CTPW(M・L)-0801) 5.5 Attaching the Torch Switch for CTPW(M)(L)-0801 Straight Torch When using the attached torch switch assembly (part number K2433A00), please follow the guidelines below. (1) Remove the rubber Hose Cable Rubber Sleeve sleeve from the cable...

  • Page 14: Maintenance And Troubleshooting

    ●Exchanging torch tip parts must be done after cooling down. CAUTION ●If parts are damaged, replace with new ones for safety and quality assurance. ●Only use OTC’s genuine parts for replacing. 6.1 Replacing of shield cup, tip, and electrode Torch body...
  • Page 15 Maintenance & Repair (continued) After performing a number of cuts, you will begin to notice some of the effects below during cutting. When this happens, inspect the tip and electrode, and if any of the consumable parts are in need of change, please change them. Please do not attempt to grind the tip or electrode Phenomena While Cutting Detection Area...
  • Page 16 Maintenance & Repair (continued) Exchanging the Detection Pin Area (1) CTZW(M)(L)-0801 (Long Handle Torch and CTPW(M)(L)-0801 (Straight Torch) Exchange Method Handle Disassembly Remove rubber sleeve from handle, remove screws from handle and body cover, and take off handle and body cover Torch Body Rubber Sleeve On the straight torch, remove the rubber tube...
  • Page 17 Maintenance & Repair (continued) Exchanging the Detection Pin Area Replacement Method for CTW(M)(L)-0801 (Short Handle Torch) Disassembly Slide back rubber sleeve towards Rubber Sleeve Handle cable side, cut the tie wraps and carefully remove the torch switch. Remove screws from the handle, and and slide back handle towards the cable side.
  • Page 18 Maintenance & Repair (continued) Replacing the Torch Body Handle Please refer to the assembly & disassembly figures Disassembly in 6.2 for the CTW(M)(L)-0801 Short Handle Torch and CTPW(M)(L)-0801 Straight Torch. Torch Body Rubber Sleeve Remove the rubber sleeve from the handle, remove Body Cover screws from the handle and disassemble.
  • Page 19 Parts List • Please use the following as a reference for purchasing replacement parts from either your distributor or one of our service centers. • Regarding Part Replacement Duration The usual minimum for part supply duration is generally 7 years after the product goes out of production.

  • Page 20: Parts List

    Parts List (Continued) Short Handle Torch Diagram...
  • Page 21 Parts List (Continued) Long Handle Torch Parts Diagram Straight Handle Torch Parts Diagram...

  • Page 22: Specifications

    Specifications Specifications Cutting Torch Rated Current Duty Cycle Cooling Method Forced Cooling (Water Cooled) Gas Type Torch Only Weight Dimensional Diagrams Power Cable • Water Inlet Air Hose Pilot Cable • Water Outlet Detection Lead Cable Torch Switch Connection Area Diagram (common for all machine types)

This manual is also suitable for:

Ctzwm-0802Ctzwl-0802Ctpwl-0802