ESAB PCC-10 Plasma Coolant Circulator User manual

Brand: ESAB

Model: PCC-10 Plasma Coolant Circulator

Category: Welding System

Type: User manual

ESAB PCC-10 Plasma Coolant Circulator is a reliable and efficient solution for cooling electric arc cutting and welding equipment, offering precise temperature control and a range of safety features. Its compact design allows for easy installation, and its durable construction ensures longevity in demanding industrial environments. The unit's adjustable by-pass valve and high-capacity pump deliver optimal coolant flow, while the copper tubing and aluminum finned radiator provide excellent heat dissipation.

PCC-10

Instruction Manual (EN)

0558004423

Plasma Coolant Circulator

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

TABLE OF CONTENTS

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

2.1 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Section / Title Page

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that

anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions

must meet the requirements that apply to this type of welding or plasma cutting equipment. The following

recommendations should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma

cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in

injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ame proof

clothing, safety gloves.

- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

SECTION 2 DESCRIPTION

2.0 Description

2.1 Specications

These instructions provide installation, operation, service and parts information for the PCC-10 Plasma Coolant

Circulator. This unit recirculates coolant to cool electric arc cutting and welding equipment.

Dimensions: 35.69" high (906 mm) x 21.75" wide (552 mm) x 25.00 deep (635 mm)

Weight: 215 lb. dry (97.5kg)/ 249 lb. wet (133kg)

Pump Type: Positive displacement, rotary vane type with adjustable by-pass valve (200 psi/13.8 bars max.), CW rotation

as viewed from nameplate.

Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.

50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power

AC Input Voltages 200/230/400/460/575V., +/- 10%

AC Input Amperage 9/8/5/4/3 Amperes

Pump Capacity 1.95 gpm at 100 psi 2.33 gpm at 100 psi

(7.4 l/min at 6.9 bars) (8.8 l/min at 6.9 bars)

Cooling Capacity @ 2gpm 23,100 BTU/hr. (6800 watts) 27,720 BTU/hr. (8120 watts)

at 45° F (7° C) temperature dierence between high coolant temperature and ambient air temperature.

Max. Delivery Pressure 160 psig (11 bars)

Reservoir Capacity 4 gallons (15.2 liters)

SECTION 2 DESCRIPTION

SECTION 3 INSTALLATION

3.0 Installation

Install the PCC-10 in an appropriate location so as to maintain adequate and unrestricted airow into and out

of the cabinetry. For permanent mounting refer to Figure 3.1 for mounting hole dimensions in the base of this

unit.

Figure 3.1 Mounting Dimensions

0.219” (5.6 mm) diameter hole, typical, 8 places

19.50”

(495 mm)

1.69”

(43 mm)

3.42”

(87 mm)

14.78”

(375 mm)

3.42”

(87 mm)

Figure 3.2 Voltage Links

SECTION 3 INSTALLATION

460

230200

575

DANGER

HIGH

VOLTAGE

115 VAC

INPUT

INPUT POWER

AUX

COOLER

400

3.1 Input Power Connections

If the power cable supplied with the circulator is missing, a 3-conductor power cable suitable to meet the re-

quired input power must be installed. The cable must have 0.25" (6.4 mm) ring lugs installed on the machine

end. Connect the power leads to the L1 and L2 terminals on TB1 Input Power Terminal Board and the ground

lead to the ground lug on the back of the fan support panel. A strain relief tting is provided to feed a power

cable through the rear panel of the cabinet. Refer to Figure 3.2 for proper Input Voltage Link placement, Figure

3.2 shows link in place for 575 volt input. Electrical installation must be in accordance with local electrical codes

for this type of equipment.

NOTE:

Motor is shipped from supplier wired for 115 VAC.

Wiring must be re-congured to use with 230 VAC.

See wiring information panel on motor for proper

230 VAC wiring conguration.

SECTION 3 INSTALLATION

Figure 3.3 Input Connection Diagram

Typical Installation -

User-supplied single phase fused power disconnect box with

receptacle and plug

Input Power Cable

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT

CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT

PROCEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE

TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH

IN THE OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT

TRIPPING. IF THE CONNECTION IS MADE FROM A FUSE BOX, REMOVE

THE CORRESPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS

NOT POSSIBLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE

DISCONNECT SWITCH OR FUSE BOX WARNING OTHERS THAT THE

CIRCUIT IS BEING WORKED ON.

WARNING

DO NOT INTERMITTENTLY OPERATE THE PUMP MOTOR AS THIS WILL

CAUSE NEEDLESS WEAR TO THE PUMP.

SECTION 3 INSTALLATION

P/N 2062106; 8-Pin

Female Plug

3.2 Control Connections

An 8-pin receptacle J1 is provided on the rear panel to supply the PCC-10 with 115 Vac control voltage for pump

motor contactor control. The PCC-10 must be supplied with this control voltage in order for the pump to operate.

Order Part No. 2062106; 8-Pin Female Plug and Part No. 182W61; Cable Clamp for plug to make a control cable us-

ing a two conductor cable. Solder the leads of this cable to Pins A and B of the plug and connect to control volt-

age device. Pump motor contactor control is supplied so as to not operate pump when cooling is not needed.

3.3 Coolant Connections

These connectors are located on the front of the unit and are marked “TO” and “FROM”. Connect the hoses to

the PCC-10 accordingly. The torch hose ends should be tted with one 0.63"-18 (16 mm) male left-hand Air/Water

hose and one 0.63"-18 (16 mm) female right-hand Air/Water hose connector.

With the torch and the PCC-10 connected, ll the reservoir with the specially formulated torch coolant (order

part no. 156F05). Do not use regular anti-freeze solutions, such as for an automobile, as the additives will harm

the pump and torch.

WARNING

DO NOT CONNECT HOSES TO A SOLENOID VALVE THAT CAN BE

CLOSED WHEN THE PUMP IS OPERATING AS DAMAGE TO PUMP CAN

RESULT.

SECTION 3 INSTALLATION

After lling the reservoir to the MAX mark, located on the front panel, run the pump with its cap removed in

order to purge air from the radiator, hoses, and torch. Re-check coolant level to ensure reservoir is lled to MAX

mark. Replace reservoir cap after purging and checking coolant level.

SECTION 3 INSTALLATION

by-pass valve adjustment screw is located under

the large acorn nut

CAUTION

pump motor

3.4 Pump Pressure Adjustment

Pump pressure is pre-set at the factory for 130 psi (9 bar), output coolant pressure may be adjusted by opening

or closing the by-pass valve on the pump. The by-pass valve adjustment screw is located under the large acorn

nut on the pump body. Pressure can be increased by turning the screw clockwise and decreased by turning the

screw counter-clockwise. When replacing acorn nut and gasket, tighten rmly to prevent air from being drawn

into pump. Do not exceed the recommended delivery pressures to torches as outlined by the manufac-

turer!

Do not operate the pump into a closed discharge line. If operated for more than a few minutes against a closed

discharge, the resulting heat build-up will cause rapid wear of the mechanical seal and eventual seizure and

failure of the pump. A thermostat will stop the pump motor if the pump temperature goes over 131 deg. F (55

deg. C).

Be careful not to touch the pump motor when adjusting pump pres-

sure as it can get very hot, up to 100 deg. F (38 deg. C). above ambient

temperature.

ESAB PCC-10 Plasma Coolant Circulator User manual

Brand: ESAB

Model: PCC-10 Plasma Coolant Circulator

Category: Welding System

Type: User manual

Download PDF

report

ESAB PCC-10 Plasma Coolant Circulator User manual

ESAB PCC-10 Plasma Coolant Circulator User manual

Related papers

Other documents