AIRCUT™ Operating Manual 15C
Contents
1. Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the information 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 combustible or explosive gases or materials are located e Phosgene a toxic gas is generated from the vapors of chlo rinated 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 defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq A 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 operator or others in the workplace Never touch any parts that are electrically live or hot e 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 mois2. PILOT RESISTOR Hirt TORCH SWITCH PIP PINS OUTPUT PCB Art A 08745 Rev _ MAL D mel IHERMAL DYNAMICS rime aK WEST LEBANON NH 03784 A A THERMADYNE Company 603 298 5711 pec pres Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent Monday January 21 2008 NOTE UNLESS OTHERWISE SPECIFIED Drawn Chk 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF SCHEMATIC Size DWG No Last Modified Wednesday September 24 2008 AIRCUT 15 SYSTEM SCHEMATIC 42X1295 Manual 0 4965 A 5 APPENDIX AIRCUT 15C APPENDIX A 6 Manual 0 4965 IHERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri
3. COMPACT and LIGHT Designed for easy transportation ENERGY EFFICIENCY Advanced tech nology reduces power consumption HIGH SPEED RECOMMENDED CUT TING The constricted plasma arc provides high speed cutting as well as a good quality genuine narrow cut LOW COST WITH COMPRESSED AIR The AirCut operates on its own com pressed air ALL KINDS OF METALS Useful for most metals such as stainless steel alumi num mild steel copper and their alloys PILOT ARC IGNITION FROM TORCH The Pilot Arc ignites the cutting arc POWERFUL CUTTING PERFORMANCE Recommended cutting capacity is 1 8 3 2 mm ABLE TO CUT PAINTED MATERIALS Pilot Arc ignition allows the AirCut to cut painted materials EXTENDED PARTS LIFE Consumable parts life is longer Manual 0 4965 AIRCUT 156 2 07 Torch Specifications 2 08 System Contents Te is A Description ITEMS 29i Power source Model AirCut 5 9 in Power source Model AirCut 75 mm i PCH 10 with 20 8 in 203 mm Work Cable Accessories amp Manual Consumables Torch Electrodes Torch Tips Input Power PCH 10 Torch Ratings Cable U S Torch Head at 70 to Torch Configuration Torch Handle Torch Leads Length 20 feet 6 1 m Duty 100 10 Amps 2 09 Transporting Methods 15 Amps DC Lift unit with handle on top of case Use hand Maximum Current Nr Straight Polarity cart or similar device of adequate capa
4. 3 5A Rawang Integrated Industrial Park Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com 16052 Swingley Ridge Road JHERMAL DYNAMICS
5. Important Safety Precautions A WARNINGS es OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS 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 Persons who work near plasma arc cutting applications should consult their medical health professional 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 instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions ET A 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 e Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Manual 0 4961 AIRCUT 15 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 metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium
6. Technician Post Flow of Air Approximately 12 Seconds Then Stops Note The Torch will be very hot Do not set on or near flammable materials Power Supply On Off Switch Off Green Power Indicator Off and Fan Stops Primary Input Power Switch or Unplugged Art A 07874 Manual 0 4965 APPENDIX AIRCUT 15C A ndix 2 Torch nnection Disconnect power Remove ten screws from cover and remove the cover Art A 08294 AB Air and Negative Plasma Lead 7 1 Pilot Wire Pink To Power Black Supply Adapter 21 iO PIP Switch Torch CI White Switch To Compressor AN AirLineand Negative Plasma Lead gt 8 Pink Torch Leads Torch Head APPENDIX A 2 Manual 0 4965 AIRCUT 15 This Page Intentionally Blank Manual 0 4965 A 3 APPENDIX AIRCUT 15C L1 115VAC BLACK PRIMARY ACINPUT 2 AC2 WHITE GND N10 POWER PCB 12VAC 18VAC 18VAC CURRENT SENSE 12VDC RY1 p O OVERTEMP ey LD1 START oy DA CSS PILOT SENSE oy LD3 COMPRESSOR ON AIR COMPRESSOR START COMPRESSOR CONTROL PCB FRONT PANEL INDICATORS Art A 08745 APPENDIX A 4 Manual 0 4965 AIRCUT 15 HV Circuit N
7. 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 The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Directive European Council Directive 89 336 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 UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides 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 manu
8. contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also include the model and serial number of the torch Address all inquiries to your authorized distributor 6 03 Power Supply Replacement Parts Description log 1 SYSTEM AIRCUT 15C DEMO 1 1110 1D 1 COMPRESSOR AIRCUT 15C 9 0385 1 COVER ASSEMBLY AIRCUT 15C 9 0386 1 CIRCUIT BREAKER AIRCUT 15C 9 0387 1 CONTROL TRANSFORMER AIRCUT 15C 9 0388 1 CABLE GROUND PG16 9 0389 1 CASE BOTTOM AIRCUT 15C 9 0390 Manual 0 4965 6 1 PARTS LISTS AIRCUT 15 PARTS LISTS 6 2 Manual 0 4965 AIRCUT 15C Block Diagram Primary Input Power On or Plugged in Power Supply On Off Switch Green Power Indicator On and Fan is Running TT Cutting Done Torch Switch On Compressor and Pilot Arc Ignition starts 4 No Pilot Arc Start Cutting Operation 4 i YES gt Release Torch Switch Check Torch parts alignment PIP switches need to be repaired by a Qualified Technician More air flow is required for Torch to Pilot than to run the power supply Compressor not functioning properly needs to be repaired by a Qualified
9. revisions for more information 1 10 11 12 13 14 15 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 749 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUT TING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAIN ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from
10. terminals are connected to front panel Make sure the Work Cable is secured prop erly to front panel Before activating turn torch away from yourself and others A DANGER Do not cut in humid or wet surroundings Before you maintain or replace torch parts wait for the post flow air cycle to stop then turn the machine off and disconnect from input power Always use original manufacturers parts The use of aftermarket parts could result in lower parts life and in unsatisfactory cut ting results Any warranty claims would be waived Recycle worn parts according to local re quirements NOTE Repairs must be done by skilled and qualified personnel only Manual 0 4965 AIRCUT 15C This Page Intentionally Installation 3 2 Manual 0 4965 SECTION 4 OPERATION 4 01 Front Control Panel AC Power Indicator On Off Switch n TOMAS AirCu 15 Overheating Air Vents Work Lead Torch Lead Connection Connection Art A 08293_AB INDICATOR LAMP Power Indicator Lights when pri mary power switch 1s turned on TEMPERATURE Indicator Indicator is normally OFF Indicator is ON when internal temperature exceeds normal lim its Shut unit OFF let the unit cool before continuing operation PRIMARY POWER SWITCH ON OFF The power switch is located on the front panel Placing the primary power switch to the ON position energizes the power source UTION When th
11. Air pressure too high or too low 1 There is no adjustment return to an authorized service center when torch switch is or repair activated 2 Torch consumables missing 2 Turn off power supply Remove shield cup Install missing parts 3 Worn or faulty torch parts 3 Inspect torch consumable parts Replace if necessary 4 Thermal Switch activated 4 Allow the cooling fan to run for 2 minutes or longer until it ill resume operation Cut performance is 1 Worn torch parts 1 Check current setting Check the Electrode and Tip for diminished excess Wear 2 Poor Work Lead connection 2 Check the connection of the Work Lead to the work piece 3 Current sensor or PWM PCB faulty Return to an authorized service center for repair or replacement See following illustrations for parts wear and work lead connection SERVICE 5 2 Manual 0 4965 Examples of parts wear New Electrode CCS 12 Worn Electrode ZZ A 01270 Good Tip Worn Tip N Art 07727 Example of Work Lead connection Make a solid work cable connection to the work piece or cutting table A 02022 Manual 0 4965 5 3 AIRCUT 15 SERVICE AIRCUT 15 This Page Intentionally Blank SERVICE 5 4 Manual 0 4965 AIRCUT 156 SECTION 6 PARTS LISTS 6 01 Introduction A Parts List Breakdown The parts list provides a breakdown of all replaceable components B Returns If a product must be returned for service
12. E COUPE ET DE SOUDAGE A LARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales Ameri can National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PRO TECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI 749 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROCEDES DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES A GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCIES disponible aupr s de la National Fire Protection As sociation Batterymarch Park Quincy MA 02269 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SO
13. E ne mer eee 4 1 4 01 Front Control Panel uere ee ee aaa 4 1 4 02 Preparations For 4 1 SECTION 5 SERVIGE n iterat tunt Ta lated 5 1 5 01 General Maintenance ii 5 1 5 02 Basic Troubleshooting 5 2 SECTION GPARTS tiir potu noie re eere an an rn 6 1 6 01 ee PE 6 1 6 02 Ordering Informations ie 6 1 6 03 Power Supply Replacement Parts sss 6 1 Appendix 1 Operating Sequence Block Diagram A 1 Appendix 2 Torch Connection ttt be tate A 2 Appendix 3 System Schematic 120V iii 4 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover TABLE OF CONTENTS This Page Intentionally Blank SECTION 1 GENERAL INFORMATION 1 01 Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as follows Notes Cautions and Warnings NOTE An operation procedure or background information which requires additional emphasis or is helpful in ef ficient operation of the system procedure which if not properly followed may cause damage to the equipment WARNING ae ee ee eee aa A procedure which if not properly followed may cause injury to the operator or others in the operating area 1 02
14. IHERMAL DYNAMICS 106 AIRCUT PLASMA CUTTING SYSTEM WITH BUILT IN AIR COMPRESSOR Operating Manual Rev AD Date March 24 2011 Manual 0 4965 Operating Features IHERMAL DYNAMICS WE APPRECIATE YOUR BUSINESS Congratulations on your new Thermal Dynamics product We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry This product is backed by our extensive warranty and world wide service network To locate your nearest distributor or service agency call 1 800 426 1888 or visit us on the web at www thermadyne com This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product Your satisfaction with this product and its safe operation is our ultimate concern Therefore please take the time to read the entire manual especially the Safety Precautions They will help you to avoid po tential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators World wide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves from our competition through market leading dependable products that have stood the test of time We pride ourselves on technical innovation competitive prices excellent delivery Superior customer service and technic
15. ION 1 GENERAL INFORMATION nnne enne 1 1 1 01 Notes Cautions and 1 1 1 02 Important Safety 1 1 1 03 PUDIICATIONS EE 1 2 1 04 Note Attention et Avertissement ss 1 3 1 05 Precautions De Securite Importantes 1 3 1 06 Documents De Reference 1 5 1 07 Declaration of 1 6 1 08 Statement of Warranty tte ets rati Fu eed 1 7 SECTION 2 INTRODUCTION 2 1 2 01 How To Use This Manual 2 1 2 02 Equipment Identification reto tanken a 2 1 2 03 Receipt Of Equipment ceti era 2 1 2 04 Introduction 2 1 2 05 General Specification cette tte ee 2 2 2 06 M LE 2 2 2 07 Torch Specifications satis ee eit nee een 2 3 2 08 Eee 2 3 2 09 Transporting Methods 2 nennen anna near 2 3 SECTION S INSTAEILAT QN 2 tritt ee nee 3 1 3 01 Site Selector uet Er ani i pte e led 3 1 3 02 Electrical Input 3 1 3 03 3 1 SECTION 4 OPERATION 4 44 vg Ses pen ess neta na rn sor pa
16. UD AGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 Manual 0 4961 14 15 AIRCUT 15C Norme AWSF4 1 de l Association Am ricaine de Soudage RECOM MANDATIONS DE PRATIQUES SURES POUR LA PREPARATION A LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION AIRCUT 156 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
17. al support together with excellence in sales and marketing expertise Above all we are committed to developing technologically ad vanced products to achieve a safer working environment within the welding industry A WARNING Read and understand this entire Manual and your employer s safety practices before install ing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judge ment the Manufacturer assumes no liability for its use Plasma Cutting Power Supply 15C AirCut PCH 10 Torch Operating Manual No 0 4965 Published by Thermadyne Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermadyne com Copyright 2008 2009 2010 2011 by Thermadyne Corporation All rights reserved Reproduction of this work in whole or in part without written permission 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 Original Publication Date January 2 2008 Revision Date March 24 2011 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial Intentionally blank TABLE OF CONTENTS SECT
18. city for Type of Cooling Ambient air and gas transporting over long distances stream through torch Parts in Place Built in Switch A gt in Torch Head WARNINGS Gas Single Gas Internal ELECTRIC SHOCK can kill DO NOT 3 Compressed Air Only TOUCH live electrical parts Disconnect input Plasma Power ma power from supply before moving the power Supply Used With eu FALLING EQUIPMENT can cause serious personal injury and equipment damage a ees 16 3 with molded plug 1 Introduction 2 3 Manual 0 4965 AIRCUT 15C This Page Intentionally Blank Introduction 2 4 Manual 0 4965 SECTION 3 INSTALLATION 3 01 Site Selection Place in a clean and dry area Provide adequate ventilation and fresh air supply Ideal ambient temperature should not ex ceed 40 C 104 F Temperatures exceed ing that may diminish cutting capacity or quality The cutting machine must be placed on an even firm surface 3 02 Electrical Input Connections Input voltage is 120V 10 50 60 Hz single phase UTION Check your power source for correct voltage before plugging in or connecting the unit The primary power source fuse breaker and any extension cords used must conform to local electrical code and the recommended circuit protection and wiring requirements as specified in Section 2 Installation AIRCUT 15C 3 03 Torch 3 1 Make sure that the torch cable and torch switch
19. e A TTENTION Toute proc dure pouvant r sulter endommagement du mat riel en cas de non respect de la proc dure en question VERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes A VERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MATERIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre pro fessionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertisse ments toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions E FUM E et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr s
20. e permanente de Pour prot ger votre ouie contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail II faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 PLOMB AVERTISSEMENT Ce produit contient des produits chimiques comme le plomb ou engendre des produits chimiques reconnus par l tat de Californie comme pouvant tre l origine de cancer de mal formations f tales ou d autres probl mes de reproduction II faut se laver les mains apr s toute manipulation Code de Californie de la s curit et sant paragraphe 25249 5 et suivants Manual 0 4961 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites a celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANTE 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 749 1 LA S CURIT DES OPERATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS D
21. e power source is overloaded the switch turns to the OFF or neutral position automati cally Return completely to the OFF positioin before attempting to turn ON again Operation 4 1 AIRCUT 156 4 02 Preparations For Operating At the start of each operating session A WARNING Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads as semblies Torch Parts Selection Check the torch for proper assembly and appropri ate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Supply 15 amps maximum Use only genuine manufacturer s parts with this torch Torch Head Assembly Electrode 9 6006 A 07723 Gas Distributor 9 6007 Tip 9 6099 8 Shield Cup 9 6003 Manual 0 4965 AIRCUT 15C Connect Work Cable Make a solid work cable connection to the work piece or cutting table A 02022 Torch Operation 1 Wear gloves and protective goggles Do not place bare hand on work piece For drag cutting keep the torch in con tact with the work piece For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the work piece as shown below Tarh Shield Cup Distance 1 8 xa NEN NEN 3 dit With the torch in starting position press and hold the Torch Trigger The pilot arc will come on and remain
22. enter des risques et des dangers de sant e Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz Manual 0 4961 attention et avertissement sont utilis s pour mettre en relief des informations caract re important AIRCUT 15 Les sortes de gaz et de fum e provenant de l arc de plasma d pen dent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseigne ments quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la
23. er on safety instructions and warnings Throughout this manual the words WARNING CAUTION and NOTE may appear Pay particu lar attention to the information provided under these headings These special annotations are easily recognized as follows A WARNING gives information regarding possible personal injury UTION A CAUTION refers to possible eguipment damage NOTE A NOTE offers helpful information concerning certain operating procedures Additional copies of this manual may be pur chased by contacting Thermal Dynamics at the address and phone number in your area listed in the inside back cover of this manual Include the Owner s Manual number and equipment identifi cation numbers Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermadyne web site listed below clicking on the Thermal Dynamics brand logo and then on the Literature link http www thermadyne com Introduction AIRCUT 15 2 02 Equipment Identification The unit s identification number specifica tion or part number model and serial number usually appear on a data tag attached to the rear panel Equipment which does not have a data tag such as torch and cable assemblies are identi fied only by the specification or part number printed on loosely attached card or the shipping container Record these numbers on the bottom of page i for future reference 2 03 Receip
24. factured 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 Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX GENERAL INFORMATION 1 6 Manual 0 4961 AIRGUT 156 1 08 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermal Dynamics Corporation warrants to the original retail purchaser that new Thermal Dynamics CUTMASTER plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermal Dynamics Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermal Dynamics specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Thermal Dynamics will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below The
25. fum e et les gaz Nutilisez pas le chalumeau au jet de plasma dans une zone se trouvent des mati res ou des gaz combustibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ce produit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq A CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de travail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 8 article 9 D branchez l alimentation lectrique avant tout travail d entretien ou de r paration Lisez et respectez to
26. n on how to test for noise see item 1 in Subsec tion 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 helmet or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to protect 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 749 1 Minimum Protective Suggested 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 workpiece Pb LEAD WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other reproductive harm Wash hands after handling California Health amp Safety Code 25249 5 et seq GENERAL INFORMATION 1 03 Publications Refer to the following standards or their latest
27. not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Basic Troubleshooting Overview This guide covers basic troubleshooting It is helpful for solving many of the common problems that can arise with this system If major complex subassemblies are faulty the unit must be returned to an authorized service center for repair Follow all instructions as listed and complete each section in the order presented Common Symptoms Problem Symptom Possible Cause Recommended Action Power Switch is on 1 Improper electrical connection 1 Check input power source and circuit breaker but the A C Indicator or fuse Check input cable and connections does not light 2 System was overloaded 2 Turn Primary Power Switch Off and then On again 3 Switch may be faulty 3 Return to authorized service center for repair or replacement Primary power switchii No power or incorrect power to fan 1 Check electrical connections to fan is on but the cooling 2 Faulty fan 2 Return to authorized service center for repair or replacement fan does not work No air flow at torch 1 Internal connection is loose or 1 Check all air line connections and fittings when torch switch is disconnected activated 2 Internal air supply compressor not 2 Return to an authorized service center for repair 3 Return to an authorized service center for repair Torch will not pilot 1
28. nt vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommenda tion qui suivent ANSI ASC 749 1 Nuance Minimum Nuance Sugger e urant Arc Protective Num r Num r Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail GENERAL INFORMATION 1 4 BRUIT Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une pert
29. o reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Thermal Dynamics Corporation 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 customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Dynamics 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 the goods covered by or furnished by Thermal Dynamics 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 liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermal Dynamics product This warranty is invalid if the Thermal Dynamics product is sold by non authorized persons Effective September 4 2007 Manual 0 4961 1 7 GENERAL INFORMATION AIRCUT 156 GENERAL INFORMATION 1 8 Manual 0 4961 SECTION 2 INTRODUCTION 2 01 How To Use This Manual This Owner s Manual applies to just specifica tion or part numbers listed on page i To ensure safe operation read the entire manual including the chapt
30. on until the cut ting arc starts Once on the cutting arc remains on as long as the Torch Trigger is held down Operation 4 2 5 To shut off the torch simply release the Torch Trigger When the trigger is re leased a gas post flow will occur If the Torch Trigger is pushed during the post flow the pilot arc will restart immediately and the cutting arc will restart when the torch is brought within range of the work piece Typical Cutting Speeds Cutting speeds vary according to torch output the type of material being cut and operator skill Speeds shown are typical for this cutting system using air plasma to cut materials shown Material Inches Thickness Minute i Mild Steel 3 16 0 4965 AIRCUT 156 SECTION 5 SERVICE 5 01 General Maintenance Maintain more often Warning if used under severe Disconnect input power before maintaining conditions Each Use Visual check of torch tip and electrode Weekly 42 TSI mmm 7 AS Visually inspect the torch body Replace as needed tip electrode and shield cup 3 Months Replace all Clean broken parts avterion of power supply 6 Months Visually check and Carefully clean the interior Art A 07891 AB Manual 0 4965 5 1 SERVICE AIRCUT 15 5 02 Basic Troubleshooting Guide There extremely dangerous voltage and power levels present inside this unit Do
31. rmal Dynamics Corporation must be notified within 30 days of any failure at which time Thermal Dynamics Corporation will provide instructions on the warranty procedures to be implemented Thermal Dynamics Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermal Dynamics Distributor LIMITED WARRANTY PERIOD Product Power Supply Components Torch and Leads Parts and Labor Parts and Labor 180 days This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused basedupon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermal Dynamics Corporation 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Thermal Dynamics 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Thermal Dynamics and are FOB West Lebanon NH or an authorized Thermadyne service station Product returned for service is at the owner s expense and n
32. t Of Equipment When you receive the equipment check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping If there is any damage notify the carrier immediately to file a claim Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual Include all equipment identification numbers as described above along with a full description of the parts in error 2 04 Introduction Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive The plasma arc cutting process uses this plasma to transfer an electrical arc to the workpiece The metal to be cut is melted by the heat of the arc and then blown away 2 1 Manual 0 4965 AIRCUT 15C 2 06 Features 2 05 General Specification Model Description 15C AirCutrM Maximum output 15 Amps 120V Input Voltage amp Phase Single Phase Frequency 2 2 Current Input fuse Hanada 20 Amps Duty cycle 104 F 30 15A 40 C Ambient 86vdc Recommended Cutting 1 8 Capacity 3 2 mm Maximum Cutting 1 4 Capacity 6 5 mm 6 5 x18 x9 5 165 mm x 457 mm x 241 mm Gross Weight 30 Ibs 11 2 kg NOTE Dimension W D H Refer to Local and National Codes or local au thority having jurisdiction for proper wiring requirements Introduction
33. t or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications e Disconnect power source before performing any service or repairs e Read and follow all the instructions in the Operating Manual A FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc e Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be protected e Ventilate all flammable or explosive vapors from the work place GENERAL INFORMATION AIRCUT 156 Do not cut or weld on containers that may have held combus tibles 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 underwater 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 dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the decibels sound do not exceed safe levels For informatio
34. the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards As sociation Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 4961 1 04 Note Attention et Avertissement Dans ce manuel les mots note Ces mises en relief sont classifi es comme suit NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst m
35. utes les consignes du Manuel de consignes A INCENDIE ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma 1 3 GENERAL INFORMATION AIRCUT 156 produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail Procurez une bonne a ration de toutes les fum es inflammables ou explosives Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Le gas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es 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 moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm LA RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiro
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