RETURN TO MAIN MENU IM944 POWERTORCH™ PLASMA 20 For use with machines having Code Number: 11453 Safety Depends on You Harris arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i WARNING SAFETY i PLASMA CUTTING or GOUGING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING. Read and understand the following safety highlights. For additional safety information it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O.
ii SAFETY 4.c. When not cutting or gouging, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. 4.d. Do not cut or gouge tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned.
iii PRÉCAUTIONS DE SÛRETÉ SAFETY Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
iv iv Thank You for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products.
v TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ...............................................................................................................A-2 Select Proper Location .......................................................
INSTALLATION A-1 TECHNICAL SPECIFICATIONS - POWERTORCH™ PLASMA 20 (K2682-1) Standard Voltage INPUT - SINGLE PHASE 1Ø Input Current at Rated Output 115/1/50/60Hz (15 Amp Branch) 115/1/50/60Hz (20 Amp Branch with 20 Amp Plug*) RATED OUTPUT Duty Cycle 115 V: 20A @ 50% 115 V: 26A @ 40% AMPS 50% on 115V (15 Amp Branch) 40% on 115V (20 Amp Branch with 20 Amp Plug*) 15 A 20 A OUTPUT Current Range 10-20 Amps REQUIRED AIR FLOW RATE 3.5 cu. ft./min. (100L/min.
INSTALLATION A-2 Read entire Installation Section before installing the POWERTORCH™ PLASMA 20. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK CAN KILL. • Only qualified personnel should perform this installation. • Only personnel that have read and understood the POWERTORCH™ PLASMA 20 Operating Manual should install and operate this equipment. • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.
INSTALLATION A-3 Use of normal 20 amp household breakers may result in over current trips. If breaker trips occur, reduce the cutting current output until nuisance trips stop. COMPRESSED AIR OR GAS INPUT CONNECTION A source of clean, dry air or nitrogen must be supplied to the POWERTORCH™ PLASMA 20. Oil in the air is a severe problem and must be avoided. The supply pressure must be between 72.5 and 150 psi (5 and 10.3 bar). The flow rate is approximately 3.5 cu. ft./min. (100L/min.).
OPERATION B-1 DESCRIPTION SAFETY PRECAUTIONS WARNING B-1 The POWERTORCH™ PLASMA 20 is a constant current, continuous control plasma cutter power source. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust to remove fumes from breathing zone.
B-2 USER RESPONSIBILITY OPERATION CONTROLS AND SETTINGS Variation such as plate chemistry, plate surface condition (oil, scale), plate thickness, preheat, quench, gas type, gas flow rate and equipment may produce results different than those expected. Some adjustments to procedures may be necessary to compensate for unique individual conditions. Test all procedures duplicating actual field conditions.
OPERATION B-3 CUTTING OPERATIONS CHECKING AIR QUALITY BEFORE CUTTING WARNING ELECTRIC SHOCK CAN KILL. Disconnect input power by removing the plug from the receptacle before assembling or disassembling torch parts, or torch and lead assemblies. -----------------------------------------------------------------------Check and follow instructions listed in the “Safety and Installation” section of this manual. TORCH PARTS Check the torch for proper assembly.
OPERATION B-4 • When ready to cut, place the torch near the work, make certain all safety precautions have been taken and pull the trigger. - The air will flow for a preflow time of 3 seconds and the pilot arc will start. - The pilot arc will run for 3.0 seconds and shut off unless the arc is brought in contact with the work and the arc is transferred. Avoid excessive pilot arc time by transferring the arc to the workpiece quickly.
B-5 PILOT ARC DISCUSSION NOTES The POWERTORCH™ PLASMA 20 has a smooth, continuous pilot arc. The pilot arc is only a means of transferring the arc to the workpiece for cutting. Repeated pilot arc starts, in rapid succession, is not recommended as these starts will generally reduce consumable life. Occasionally, the pilot arc may sputter or start intermittently. This is aggravated when the consumables are worn or the air pressure is too high.
B-6 WARNING OPERATION ELECTRIC SHOCK CAN KILL. • Disconnect input power by removing the plug from the receptacle before assembling or disassembling torch parts, or torch and lead assemblies. Frequently review the Important Safety Precautions at the front of this Manual. ---------------------------------------------------------------------------Be sure the operator is equipped with proper gloves, clothing, eye and ear protection.
D-1 WARNING MAINTENANCE ELECTRIC SHOCK can kill. • Have a qualified person service this equipment. • Turn off machine and disconnect input power by removing the plug from the receptacle before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- ROUTINE MAINTENANCE 1. Keep the cutting or gouging area and the area around the machine clean and free of combustible materials.
D-2 COMPRESSED AIR FILTER MAINTENANCE The unit is supplied with a filter for the compressed air and fitted with a manual drain for condensation. (Drain is located on the bottom of the filter). Purge periodically to remove the water in the filter by opening the drain knob. Do not use solvents to clean the filter; use soapy water only.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE GREEN LED OFF, Fan not operating. No Input Power. 1. Plug unit into 115V outlet. GREEN LED ON, YELLOW Overtemperature / under pressure LED ON. Unit is overheated. 1. Make sure the unit has not been operated beyond duty cycle limits. GREEN LED ON, YELLOW Over temperature / under pressure LED blinks. No air flow in purge or preflow.
CONTROL BOARD INVERTER BOARD WIRING DIAGRAM POWERTORCH™ PLASMA 20 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTES POWERTORCH™ PLASMA 20
WARNING AVISO DE PRECAUCION Spanish ATTENTION French WARNUNG German ATENÇÃO Portuguese Japanese ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
Gainesville, GA 30504-6000 U.S.A. TEL: 866.236.0044 FAX: 800.840.
