Thermal Dynamics SureLok PCM-102 User manual

March 9, 2001 Manual No. 0-2815
PLASMA
CUTTINGTORCH
Instruction Manual
For UseWith:
• Automated Pak Master 75XL Plus
• Automated Pak Master 100XL Plus
• CE Automated Pak Master 75XL Plus
• CE Automated Pak Master 100XL Plus
PCM-102 For Automated Systems

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.
Record the following information for Warranty purposes:
Where Purchased: _______________________________________
Purchase Date: _______________________________________
Power Supply Serial #: _______________________________________
Torch Serial #: _______________________________________
Plasma Cutting Torch
PCM-102 For Automated Systems
Instruction Manual Number 0-2815
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
Copyright 2000 by
Thermal Dynamics Corporation
All rights reserved.
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: March 9, 2001

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions andWarnings ..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications.................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes........................................................... 1-3
1.06 Documents De Reference ............................................................................ 1-5
1.07 Declaration of Conformity............................................................................. 1-7
1.08 Statement ofWarranty.................................................................................. 1-8
SECTION 2:
INTRODUCTION & DESCRIPTION.................................................................................. 2-1
2.01 Scope of Manual .......................................................................................... 2-1
2.02 General Description ..................................................................................... 2-1
2.03 Specifications & Design Features................................................................. 2-1
2.04 Options And Accessories ............................................................................. 2-2
2.05 Introduction to Plasma.................................................................................. 2-2
SECTION 3:
INSTALLATION PROCEDURES ....................................................................................... 3-1
3.01 Introduction .................................................................................................. 3-1
3.02 Site Location ................................................................................................ 3-1
3.03 Unpacking .................................................................................................... 3-1
3.04 Setting Up MachineTorch ............................................................................ 3-1
3.05 ConnectingTorch ......................................................................................... 3-1
3.06 Gas Connection ........................................................................................... 3-2
SECTION 4:
OPERATION ..................................................................................................................... 4-1
4.01 Introduction .................................................................................................. 4-1
4.02 Functional Overview..................................................................................... 4-1
4.03 Getting Started............................................................................................. 4-1
4.04 Torch Parts Selection ................................................................................... 4-2
4.05 Cut Quality ................................................................................................... 4-2
4.06 Operating the System .................................................................................. 4-3
4.07 MachineTorch Operation ............................................................................. 4-4
4.08 Recommended Cutting Speeds.................................................................... 4-5
4.09 Gouging ....................................................................................................... 4-5
SECTION 5:
CUSTOMER/OPERATOR SERVICE ................................................................................. 5-1
5.01 Introduction .................................................................................................. 5-1
5.02 GeneralTorch Maintenance.......................................................................... 5-1
5.03 Common Operating Faults ........................................................................... 5-2
5.04 Inspection and Replacement ConsumableTorch Parts ................................ 5-2
5.05 TroubleshootingGuide.................................................................................. 5-3
5.06 Torch & LeadsTroubleshooting..................................................................... 5-4
5.07 Servicing MachineTorch (PCM) Components .............................................. 5-6

TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS.................................................................................................................... 6-1
6.01 Introduction .................................................................................................. 6-1
6.02 Ordering Information .................................................................................... 6-1
6.03 Replacement MachineTorch With Pinch Block Mounting Parts .................... 6-2
6.04 ReplacementTorch Lead Parts .................................................................... 6-4
6.05 Complete Assembly Replacement ............................................................... 6-5
6.06 Options & Accessories ................................................................................. 6-5
6.07 Torch Spare Parts Kits.................................................................................. 6-6
APPENDIX 1: TYPICAL SYSTEM SEQUENCE OF OPERATION BLOCK DIAGRAM..............A-1
APPENDIX 2: TORCH CONTROL CABLE WIRING DIAGRAM FOR
MECHANIZED SYSTEMS ................................................................................................A-2
APPENDIX 3: GENERAL APPLICATION NOTES.....................................................................A-3
APPENDIX 4: PAK MASTER 75XL PLUS AUTOMATED SYSTEM DATA..................................A-4
APPENDIX 5: CE AUTOMATED PAK MASTER 75XL PLUS SYSTEM DATA............................A-8
APPENDIX 6: AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA..............................A-12
APPENDIX 7: CE AUTOMATED PAK MASTER 100XL PLUS SYSTEM DATA........................A-16

Date: May 1, 2000 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
areused tohighlight important information. Thesehigh-
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-
structionsbefore usingthe equipment. Call1-603-
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-
formationregardingthe kind andamount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
inyour workplace,referto item1 inSubsection1.03,
Publications in this manual.
• Usespecial equipment, suchas wateror downdraft
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.”

GENERAL INFORMATION 1-2 Date: May 1, 2000
• 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, 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.
• Provideafirewatchwhenworkinginanareawhere
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
Noisecancause permanenthearingloss. Plasma arcpro-
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.
• Noiselevels shouldbemeasuredtobesurethe 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.
PLASMAARC RAYS
PlasmaArcRays caninjure youreyesand burnyour skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyesand burnyourskin ifyou arenotproperlyprotected.
• To protect your eyes, always wear a welding hel-
metorshield. Also alwayswearsafety 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
* Thesevaluesapply wherethe actualarc isclearly
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, SAFETYAND 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 theAmerican 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-
PATIONAND EDUCATIONAL EYEAND 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-TOEFOOTWEAR,obtainable fromtheAmeri-
can National Standards Institute, 1430 Broadway, New
York, NY 10018

Date: May 1, 2000 1-3 GENERAL INFORMATION
6. ANSI Standard Z49.2,FIRE PREVENTIONIN THEUSE
OF CUTTING AND WELDING PROCESSES, obtain-
able fromAmerican National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS StandardA6.0, WELDINGAND 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. NFPAStandard 51B, CUTTINGAND 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, VA22202
12. CSAStandard 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 SocietyStandardAWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARA-
TION FOR WELDINGAND CUTTING OF CONTAIN-
ERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from theAmerican 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 àl’efficacitéde 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 ÀL’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupantàl’arcau jetde plasmaproduitde 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 santéelectronique.
Ceux qui travail près d’une application àl’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santépour 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
lesavertissements, toutesles précautionsde 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 1-4 Date: May 1, 2000
• 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
sil’aérationfournie nepermetpas d’éliminerlafumée
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 chocsgraves, voiremortels, pourl’opérateur
et les autres personnes sur le lieu de travail.
• Netouchez jamais unepièce “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
Lesincendies etles explosionspeuvent résulterdes 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.
• Prévoyezune veilled’incendie lorsde touttravail 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’échapperou se dissiper. Le gas hydrogèneaccumulé
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: May 1, 2000 1-5 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.
• Portezdes gants desoudeur etun vêtementprotecteur
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 suiventANSI/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 valeurss’appliquent oul’arcactuel estobservé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
cachépar 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. Protégezégalement 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, NORMESDESÉCURITÉ DUTRAVAILETDE
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 VISAGEAU TRA-
VAILET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na-
tionalStandards Institute),1430 Broadway, NewYork,
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. NormeANSI 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. NormeA6.0 de l’AssociationAméricaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURSAYANT RENFERMÉDESPRODUITS
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 ProtectionAssociation, Batterymarch Park,
Quincy, MA 02269

GENERAL INFORMATION 1-6 Date: May 1, 2000
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL, disponible auprès de la National Fire Pro-
tectionAssociation, BatterymarchPark, 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 LAPRÉPARATIONÀLACOUPE 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. NormeANSI Z88.2,PRATIQUES DEPROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

Date: May 1, 2000 1-7 GENERAL INFORMATION
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc-
tive’ (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 manufac-
ture 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 StandardsAssociation) standard C22.2 number 60 forArc 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
manufacturing 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 1-8 Date: May 1, 2000
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 XLPlus 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 XLPlus Series and CutMaster Series shall be as follows: Amaximum 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
PCH/M-62 & PCH/M-102 Torches 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 May 1, 2000

Manual0-2815 2-1 INTRODUCTION &DESCRIPTION
SECTION 2:
INTRODUCTION &
DESCRIPTION
2.01 Scope of Manual
Thismanualcontains descriptions,operatinginstructions
and maintenance procedures for the PCM-102 Torch us-
ingtheSureLok electrodedesignfor Automated Systems.
Service of this equipment is restricted to properly trained
personnel; unqualified personnel are strictly cautioned
against attempting repairs or adjustments not covered in
this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. Acomplete understanding
of the characteristics and capabilities of this equipment
will assure the dependable operation for which it was
designed.
2.02 General Description
NOTE
RefertoSection 2.05, IntroductionTo Plasma,for a
more detailed description on plasma theory.
The Torch provides cutting capacity of up to 1 inch (25.4
mm) at 100 amperes. In the torch, a single torch lead pro-
videscompressed airor nitrogen(N2) fromasinglesource
to be used as both the plasma and secondary gas. The air
flow is divided inside the torch head. Single-gas opera-
tion provides a smaller sized torch and inexpensive op-
eration.
Plasma torches are similar in design to the common auto-
motive spark plug. They consist of negative and positive
sections which are separated by a center insulator. Inside
the torch, the pilot arc is initiated in the gap between the
negatively charged electrode and the positively charged
tip. Once the pilot arc has ionized the plasma gas, the
superheatedcolumn ofgasflows throughthe smallorifice
in the torch tip, which is focused on the metal to be cut.
2.03 Specifications & Design
Features
NOTE
Refer to Appendix Pages for additional specifica-
tions as related to the Power Supply used.
A. Torch Configuration
Thestandardmachine torch hasa fiberglass position-
ing tube with rack & pinch block assembly.
Available options include a kit with metal mounting
tube with rack & pinion assembly or a kit with the
pinion assembly only.
A-02805
Figure 2-1 Machine Torch
B. Torch Leads Lengths
25 ft (7.6 m) or 50 ft (15.2 m)
C. Torch Parts
Gas Distributor, Electrode, Tip, Shield Cup
D. Parts-In-Place (PIP)
Torch Head has built-in contacts
12 vdc circuit rating
E. Type Cooling
Combination of ambient air and gas stream through
torch
F. Torch Ratings
Ambient
Temperature 104° F
(40° C)
Duty Cycle 100% @ 100 Amps @ 400 scfh
Maximum Current 100 Amps
Voltage (Vpeak)500V
Arc Striking Voltage 12 kV
Torch Ratings
G. Product Used With
•Automated Pak Master 75XL Plus
•Automated Pak Master 100XL Plus
•CE Automated Pak Master 75XL Plus
•CE Automated Pak Master 100XL Plus

INTRODUCTION&DESCRIPTION 2-2 Manual0-2815
H. Torch Dimensions
A-02804
()
14.1 in
(358 mm)
0.62 in
(15.2 mm)
0.75 in
(19 mm)
5.1 in
(129.5 mm)
1.1 in
(28 mm)
1.4 in
(35.6 mm)
13.5 in (343 mm) Max
3.7 in (94 mm) Min
Figure 2-2 Torch Dimensions
2.04 Options And Accessories
These items can be used to customize a standard system
for a particular application or to further enhance perfor-
mance(referto Section 6 forordering information).
•Spare Parts Kits - Various kits containing replace-
ment front-end torch parts for various applications.
•1-3/8" Metal Mounting Tube w/Rack & PinionAs-
sembly
•Pinion Assembly
•ComputerControl (CNC) Cable25 Ft(7.6 m)or50 Ft
(15.2 m)
2.05 Introduction to Plasma
A. Plasma Gas Flow
Plasma is defined as a gas which has been heated to
an extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc cut-
ting and gouging process use this plasma to transfer
an electrical arc to the workpiece. The metal to be cut
or removed is melted by the heat of the arc and then
blown away.
While the goal of plasma arc cutting is separation of
the material, plasma arc gouging is used to remove
metals to a controlled depth and width.
In a Thermal Arc Plasma Cutting Torch a cool gas
such as air or nitrogen (N2) enters Zone B (refer to
Figure 2-3), where a pilot arc between the electrode
and the torch tip heats and ionizes the gas. The main
cutting arc then transfers to the workpiece through
the column of plasma gas in Zone C.
;;
;;
;;
;
;
;
;
;
;;
;;
A-00002
Workpiece
Power
Supply
+
_
C
B
A
Figure 2-3 Typical Torch Head Detail
By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C (Figure 2-3). Direct current
(DC) straight polarity is used for plasma cutting, as
shown in the illustration.
Zone A (Figure 2-3) is used as a secondary gas that
cools the torch. This gas assists the high velocity
plasmagasin blowing themolten metal outof the cut
allowing for a fast, slag-free cut.
B. Gas Distribution
The single gas used is internally split into plasma
and secondary gases.
Theplasma gas flowsinto the torchthrough thenega-
tivelead,throughthe gas distributor, aroundthe elec-
trode, and out through the tip orifice.
The secondary gas flows down around the outside of
the torch gas distributor, and out between the tip and
shield cup around the plasma arc.
C. Pilot Arc
When the torch is started a pilot arc is established
between the electrode and cutting tip. This pilot arc
creates a path for the main arc to transfer to the work.
D. Capacitive Discharge
Because direct current (DC) alone is not sufficient to
strikeandmaintain the pilotarc, capacitive discharge
is also used. The high voltage jumps between the tip
and electrode with the DC following.

Manual0-2815 2-3 INTRODUCTION &DESCRIPTION
E. Main Cutting Arc
DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is con-
nected to the workpiece via the work cable and to the
torch through a pilot wire.
F. Interlocks
One pressure switch acts as an interlock for the gas
supply. If supply pressure falls below minimum re-
quirements the pressure switch will open, shutting
off the DC power, and the GAS indicator will go off.
When adequate gas supply pressure is available the
pressure switch will close, allowing power to be re-
sumedfor cutting.
G. Parts-In-Place (PIP)
The torch head has built-in contacts called Parts-In-
Place(PIP). Thesetwo contacts aremade through the
canted coiled spring inside the shield cup when it is
installed. The torch will fail to operate if these con-
tacts are not made.

INTRODUCTION&DESCRIPTION 2-4 Manual0-2815

Manual 0-2815 3-1 INSTALLATION PROCEDURES
SECTION 3:
INSTALLATION
PROCEDURES
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, Op-
tions and Accessories are given in Manuals specifically
provided for those parts.
The complete installation consists of:
•Site Selection
•Unpacking
•Setting Up Torch
•Connecting Torch
•Gas Connection
3.02 Site Location
Select a clean, dry location with good ventilation and ad-
equate working space around all components.
Review the safety precautions in the front of this manual
to be sure that the location meets all safety requirements.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify
and account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distributor and/or
shipping company before proceeding with system
installation.
3.04 Setting Up MachineTorch
WARNING
Disconnect primary power at the source before dis-
assembling the torch or torch leads.
The standard machine torch includes a fiberglass posi-
tioningtubewith rack andpinchblock assembly. Ametal
mounting tube with rack & pinion assembly or the pin-
ion assembly only are available as options.
1. Mount the torch assembly on the cutting table.
2. To obtain a clean vertical cut, use a square to align
the torch perpendicular to the surface of the
workpiece.
A-02585
Workpiece
Square
Pinch Block
Assembly
Figure 3-1 Machine Torch Set-Up
3. The proper torch parts (shield cup, tip, gas dis-
tributor, and electrode) must be installed for the
type of operation. Refer to Section 4.04, Torch
Parts Selection for more information.
3.05 ConnectingTorch
The instructions for connecting the Torch Leads to the
Automated Power Supply.
The Torch Leads must be properly installed to the Power
Supply for proper operation. If the torch leads were not
factory-installed, make all torch connections to the Torch
Bulkhead Panel.
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
1. Remove the retaining nut from the Strain Relief.

INSTALLATION PROCEDURES 3-2 Manual 0-2815
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-02826
Figure 3-2 Strain Relief Nut Removal
2. Feed the torch lead ends and the Strain Relief into
the hole in the unit.
3. Secure the Strain Relief with the retaining nut re-
moved earlier.
Adapter
(Supplied With
Power Supply)
Pilot Lead
Torch Lead
Assembly
Negative/Plasma
Lead
Adapter Connector
Pilot Lead
Stud
Negative/Plasma
Lead Connection
A-02831
Control (PIP) Circuit
Connectors
Shield Connectors
Figure 3-3 Torch Lead Connections
4. Connect the torch Negative/Plasma Lead to the
bulkhead connection inside the Power Supply.
5. Connect the PIP and Shield Cables to the mating
connectors on theAdapter supplied on the Power
Supply.
6. Remove the top nut and washer from the Pilot
Stud.
7. Place the lug on the Pilot Control Wire onto the
studand securewith the nutand washerremoved
in the above Step.
8. Tighten the Strain Relief onto the Torch Leads.
9. Check the torch for proper parts assembly.
CAUTION
The torch parts must correspond with the type of
operation. Refer to Section 4.04, Torch Parts Se-
lection.
3.06 Gas Connection
A. Connection
Connect the gas , compressed air or nitrogen (N2)
only, to the Power Supply as described in the Manual
supplied with the Power Supply.
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive oil and moisture may
cause double-arcing, rapid tip wear, or even com-
plete torch failure. Contaminants may cause poor
cutting performance and rapid electrode wear.
B. Checking Air Quality
To test the quality of air, place a welding filter lens in
front of the torch and turn on the gas. Any oil or
moisture in the air will be visible on the lens. Do not
initiate an arc!
C. Filtering
An in-line pneumatic dryer/evaporator type air fil-
ter,capable offilteringto atleast 5microns,is required
when using air from a compressor. This type filter
willinsure thatmoisture,oil, dirt,chips, rustparticles,
and other contaminants from the supply hose do not
enter the torch. For highly automated applications,
a refrigerated drier may be used.