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ManualsBrandsTweco ManualsHardwareM-42 RPT

January 23, 2004 1 Manual 0-2856

General Information

The PCH / M-42 RPT Replacement Torches are suitable

for use with various Power Supplies and are connected

using various Adapter Kits purchased separately.

The Torches are supplied with 20 ft (6.1 m), 25 ft (7.6 m)

or 50 ft (15.2 m) Leads as follows:

Description Catalog #

PCH-42R RPT Hand Torches With Standard Handle

70° Head, 20 ft (6.1 m) Leads 7-4226

90° Head, 20 ft (6.1 m) Leads 7-4227

PCH-42ER RPT Hand Torches With Ergonomic Handle

70° Head, 20 ft (6.1 m) Leads 7-4220

90° Head, 20 ft (6.1 m) Leads 7-4222

70° Head, 50 ft (15.2 m) Leads 7-4221

90° Head, 50 ft (15.2 m) Leads 7-4223

PCM-42 RPT Machine Torches

180° Head, 25 ft (7.6 m) Leads 7-4224

180° Head, 50 ft (15.2 m) Leads 7-4225

These instructions are supplied to ensure the proper in-

stallation of the Replacement Torches. It is recommended

to thoroughly read the instructions first, before attempt-

ing the installation of the kit.

Supplied Parts

The following parts are supplied:

• PCH-42R, PCH-42ER or PCM-42 RPT Torch With

Leads - 1 each

• Installation Instructions - 1 each

Manual 0-2856

PCH / M-42 RPT

Replacement Torches

Installation Instructions

General Torch Description

The Replacement Torches provide cutting capabilities of

up to 40 amperes. In the torch, a single torch lead pro-

vides gas from a single source to be used as both the

plasma and secondary gas. The gas flow is divided in-

side the torch head. Single - gas operation provides a

smaller sized torch and inexpensive operation.

Torch Specifications & Design

Features

The following applies to the Replacement Torches only:

A. Torch Configurations

1. Hand Torches

Available with torch head at 70° or 90° to the torch

handle. The hand torches include a torch handle

and torch switch assembly.

Torches with 20 ft (6.1 m) leads use the standard

handle with top mounted switch or the ergonom-

ics handle with bottom mounted switch.

Torches with 50 ft (15.2 m) leads use only the er-

gonomics type handle and switch.

A-02540

Hand Torches

'R' Type

Handle

'ER' Type

Handle

82 Benning Street, West Lebanon, NH 03784 USA

(603) 298-5711 • www.thermal-dynamics.com

Summary of content (18 pages)

PAGE 1
Manual 0-2856 PCH / M-42 RPT Replacement Torches 82 Benning Street, West Lebanon, NH 03784 USA (603) 298-5711 • www.thermal-dynamics.com Installation Instructions General Information General Torch Description The PCH / M-42 RPT Replacement Torches are suitable for use with various Power Supplies and are connected using various Adapter Kits purchased separately. The Replacement Torches provide cutting capabilities of up to 40 amperes.
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. Machine Torches E. Parts - In - Place (PIP) Available with fiberglass mounting tube & rack and phenolic (plastic) pinch block assembly. The torch head has built - in contacts called Parts - In - Place (PIP). These two contacts are made through the inside of the shield cup when it is installed. The torch will fail to operate if these contacts are not made. Torch Switch A-02812 PIP Pin To Control Cable Wiring B. Torch Leads Lengths Shield Cup PIP Pin • Hand Torches: A-00458 20 ft (6.
PAGE 3
G. Dimensions Connecting Torch 1. Follow the instructions supplied with the appropriate Adapter Kit to connect the torch lead connections to the Adapter Kit parts for connection to the Power Supply. 2.95 in (75 mm) 2. Refer to Torch Parts Selection and check the torch for proper parts assembly (see CAUTION). 7.98 in (203 mm) 3.13 in (80 mm) CAUTION The torch parts must correspond with the type of operation. Refer to Torch Parts Selection. 7.31 in (186 mm) 3 in (76.
PAGE 4
Change the torch parts for a different operation as follows: General Torch Maintenance A. Cleaning Torch NOTE Even with only clean air, eventually the inside of the torch becomes coated with residue. This buildup can affect the pilot arc initiation and the overall cut quality of the torch. The shield cup holds the tip and gas distributor in place. Position the torch with the shield cup facing upward to prevent these parts from falling out when the cup is removed. 1.
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1. Remove the shield cup, tip, gas distributor, and electrode from the torch. Disconnect the torch leads from the power supply to isolate the torch from power supply circuits. Inspection and Replacement of Consumable Torch Parts 2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch fittings. Infinite resistance (no continuity) should be found. If continuity is found there is a problem in the Torch or Torch Leads.
PAGE 6
4. Remove the gas distributor and check for excessive wear, plugged gas holes, or discoloration. Replace if necessary. Electrode Selection The new SureLok PCH / M-42 RPT Torch offers a new General Purpose Electrode. The information supplied in this section is to describe the new electrode. 5. Remove the SureLok Electrode by pulling it straight out of the Torch Head. Refer to the following figure and check the face of the electrode for excessive wear. General Purpose SureLok Electrode (Cat. No.
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January 23, 2004 7 Manual 0-2856
PAGE 8
Replacement Hand Torch Parts With Standard Handle (Non - Ergonomic) Item # Qty Description Catalog # 1 2 PIP (Parts - In - Place) Pins 9-5723 2 2 O - Ring 8-0533 3 1 Assembly, Basic Head 70° Head 9-8442 90° Head 9-8443 (For complete Torch Head Assembly refer to Complete Assembly Replacement) 4 1 Handle, Split, Two Parts (Includes Items #9 - 11) 9-6291 5 1 Lead Assembly, 20 ft (6.
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PCH-42R RPT 4 9 10 10 6 2 4 8 3 11 7 5 1 Requires Adapter Kit For Proper Installation Art # A-03549 January 23, 2004 9 Manual 0-2856
PAGE 10
Replacement Hand Torch Parts With Ergonomic Handle Item # Qty 1 1 Description Catalog # Assembly, Basic Head 70° Head 9-8442 90° Head 9-8443 2 2 PIP (Parts - In - Place) Pins 9-5723 3 1 #6-32 x 3/16" Phillips Pan Head Screw See Note 4 1 #6 Internal Star Washer See Note 1 Ergonomic Handle, Split, with Trigger (includes items #5 - 12) 9-8076 5 1 Trigger, Lexan, Orange 9-8059 6 1 Handle 9-8060 7 1 Spring, 0.390 O.D. x 0.
PAGE 11
PCH-42ER RPT 10 6 13 & 14 4 3 9 11 & 12 7 1 6 5 8 2 15 Requires Adapter Kit For Proper Installation Art # A-03547 January 23, 2004 11 Manual 0-2856
PAGE 12
Replacement Machine Torch Parts With Pinch Block Mounting Parts Item # Qty Description Catalog # 1 1 Assembly, PIP (Parts - In - Place) Pins and Wire 9-5723 2 1 Assembly, Basic Head, Machine (Includes items #3 & 4) 9-8444 3 1 #6-32 x 1/16 Phillips Pan Head Screw See Note 1 4 1 #6 Internal Star Washer See Note 1 5 1 Lead Assembly 25 ft (7.6 m) Length 4-2987 50 ft (15.
PAGE 13
PCM-42 RPT 11 7 6 10 7 2 4 1 8 12 3 9 5 Requires Adapter Kit For Proper Installation 13 Optional CNC/Remote Control Standard (Start/Stop Control Only) Art #A-03548 January 23, 2004 13 Manual 0-2856
PAGE 14
Complete Assembly Replacement NOTE All Complete Torch and Lead Assemblies require a Torch Adapter Kit for proper installation of the Torch. Description Catalog # Hand Torches with Two Piece Standard Handle: PCH-42R RPT 70° Hand Torch, 20 ft (6.1 m) Leads 7-4226 PCH-42R RPT 90° Hand Torch, 20 ft (6.1 m) Leads 7-4227 Hand Torches with Two Piece Ergonomic Handle: PCH-42ER RPT 70° Hand Torch, 20 ft (6.1 m) Leads 7-4220 PCH-42ER RPT 90° Hand Torch, 20 ft (6.
PAGE 15
Torch Consumables WARNINGS Use only the parts shown. Do Not attempt to use older parts that are not shown. The use of any consumable parts other than those specified by the Manufacturer may cause irreparable damage to the torch head.
PAGE 16
WARNING - Replacing Original Machine Torch with RPT Mechanized Torch Thermal Dynamics RPT mechanized torches have two control wires that are used for Parts - In - Place (PIP) only. Do not connect these PIP connections directly into any start input because when the torch parts are in place, the start signal will always be energized.
PAGE 17
Wiring Diagram Optional Torch Control Cable For CNC / Remote Pendant Systems Mate & Lock Connectors A-02821 Torch Head PIP Pin Torch Leads 2 Shield Return Shield Cup PIP Pin Mate & Lock Connectors 1 Power Supply Control 3 3 4 4 12 12 14 14 13 13 Control OK-To-Move Relay OK-To-Move Pendant Ground Remote Pendant/CNC Cable Connector Torch Control Cable Connector NOTE Every effort has been made to provide complete and accurate information in this manual.
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Statement of Warranty LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.