Thermal Dynamics SureLok PCM-102 Instruction Manual
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Thermal Dynamics SureLok PCM-102 Instruction Manual

Thermal Dynamics SureLok PCM-102 Instruction Manual

Surelok plasma cutting torch 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
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PLASMA
CUTTING TORCH
PCM-102 For Automated Systems
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
Instruction Manual
March 9, 2001
Manual No. 0-2815

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Summary of Contents for Thermal Dynamics SureLok PCM-102

  • Page 1 PLASMA CUTTING TORCH PCM-102 For Automated Systems 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 Instruction Manual March 9, 2001...
  • Page 3 While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Torch PCM-102 For Automated Systems Instruction Manual Number 0-2815 Published by: Thermal Dynamics Corporation Industrial Park No.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • Page 5 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ........................6-1 6.01 Introduction ....................6-1 6.02 Ordering Information ..................6-1 6.03 Replacement Machine Torch With Pinch Block Mounting Parts ....6-2 6.04 Replacement Torch Lead Parts ..............6-4 6.05 Complete Assembly Replacement ............... 6-5 6.06 Options &...

  • Page 7: Section

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...

  • Page 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.

  • Page 13: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 14: Statement Of Warranty

    None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.

  • Page 15: Introduction & Description

    2.01 Scope of Manual This manual contains descriptions, operating instructions and maintenance procedures for the PCM-102 Torch us- ing the SureLok electrode design for Automated Systems. Service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly cautioned...

  • Page 16: Options And Accessories

    H. Torch Dimensions 14.1 in (358 mm) 13.5 in (343 mm) Max 3.7 in (94 mm) Min 1.1 in (28 mm) Power Supply 1.4 in 5.1 in 0.75 in (35.6 mm) (129.5 mm) (19 mm) 0.62 in A-02804 (15.2 mm) Figure 2-2 Torch Dimensions Workpiece 2.04 Options And Accessories...
  • Page 17 E. 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 positive output is con- nected to the workpiece via the work cable and to the torch through a pilot wire.
  • Page 18 INTRODUCTION & DESCRIPTION Manual 0-2815...

  • Page 19: Installation Procedures

    The standard machine torch includes a fiberglass posi- SECTION 3: tioning tube with rack and pinch block assembly. A metal INSTALLATION mounting tube with rack & pinion assembly or the pin- ion assembly only are available as options. PROCEDURES 1. Mount the torch assembly on the cutting table. 2.

  • Page 20: Gas Connection

    7. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed Torch Leads in the above Step. Assembly Strain Relief 8. Tighten the Strain Relief onto the Torch Leads. 9. Check the torch for proper parts assembly. CAUTION A-02826 The torch parts must correspond with the type of...

  • Page 21: Operation

    Place the ON/OFF Switch on the Power Supply to the ON position. If the RUN/SET/LATCH switch This section provides a description of the PCM-102 Torch is in SET position, gas will flow. If the switch is in Assembly for Automated Systems followed by operat- RUN position there will be no gas flow.

  • Page 22: Torch Parts Selection

    4.04 Torch Parts Selection 4.05 Cut Quality Depending on the type of operation to be done determines NOTES the torch parts to be used. Cut quality depends heavily on set-up and param- Type of operation: eters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and op- Standoff cutting or gouging erator ability.

  • Page 23: Operating The System

    E. Bottom Dross Build-up C. Edge Starting Molten material which is not blown out of the cut For edge starts, hold the torch perpendicular to the area and re-solidifies on the plate. Excessive dross workpiece with the front of the tip near(not touch- may require secondary clean-up operations after cut- ing) the edge of the workpiece at the point where the ting.

  • Page 24: Machine Torch Operation

    3. Trailing Arc 4.07 Machine Torch Operation The trailing arc is directed in the opposite direc- A. Cutting With Machine Torch tion as torch travel. Generally recommended for Nitrogen plasma. The machine torch can be activated by remote con- trol pendant or by a remote interface device such as CNC.

  • Page 25: Recommended Cutting Speeds

    spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup WARNING in anti-spatter compound will minimize the amount of scale which adheres to it. Disconnect primary power to the system before 4.08 Recommended Cutting Speeds disassembling the torch, leads, or power supply.
  • Page 26 E. Standoff Distance The tip to work distance affects gouge quality and depth. Standoff distance of 1/8 - 1/4 inch (3 - 6 mm) allows for smooth, consistent metal removal. Smaller standoff distances may result in a severance cut rather than a gouge.

  • Page 27: Customer/Operator Service

    The inside of the torch should be cleaned with elec- SECTION 5: trical contact cleaner using a cotton swab or soft wet CUSTOMER/OPERATOR rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring SERVICE electrical contact cleaner into the torch and blowing it through with compressed air.

  • Page 28: Common Operating Faults

    Cutting current too low 1. Unscrew and remove the shield cup from the torch. f. Non-Genuine Thermal Dynamics Parts NOTE 2. Main Arc Extinguishes Slag built up on the shield cup that cannot be re- moved may effect the performance of the system.

  • Page 29: Troubleshooting Guide

    5.05 Troubleshooting Guide Worn Tip Good Tip This subsection covers troubleshooting that requires dissasembly and electronic measurements. It is helpful for solving many of the common problems that can arise with this torch assembly. How to Use This Guide A-00942 The following information is a guide to help the Cus- Figure 5-2 Tip Wear tomer/Operator determine the most likely causes for...

  • Page 30: Torch & Leads Troubleshooting

    B. No cutting output E. No gas flow 1. Torch not properly connected to power supply 1. Gas not connected or pressure too low a. Check that torch leads are properly attached a. Check source for at least 70 psi (4.8 bar). to power supply 2.
  • Page 31 B. Quick Check Procedure NOTE This quick check will identify major isolation failures in the Torch Head or Torch Lead components using an ohm- meter. It is possible that the Torch Head and Torch Leads will test properly with an ohmmeter. The Torch The actual assembly and consumables may vary for dif- Head and Torch Leads should be tested further for ferent torches but the basic procedure is the same for all...

  • Page 32: Servicing Machine Torch (Pcm) Components

    • If the voltage drops to 0VAC or leakage cur- rent is detected, then the insulation between the Pinch Block Assembly Torch Leads is breaking down and the Torch Leads must be replaced. Positioning • If the Torch Leads passes the test, then proceed Tube to Step 3.

  • Page 33: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. Torch Assemblies are field serviceable, so a complete breakdown of parts is provided. The parts lists are arranged as follows: Section 6.03: Replacement Machine Torch Parts Section 6.04: Replacement Torch Leads Section 6.05: Complete Assembly Replacements...

  • Page 34: Replacement Machine Torch With Pinch Block Mounting Parts

    Tip (Refer to Appendix Page for the proper application) Distributor, Gas (Refer to Appendix Page for the proper application) Electrode (Refer to Appendix Page for the proper application) Assembly, Torch Head, PCM-102 RPT (Includes items #7 - 9) 9-8403 O-Ring...
  • Page 35 Shield Cup Body Hi-Vis Shield Heat Shield Cup (Black) (Copper) Copper Shield Cup Assembly A-02833 Manual 0-2815 PARTS LISTS...

  • Page 36: Replacement Torch Lead Parts

    6.04 Replacement Torch Lead Parts Item # Description Catalog # Nylon Sleeving 25 ft (7.6 m) Length 8-1498 50 ft (15.2 m) Length 9-3035 Strain Relief, Knotched 9-7016 Boot 9-7017 Lead, Pilot Return, 14 AWG 25 ft (7.6 m) Length 8-6460 50 ft (15.2 m) Length 8-6461...

  • Page 37: Complete Assembly Replacement

    6.05 Complete Assembly Replacement Description Catalog # Machine Torches with Shielded Leads (Fiberglass Mounting Tube w/Rack & Phenolic Pinch Block Assembly): PCM-102 RPT Machine Torch, 25 ft (7.6 m) Leads 7-7538-SL PCM-102 RPT Machine Torch, 50 ft (15.2 m) Leads 7-7539-SL 6.06 Options &...

  • Page 38: Torch Spare Parts Kits

    6.07 Torch Spare Parts Kits A. For Automated Pak Master 75XL Plus Applications Description Catalog # VIP Spare Parts Kit Includes: 5-3511 Electrode (SureLok), MaximumLife™ 9-8407 Tip, Cutting, Air/N2, 60 Amp (0.049" Orifice) 9-7726 Gas Distributor 8-7501 Standard Shield Cup 8-7500 Shield Cup, Copper 8-7496...

  • Page 39: Appendix 1: Typical System Sequence Of Operation Block Diagram

    APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM LATCH ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET/LATCH RUN/SET/LATCH switch to ON. disconnect switch. switch to RUN. to SET. RESULT RESULT RESULT RESULT AC indicator blinks for 8 Power to system. Gas flow stops.

  • Page 40: Appendix 2: Torch Control Cable Wiring Diagram For Mechanized Systems

    APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS Torch Control Cable Control Connector Plug with Connectors Torch Control Connectors Control Shield Connector Torch Lead Lead Shield A-02801 Assembly Connectors only on Connector Shielded Leads Mate & Lock Torch Head Connectors A-02821 PIP Pin...

  • Page 41: Appendix 3: General Application Notes

    APPENDIX 3: GENERAL APPLICATION NOTES A. Electrode Selection The SureLok Torches offer two Electrodes, General Purpose and MaximumLife . The information supplied in this section is to help determine which electrode to use for best performance. General Purpose SureLok Electrode (Cat.No. 9-8402) •...

  • Page 42: Appendix 4: Pak Master 75Xl Plus Automated System Data

    APPENDIX 4: PAK MASTER 75XL PLUS AUTOMATED SYSTEM DATA Description of Cut Characteristics: Torch Specifications Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x Torch Specifications For tip orifice diameter), little or no dross, smooth Pak Master 75XL Plus Power Supply cut surface.
  • Page 43 9-8403 9-8407 (See Chart) (See Chart) (See Chart) A-02889 US 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 Shield Output Plasma Pierce...
  • Page 44 9-8407 (See Chart) (See Chart) (See Chart) A-02889 US 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 Shield Output Plasma Pierce...
  • Page 45 9-8407 (See Chart) (See Chart) (See Chart) A-02889 US 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 Shield Output Plasma Pierce...

  • Page 46: Appendix 5: Ce Automated Pak Master 75Xl Plus System Data

    APPENDIX 5: CE AUTOMATED PAK MASTER 75XL PLUS SYSTEM DATA Description of Cut Characteristics: Torch Specifications Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x Torch Specifications For tip orifice diameter), little or no dross, smooth Pak Master 75XL Plus Power Supply cut surface.
  • Page 47 9-8402 (See Chart) (See Chart) (See Chart) A-02946 US 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 Shield Output Plasma Pierce...
  • Page 48 9-8402 (See Chart) (See Chart) (See Chart) A-02946 US 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 Shield Output Plasma...
  • Page 49 9-8402 (See Chart) (See Chart) (See Chart) A-02946 US 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 Shield Output Plasma...

  • Page 50: Appendix 6: Automated Pak Master 100Xl Plus System Data

    APPENDIX 6: AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA Description of Cut Characteristics: Torch Specifications Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x Torch Specifications For tip orifice diameter), little or no dross, smooth Pak Master 100XL Plus Power Supply cut surface.
  • Page 51 9-8403 9-8407 (See Chart) (See Chart) (See Chart) A-02889 US 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 Shield Output Plasma Pierce...
  • Page 52 9-8407 (See Chart) (See Chart) (See Chart) A-02889 US 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 Shield Output Plasma Pierce...
  • Page 53 9-8407 (See Chart) (See Chart) (See Chart) A-02889 US 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 Shield Output Plasma Pierce...

  • Page 54: Appendix 7: Ce Automated Pak Master 100Xl Plus System Data

    APPENDIX 7: CE AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA Description of Cut Characteristics: Torch Specifications Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x Torch Specifications For tip orifice diameter), little or no dross, smooth Pak Master 100XL Plus Power Supply cut surface.
  • Page 55 9-8402 (See Chart) (See Chart) (See Chart) A-02946 US 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 Shield Output Plasma Pierce...
  • Page 56 9-8402 (See Chart) (See Chart) (See Chart) A-02946 US 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 Shield Output Plasma...
  • Page 57 9-8402 (See Chart) (See Chart) (See Chart) A-02946 US 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 Shield Output Plasma...

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