Tweco GCM-6000 Gas Control Manuel d'utilisateur

Instruction ManualJuly 19, 2002GAS CONTROL MODULEModel GCM-6000 For Use WithMerlin 6000GST SystemManual No. 0-2641A-01791

GENERAL INFORMATION 4 Date: November 15, 2001• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fumé

Date: November 15, 2001 5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous pr

GENERAL INFORMATION 6 Date: November 15, 20019. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection Ass

Date: November 15, 2001 7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest L

GENERAL INFORMATION 8 Date: November 15, 20011.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warra

Manual 0-2641 9 INTRODUCTION & DESCRIPTIONSECTION 2:INTRODUCTION &DESCRIPTION2.01 Scope of ManualThis manual contains descriptions, operating

INTRODUCTION & DESCRIPTION 10 Manual 0-2641

Manual 0-2641 11 INSTALLATION PROCEDURESSECTION 3:INSTALLATIONPROCEDURES3.01 IntroductionThis Section describes installation of the Gas Control andOp

INSTALLATION PROCEDURES 12 Manual 0-2641A-01794Rear PanelRear PanelScrews (4 Places)Figure3-1 Rear Panel Removal3. Remove the eight screws securing

Manual 0-2641 13 INSTALLATION PROCEDURES7. Before tighting the bolts make sure that the unitFlowmeters are plumb.8. Tighten the four bolts to secure

INSTALLATION PROCEDURES 14 Manual 0-264116. Connect the other end of the Preflow RAS GasHose to the mating connector at the end of the ArcStarter Box

Manual 0-2641 15 INSTALLATION PROCEDURESHoseSECONDARYOutput FittingA-02373Figure 3-8 Secondary Gas Hose Removal6. Locate the free end of the hose co

INSTALLATION PROCEDURES 16 Manual 0-2641If the Gas Control Module serial number ends withthe letter 'B' or earlier install additional parts

Manual 0-2641 17 INSTALLATION PROCEDURESA-02379Screws(4 Places)Secondary Gas/WaterFlow Control Rear PanelFigure 3-15 Optional Secondary Gas/Water Flo

INSTALLATION PROCEDURES 18 Manual 0-2641

Manual 0-2641 19 OPERATIONSECTION 4:OPERATION4.01 IntroductionThis Section provides a description of the Gas ControlModule.4.02 Functional OverviewT

OPERATION 20 Manual 0-26419. PLASMA Gas Pressure GaugeIndicates plasma gas pressure from 0 - 160 psi (0 - 11bar).10. PREFLOW Gas RegulatorAdjusts pr

Manual 0-2641 21 OPERATION1243A-02381Figure 4-3 Optional Secondary Gas/Water FlowControl4.04 Sequence Of OperationsThis Subsection contains four Sequ

OPERATION 22 Manual 0-26419. Place the MODE switch to the RUN position.NOTEWhen switching gases between operations, allowenough purge time to clear t

Manual 0-2641 23 OPERATIONNOTEWhen switching gases between operations, allowenough purge time to clear the old gas from thetorch leads. Pilot, plasma

Read and understand this entire Instruction Manual and youremployer’s safety practices before installing, operating, orservicing the equipment.While t

OPERATION 24 Manual 0-2641

Manual 0-2641 25 SERVICESECTION 5:CUSTOMER/OPERATORSERVICE5.01 IntroductionThis Section describes basic maintenance procedures per-formable by operat

SERVICE 26 Manual 0-2641

Manual 0-2641 27 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provides a breakdown of all replaceablecompo

PARTS LISTS 28 Manual 0-26416.03 Front Panel Replacement PartsItem # Qty Description Catalog #1 TDC STYLE GCM-6000 GAS CONTROL MODULEComplete Unit Wi

Manual 0-2641 29 PARTS LISTS6.04 Lower Rear Panel Replacement PartsItem # Qty Description Catalog #1 2 BODY BULKHEAD 1/8 NPT LH 9-68422 2 BODY BULKHE

PARTS LISTS 30 Manual 0-26416.05 Internal Control Replacement PartsItem # Qty Description Catalog #1 1 ASS’Y, GAS CONTROL PCB 9-68472 2 FLOWMETER, 15

Manual 0-2641 31 PARTS LISTS6.06 Internal Fitting Replacement PartsItem # Qty Description Catalog #Units with no letter or the letter 'A' a

PARTS LISTS 32 Manual 0-26416.07 Optional Secondary Gas/Water Flow Control Replacement PartsNOTEThis Subsection is only for repair parts for systems

Manual 0-2641 33 PARTS LISTS314510829112851084112713925146To GCMTo GCMA-023821313

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 11.0

PARTS LISTS 34 Manual 0-26416.08 Optional Secondary Water Control Replacement Parts (Obsolete)NOTEThis Subsection is supplied only for repair parts f

Manual 0-2641 35 APPENDIXAPPENDIX I: TIMING CHARTS OF GAS SEQUENCESA-01801PILOT SET PLASMA SET SEC SETSOL1 PlasmaSOL2 Pre-Flow N2SOL3 Cut-flow O2SOL4

APPENDIX 36 Manual 0-2641APPENDIX II: UNIT SCHEMATICA-01800

Manual 0-2641 37 APPENDIXA-01800

APPENDIX 38 Manual 0-2641APPENDIX III: GAS SOLENOID CIRCUIT DIAGRAMGas ControlConnectorMerlin 6000GST Power SupplyJ55-15Arc Starter BoxPanel Connecto

Manual 0-2641 39 APPENDIXAPPENDIX IV: PLUMBING DIAGRAMInformation proprietary to Thermal Dynamics Corporation.DateByREVISIONSRevDateByREVISIONSRev HE

APPENDIX 40 Manual 0-2641

Manual 0-2641 41 APPENDIX0.5" (12.7 mm)To Side of Gas Control Module3.0"(76.2 mm)0.281" (7.14 mm)Mounting Hole4 Places9.0"(228.6 m

TABLE OF CONTENTS (continued)SECTION 6:PARTS LISTS...

Date: November 15, 2001 1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, a

GENERAL INFORMATION 2 Date: November 15, 2001• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircu

Date: November 15, 2001 3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from Ame