Tweco Thermal Arc TA 500 Manuel d'utilisateur

Plasma CuttingSystemThermal Arc TA 500August 7, 2001 Manual No. 0-0470Instruction Manual

General Information iv Date: May 1, 2000 (SPECIAL)• Utilisez un appareil respiratoire à alimentation en airsi l’aération fournie ne permet pas d’élim

Date: May 1, 2000 (SPECIAL) v General Information• Pour protéger vos yeux, portez toujours un casque ouun écran de soudeur. Portez toujours des lune

General Information vi Date: May 1, 2000 (SPECIAL)11. Brochure GCA P-1, LA MANIPULATION SANSRISQUE DES GAZ COMPRIMÉS EN CYLINDRES,disponible auprès d

Date: May 1, 2000 (SPECIAL) vii General InformationDeclaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: Industrial Park #2West

General Information viii Date: May 1, 2000 (SPECIAL)Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) war

Manual No 0-0470 1-1 General InformationSECTION 1: DESCRIPTIONOF EQUIPMENT1.1 General InformationA. 500 Amp SystemA complete 500 amp TA500 system inc

General Information 1-2 Manual No 0-047042" (106.7 cm)47" (119.4 cm)32" (81.3 cm) TAC 500 DimensionsC. Supply Console• Power Input: Fr

Manual No 0-0470 1-3 General Information1.3 PlasmaPlasma is a gas which has been heated to an extremelyhigh temperature and ionized so that the gas be

General Information 1-4 Manual No 0-0470Current ControlThe desired cutting current is set with the control knob, lo-cated to the left of the ammeter,

Manual No 0-0470 1-5 General InformationSystem Block Diagram

General Information 1-6 Manual No 0-0470

Manual No 0-0470 2-1 InstallationSECTION 2:INSTALLATION2.1 Unpacking New EquipmentThe TA-500 is skid mounted and protected with a carton andpadding m

Installation 2-2 Manual No 0-0470InputStrainRelief Figure 2-C Power Supply Rear Panel. Input ofPrimary Power CablesPowerTransformer(T1)LineVoltagesA

Manual No 0-0470 2-3 InstallationL1L2L3 Figure 2-E Input Power ConnectionsSupply Console10. Place the Supply Console in the desired location andremove

Installation 2-4 Manual No 0-0470HE 200CAUTIONDo not attempt to run the HE 200 until the torchleads are connected to the Control Console (steps28-33).

Manual No 0-0470 2-5 Installation25. Connect the plasma gas supply hose (BLACK) tothe plasma gas cylinder and the fitting on the rearpanel of the Cont

Installation 2-6 Manual No 0-0470CAUTIONDo not attempt to operate this system unless allparts of all enclosures are in place. This is im-portant for

Manual No 0-0470 3-1 OperationSECTION 3: OPERATION3.1 Operating ControlsAC POWERSTART34567891012STOPD.C. AMPERES0 200 400 600 800 10

Operation 3-2 Manual No 0-047010131514111216VOLTSD.C.100200 300400500AMPERESD.C.100200 300400500AC POWER1FU2FU3FU4FUHI-FLOWWATER SHIELDONOFFDC POWERPI

Manual No 0-0470 3-3 Operation3.2 Pre-Operation Set-upThis procedure should be followed at the beginning of eachshift: WARNINGCheck to be sure main di

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

Operation 3-4 Manual No 0-0470Figure 3-F Using a Square to set up the M200 Torch2. To start a cut at the edge of the plate, line up thetorch away from

Manual No 0-0470 3-5 Operation5. In continuous cutting applications, it is often neces-sary to manifold 4 to 6 CO2 cylinders together tomaintain pres

Operation 3-6 Manual No 0-0470Table 3-B Recommended Cutting SpeedsThe following charts are intended as a guide in determining approximate conditions

Manual No 0-0470 3-7 Operation750 AmperesThe speeds below are typical for cutting at 750 amperes using the 8-6045 tip and the 8-6006 end piece.GENERAL

Operation 3-8 Manual No 0-0470

Manual No 0-0470 4-1 ServiceSECTION 4: SERVICEThe Service Section is divided into nine parts:4.1 Torch Maintenance4.2 TAC 500 Power Supply Maintenanc

Service 4-2 Manual No 0-0470For routine disassembly of the torch, no other parts needto be removed. The electrode seat (4) does not requirereplacemen

Manual No 0-0470 4-3 Service5. Install the new tip (6) in the inner tip retainer.This is installed by pressing it in from the back.If the O-rings are

Service 4-4 Manual No 0-0470The pump is pre-greased at the factory and should only re-quire lubrication every two years. To lubricate, remove screwsf

Manual No 0-0470 4-5 ServiceACTION1. Close all three external disconnectswitches (TA500, HE200, Hi-Flow Water Shield)RESULT1. Red AC POWER light (LT3)

ContentsGENERAL INFORMATION ... iNotes, Caut

Service 4-6 Manual No 0-04704.5 Troubleshooting GuideIf the TA-500 System malfunctions the troubleshooting guidewill be helpful in correcting the pro

Manual No 0-0470 4-7 ServiceH. No red DC POWER Light.1. Pressure switch PS3 in Supply Console not satis-fied.a. Check gas pressure setting (Plasma 60

Service 4-8 Manual No 0-0470d. Check jumper wire in J8 connector; replace if faulty.5. Reactor and/or transformer overheated due to ex-ceeding the amp

Manual No 0-0470 4-9 Service4.9 Test ProceduresThe following tests are suggested for specific problemslisted in the preceding trouble shooting chart.

Service 4-10 Manual No 0-047022192016L. With the control bridge connected to the circuit, mea-sure the resistance across the diode on the centerheat s

Manual No 0-0470 5-1 Parts ListsSECTION 5: PARTSLISTSAssembly Parts ListThe Assembly Parts List illustrates the parts of theThermal Arc 500 Cutting Sy

Parts Lists 5-2 Manual No 0-0470Item No. Qty. Description Ref. Cat. No.1 1 TA500 Power Supply 3-50012 1 Supply Console 3-50023 1 Operator Control Pane

Manual No 0-0470 5-3 Parts ListsFigure 5-1 Thermal Arc 500 Cutting SystemM200 Torchwith Arc StarterOperator Control PanelSupply ConsoleTA500 Power Su

Parts Lists 5-4 Manual No 0-04705.2 Front Panel ComponentsItem No. Qty. Description Ref. Cat. No.1 2 Fuse Holder 1FU, 2FU 9-29372 2 Fuse- 20 amp 1FU,

Manual No 0-0470 5-5 Parts Lists Figure 5-2 TA 500 Front View3, 493, 51, 267810131915, 2014, 2011, 121617186AC POWER1FU2FU3FU

SECTION 5: PARTS LISTS ... 5-15.1 System Componen

Parts Lists 5-6 Manual No 0-04705.3 Rear Panel ComponentsItem No. Qty. Description Ref. Cat. No.1 1 Input Strain Relief 9-32912 3 Fuse Holder 5FU, 6FU

Manual No 0-0470 5-7 Parts Lists5.4 Right Side ComponentsItem No. Qty. Description Ref. Cat. No.1 2 Resistor 8.5 ohm, 1000w R2 9-54882 1 Fastener 9-3

Parts Lists 5-8 Manual No 0-04705.5 Left Side ComponentsItem No. Qty. Description Ref. Cat. No.1 2 Motor Mounting Bracket 9-53122 2 Motor Bracket Stru

Manual No 0-0470 5-9 Parts Lists5.6 Equipment Board AssemblyItem No. Qty. Description Ref. Cat. No.1 1 Printed Circuit Board Cover 9-5350(2) 1 Printed

Parts Lists 5-10 Manual No 0-04705.7 Bridge AssembliesItem No. Qty. Description Ref. Cat. No.1 1 Bridge Assembly2 7 Capacitor- .25 mfd C1, 2, 5, 6, 7

Manual No 0-0470 5-11 Parts Lists5.8 Bridge AssembliesItem No. Qty. Description Ref. Cat. No.1 1 Heat Sink (neg) 9-51562 1 Heat Sink (pos) 9-53573 3 D

Parts Lists 5-12 Manual No 0-04705.9 Supply Console ComponentsItem No. Qty. Description Ref. Cat. No.1 4 Connecting Bolt 9-32782 1 Power Connection Bl

Manual No 0-0470 5-13 Parts ListsFigure 5-9 Supply Console619, 3118, 30(9)512, 3, 478101315, 161411121718, 3020212223242526272829142121

Parts Lists 5-14 Manual No 0-04705.10 M200 Torch ComponentsItem No. Qty. Description Ref. Cat. No.1 1 M200 Head Assembly 8-60542 1 Water Tube 9-16403

Manual No 0-0470 5-15 Parts Lists Figure 5-10 M200 Torch395412678101319151411121617182018213121425242322

M200 Torchwith Arc StarterOperator Control PanelSupply ConsoleTA500 Power SupplyHE200 Coolant Recirculator

Parts Lists 5-16 Manual No 0-04705.11 Operator Control PanelItem No. Qty. Description Ref. Cat. No.1 1 Toggle Switch- SPST SW1 9-33252 2 Toggle Switch

Manual No 0-0470 5-17 Parts Lists5.12 Gas Pressure RegulatorsItem No. Qty. Description Ref. Cat. No.1 Lubricant 9-28711 Regulator, CO29-27591 Regulato

Manual No. 0-0470 A-1 AppendixArt # A-04077APPENDIX 1

Appendix A-2 Manual No. 0-0470Art #A-04078APPENDIX 2

Manual No. 0-0470 A-3 AppendixArt # A-04081APPENDIX 3

Appendix A-4 Manual No. 0-0470REDR-BLUR-YELREDBRNR-BLU395412678101112BRNGRNGRNGRN-YELBLKBLKARC STARTER TRANSFORMERPHASING DIAGRAM42A519 10/18/78

Manual No. 0-0470 A-5 AppendixArt # A-04080APPENDIX 5

Appendix A-6 Manual No. 0-0470Art # A-0398235412APPENDIX 6

Manual No. 0-0470 A-7 AppendixArt # A-03982967810

Date: May 1, 2000 (SPECIAL) i General InformationGENERAL INFORMATIONNotes, Cautions and WarningsThroughout this manual, notes, cautions, and warnings

Appendix A-8 Manual No. 0-0470Art # A-0398118PC10221 2 3 4 5ABCDEF1 2 3 4 5RLT3SC504 ChassisJ101-7J101-9J103-14J101-3J102-14J102-12J102-16J102-2J101-2

Manual No. 0-0470 A-9 Appendix6 7 8 9 10ABCDEF6 7 8 9 10SC504 Control PanelComputer SignalsInput / OutputDisable Standoff Control, ResampleNew Arc Vo

General Information ii Date: May 1, 2000 (SPECIAL)• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the welding

Date: May 1, 2000 (SPECIAL) iii General Information6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able fr