LIQUID COOLED PLASMA TORCH Model Maximizer 300 For Use With: • Merlin 1000 Cutting Systems Instruction Manual May 17, 2004 Manual No.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Liquid Cooled Plasma Torch Model Maximizer 300 Instruction Manual No. 0-2710 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ................................................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ...................................................................... Important Safety Precautions ....................................................................... Publications ..................................................................................................
TABLE OF CONTENTS (continued) SECTION 5: SERVICE .......................................................................................................................... 5-1 5.01 5.02 5.03 5.04 5.05 5.06 5.07 Introduction ................................................................................................... General Torch Maintenance ........................................................................... Common Operating Faults .............................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the workplace is moist or damp. • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 ATTENTION Toute procédure pouvant résulter l’endommagement du matériel en cas de nonrespect de la procédure en question. 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 AVERTISSEMENT 8.
• Eloignez toute fumée et gaz de votre zone de respiration. 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.
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.
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection 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.
1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
1.08 Statement of Warranty LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.
SECTION 2: INTRODUCTION 2.01 Scope of Manual This manual contains descriptions, operating instructions and maintenance procedures for the Liquid Cooled Maximizer 300 Torch Assemblies. 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. 2.
2. Torch Leads Length c. Cold Flow Cutting: 60 - 90 scfh (28.3 - 42.5 lpm) • 10 ft (3.05 m) • 15 ft (4.57 m) scfh = standard cubic feet per hour • 20 ft (6.1 m) NOTE • 25 ft (7.6 m) Cold flow is measured before the main arc is activated. When pressure is set correctly the plasma gas flow rate is significantly lower when the arc is initiated. • 50 ft (15.2 m) 3. Torch Ratings 9. Secondary Gas Requirements Torch Ratings Ambient Temperature 104° F (40° C) Duty Cycle 100% @ 100 Amps @ 0.5 gpm (1.
2.04 Options And Accessories These items can be used to customize a standard system for a particular application or to further enhance performance (refer to Section 6 for ordering information). • Remote Arc Starter Optional Remote Arc Starter Assembly use to place the torch arc starting circuits closer to the torch head. Requires the Optional Torch Supply Leads. _ • Torch Supply Leads (Optional) NOTE Lead lengths are from the Optional Remote Arc Starter to the Torch Head Assembly .
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. High Frequency Because direct current (DC) alone is not sufficient to strike the pilot arc, high frequency is also used. The high frequency jumps between the tip and electrode with the DC following, then the high frequency turns off. E. Main Cutting Arc DC power is also used for the main cutting arc.
SECTION 3: INSTALLATION 3.04 Setting Up Torch WARNING 3.01 Introduction Disconnect primary power at the source before disassembling the torch or torch leads. This Section describes installation of the Liquid Cooled Maximizer 300 Torch. These instructions apply to the Torch and Leads Assemblies only; installation procedures for the Power Supply, Options, and Accessories are given in Manuals specifically provided for those units. 1. Mount the torch assembly on the cutting table. 2.
3. Remove the hardware attached to the power supply end of the leads assembly with a tie wrap. 3.05 Connecting Torch Depending on the system ordered connect the torch per one of the following procedures. 4. Feed the connector on the end of the CNC Control Cable through the rubber boot on the front panel of the Power Supply (see NOTE). A.
4. Connect the torch leads connectors to the bulkhead connections per the following figure. Torch Leads Shield Stud Coolant (for OUTER Shields) Supply (-) Plasma (+) Secondary Gas Power Gas Supply Torch Leads Chassis Shield Stud (for INNER Shields) Coolant Return CAUTION If the Arc Starter Box does not include a drilled hole in the front panel as shown below for the outer (GREEN / YELLOW) torch lead shields, perform the following steps: • Drill a hole in the area shown.
5. Connect the inner shield leads with red wires and ring terminals to the mounting stud on the bulkhead panel. 6. Remove the nut and bolt mounted to the Remote Arc Starter front panel. Connect the outer shield leads with green/yellow wires and ring terminals to the mounting stud on the inside of the front panel. Secure the stud to the front panel with a hex nut. Connect a customer-supplied external ground wire to the stud, outside the front panel, and secure with a hex nut. A.
B. Secondary Gases NOTE 3.07 Gas Connection A. Connection Refer to Section 2.03, Specifications & Design Features, for proper gas pressure and flow rate. Connect the gases to the Plasma Power Supply as described in the Power Supply Operating Manual (0-2708) supplied with the Power Supply. 1. Compressed Air Secondary • Air secondary is normally used when operating with air plasma and occasionally with nitrogen plasma. CAUTION • Improves cut quality on some ferrous materials.
INSTALLATION 3-6 Manual 0-2710
SECTION 4: OPERATION D. Gas Supplies Select desired gas supplies. Make sure gas sources meet requirements (refer to Section 2.03, Specifications & Design Features). Check connections and turn gas supplies on. 4.01 Introduction E. Purge System This Section provides a description of the Liquid Cooled Model Maximizer 300 Torch Assembly followed by operating procedures. On the Power Supply place the ON/OFF switch to the ON position.
4.04 Torch Parts Selection Torch Head Depending on the type of operation to be done determines the torch parts to be used. Electrode Torch parts: Shield Cup Body, End Cap, Tip, Electrode, Gas Distributor Tip Gas Distributor Type of operation: Shield Cup Body Standoff cutting or gouging Refer to Section 6.05, Torch Consumables, for the various torch parts. Figure 4-2 Liquid Cooled Torch Parts CAUTION Do not interchange parts.
quality is desired to avoid a secondary cleaning operation. Cut quality characteristics are illustrated in the following figure: Kerf Width Cut Surface Bevel Angle G. Top Spatter (Dross) Top Spatter or dross on the top of the cut caused by slow travel speed, excess cutting height, or cutting tip whose orifice has become elongated. H.
Typical Cut Quality on Various Materials Type of Material Type of Gases Material Thickness Carbon Steel Stainless Aluminum Air Plasma and Air Secondary Gauge to 1 inch (Gauge to 25.4 mm) Good Good Good Gauge to 1/4 inch (Gauge to 6.4 mm) NR Good Good 1/4 to 1/2 inch (6.4 to 12.7 mm) NR Excellent Good - Excellent 1/4 to 1/2 inch (6.4 to 12.7 mm) NR NR Excellent 1/2 to 1 inch (12.7 to 25.4 mm) NR Excellent Excellent Gauge to 3/8 inch (Gauge to 9.5 mm) Good NR NR 3/8 to 1 inch (9.
A. Piloting E. Dross Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece. Whenever possible, avoid excessive pilot arc time to improve parts life. When dross is present on carbon steel, it is commonly referred to as either “high speed, slow speed, or top dross”. Dross present on top of the plate is normally caused by too great a torch to plate distance.
3. The torch can be activated by the remote operator control panel, remote control pendant, or by remote interface device such as CNC. After a two second gas purge, the pilot arc will start. The pilot arc will stay on as long as the torch is activated or until main arc starts. 4. With the pilot arc on, the main cutting arc will be established when the torch is brought within 1/ 16 - 1/4 in (1.6 - 6.4 mm) of the workpiece.
C. Piercing With Torch • Torch standoff height • Proper work cable connection To pierce with the torch, the arc should be started with the torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid having molten metal blow back onto the front end of the torch. When operating with a cutting machine, a pierce or dwell time is required. Torch travel should not be enabled until the arc penetrates the bottom of the plate.
A. Recommended Gases F. Standoff Distance Refer to the following table for characteristics of recommended gases when gouging with Maximizer 300 Torch: The tip to work distance affects gouge quality and depth. A standoff of 1/4 - 3/8 in (6.3 - 9.5 mm) allows smooth, consistent metal removal. A smaller standoff may result in a severance cut rather than a gouge. A standoff greater than 3/8 in (9.5 mm) may result in minimal metal removal or loss of transferred main arc. B.
The inside of the torch should be cleaned with electrical contact cleaner using a cotton swab or soft wet rag. In severe cases, the torch can be removed from the leads (refer to Section 5.06, Servicing Machine Torch Components) and cleaned more thoroughly by pouring electrical contact cleaner into the torch and blowing it through with compressed air. SECTION 5: SERVICE 5.01 Introduction This Section describes basic maintenance procedures performable by operating personnel.
h. Damaged or loose torch head components NOTE DO NOT use other lubricants or grease, they may not be designed to operate within high temperatures or may contain “unknown elements” that may react with the atmosphere. This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life. i. Non-Genuine Thermal Dynamics Parts j. Restricted coolant flow (over heating) 5. Poor Pilot Starting a. Non-Genuine Thermal Dynamics Parts b.
2. Inspect the end cap for damage. Wipe it clean or replace if damaged. 5. Using the multi-purpose wrench (electrode area) remove the electrode. Refer to Figure 5-4 and check the face of the electrode for excessive wear. New Electrode Multi-Purpose Wrench (Catalog Number 20-0001) Gas Distributor Notch Used with 11/16" (17.5 mm)Tip Used for 11/16" ( 17.5 mm) Across Tip Flats Worn Electrode This Side Towards Torch A-00256 Used for Electrodes Used for 5/8" (15.
B. No cutting output 5.05 Troubleshooting Guide 1. Torch not properly connected to power supply A. Troubleshooting a. Check that torch leads are properly attached to power supply This Sub-Section covers troubleshooting that requires disassembly and electronic measurements. It is helpful for solving many of the common problems that can arise with this torch assembly. 2. Faulty components in torch and leads assembly a. Inspect torch assemblies and replace if necessary. Refer to Section 5.
E. Erratic or improper cutting output 5.06 Servicing Torch Components 1. Poor input or output connections to power supply a. Check all input and output connections. WARNINGS 2. Current set too low at power supply Disconnect primary power to the system before disassembling the torch or torch leads. a. Increase current setting. 3. Torch is being moved too fast across workpiece DO NOT touch any internal torch parts while the AC indicator light on the front panel of the Power Supply is ON. a.
7. Slide the torch adapter down over the leads and screw the adaptor securely onto the back of the torch head assembly. Coolant Supply (-) Lead (LH Threads) 8. Slide the positioning tube down over the leads and thread it into the torch adaptor on the torch head assembly. Coolant Return Lead 9. Apply tape to the torch leads sleeving at the back end of the positioning tube. Secondary Lead 10. Position the shrink-on tubing over the taped area and shrink into place. Plasma (+) Lead 11.
WARNINGS Disconnect primary power to the system before disassembling the torch or torch leads. C. Checking Proper Isolation Resistance Procedure The Torch Head and Torch Leads should be tested further for insulation breakdown if no other fault has been found. This procedure requires the use of a Hi-Pot Tester. DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON. WARNING 1. Remove the consumables from the torch.
3. Visually check that the torch switch wires, pilot lead connection, and negative lead connections are properly connected and in good condition (no shorts or arcing). • If problems are evident, repair or replace as required. • If there are no visual problems, then proceed to Step 4. 4. Check the pilot lead, negative lead and switch control wires for opens from one end of the torch leads to the other. • If open, replace leads or open component of the Torch Leads Assembly.
SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable components. Torch Assemblies are field serviceable, so a complete breakdown of parts is provided. The parts lists are arranged as follows: Section 6.03: Replacement 70° and 90° Torch Parts Section 6.04: Replacement 180° Torch Parts Section 6.05: Replacement Rack & Pinion Parts Section 6.06: Torch Consumables Section 6.07: Torch Options And Accessories Section 6.
6.03 Replacement 70° and 90° Torch Parts Item # Qty 1 1 2 3 4 5 1 1 1 1 1 Description Catalog # Assembly, Torch Head, Maximizer 300 70° Torch Head 90° Torch Head Lead Assembly 10 ft (3.05m) Length 15 ft (4.57m) Length 20 ft (6.01m) Length 25 ft (7.6m) Length 50 ft (15.
3 4 1 ;; 5 2 Manual 0-2710 6-3 A-03117 PARTS LISTS
6.04 Replacement 180° Torch Parts Item # Qty 1 2 1 1 Description Catalog # 3 4 5 6 7 1 1 2 1 1 Assembly, 180° Torch Head, Maximizer 300 (See Note 2) Lead Assembly (See Note 2) 10 ft (3.05m) Length 15 ft (4.57m) Length 20 ft (6.01m) Length 25 ft (7.6m) Length 50 ft (15.
8 5 4 9 3 5 1 6 10 11 7 2 Art # A-04698 Manual 0-2710 6-5 PARTS LISTS
6.05 Rack & Pinion Mounting Tube Replacement Parts Item # Qty Description Catalog # 1 1 Adapter, 1-3/8 O.D.
10 9 6 13 11 11 3 2 1 7 5 12 Art # A-04001 8 4 Manual 0-2710 6-7 PARTS LISTS
6.06 Torch Consumables Maximizer 300 With Merlin 1000 Cutting Consumables Consumables Cutting End Caps Using Air (50 - 100 amps) Shield Cup Body Tips Electrode Gas Distributor 0.043" Orifice, 50 amps Catalog No. 20-1030 Standard Cutting Catalog No. 20-1002 Standard Cutting 50 amps Catalog No. 20-1003 50 - 225 amps 50 - 225 amps Catalog No. 20-1018 Catalog No. 20-0008 O-Ring Cat. No. 8-3484 0.055" Orifice, 100 amps Catalog No. 20-1031 Art # A-03114 Ohmic Clip Shield Cup Body Catalog No.
Maximizer 300 With Merlin 1000 Using N2 or ArH2 (50 - 100 amps) Cutting Consumables Consumables Cutting Electrodes 50 - 300 amps - N2 Catalog No. 20-1023 Tips Gas Distributor 0.043" Orifice, 50 amps Catalog No. 20-1030 End Caps Shield Cup Body Standard Cutting Catalog No. 20-1002 Standard Cutting 50 amps Catalog No. 20-1003 50 - 225 amps Catalog No. 20-0008 100 - 300 amps - ArH2 Catalog No. 20-1025 O-Ring Cat. No. 8-3484 0.055" Orifice, 100 amps Catalog No.
6.07 Torch Options And Accessories Qty 1 Description Catalog # Optional Remote Arc Starter Kit 3-6825 Includes internal Power Supply conversion and Remote Arc Starter assembly 1 Arc Starter Supply Leads (Used with Remote Arc Starter only) Requires one each of the following: 1 1 1 1 1 PARTS LISTS Remote Arc Starter Control Cable 35 ft (10.7 m) 9-9016 50 ft (15.2 m) 9-9017 75 ft (22.8 m) 9-9018 100 ft (30.5 m) 9-9019 Coolant Supply/Negative Hose 35 ft (10.7 m) 9-9000 50 ft (15.
6.08 Complete Assembly Replacements Description Qty. Catalog # 180° Torches with Leads and Rack & Pinion Mounting Assembly: 10 ft (3.05 m) Leads 15 ft (4.57 m) Leads 20 ft (6.01 m) Leads 25 ft (7.6 m) Leads 50 ft (15.2 m) Leads 1 1 1 1 1 2-9900 2-9901 2-9902 2-9903 2-9904 180° Torches with Leads and Non-Conductive Mounting Assembly: 10 ft (3.05 m) Leads 15 ft (4.57 m) Leads 20 ft (6.01 m) Leads 25 ft (7.6 m) Leads 50 ft (15.
6.09 Spare Parts Kit Qty 1 Description Catalog # Cutting, Spare Parts Kit - Includes: 5-9900 2 Tip, Cutting, 0.055" Orifice, 100 amps 20-1031 2 Tip, Cutting, Oxygen/Air, 0.043" Orifice, 50 amps 20-1030 2 Tip, Cutting, Oxygen/Air, 0.
APPENDIX 1: SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION Close external disconnect switch ACTION Enable ON ON/OFF switch to ON ACTION RUN/SET switch to SET ACTION RUN/SET switch to RUN RESULT • Power to system RESULT • AC indicator ON • TEMP Indicator ON • GAS indicator ON • Fan and pump ON • 20 second auto-purge RESULT • Gas solenoids open, gases flow to set pressures • GAS indicator ON RESULT • Gas flow stops • Power circuit ready • GAS indicator OFF ACTION Protect eyes and activate torch ACTION T
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Electrode (See Chart) Gas Distributor 20-0008 Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) Art # A-02204 NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Gas Distributor 20-0008 Electrode (See Chart) Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) Art # A-02204 NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Gas Distributor 20-0008 Electrode (See Chart) Art # A-02204 Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Gas Distributor 20-0008 Electrode (See Chart) Art # A-02204 Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Gas Distributor 20-0008 Electrode (See Chart) Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) Art # A-02204 NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Gas Distributor 20-0008 Electrode (See Chart) Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) Art # A-02204 NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Electrode (See Chart) Gas Distributor 20-0008 Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) Art # A-02204 NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
APPENDIX 2: CUTTING SPEED CHARTS FOR MERLIN 1000 SYSTEMS (continued) Torch Body 180˚ 9-6410 70˚ 9-6457 90˚ 9-6459 Gas Distributor 20-0008 Electrode (See Chart) Tip (See Chart) Shield Cup Body 20-1002 End Cap (See Chart) Art # A-02204 NOTE: If using a torch height control which offers an ohmic sensing feature, select catalog # 20-1427 shield cup body with an ohmic clip tab.
