PLASMA CUTTING TORCH • Model PCH-62 Hand Torch • Model PCM-62 Machine Torch Instruction Manual January 28, 2004 Manual No.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. 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-62 & PCM-62 Instruction Manual Number 0-2817 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ............................................................................................... 1-1 1.01 1.02 1.03 1.07 Notes, Cautions and Warnings ..................................................................... 1-1 Important Safety Precautions ....................................................................... 1-1 Publications ..................................................................................................
TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................................................................................................................... 5-1 5.01 5.02 5.03 5.04 5.05 5.06 5.07 5.08 Introduction .................................................................................................. 5-1 General Torch Maintenance ......................................................................... 5-1 Common Operating Faults ...................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the workplace is moist or damp. • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8.
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
1.08 Statement of Warranty LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.
GENERAL INFORMATION 1-6 May 14, 2002
SECTION 2: INTRODUCTION 2.01 Scope of Manual 2.03 Specifications & Design Features Refer to Appendix Pages for additional specifications as related to the Power Supply used. A. Torch Configurations and Dimensions This manual contains descriptions, operating instructions and maintenance procedures for the PCH/M-62 Torch.
B. Torch Leads Lengths 2.04 Options And Accessories Hand Torch: 20 ft (6.1 m) or 50 ft (15.2 m) These items can be used to customize a standard system for a particular application or to further enhance performance (refer to Section 6 for ordering information). Machine Torch: 25 ft (7.6 m) or 50 ft (15.2 m) C. Torch Parts • Spare Parts Kits - Various kits containing replacement front - end torch parts for various applications. Gas Distributor, Electrode, Tip, Shield Cup D.
; ;; ;; ; ;; ; ;; ; D. Capacitive Discharge (CD) Because direct current (DC) alone is not sufficient to strike and maintain the pilot arc, capacitive discharge is also used. The high voltage jumps between the tip and electrode with the DC following. E. Main Cutting Arc _ Power Supply + DC power is also used for the main cutting arc. The negative output is connected to the torch electrode through the torch lead.
INTRODUCTION 2-4 Manual 0-2817
SECTION 3: INSTALLATION 3.05 Setting Up Machine Torch WARNING 3.01 Introduction This section describes installation of the Torch. These instructions apply to the Torch and Leads Assemblies only. Installation procedures for the Power Supply, Options and Accessories are provided in Manuals specifically provided for those products. The complete installation consists of: Disconnect primary power at the source before disassembling the torch or torch leads.
4. Connect the torch Negative / Plasma Lead to the bulkhead connection inside the Power Supply. 3.06 Connecting Torch NOTE Equipment ordered as a system will have the Torch factory connected to the Power Supply. Note: Actual Bulkhead configuration may differ from that shown. The instructions for connecting the Torch Leads to the Power Supply are different depending on the type of leads.
7. Place the lug on the Pilot Control Wire onto the stud and secure with the nut and washer removed in the above Step. Negative/Plasma Lead Connection Adapter Adapter (Supplied With Connector Power Supply) Note: Actual Bulkhead configuration may differ from that shown. 8. Tighten the Through - hole protector onto the Torch Leads. 9. Check the torch for proper parts assembly.
4. Connect the Control (PIP) Circuit Connectors to the mating connectors on the Adapter supplied on the Power Supply (see Warning). Torch Control Cable Connector Remote Pendant/CNC Cable Connector 2 WARNING 3 Control The Adapter supplied with the Power Supply has two additional Shield Connectors that are used for Shielded Systems only. These two connectors are not used and need to be taped out of the way to prevent contacting the Negative / Plasma or Pilot Leads.
NOTE SECTION 4: OPERATION Refer to Appendix Pages for additional information as related to the Power Supply used. E. Power On 4.01 Introduction Place the ON / OFF Switch on the Power Supply to the ON position. If the RUN / SET or RUN / SET / LATCH switch is in SET position, gas will flow. If the switch is in RUN position there will be no gas flow. This section provides a description of the Torch Assembly followed by operating procedures. 4.
4.04 Torch Parts Selection 4.05 Cut Quality The type of power supply and the type of operation to be performed determine the torch parts to be used: NOTES Cut quality depends heavily on set-up and parameters such as torch standoff, alignment with the workpiece, cutting speed, gas pressures, and operator ability.
E. Bottom Dross Build-up C. Edge Starting Molten material which is not blown out of the cut area and re-solidifies on the plate. Excessive dross may require secondary clean-up operations after cutting. For edge starts, hold the torch perpendicular to the workpiece with the front of the tip near (not touching) the edge of the workpiece at the point where the cut is to start. When starting at the edge of the plate, do not pause at the edge and force the arc to "reach" for the edge of the metal.
4. Once on, the main arc remains on as long as the Torch Trigger is held down, unless the torch is withdrawn from the work or torch motion is too slow. If the cutting arc is interrupted, the pilot arc comes back on automatically. 4.07 Hand Torch Operation A. Standoff Cutting With Hand Torch NOTE For best performance and parts life, always use the correct parts for the type of operation. NOTE Most cutting is performed with the power supply in the RUN position.
NOTE C. Drag Cutting With a Hand Torch The tip should never come in contact with the workpiece except during drag cutting operations. Drag cutting works best on metal 3/16" (4.7 mm) thick or less. 2. Angle the torch slightly to direct blowback particles away from the torch tip (and operator) rather than directly back into it until the pierce is complete. NOTE For best parts performance and life, always use the correct parts for the type of operation. 1.
Travel speed also affects the bevel angle of a cut. When cutting in a circle or around a corner, slowing down the travel speed will result in a squarer cut. The power source output should be reduced also. Refer to the approriate Power Supply Operating Manual for any Corner Slowdown (CSD) adjustments that may be required. B. Travel Speed Proper travel speed is indicated by the trail of the arc which is seen below the plate ( Figure 4-7). The arc can be one of the following: 1.
35°), less material may be removed, requiring more passes. In some applications, such as removing welds or working with light metal, this may be desirable. 4.10 Gouging WARNINGS Torch Head Be sure the operator is equipped with proper gloves, clothing, eye and ear protection and that all safety precautions at 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 is activated.
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The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air. SECTION 5: SERVICE 5.01 Introduction Refer to Section 5.07, Servicing Hand Torch (PCH) Components, or Section 5.08, Servicing Machine Torch Components (PCM) for disassembling the Torch and Leads Assembly.
NOTE 5.04 Inspection and Replacement Consumable Torch Parts DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life. WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads.
This guide is set up in the following manner: Good Tip Worn Tip X. Symptom (Bold Type) Any Special Instructions (Text Type) 1. Cause (Italic Type) a. Check / Remedy (Text Type) Locate your symptom, check the causes (easiest listed first) then remedies. Repair as needed being sure to verify that unit is fully operational after any repairs. A-00942 Figure 5-2 Tip Wear 4. Remove the gas distributor and check for excessive wear, plugged gas holes, or discoloration. Replace if necessary. Troubleshooting A.
4. Faulty components in torch and leads assembly F. Torch cuts but not adequately a. Inspect torch assemblies and replace if necessary. Refer to subsection 5.06, Torch and Leads Troubleshooting. 1. Current set too low at power supply a. Increase current setting 2. Torch is being moved too fast across workpiece 5. Faulty components in power supply system a. Reduce cutting speed (refer to Appendix Page for the Power Supply being used). a.
WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads. C. Checking Proper Isolation Resistance Procedure The Torch Head and Torch Leads should be tested further for insulation breakdown if no other fault has been found. This procedure requires the use of a Hi - Pot Tester. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. WARNING 1. Remove the consumables from the torch.
3. Visually check that the PIP wires, torch switch wires, pilot lead connection, and negative lead connections are properly connected and in good condition (no shorts or arcing). 5.07 Servicing Hand Torch (PCH) Components WARNINGS To Control Cable Wiring Torch Switch PIP Pins Torch Trigger Disconnect primary power to the system before disassembling the torch, leads, or power supply. Shield Cup A-03540 NEVER touch any internal torch parts while the AC indicator light on the Power Supply is ON.
Negative / Plasma Lead Insulation Sleeving Pilot Lead A-03544 Insulation Sleeving Negative/Plasma Lead Insulation Sleeving Handle Shell Torch Switch Spring Trigger A-03545 Handle Shell Figure 5-6 Hand Torch Assembly Figure 5-7 Insulation Sleeving Position for Negative / Plasma Lead 4. Insert the screw through the Pilot Lead lug and then install the star washer before securing it to the Torch Head Assembly. 6. Disconnect the Negative / Plasma Lead from the torch head. 7.
7. Place the Torch Head Assembly in the handle shell halves keeping in mind the following: C. Removing Hand Torch Control Switch • Place the torch head assembly switch leads so that no connectors or wires extend beyond the edge of the handle.
D. Replacing Hand Torch Control Switch 1. Strip back the insulation from the Torch Switch leads approximately 3/16". Install heat-shrink insulation on the Torch Switch leads. Crimp butt splices onto the two Torch Switch leads and onto the switch leads in the Torch Leads assembly. Slide the sheat-shrink insulator over the butt splices. Use a heat gun to shrink the heat-shrink insulation into position on the butt splices. 5.
C. Reassembling Machine Torch Assembly 1. Connect the two PIP lead connectors, the Negative / Plasma and Pilot leads. NOTE Tape the PIP lead connectors to the leads covering. 2. Screw the positioning tube tightly onto the Torch Head Assembly.
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: Replacement Machine Torch Lead Parts Section 6.06: Complete Assembly Replacement Section 6.07: Options and Accessories Section 6.
6.
11 14 &15 10 12 &13 17 12 &13 9 12 &13 14 &15 19 18 7 8 16 20 17 2 6 21 5 4 3 1 22 23 NOTE Illustration may vary slightly from actual torch.
6.
16 24 12 15 11 12 6 7 9 4 2 21 & 22 3 8 1 19 & 20 13 5 17 14 10 23 18 Art # A-02787 21 & 22 Manual 0-2817 6-5 19 & 20 PARTS LISTS
6.05 Replacement Torch Lead Parts Item # Qty 1 1 Description Catalog # Nylon Sleeving 25 ft (7.6 m) Length 9-5515 50 ft (15.2 m) Length 9-5516 2 1 Through - hole Protector , Notched (Supplied with Nut) 9-7016 3 1 Boot 9-7017 4 1 Lead, Pilot Return, 14AWG 5 6 1 1 25 ft (7.6 m) Length 8-6460 50 ft (15.2 m) Length 8-6461 Lead, Negative, #4 Hose - #12 AWG 25 ft (7.6 m) Length 9-9032 50 ft (15.2 m) Length 9-9033 Assembly, Control Cable (Unshielded Leads) 25 ft (7.
6.06 Complete Torch & Leads Assembly Replacement NOTE The Complete Torch & Leads Assembly Replacement does not include the Torch Control Cable Adapter (refer to Section 6.03 or 6.04) Description Catalog # Hand Torches with Ergonomic Handle: PCH-62 RPT 70° Hand Torch, 20 ft (6.1 m) Leads PCH-62 RPT 70° Hand Torch, 50 ft (15.2 m) Leads 7-6220 7-6221 PCH-62 RPT 90° Hand Torch, 20 ft (6.1 m) Leads PCH-62 RPT 90° Hand Torch, 50 ft (15.
6.07 Options and Accessories Item # Qty Description 1 1 1 1 1 Standoff Cutting Guide Cutting Guide Kit Trigger Guard Kit Hand Pendant Extension - 25 ft Computer Control (CNC) Cable 25 Ft (7.6 m) 50 Ft (15.2 m) Kevlar Sleeving: 25 ft. (7.6 m) 50 ft. (15.
6.08 Torch Spare Parts Kits A. For CutMaster 50 Applications 1. For Non - CE CutMaster 50 Applications Qty 2. Description Catalog # 3 5 1 1 1 1 1 1 2 2 Introductory Spare Parts Kit Includes: Electrode (SureLok), MaximumLife Tip, Cutting, Air, 40 Amp (0.031" Orifice) O - Ring Canted Coil Spring, 0.985" I.D.
B. For PakMaster 50XL Plus Applications Qty 1. 2. Description Catalog # For Non - CE PakMaster 50XL Plus Applications 3 2 5 1 1 1 1 1 2 2 Standard Spare Parts Kit Includes: Electrode (SureLok), MaximumLife Tip, Cutting/Drag, Air, 40 Amp (0.031" Orifice) Tip, Cutting (Standoff), Air, 40 Amp (0.
APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAMS For CutMaster 50 Applications ACTION ACTION ACTION ACTION Close external disconnect switch. ON/OFF switch to ON. RUN/SET switch to SET. RUN/SET switch to RUN. RESULT RESULT RESULT RESULT Power to system. AC indicator blinks for 8 seconds then steady on. Fans on. Power circuit ready. Gas solenoid open, gas flows to set pressure. GAS indicator on. Gas flow stops. GAS indicator off.
For PakMaster 50XL Plus Applications LATCH ACTION ACTION ACTION ACTION Close external disconnect switch. ON/OFF switch to ON. RUN/SET/LATCH switch to SET. RUN/SET/LATCH switch to RUN. RESULT RESULT RESULT RESULT Power to system. AC indicator blinks for 8 seconds then steady on. Fans on. Power circuit ready. Gas solenoid open, gas flows to set pressure. GAS indicator on. Gas flow stops. GAS indicator off. ACTION ACTION Torch moved away from work (while still activated).
APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM FOR MECHANIZED SYSTEMS To Torch Control Device Torch Control Cable Control Connector Plug with Connectors Torch Control Connectors To Power Supply Control Connector Control Shield Connector Torch Lead Assembly Lead Shield Connector Mate & Lock Connectors A-02821 A-02801 Connectors only on Shielded Leads Torch Head PIP Pin Torch Leads 2 Shield Return Power Supply Control OK-To-Move Relay PIP Pin Mate & Lock Connectors 1 3 3 4 4 12 12 14 14
APPENDIX 3: GENERAL APPLICATION NOTES A. Electrode Selection The SureLok TM Torches offer two Electrodes, General Purpose and MaximumLifeTM. The information supplied in this section is to help determine which electrode to use for best performance. General Purpose SureLokTM Electrode (Cat.No. 9-8402) • General Purpose- Good performance with all systems. • Design of electrode is similar to previous designed electrodes used in the PCH/M-60, 75, 76, 80, and 100XL Torches.
B. Hand Cutting Versus Machine (Mechanized) Cutting Speeds A-02947 Hand Cutting Speeds (Shaded Area) Speed Machine Cutting Speeds Material Thickness Hand cutting speeds can be much less than those obtained from Machine (Mechanized) Type applications. Hand cutting application speeds mostly depend on operator experience. The cut quality obtained at slower speeds for a Hand application is just as good as those obtained from a Machine application.
APPENDIX 4: CUTMASTER 50 APPLICATION NOTE Cut Quality (Various Materials and Thicknesses) System data in this Appendix is for CutMaster 50 and CE CutMaster 50 applications. The following table defines the cut quality on various materials and thicknesses: Torch Specifications Cut Quality on Various Materials Torch Specifications For CutMaster 50 Power Supply Cutting Range Material Mild Steel Production Cut: Up to 1/4 inch (6.3 mm) Speed 28 ipm (0.71 mpm) Genuine Cut: Up to 1/2 inch (12.
Consumables Matrix Consumable Matrix For CutMaster 50 & CE CutMaster 50 Application Shield Cup Tip Gas Dist Electrode Drag Cutting 9-8400 9-8411 9-8401 9-8407 Cutting (w/o Standoff Cutting Guide) 9-8400 9-8411 or 9-8412 9-8401 9-8407 Cutting (w/Standoff Cutting Guide) 9-8400 9-8411 or 9-8412 9-8401 9-8407 Gouging 9-8400 9-8416 9-8401 9-8407 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For CutMaster 50 Type Torch: PCM-62 Type Material: Aluminum Type Plasma Gas: Air Thi
APPENDIX 5: PAKMASTER 50XL PLUS APPLICATION NOTE Cut Quality (Various Materials and Thicknesses) Refer to Appendix 6 for CE PakMaster 50XL Plus applications. The following table defines the cut quality on various materials and thicknesses: Torch Specifications Torch Specifications For PakMaster 50XL Plus Power Supply Cut Quality on Various Materials Cutting Range Material Mild Steel Production Cut: Up to 1/4 inch (6.3 mm) Speed 40 ipm (1.02 mpm) Genuine Cut: Up to 1/2 inch (12.
Consumables Matrix Consumable Matrix For PakMaster 50XL Plus Application Shield Cup Tip Gas Dist Electrode Drag Cutting 9-8400 9-8411 9-8401 9-8407 Cutting (w/o Standoff Cutting Guide) 9-8400 9-8411 or 9-8412 9-8401 9-8407 Cutting (w/Standoff Cutting Guide) 9-8400 9-8411 or 9-8412 9-8401 9-8407 Gouging 9-8400 9-8416 9-8401 9-8407 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus Type Torch: PCM-62 Type Material: Aluminum Type Plasma Gas: Air Thickne
APPENDIX 6: CE PAKMASTER 50XL PLUS APPLICATION NOTE Cut Quality (Various Materials and Thicknesses) Refer to Appendix 5 for PakMaster 50XL Plus applications. The following table defines the cut quality on various materials and thicknesses: Torch Specifications Cut Quality on Various Materials Torch Specifications For PakMaster 50XL Plus Power Supply Cutting Range Material Mild Steel Production Cut: Up to 1/4 inch (6.3 mm) Speed 40 ipm (1.02 mpm) Genuine Cut: Up to 1/2 inch (12.7 mm) Speed 10-12 ipm (0.
Consumables Matrix Consumable Matrix For CE PakMaster 50XL Plus Application Shield Cup Tip Gas Dist Electrode Drag Cutting 9-8400 9-8411 9-8401 9-8402 Cutting (w/o Standoff Cutting Guide) 9-8400 9-8411 or 9-8412 9-8401 9-8402 Cutting (w/Standoff Cutting Guide) 9-8400 9-8411 or 9-8412 9-8401 9-8402 Gouging 9-8400 9-8416 9-8401 9-8402 Cutting Speed Charts Air Plasma Cutting Speed Data Chart For PakMaster 50XL Plus Type Torch: PCM-62 Type Material: Aluminum Type Plasma Gas: Air Thic
APPENDIX 7: HAND TORCH CONNECTION Hand Torch and Leads Torch Head Torch Leads PIP Contacts Black Orange Torch Switch Green White Power Supply Adapter Negative / Plasma Pilot Art # A-03863 Pilot Power Supply Bulkhead
