Tweco Maximizer 300 Torch for BNFL Manuel d'utilisateur

LIQUID COOLEDPLASMA TORCH90° Model Maximizer 300For Use With:• Merlin 6000 Cutting SystemsInstruction ManualDecember 1, 2003 Manual No. 0-2990

GENERAL INFORMATION 1-4 Date: November 15, 2001• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fu

Date: November 15, 2001 1-5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous

GENERAL INFORMATION 1-6 Date: November 15, 20019. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection A

Date: November 15, 2001 1-7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest

GENERAL INFORMATION 1-8 Date: November 15, 20011.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) war

Manual 0-2990 2-1 INTRODUCTIONSECTION 2:INTRODUCTION2.01 Scope of ManualThis manual contains descriptions, operating instructionsand maintenance proce

INTRODUCTION 2-2 Manual 0-29906. Transfer Distance3/8 inch (10 mm)7. Torch PartsGas Distributor, Electrode, Tip, Shield Cup Body,End Cap8. Plasma Gas

Manual 0-2990 2-3 INTRODUCTION2.04 Introduction to PlasmaA. Plasma Gas FlowPlasma is defined as a gas which has been heated toan extremely high temper

INTRODUCTION 2-4 Manual 0-2990

Manual 0-2990 3-1 INSTALLATIONSECTION 3:INSTALLATION3.01 IntroductionThis Section describes installation of the Liquid CooledMaximizer 300 Torch. The

INSTALLATION 3-2 Manual 0-29904. Feed the torch leads through the boot on the torchend of the Arc Starter Box.Torch LeadsHose ClampShield BraidTorch L

Manual 0-2990 3-3 INSTALLATIONHose ClampShield BraidUnder ClampTorch LeadsA-01443Figure 3-4 Hose Clamp Installation9. Check the torch for proper part

INSTALLATION 3-4 Manual 0-2990B. Secondary GasesNOTERefer to Appendix 2, Cutting Speed Charts, forproper gas pressure and flow rates.1. Compressed Air

Manual 0-2990 4-1 OPERATIONSECTION 4:OPERATION4.01 IntroductionThis Section provides a description of the Liquid CooledModel Maximizer 300 Torch Assem

OPERATION 4-2 Manual 0-29904.04 Torch Parts SelectionDepending on the type of operation to be done determinesthe torch parts to be used.Torch parts:Sh

Manual 0-2990 4-3 OPERATION4.05 Cut QualityNOTECut quality depends heavily on setup and param-eters such as torch standoff, alignment with theworkpiec

OPERATION 4-4 Manual 0-2990H. Various Materials and ThicknessesThe table defines the cut quality on various materi-als and thicknesses:Description of

Manual 0-2990 4-5 OPERATIONB. Torch StandoffImproper standoff (the distance between the torchtip and workpiece) can adversely affect tip life as wella

OPERATION 4-6 Manual 0-29904. With the pilot arc on, the main cutting arc will beestablished when the torch is brought within 1/8- 3/8 in (3 - 10 mm)

Manual 0-2990 4-7 OPERATIONC. Piercing With Machine TorchTo pierce with a machine torch, the arc should bestarted with the torch positioned as high as

WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing, oper-ating, or servicing the equipment.While th

OPERATION 4-8 Manual 0-2990E. Lead AngleThe angle between the torch and workpiece dependson the output current setting and torch travel speed.At 50 am

Manual 0-2990 5-1 SERVICESECTION 5:SERVICE5.01 IntroductionThis Section describes basic maintenance procedures per-formable by operating personnel. N

SERVICE 5-2 Manual 0-29902. Using an ohmmeter (set to 10K or higher), checkfor continuity between the positive and negativetorch fittings. Infinite re

Manual 0-2990 5-3 SERVICE5.04 Inspection and ReplacementConsumable Torch PartsWARNINGSDisconnect primary power to the system beforedisassembling the t

SERVICE 5-4 Manual 0-29904. Tilt the torch head to remove the gas distributor. Theend of the multipurpose wrench can be used to helpremove the gas di

Manual 0-2990 5-5 SERVICEB. No cutting output1. Torch not properly connected to power supplya. Check that torch leads are properly attachedto power su

SERVICE 5-6 Manual 0-29905.06 Servicing Machine TorchComponentsWARNINGSDisconnect primary power to the system beforedisassembling the torch or torch l

Manual 0-2990 5-7 SERVICE3. Secure the rigid insulator in place with electricaltape.4. Connect the plasma, secondary (+), coolant sup-ply, and coolant

SERVICE 5-8 Manual 0-29906. Check the torch leads by measuring the resistancebetween the positive pilot lead connector and thenegative lead fitting.•

Manual 0-2990 6-1 PARTS LISTSSECTION 6:PARTS LISTS6.01 IntroductionA. Parts List BreakdownThe parts list provides a breakdown of all replaceablecomp

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.01

PARTS LISTS 6-2 Manual 0-29906.03 Replacement Machine Torch PartsItem # Qty Description Catalog #1 1 Assembly, Torch Head, Maximizer 300, 90° Torch

Manual 0-2990 6-3 PARTS LISTS6.04 Complete Assembly ReplacementsDescription Qty Catalog #90° Head Machine Torches with Leads and Mounting Tube Assemb

PARTS LISTS 6-4 Manual 0-29906.05 Torch ConsumablesMaximizer 300 With Merlin 6000TipsGasDistributorEnd CapsElectrode50 - 225 ampsCatalog No. 20-1018St

Manual 0-2990 6-5 PARTS LISTSMaximizer 300 With Merlin 6000TipsGasDistributorArt # A-03776Electrodes50 - 225 ampsCatalog No. 20-0008O-RingCat. No. 8-3

PARTS LISTS 6-6 Manual 0-2990Maximizer 300 With Merlin 6000Art # A-03019Electrodes (All)Gas Distributors (All)Tips (All)Included withShield Cup BodySm

Manual 0-2990 A-1 APPENDIXAPPENDIX 1: SEQUENCE OF OPERATION BLOCKDIAGRAMA-01016ACTIONClose externaldisconnect switchRESULT• Power to systemACTIONEna

APPENDIX A-2 Manual 0-2990APPENDIX 2: GAS FLOW COMPARISON CHARTMaterial Plasma Secondary Amperage SCFH lpm SCFH lpm NotesAluminum Air Air 50 63 30 19

TABLE OF CONTENTS (continued)SECTION 5:SERVICE ...

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

GENERAL INFORMATION 1-2 Date: November 15, 2001• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcir

Date: November 15, 2001 1-3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from A