Thermal Dynamics PCH-100XL Instruction Manual
Thermal Dynamics PCH-100XL Instruction Manual

Thermal Dynamics PCH-100XL Instruction Manual

Plasma cutting torch

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PLASMA
CUTTING TORCH
• Model PCH-100XL Hand Torch
• Model PCM-100XL Machine Torch
Instruction Manual
January 15, 2001
Manual No. 0-2583

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Summary of Contents for Thermal Dynamics PCH-100XL

  • Page 1 PLASMA CUTTING TORCH • Model PCH-100XL Hand Torch • Model PCM-100XL Machine Torch Instruction Manual January 15, 2001 Manual No. 0-2583...
  • 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 Model PCH-100XL & PCM-100XL Instruction Manual Number 0-2583 Published by: Thermal Dynamics Corporation Industrial Park No.
  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1 1.01 Notes, Cautions and Warnings ................ 1 1.02 Important Safety Precautions ................1 1.03 Publications ..................... 2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes .............. 3 1.06 Documents De Reference ................
  • Page 5 TABLE OF CONTENTS (continued) SECTION 5: CUSTOMER/OPERATOR SERVICE .................. 25 5.01 Introduction ....................25 5.02 General Torch Maintenance ................25 5.03 Common Operating Faults ................25 5.04 Inspection and Replacement Consumable Torch Parts ......... 26 5.05 Troubleshooting Guide .................. 27 5.06 Servicing Machine Torch Components ............
  • Page 7: General Information

    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

    A. Torch Configurations 1. Hand Torch PCH-100XL 2.01 Scope of Manual PCH-100XL is available with torch heads at 70° This manual contains descriptions, operating instructions and 90° to the torch handle. The hand torches in- and maintenance procedures for the PCH/M-100XL clude a torch handle and torch switch assembly.
  • Page 16: Options And Accessories

    D. Duty Cycle 40% on 1 inch (25.4 mm) material 3.03 in (77 mm) E. Cutting Range 1.16 in (29 mm) 8.21 in Most materials up to 1 inch (25.4 mm) at 5 IPM (inches (209 mm) per minute) F. Pierce Rating 3.16 in (80 mm) 1.16 in...
  • Page 17 torch tip heats and ionizes the gas. The main cutting D. High Frequency arc then transfers to the workpiece through the col- Because direct current (DC) alone is not sufficient to umn of plasma gas in Zone C. strike and maintain the pilot arc, high frequency is also used.
  • Page 18 INTRODUCTION & DESCRIPTION Manual 0-2583...
  • Page 19: Installation Procedures

    1. Mount the torch assembly on the cutting table. • PCH/M-100XL Torch with parts installed and leads attached. PCH-100XL hand torches include a handle 2. To obtain a clean vertical cut, use a square to align assembly with torch switch. PCM-100XL machine...
  • Page 20: Connecting Torch

    CAUTION Rack and The torch parts must correspond with the type of Pinion Mounting operation. Refer to Section 4.04, Torch Parts Se- Assembly lection. 3. In machine type operations the Machine Torch Square (PCM-100XL) has an extra cable connector sup- plied at the control cable connector.
  • Page 21 C. Filtering An inline pneumatic dryer/evaporator type air filter, capable of filtering to at least 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.
  • Page 22 INSTALLATION PROCEDURES Manual 0-2583...
  • Page 23: Operation

    E. Purge System SECTION 4: On the Power Supply place the ON/OFF switch to OPERATION the ON position. An automatic gas purge (pre-flow) will remove any condensation that may have accu- mulated in the torch and leads while the system was 4.01 Introduction shut down.
  • Page 24: Cut Quality

    Torch Head Assembly (70˚ Hand Torch Shown) Electrode Distributor Standard Shield Cup Castle Shield Cup Catalog No. 8-7500 Catalog No. 8-7507 A-00937 Shield Cup Hi-Vis Shield Cup (Black) Catalog No. 8-7525 Figure 4-2 PCH/M-100XL Torch Parts Cutting Tip, Air/N2 Cutting Tip, Air/N2 2.
  • Page 25: Operating The System

    H. Various Materials and Thicknesses Kerf Width The following table defines the cut quality on various Cut Surface materials and thicknesses: Bevel Angle Table 4-A Cut Quality on Various Materials Spatter M aterial Type of Type of Thickness M aterial Characteristics Top Edge Carbon Steel...
  • Page 26: Hand Torch Operation

    A. Piloting be wiped off with a welding glove. "Slow speed dross" is normally present on the bottom edge of the plate. Piloting is harder on parts life than actual cutting be- It can vary from a light to heavy bead, but does not cause the pilot arc is directed from the electrode to adhere tightly to the cut edge, and can be easily the tip rather than to a workpiece.
  • Page 27: Machine Torch Operation

    4. Clean spatter and scale from the shield cup and the tip as soon as possible. Spraying or dipping the shield cup in anti-spatter compound will mini- mize the amount of scale which adheres to it. Torch C. Castle Shield Cup With Straight Edge NOTE Other common terms for the Castle Shield Cup are Crown or Standoff Shield Cup.
  • Page 28: Recommended Cutting Speeds

    Rack and Shown with Pinion Mounting Rack and Pinion Assembly Mounting Assembly Square D i r e c t i o n o f T o r c Standoff Distance r a v A-00934 Workpiece Straight Arc Figure 4-7 Checking Alignment Trailing Arc 2.
  • Page 29: Gouging

    tance for optimum speed and cut quality. Clean spat- ter and scale from the shield cup and the tip as soon WARNING as possible. Spraying or dipping the shield cup in anti-spatter compound will minimize the amount of scale which adheres to it. Disconnect primary power to the system before disassembling the torch, leads, or power supply.
  • Page 30 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 31: Customer/Operator Service

    SECTION 5: WARNINGS CUSTOMER/OPERATOR SERVICE Disconnect primary power to the system before disassembling the torch or torch leads. DO NOT touch any internal torch parts while the 5.01 Introduction AC indicator light of the Power Supply is ON. This Section describes basic maintenance procedures per- formable by operating personnel.
  • Page 32: Inspection And Replacement Consumable Torch Parts

    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- a.
  • Page 33: Troubleshooting Guide

    2. Torch switch activated during pre-flow New Electrode a. Release torch switch and wait at least 20 sec- onds before activating switch again 3. Parts-In-Place (PIP) not satisfied. a. Check canted coiled spring inside shield cup 4. Faulty torch parts a.
  • Page 34: Servicing Machine Torch Components

    3. Faulty components in power supply system components 2. Torch is being moved too fast across workpiece a. Return for repair or have qualified technician a. Reduce cutting speed (refer to Appendix I, Cut- repair per Service Manual. ting Speed Charts). D.
  • Page 35: Servicing Hand Torch Components

    Sheath Negative/Plasma Connectors From Lead Connection Torch Switch Torch Control Switch Torch Handle Parts-In-Place (PIP) A-00947 Wires Figure 5-6 Removing Torch Control Switch Pilot Lead A-00945 Connection 2. Carefully cut and remove the heat shrink from the leads and handle being careful not to damage the wires under the heat shrink.
  • Page 36: Torch And Leads Troubleshooting

    9. Pull the heat shrink tube back over the connectors and onto the end of the torch handle tube. Shrink the tubing into place. Figure 5-7 Torch Head Removal (PCH-100XL) 10. Roll the torch switch sheath back over the handle. 10. Disconnect the negative (plasma) lead from the torch head.
  • Page 37 4. Remove the torch head from the leads (refer to Sec- This completes the checks for the proper operation of the tion 5.06, Servicing Machine TorchComponents or center insulator of the torch head and leads. Proceed to Section 5.07, Servicing Hand Torch Components). paragraph 'C' to check pilot and switch control wires..
  • Page 38 SERVICE Manual 0-2583...
  • Page 39: 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 Hand Torch Parts Section 6.04: Replacement Machine Torch Parts Section 6.05: Torch Options And Accessories...
  • Page 40: Replacement Hand Torch Parts

    8-7506 Distributor, Gas 8-7501 Distributor, Gas, Gouging 8-7508 Electrode, Air/N2 8-7502 Assembly, Torch Head (Includes items #8 - 10) PCH-100XL 70° Torch Head 8-7510 PCH-100XL 90° Torch Head 8-7511 O-Ring 8-0533 #6-32 x 1/16 Phillips Pan Head Screw See Note...
  • Page 41 A-00948 Shield Cup Shield Cup Body Body Hi-Vis Shield Heat Shield Heat Shield Cup (Black) (Copper) (Copper) Castle Shield Copper Shield Cup Assembly Cup Assembly Manual 0-2583 PARTS LISTS...
  • Page 42: Replacement Machine Torch Parts

    6.04 Replacement Machine Torch Parts Item # Description Catalog # Shield Cup Assemblies (All include item #3) Standard Shield Cup 8-7500 Copper Shield Cup Assembly 8-7496 Shield Cup Body (Includes item #3) 8-7498 Shield Cup Heat Shield (Copper) 8-7497 Hi-Vis Shield Cup (Black) 8-7525 O-Ring 8-0532...
  • Page 43 23 22 Shield Cup Body Hi-Vis Shield Heat Shield Cup (Black) (Copper) A-00949 Copper Shield Cup Assembly Manual 0-2583 PARTS LISTS...
  • Page 44: Options And Accessories

    6.05 Options and Accessories Description Catalog # Remote Pendant Control includes: 7-3114 Switch Handle 8-1662 Switch Plate 8-1712 Eyebolt 1/4-20 x 1/2" Long 9-3096 Paddle Switch 9-4229 Cord Grip 9-4428 23/5 AWG Coil Cord 8-4246 Plug, 14 Pin 9-3294 Cable Clamp for #93294 9-3295 Circle Cutting Guide 7-7501...
  • Page 45: Complete Assembly Replacement

    6.06 Complete Assembly Replacement Description Catalog # Hand Torches with Leads: Unshielded Leads PCH-100XL 70° Hand Torch, 25 ft (7.6 m) Leads 2-0001 PCH-100XL 70° Hand Torch, 50 ft (15.2 m) Leads 2-0002 PCH-100XL 90° Hand Torch, 25 ft (7.6 m) Leads 2-0003 PCH-100XL 90°...
  • Page 46: Spare Parts Kits

    6.07 Spare Parts Kits Description Catalog # Cutting, Air, Spare Parts Kit Includes: 5-0001 Lubricant 8-4025 Box, Utility 8-3141 Nut Driver, 7/32" 8-4220 Electrode, Air/N2 8-7502 Cutting Tip, Air/N2, 0.052" Orifice, 70 Amp 8-7505 Tip, Drag, Air/N2, 0.039" Orifice, 35 Amps 8-7503 Canted Coil Spring 9-7501...
  • Page 47: Appendix I: Cutting Speed Charts

    APPENDIX I: CUTTING SPEED CHARTS Air Plasma Cutting Speed Data Chart Type Torch: PCH/M-100XL Type Material: Mild Steel Type Plasma Gas: Air Type Secondary Gas: Single Gas Torch Thickness Output Volts Amperage Speed (Per Minute) Standoff Plasma Gas Press Flow (SCFH) Pierce Pierce Height Inches...
  • Page 48: Appendix Ii: Typical System Sequence Of Operation Block Diagram

    APPENDIX II: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ACTION ACTION ON/OFF switch Close external RUN/SET RUN/SET 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.

This manual is also suitable for:

Pcm-100xl

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