Thermal Dynamics Plasma Welding Torch Model PWH/M-2A Manuel utilisateur

Marque: Thermal Dynamics

Modèle: Plasma Welding Torch Model PWH/M-2A

Catégorie: Système de soudage

Taper: Manuel utilisateur

Instruction Manual

Plasma Welding Torch

Model PWH/M-2A

April 19, 2002 Manual No. 0-2005

Plasma Welding Torch

PWH/M-2A

Instruction Manual Number 0-2005

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written per-

mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to

any party for any loss or damage caused by any error or omission in

this Manual, whether such error results from negligence, accident, or

any other cause.

Printed in the United States of America

Publication Date: April 19, 2002

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-

ating, 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.

Contents

GENERAL INFORMATION.............................................................................................................i

1.01 Notes, Cautions and Warnings ..........................................................................i

1.02 Important Safety Precautions ............................................................................i

1.03 Publications......................................................................................................ii

1.04 Note, Attention et Avertissement ..................................................................... iii

1.05 Precautions De Securite Importantes.............................................................. iii

1.06 Documents De Reference ............................................................................... v

1.07 Declaration of Conformity............................................................................... vii

1.08 Statement of Warranty................................................................................... viii

SPECIFICATIONS ..................................................................................................................... 1-1

1.1. DESCRIPTION OF EQUIPMENT ................................................................ 1-1

1.2. SPECIFICATIONS........................................................................................ 1-1

1.3. THERMAL ARC PLASMA ............................................................................ 1-3

1.4. THEORY OF OPERATION........................................................................... 1-3

INSTALLATION.......................................................................................................................... 2-1

2.1. UNPACKING NEW EQUIPMENT................................................................. 2-1

2.2. HAND TORCH INSTALLATION .................................................................... 2-1

2.3. MACHINE TORCH INSTALLATION.............................................................. 2-1

OPERATION.............................................................................................................................. 3-1

3.1. PRE-OPERATION SET-UP .......................................................................... 3-1

3.2. HAND TORCH OPERATION........................................................................ 3-3

3.3. MACHINE TORCH OPERATION.................................................................. 3-3

SERVICE ................................................................................................................................... 4-1

4.1. TORCH MAINTENANCE ............................................................................... 4-1

4.2. TORCH LEADS REPLACEMENT ................................................................ 4-2

4.3 TORCH LEADS REPAIR.............................................................................. 4-4

PARTS LIST .............................................................................................................................. 5-1

5.1. GENERAL ARRANGEMENT......................................................................... 5-1

Date: November 15, 2001 i GENERAL INFORMATION

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

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.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formation regarding the kind and amount of fumes

and gases that may be dangerous to your health.

• For information on how to test for fumes and gases

in your workplace, refer to item 1 in Subsection 1.03,

Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects and, in some cases, cancer. (California Health

& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

• 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.

GENERAL INFORMATION ii Date: November 15, 2001

• 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, Publica-

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable ma-

terial in the workplace. Any material that cannot

be removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have

held combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

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. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

ments, U.S. Government Printing Office, Washington,

D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding So-

ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

from the Superintendent of Documents, U.S. Govern-

ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES, ob-

tainable from American National Standards Institute,

1430 Broadway, New York, NY 10018

Date: November 15, 2001 iii GENERAL INFORMATION

7. AWS Standard A6.0, WELDING AND CUTTING CON-

TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-

tainable from American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

GENERAL INFORMATION iv Date: November 15, 2001

• Eloignez toute fumée et gaz de votre zone de respira-

tion. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air

si l’aération fournie ne permet pas d’éliminer la fumée

et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un ou

plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des gaz

pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une

zone où se trouvent des matières ou des gaz combus-

tibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe,

produit de la fumée ou des gaz pouvant contenir des

éléments reconnu dans L’état de la Californie, qui

peuvent causer des défauts de naissance et le cancer.

(La sécurité de santé en Californie et la code sécurité

Sec. 25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voire mortels, pour l’opérateur

et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”;

portez des gants et des vêtements secs. Isolez-vous

de la pièce de travail ou des autres parties du circuit

de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la page

5, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de

consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail. Protégez

toute telle matière qu’il est impossible de retirer de la

zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans

une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous

les pièces de travail en aluminium lorsqu’elles sont

coupées sous l’eau ou sur une table d’eau. NE PAS

couper les alliages en aluminium sous l’eau ou sur

une table d’eau à moins que le gas hydrogène peut

s’échapper ou se dissiper. Le gas hydrogène accumulé

explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de

plasma produit une lumière infra-rouge et des rayons

Date: November 15, 2001 v GENERAL INFORMATION

ultra-violets très forts. Ces rayons d’arc nuiront à vos

yeux et brûleront votre peau si vous ne vous protégez

pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou

un écran de soudeur. Portez toujours des lunettes de

sécurité munies de parois latérales ou des lunettes de

protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur

approprié pour protéger votre peau contre les

étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection

en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant des

cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le

recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé

clairement. L’experience a démontrer que les filtres

moins foncés peuvent être utilisés quand l’arc est

caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

normalement acceptables. Vous dú4ez vous protéger les

oreilles contre les bruits forts afin d’éviter une perte

permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez

des tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres personnes

se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que

les décibels (le bruit) ne dépassent pas les niveaux

sûrs.

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page 5.

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus

récentes ayant été faites à celles-ci pour de plus amples

renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE

PROTECTION DE LA SANTÉ, 29CFR 1910,

disponible auprès du Superintendent of Documents,

U.S. Government Printing Office, Washington, D.C.

20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES

OPÉRATIONS DE COUPE ET DE SOUDAGE,

disponible auprès de la Société Américaine de

Soudage (American Welding Society), 550 N.W.

LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES

OPÉRATIONS DE COUPE ET DE SOUDAGE À

L’ARC ET AU GAZ, disponible auprès du Superin-

tendent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA

PROTECTION DES YEUX ET DU VISAGE AU TRA-

VAIL ET DANS LES ECOLES, disponible de l’Institut

Américain des Normes Nationales (American Na-

tional Standards Institute), 1430 Broadway, New York,

NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES

LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET

DE SOUDAGE, disponible auprès de l’American Na-

tional Standards Institute, 1430 Broadway, New York,

NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage

(AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES PRODUITS

COMBUSTIBLES, disponible auprès de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA COUPE ET LES

PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-

tional Fire Protection Association, Batterymarch Park,

Quincy, MA 02269

GENERAL INFORMATION vi Date: November 15, 2001

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. 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,

Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA

SÉCURITÉ DU SOUDAGE, disponible auprès de

l’Association Nationale de Fournitures de Soudage

(National Welding Supply Association), 1900 Arch

Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRATIQUES

SURES POUR LA PRÉPARATION À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION

RESPIRATOIRE, disponible auprès de l’American

National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 vii GENERAL INFORMATION

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.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit

and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related

industry standards, and performs as specified. 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.

Manufacturers responsible representative: Giorgio Bassi

Managing Director

Thermal Dynamics Europe

Via rio Fabbiani 8A

40067 Rastignano (BO)

Italy

GENERAL INFORMATION viii Date: November 15, 2001

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. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days 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. All returned goods shall

be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

Specifications 1-1 Manual 0-2005

SPECIFICATIONS

1.1. DESCRIPTION OF

EQUIPMENT

The Thermal Arc 2A Plasma Welding Torch is designed

for direct current plasma arc welding of ferrous and

non-ferrous metals, including aluminum, using the

transferred arc plasma process. It is used as part of a

welding system that includes a control console, a di-

rect current power source, a coolant supply and a gas

supply (Figure 1-A).

Figure 1-A Plasma Welding System

Primary Power

D.C. Power Supply

Power Supply Control

Torch

Work

Plasma Welding Console Control Switch

Plasma Gas

Shield Gas

Coolant Recirculator

1.2. SPECIFICATIONS

• Straight Polarity Current Rating: 75 amperes DC

maximum.

• Plasma Gas: Argon (Consumption: 0.5-2.5 SCFH

(0.24-1.18 1pm).

• Shield Gas Straight Polarity: Argon or Argon/

Hydrogen (Consumption: 8-15 SCFH (3.8-7.1

1pm).

• Shipping Weight: Hand torch: PWH-2A- 1 lbs.

(0.45 kg); machine mounted torch PWM-2A – 2

lbs. (0.9 kg).

• Cooling Requirements: 2,000 BTU/hr; 114 gpm

of TDC Torch Coolant @ 50 psi.

Specifications 1-2 Manual 0-2005

Inches cm Inches cm Inches cm Inches cm

PWH-2A (70°) 8.00 20.32 1.62 4.11 0.62 1.57 0.88 2.24

PWH-2A (90°) 7.75 19.68 1.62 4.11 0.62 1.57 0.88 2.24

PWM-2A 18.00 45.72 0.81 2.06 7.12 18.08 1.38 3.50

15.00 38.10

ABCD

PWH/M-2A Torch Dimensions

Specifications 1-3 Manual 0-2005

1.3. THERMAL ARC PLASMA

Plasma is a gas which has been heated to an extremely

high temperature and ionized so that the gas becomes

electrically conductive. The welding process uses this

plasma to transfer an electric arc to the workpiece. The

metal to be welded is melted by the heat of the arc.

In a plasma torch, a cool gas such as Argon enters in

Zone A, Figure 1-C. In Zone B a pilot arc between the

electrode and the front of the torch heats and ionizes

the gas. An arc transfers to the workpiece through a

column of plasma gas in Zone C.

POWER

SUPPLY

Workpiece

Figure 1-C Thermal Arc Plasma

By forcing the plasma gas and electric arc through a

small orifice, Thermal Arc torches deliver a high con-

centration of heat to a very small area. The stiff, con-

stricted plasma arc is shown in Zone C. Direct current

straight polarity is used for most plasma welding, as

shown in the illustration.

The Dual-Flow design of Thermal Arc welding torches

uses a shield gas, shown by the small arrows. The shield

gas surrounds the plasma arc and channels it to the

workpiece, thus improving weld characteristics and

shielding the weld puddle from atmospheric contami-

nation.

Coolant from the coolant recirculator flows through the

liquid-cooled power leads to the torch head and back.

The plasma arc is infinitely variable from soft to stiff.

Most applications can best be accomplished with a

softer arc, i.e. lower plasma gas flow. Full penetration

or Key-hole welds require a stiff arc, i.e. high plasma

gas flow.

1.4. THEORY OF OPERATION

TORCH CONNECTIONS

The plasma gas flows to the torch through the black

lead, around the electrode and gas distributor and out

through the tip orifice.

The shield gas flows through the yellow torch lead,

around the torch front end and out through the shield

cup.

The torch coolant and negative (-) power flow to the

front end of the torch through the green (color coded)

lead.

The coolant return and positive (+) power for the pilot

arc flow through the red (color coded) lead.

PILOT ARC

When the torch is started, an arc is established between

the electrode and welding tip. This pilot arc appears as

a small “flame” at the front of the torch. This serves to

illuminate the workpiece and assists in starting the main

(welding) arc. It can also be left on while welding at

low current levels to stabilize the welding arc.

HIGH FREQUENCY

A high voltage, high frequency current is superimposed

on the direct current to establish the pilot arc.

WELDING ARC

The power supply provides the direct current (DC) for

welding. The negative output is connected to the torch

electrode through the negative liquid cooled lead. The

positive output is connected to the workpiece through

the work cable. The electrically charged plasma gas

serves to close this electrical circuit and thus becomes

the welding arc.

Installation 2-1 Manual 0-2005

INSTALLATION

Figure 2-A

2.1. UNPACKING NEW

EQUIPMENT

Unpack the equipment, check for possible damage dur-

ing shipment. Check to be sure all items on the pack-

ing list are identified and accounted for.

WARNING

Check to be sure the main disconnect switch sup-

plying power to the welding system is open.

2.2. HAND TORCH INSTALLATION

(Figure 2-A)

If the torch is not already attached to the leads, as-

semble as follows:

1) Remove the handle (Item 2) from the head as-

sembly (Item 1).

2) Feed the end of the leads with the torch fittings

through the shrink tubing (Item 3) and then the

handle (Item 2) and connect to the torch (Item

1), matching the color coded lead to the color

coded torch fitting. Do not overtighten.

3) Screw the handle onto the torch.

4) Slide the shrink tubing over the handle until

about 1/2 on. With a heat gun shrink the tubing

until it is snug on the handle and the leads (Fig.

2-B).

5) Connect the other end of the leads to the appro-

priate fittings on the plasma welding console.

Shrink 0n

Figure 2-B

2.3. MACHINE TORCH

INSTALLATION (Figure 2-C)

If the torch is not already attached to the leads, assemble

as follows:

1) Loosen the nut (Item 2) and remove the posi-

tioning tube assembly (Item 4).

2) Unscrew the sleeve adaptor (Item 3).

Figure 2-C

Installation 2-2 Manual 0-2005

3) Feed the end of the leads with the torch fittings

through Items 4, 3 and 2 connect to the torch,

matching the color coded lead to the color coded

torch fitting. Do not overtighten.

4) Pass the sleeve adaptor through the nut and

screw onto the torch.

5) Slide the positioning tube onto the sleeve adap-

tor and secure with the nut (Item 2).

6) Connect the other end of the leads to the ap-

propriate fittings on the plasma welding con-

sole.

Check the instructions for the other components of the

welding system to insure they are installed properly.

Operation 3-1 Manual 0-2005

OPERATION

3.1. PRE-OPERATION SET-UP

The selection of specific parameters for a given weld-

ing application depend on the type of material, con-

figuration of the joint and type of weld desired. Proper

settings for a given joint have to be developed on the

job.

Table 3-A gives the maximum operating range of the

various tips. These values are for a stiff collimated arc

with the electrode setback at its maximum. A softer,

less constricted arc can be obtained by decreasing the

electrode setback (see Fig. 3-A). The minimum setback

is with the electrode point flush with the face of the tip

(see Fig. 3-B). By decreasing the electrode setback the

plasma gas flow can be decreased while maintaining

the higher current ratings of the tip. This gives a wider

weld bead and in most cases allows for faster travel

speeds.

Max Setback

Figure 3-A

The electrode gauge values given in Table 3-A will re-

sult in maximum electrode setback for the given tip.

This setback, when used with the given values for cur-

rent and plasma gas flow will produce a stiff collimated

arc that results in a narrower weld bead.

CAUTION

Decreasing the electrode standoff can only be

done with tip orifice diameters of 0.046 or larger.

This procedure should be followed at the beginning of

each shift:

WARNING

Check to be sure the main disconnect switch is

open.

1) Check the torch to be sure that it has the proper

components (see Section 4.1) and is adjusted

properly (see Table 3-A).

2) Close the main disconnect switch supplying

power to the welding system.

Min Setback

Figure 3-B

When the electrode is at minimum setback (flush with

tip face) the plasma gas flow rate can be reduced be-

low the levels given in Table 3-A while maintaining the

given current levels. This produces a softer arc that re-

sults in less depth of penetration, giving a wider weld

bead, and allowing faster travel speeds.

Operation 3-2 Manual 0-2005

Table 3-A Suggested Starting Parameters for Manual Fusion Welding - Thermal Arc 2A Torch

Std. Ext. SCFH lpm

0.005 0.13 8-2077 0.014 8-2044 8-2046 4 3-5 0.25-0.5 0.12-0.24

8-2078 0.022 8-2044 8-2046 4 3-5 0.25-0.5 0.12-0.24

8-2079 0.031 8-2044 8-2046 4 3-5 0.25-0.5 0.12-0.24

0.010 0.25 8-2080 0.046 8-2044 8-2046 4 4-10 0.25-0.5 0.12-0.24

0.020 0.051 8-2082 0.062 8-2044 8-2046 4 10-15 0.25-0.5 0.12-0.24

8-2024 0.062 8-2033 0 10-15 0.25-0.5 0.12-0.24

1/32 0.80 8-2083 0.081 8-2044 8-2046 4 20-25 0.4-0.5 0.19-0.24

8-2033 4 0.19-0.24

8-2023 0.046 8-2033 0 20-30 0.4-0.6 0.19-0.28

1/16 1.6 8-2023 0.046 8-2033 0 30-35 0.6-0.7 0.28-0.33

8-2024 0.062 8-2033 0 30-45 0.6-0.9 0.28-0.42

3/32 2.4 8-2024 0.062 8-2033 0 45-55 0.9-1.1 0.42-0.52

8-2025 0.081 8-2033 0 45-60 0.9-1.2 0.47-0.57

1/8 3.2 8-2025 0.081 8-2033 0 60-75 1.2-1.5 0.57-0.71

0.050 1.3 8-2023 0.046 8-2033 0 25-35 0.5-0.7 0.24-0.33

8-2024 0.062 8-2033 0 25-40 0.5-0.8 0.24-0.38

1/16 1.6 8-2024 0.062 8-2033 0 30-50 0.6-1.0 0.28-0.47

3/32 2.4 8-2025 0.081 8-2033 0 60-75 0.9-1.4 0.42-0.66

0.010 0.25 8-2080 0.046 8-2044 8-2046 4 4-8 0.25-0.5 0.12-0.24

0.020 0.51 8-2082 0.062 8-2044 8-2046 4 10-15 0.25-0.5 0.12-0.24

8-2024 0.062 8-2033 0 10-15 0.25-0.5 0.12-0.24

8-2023 0.081 8-2044 8-2046 4 10-15 0.25-0.5 0.12-0.24

Carbon Steel

Ar(95%)/H

(5%)

or Argon

Titanium

Argon

Inch mm Cat. No.

Orifice

Dia.

(inch)

aterial/Thicknes

Tip Electrode

Ar(95%)/H

(5%)

or Argon

Catalog Number

Shield Gas

8-15 SCFH

(3.8-7.1 lpm)

Stainless Steel

Current Range

(Amps)

Plasma Gas

(Argon) Flow

Gauge*

* Gauge settings are identified by the number of rings on the gauge and are for maximum elec-

trode setback. See Torch Assembly, step 4 for proper adjustment procedure.

NOTE: This information represents our best judgement but Thermal Dynamics Corporation assumes no

liability for its use. The parameters listed above may be varied to optimize performance.

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Thermal Dynamics Plasma Welding Torch Model PWH/M-2A Manuel utilisateur

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