Table of Contents
Troubleshooting
Related Manuals for Thermal Dynamics SIGNATURE PAK 1250XRTM
Summary of Contents for Thermal Dynamics SIGNATURE PAK 1250XRTM
- Page 1 PLASMA ARC CUTTING SYSTEM ® ® SIGNATURE 1250XR • PAK 1250 XR POWER SUPPLY • PCH/M-52 TORCH WITH WITH LEADS • WORK CABLE WITH CLAMP • TORCH SPARE PARTS KIT • RUNNING GEAR WITH HANDLE • AIR LINE FILTER AND REGULATOR April 4, 2001 Manual No.
- Page 3 Manufacturer assumes no liability for its use. Plasma Arc Cutting System Signature ® ® 1250XR Operating Manual Number 0-2377 Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA 03784 (603) 298-5711 Copyright 1993 by Thermal Dynamics Corporation All rights reserved.
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Page 4: Table Of Contents
Contents GENERAL INFORMATION ......................i Notes, Cautions and Warnings .................. i Important Safety Precautions ..................i Publications ......................ii Note, Attention et Avertissement ................iii Precautions De Securite Importantes ..............iii Documents De Reference ..................v Declaration of Conformity ..................vii Statement of Warranty ................... -
Page 5: General Information
GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 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 6: 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 7: 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 8 • Utilisez un appareil respiratoire à alimentation en air • Réparez ou remplacez toute pièce usée ou si l’aération fournie ne permet pas d’éliminer la fumée endommagée. et les gaz. • Prenez des soins particuliers lorsque la zone de tra- •...
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Page 9: Documents De Reference
• Pour protéger vos yeux, portez toujours un casque ou 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE un écran de soudeur. Portez toujours des lunettes de PROTECTION DE LA SANTÉ, 29CFR 1910, sécurité munies de parois latérales ou des lunettes de disponible auprès du Superintendent of Documents, protection ou une autre sorte de protection oculaire. - Page 10 11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Stan- dards Sales, 178 Rexdale Boulevard, Rexdale,...
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Page 11: 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 12: 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 13: Section 1: System Description
SECTION 1: SYSTEM DESCRIPTION 1.1 GENERAL DESCRIPTION Signature PAK 1250 XR Power Supply PCH/M-52 Spare Parts Kit Torch with Leads Work Cable and Clamp A-01451 Figure 1-A The Signature PAK 1250 XR Plasma Arc Cutting/Gouging System The complete Signature PAK 1250 XR System includes: •... -
Page 14: Power Supply Specifications
1.2 POWER SUPPLY SPECIFICATIONS Power Input The PAK 1250 XR is available in the following volt-amp combinations: Voltage Frequency Phase Amperage 200/220 60 Hz 74/68 200/220 50 Hz 74/68 200/220 50/60 Hz * 74/68 380/415 50 Hz 40/37 60 Hz 380/500 50 Hz 40/30... -
Page 15: Torch Specifications
1.3 TORCH SPECIFICATIONS Torch Configurations PCH-52 70° or 90° Hand Torch PCM-52 180° Machine Torch Torch Leads Lengths Standard lengths of 25 ft (7.6 m) or 50 ft (15.2 m). Extendable in increments of 25 ft or 50 ft up to maximum 100 ft (30.4 m) with leads extension package (see Torch Accessories, page 4) Current Rating... -
Page 16: System Accessories
1.4 SYSTEM ACCESSORIES Power Supply Accessories SC2/XR Standoff Control - For machine mounted torches, the SC2/XR automatically maintains torch standoff by controlling a customer-supplied torch lifter motor. Cylinder Rack Running Gear - For transporting up to two full-sized gas cylinders along with the system. Computer Control Cable Kit - For interfacing the power supply with a computer or auxiliary control device. - Page 17 1.5 THEORY OF OPERATION (continued) Plasma Gas Flow The cutting torch also uses a secondary gas (Zone A, Figure 1-D) which assists the high velocity plasma gas in (continued) blowing the molten metal out of the cut and allowing a fast, slag-free cut.
- Page 18 1.5 THEORY OF OPERATION (continued) Thermal Protection Thermal overload switches are located in the coils of the main transformers in the power supply. If one of these components is overheated the appropriate switch will open, causing the temperature light to go out and shutting off power to the main contactor.
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Page 19: Section 2: Unit Assembly
SECTION 2: UNIT ASSEMBLY 2.1 UNPACKING THE SYSTEM The power supply is skid-mounted and protected with a carton and padding material to prevent damage during shipment. The two front casters are factory-installed on the unit. The power supply, running gear, work cable, torch, torch leads, and spare parts kit are packed together. - Page 20 2.2 EQUIPMENT ASSEMBLY (continued) Standard Running Gear 7. Mount the handle on the rear panel of the power supply Assembly (continued) (see Figure 2-B). Figure 2-B Handle Assembly Cylinder Rack Running Refer to Figure 2-C and: Gear Assembly 1. Remove all packing material. 2.
- Page 21 2.2 EQUIPMENT ASSEMBLY (continued) Cylinder Rack Running 7. Press the retaining ring into the groove in the axle to secure the wheel assembly. Gear Assembly (continued) 8. Follow the same procedure to install the second wheel assembly. 9. Mount the cylinder support bracket to the back of the power supply as shown.
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Page 22: Installation
2.3 INSTALLATION The power supply is shipped with the torch and torch leads, control cable, and work cable connected. The following steps are required to complete installation. Location Select a clean, dry location with good ventilation and adequate working space. CAUTION Air flow under the base and out the rear must not be obstructed. - Page 23 2.3 INSTALLATION (continued) Air Line Filter and 9. Install the secondary air line regulator and bracket assembly on the rear panel (secondary side). Regulator Installation (continued) 10. Connect the Y-hose assembly to the supply air line from the source. The supply hose from the source to the Y-hose must be 3/8 in (10 mm) minimum inside diameter to provide adequate air flow.
- Page 24 2.3 INSTALLATION (continued) Input Power Connections 1. Units with 200/220V transformers are factory-wired for 220V input. If actual input power to the unit is less than 210V it is recommended that the unit be rewired to the low voltage taps on the transformers. 380/415V units are factory-wired for 415V input and should similarly be rewired if input voltage falls below 390V.
- Page 25 2.3 INSTALLATION (continued) Input Power Supply 2. Connect the power cable to the appropriate three-phase power source. Input power cable connections to the (continued) contactors are shown in Figure 2-F. 3. Check that power source meets fuse and wiring require- ments (see Table 2-A below).
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Page 26: Lifting The Power Supply
2.4 LIFTING THE POWER SUPPLY Do not lift the power supply by the handle. WARNING CAUTION Do not lift a power supply equipped with a cylinder rack running gear. The recommended method for lifting the power supply is to use a forklift (see Figure 2-G). Approach from either side of the unit. -
Page 27: Section 3: Operation
SECTION 3: OPERATION 3.1 OPERATING CONTROLS A-01461 Figure 3-A PAK 1250 XR Operating Controls Control Indicator Function 1. ON/OFF Switch (SW1) Move up to ON position to activate the control circuits. All control circuits are deactivated in OFF position. 2. RUN/SET Switch (SW2) Move up to RUN position for torch operation. -
Page 28: Pre-Operation Set-Up
3.2 PRE-OPERATION SET-UP The pre-operation set-up procedure should be followed at the beginning of each shift: Disconnect primary power to the system before WARNING disassembling the torch, leads, or power supply. 1. Check the torch for proper assembly (see page 27). Make sure the proper torch parts are installed: Shield Cup Selection Standard Shield Cup (Ceramic) ...... -
Page 29: Cutting Operation
3.3 CUTTING OPERATION Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at WARNING the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch switch is pressed. - Page 30 3.3 CUTTING OPERATION (continued) 4. With the pilot arc on the main cutting arc is established Hand Torch Operation as soon as the torch tip is brought within 1/8 - 3/8 in (continued) (3 - 10 mm) of the workpiece. NORMAL/DELAYED The NORMAL/DELAYED RESTART switch (SW1) is RESTART Switch (SW1)
- Page 31 3.3 CUTTING OPERATION (continued) Cutting with a When using a machine torch, the torch should be aligned perpendicular to the workpiece to obtain a clean, vertical Machine Torch (continued) cut. Use a square to align the torch (see Figure 3-D). The torch can be activated by remote control pendant or by remote interface device.
- Page 32 3.3 CUTTING OPERATION (continued) Piercing Technique In some cutting operations, it may be desirable to start the cut within the plate area rather than at the plate edge. Piercing the plate is not recommended on plates having a thickness greater than 1/2 in (13 mm). Blowback from the piercing operation can shorten the life of torch parts.
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Page 33: Gouging Operation
3.4 GOUGING OPERATION Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all precautions at WARNING the front of this manual have been followed. Make sure no part of the operator’s body comes in contact with the workpiece when the torch switch is pressed. - Page 34 3.4 GOUGING OPERATION (continued) Lead Angle The angle at which the torch is held depends on the current setting and the torch travel speed. At 35 amps, (Range I), the recommended lead angle is 35°. At 105 amps (Range III), the recommended lead angle increases to 45°.
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Page 35: General Operating Notes
3.5 GENERAL OPERATING NOTES The suggestions below should be followed in all cutting and gouging operations: 1. Wait five minutes before opening the main disconnect switch after shutdown. This allows the cooling fan to run to dissipate operating heat from the unit. 2. -
Page 36: Cutting Speeds
3.7 CUTTING SPEEDS When hand cutting, cutting speeds primarily depend on the material being cut, the thickness, and how fast the operator can comfortably and accurately follow the line. The following charts show optimum cutting speed ranges for most materials using a machine torch with air plasma/ air secondary and nitrogen plasma/CO2 secondary. - Page 37 3.7 CUTTING SPEEDS (continued) This information represents realistic expectations using recommended practices and well maintained systems. Actual speeds may vary up to 50% from those shown. Factors such as parts wear, air quality, line voltage fluctua- tions, operator experience, standoff variation and quality of ground may impact system performance.
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Page 38: Sequence Of Operation
3.8 SEQUENCE OF OPERATION Figure 3-J Sequence of Operation OPERATION... -
Page 39: Section 4: Maintenance
SECTION 4: MAINTENANCE 4.1 TORCH MAINTENANCE Disconnect primary power to the system before WARNING disassembling the torch, leads, or power supply. Routine Inspection Refer to Figure 4-A and: 1. Remove the shield cup (7) from the torch. and Replacement of Consumable Parts: 2. -
Page 40: Torch Leads Replacement
4.1 TORCH MAINTENANCE (continued) Routine Inspection 4. Replace the electrode in the torch body. Secure in place and Replacement of with the electrode wrench. 5. Replace the tip in the front of the torch and secure it Consumable Parts: with the tip wrench. CAUTION Do not overtighten the electrode or tip. - Page 41 4.2 TORCH LEADS REPLACEMENT (continued) Hand Torch Leads 4. With a slight twisting motion, pull the handle from Replacement (continued) the torch head. Slide it back over the leads to expose the leads connections. 5. Remove the tape that secures the torch leads connec- tions around the insulating tab.
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Page 42: Power Supply Maintenance
4.3 POWER SUPPLY MAINTENANCE Fan Motor Lubrication The fan motor in the power supply should be oiled twice per year or once for each 100 hours of operation. To oil the motor, remove one side panel and add two or three drops of 20 SAE oil to the front and rear oil holes on the motor. -
Page 43: Troubleshooting Guide
4.4 TROUBLESHOOTING GUIDE If the power supply malfunctions, the following table will be helpful in correcting the problem. Since the problem may be due to a faulty connection rather than a faulty component, be sure to check all connections to a component that appears to be malfunctioning. The troubleshooting guide is arranged in the normal operating sequence of the system for easy reference (refer to the Sequence of Operation on page 26). - Page 44 4.4 TROUBLESHOOTING GUIDE (continued) TROUBLE POSSIBLE CAUSE REMEDY 1. Turn gas supply on, or D. No gas flow in SET 1. Gas supply not turned on, replace cylinder. position or empty cylinder 2. Check and replace sole- 2. Faulty solenoid (SOL) noid if necessary.
- Page 45 4.4 TROUBLESHOOTING GUIDE (continued) The pilot arc should start two seconds after the torch switch is pressed. If it does not, check the following: TROUBLE POSSIBLE CAUSE REMEDY J. No spark in torch or at 1. Faulty time delay circuit 1.
- Page 46 4.4 TROUBLESHOOTING GUIDE (continued) Once the cutting arc is established it should remain on until the torch control switch is released or the torch is moved away from the metal enough to break the arc (pilot arc should re-ignite). TROUBLE POSSIBLE CAUSE REMEDY N.
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Page 47: Test Procedures
4.5 TEST PROCEDURES The following tests are suggested for specific problems listed in the troubleshooting guide. The letter designations correspond to those listed in the “Remedy” column of the troubleshooting section. Several of these tests involve voltage measurements that must be made with power on. Use extreme care when making these tests. - Page 48 4.5 TEST PROCEDURES (continued) E. Diode Check (continued) 3. To check capacitor C9 to be sure it is in the circuit, first disconnect primary power to the system. The resistance from wire 38 to wire 10 should be 2.5 ohms. The resistance from wire 12 to the negative heatsink should be 0 ohms.
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Page 49: Section 5: Parts Lists
SECTION 5: PARTS LISTS ABOUT THE PARTS LIST Parts List Contents Figure 5-1 System and Accessories Figure 5-2 Front Panel Components Figure 5-3 Rear Panel Components Figure 5-4 Base Components Figure 5-5 Upper Equipment Panel Components Figure 5-6 Bulkhead Components Figure 5-7 Torch Components Figure 5-8 Torch Accessories An item number in parentheses indicates a component... -
Page 50: System Components & Accessories
5.1 SYSTEM COMPONENTS & ACCESSORIES Fig. Item Qty. Catalog Description Number 3-6570A PAK 1250 XR Power Supply with Running Gear and Work Cable 2-2936 PCH-52 70° Hand Torch with 25 ft (7.6 m) Leads 2-2937 PCH-52 70° Hand Torch with 50 ft (15.2 m) Leads 2-2330 PCH-52 90°... - Page 51 5.1 SYSTEM COMPONENTS & ACCESSORIES (continued) A-01464 Figure 5-1 PAK 1250 XR System Components PARTS LIST...
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Page 52: Front Panel Components
5.2 FRONT PANEL COMPONENTS Fig. Item Qty. Catalog Description Reference Number Designator 9-4418 Control Panel with Overlay - English 9-4419 Control Panel Overlay - English 9-4420 Control Panel with Overlay - International 9-4421 Control Panel Overlay - International 9-4210 Torch Leads Boot 8-1119 Top Panel 9-5607... -
Page 53: Rear Panel Components
5.3 REAR PANEL COMPONENTS Fig. Item Qty. Catalog Description Reference Number Designator 8-1123 Rear Panel 8-1154 Pilot Resistor Assembly R6,R10 9-5586 Contactor - 24 VAC 9-5610 Resistor - 100k ohm, 1/2 W 9-3568 Resistor - 100 ohm, 100 W 9-4337 Solenoid Assembly (Includes All Fittings) SOL1,2 9-4078... -
Page 54: Base Components
5.4 BASE COMPONENTS Fig. Item Qty. Catalog Description Reference Number Designator 8-3241 Base Main Transformers: T1,T2,T3 9-5672 200/220V, 3-phase, 60 Hz 9-5674 200/220V, 3-phase, 50 Hz 9-5676 200/220V, 3-phase, 50/60 Hz 9-5680 380/415V, 3-phase, 50 Hz 9-5682 460V, 3-phase, 60 Hz 9-5684 380/500V, 3-phase, 50 Hz 9-5686... - Page 55 5.4 BASE COMPONENTS (continued) A-01467 Figure 5-4 Base Components PARTS LIST...
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Page 56: Upper Equipment Panel Components
5.5 UPPER EQUIPMENT PANEL COMPONENTS Fig. Item Qty. Catalog Description Reference Number Designator 9-4338 Ceramic Disc Capacitor Assembly - .002 mfd 9-5589 Spark Gap Assembly Set Screw - #6-32UNC X 1/8" lg 9-3841 Electrode - HF Spark Gap 9-4107 Resistor - 2500 ohm, 50 w 9-5161 Resistor - 100 ohm, 50 w 9-5614... - Page 57 5.5 UPPER EQUIPMENT PANEL COMPONENTS (continued) 13,14 A-01468 Figure 5-5 Upper Equipment Panel Components PARTS LIST...
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Page 58: Bulkhead Components
5.6 BULKHEAD COMPONENTS Fig. Item Qty. Catalog Description Reference Number Designator 9-4045 Bulkhead Fitting - 1/8 NPT, Standard Thread 9-4046 Bulkhead Fitting - 1/8 NPT, Left-Hand Thread 8-2141 Insulator - Bulkhead & Bridge 9-4333 Filter PC Board - Main Bridge 8-1129 Negative Heatsink 8-1130... -
Page 59: Torch Components
5.7 TORCH COMPONENTS Fig. Item Qty. Catalog Description Number 2-2940 PCH-52 70° Hand Torch with Parts 2-2398 PCH-52 90° Hand Torch with Parts 2-2941 PCM-52 180° Machine Torch with Parts 9-5642 PCH-52 Basic 70° Hand Torch Body 9-5854 PCH-52 Basic 90° Hand Torch Body 9-5643 PCM-52 Basic 180°... -
Page 60: Torch Accessories
5.8 TORCH ACCESSORIES Fig. Item Qty. Catalog Description Number 9-5644 Handle 9-5522 Switch Assembly 8-4216 Switch Retaining Sheath 8-4018 Retaining Nut 9-1901 Adaptor 8-5005 Positioning Tube 7-2827 Pinion Assembly 8-4204 Bushing (End Cap) 7-3124 Circle Cutting Attachment 4-5034 PCH-52 Replacement Hand Torch Leads - 25 ft (7.6 m) 4-5035 PCH-52 Replacement Hand Torch Leads - 50 ft (15.2 m) 4-5036... - Page 61 5.8 TORCH ACCESSORIES (continued) A-01484 Figure 5-8 Torch Accessories PARTS LIST...
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Page 62: Troubleshooting Diagram
5.9 TROUBLESHOOTING DIAGRAM PARTS LIST... -
Page 63: Cnc Interface Schematic
5.10 CNC INTERFACE SCHEMATIC CNC SIGNAL INTERFACE CABLE POWER SUPPLY 24 VAC CONTACTOR Start/Stop BLACK WHITE Ready to Move BROWN Ground GREEN 24 VAC BLUE Corner Slowdown (Customer- Supplied) ORANGE PARTS LIST... -
Page 64: Signature Pak 1250 Xr System Schematic (Sheet 1)
5.11 SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC (SHEET 1) A-01583 PARTS LIST... - Page 65 A-01583 PARTS LIST...
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Page 66: Signature Pak 1250 Xr System Schematic (Sheet 2)
SIGNATURE PAK 1250 XR SYSTEM SCHEMATIC (SHEET 2) A-01584 PARTS LIST... - Page 67 A-01584 PARTS LIST...
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