ESAB EtchArc®-1125 Plasma Marking System User manual

F15-727

May, 2005

Installation, Operation and Maintenance for the

EtchArc

®

-1125

PLASMA MARKING SYSTEM

411 South Ebenezer Road

Florence, SC 29501-0545

The equipment described in this manual is

potentially hazardous. Use caution when installing,

operating and maintaining this equipment.

Purchaser is solely responsible for the safe

operation and use of all products purchased,

including compliance with OSHA and other

government standards. ESAB Cutting

Systems has no liability for personal injury or

other damage arising out of the use of any

product manufactured or sold be ESAB. See

standard ESAB terms and conditions of sale

for a specific statement of ESAB’s

responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total

customer satisfaction. We constantly look for

ways to improve our products, service and

documentation. As a result, we make

enhancements and/or design changes as

required. ESAB makes every possible effort to

ensure our documentation is current. We

cannot guarantee that each piece of

documentation received by our customers

reflects the latest design enhancements.

Therefore, the information contained in this

document is subject to change without notice.

This manual is ESAB Part Number F15727

This manual is ESAB Part Number F15727This manual is ESAB Part Number F15727

This manual is ESAB Part Number F15727

.

..

.

This manual is for the convenience and use of the

cutting machine purchaser. It is not a contract or

other obligation on the part of ESAB Cutting

Systems.

©

©©

Printed in U.S.A.

EtchArc-1125 Table of Contents

i

Page

Section 1 Safety

1.1 Introduction.................................................................................................... 1

1.2 Safety Notations And Symbols........................................................................ 1

1.3 General Safety Information.............................................................................. 2

1.4 Installation Precautions ................................................................................... 3

1.5 Electrical Grounding ....................................................................................... 4

1.6 Operating A Plasma Cutting Machine.............................................................. 4-7

1.7 Service Precautions........................................................................................ 8

1.8 Safety References .......................................................................................... 9

1.8.1 National Standards ................................................................................. 9

1.8.2 International Standards........................................................................... 10-11

Section 2 Description

2.1 Introduction Overview...................................................................................... 1

2.1.1 Interconnection Diagram......................................................................... 2

2.2 System Description ........................................................................................ 3

2.2.1 EtchArc-1125 Systems........................................................................... 3

2.2.2 EtchArc-1125 Power Supply (only).......................................................... 3

2.2.3 PM60 Plasma Marker Torch.................................................................... 4

2.2.4 PM60 Torch Lead Assemblies ................................................................ 4

2.2.5 Options .................................................................................................. 4

Section 3 Installation

3.0 General .......................................................................................................... 1

3.1 Interface......................................................................................................... 2

3.2 Requirements................................................................................................. 3

3.3 Connecting the EtchArc.................................................................................. 4

3.3.1 Rear Panel.............................................................................................. 4

3.3.2 Converting a 230 VAC unit to a 208 VAC unit.......................................... 5

3.3.3 Torch Lead Connections, Front Panel ..................................................... 6-7

3.3.4 Torch Bundle (Leads) to PM60 Torch...................................................... 8-13

EtchArc-1125 Table of Contents

ii

Page

Section 4 Operation

4.0 Set-up ............................................................................................................ 1

4.1 Power Supply ................................................................................................. 1

4.2 Gas Set-up..................................................................................................... 2

4.3 CNC Set-up.................................................................................................... 3

4.4 Process Data................................................................................................... 4-10

Section 5 Maintenance

5.0 General........................................................................................................... 1

5.1 Routine Maintenance ...................................................................................... 2

5.2 Flow Switch .................................................................................................... 3

Section 6 Troubleshooting

6.0 General........................................................................................................... 1

6.1 Troubleshooting Guide.................................................................................... 1-5

6.2 Power Supply Schematic, 208/230v (P/N 0588000967)................................. 6-7

6.3 Wiring Diagram, 208/230v............................................................................... 8-11

6.4 Power Supply Schematic, 460v (P/N 0588000949)........................................ 12-13

6.5 Wiring Diagram, 460v...................................................................................... 14-17

6.6 Power Supply Schematic, 575v (P/N 0588000966)........................................ 18-19

6.7 Wiring Diagram, 575v...................................................................................... 20-23

6.8 Plasma (CUT) Gas Circuit................................................................................ 24

EtchArc-1125 Table of Contents

iii

Page

Section 7 Replacement Parts

7.1 General .......................................................................................................... 1

7.2 Ordering......................................................................................................... 1

7.3 EtchArc-1125, Front and Rear Exterior, all models .......................................... 2-3

7.4 EtchArc-1125, Right interior view, 208/230V model......................................... 4-5

7.5 EtchArc-1125, Left interior view, 208/230v model ........................................... 6-7

7.6 EtchArc-1125, Top interior view with cover removed, 208/230v model ............ 8-9

7.7 EtchArc-1125, Top interior cross section view 1, 208/230v model................... 10-11

7.8 EtchArc-1125, Top interior cross section view 2, 208/230v model................... 12-13

7.9 EtchArc-1125, Right interior view, 460v and 575v models ............................... 14-15

7.10 EtchArc-1125, Left interior view, 460v and 575v models ............................... 16-17

7.11 EtchArc-1125, Top interior view with cover removed, 460v and 575v models 18-19

7.12 EtchArc-1125, Top interior cross section view 1, 460v and 575v models ....... 20-21

7.13 EtchArc-1125, Top interior cross section view 2, 460v and 575v models ....... 22-23

7.14 TechArc-1125 Inside View, 460v and 575v models ....................................... 24-25

7.15 Argon Gas Circuit (Cut Gas).......................................................................... 26-27

7.16 PM60 Plasma Torch ..................................................................................... 28-29

7.17 Torch Leads and Other System Parts............................................................ 30-31

7.18 PM-60 Plasma Marking Torch Starter Spare Parts Kit.................................... 32-33

Customer/Technical Information

Back Manual

Cover

EtchArc-1125 Table of Contents

iv

This page intentionally left blank

SECTION 1 Safety

EtchArc-1125 Power Source 1-1

1.1 Introduction

The process of cutting metals with plasma equipment

provides industry with a valuable and versatile tool.

ESAB cutting machines are designed to provide both

operation safety and efficiency. However, as with any

machine tool, sensible attention to operating

procedures, precautions, and safe practices is

necessary to achieve a full measure of usefulness.

Whether an individual is involved with operation,

servicing, or as an observer, compliance with

established precautions and safe practices must be

accomplished. Failure to observe certain precautions

could result in serious personnel injury or severe

equipment damage. The following precautions are

general guidelines applicable when working with

cutting machines. More explicit precautions pertaining

to the basic machine and accessories are found in the

instruction literature. For a wide scope of safety

information on the field of cutting and welding

apparatus, obtain and read the publications listed in

the Recommended References.

1.2 Safety Notations And Symbols

The following words and symbols are used throughout

this manual. They indicate different levels of required

safety involvement.

!

ALERT or ATTENTION. Your safety is involved

or potential equipment failure exists. Used with

other symbols and information.

DANGER

!

Used to call attention to immediate hazards

which, if not avoided, will result in serious

personal injury or loss of life.

WARNING

!

Used to call attention to potential hazards that

could result in personal injury or loss of life.

CAUTION

!

Used to call attention to hazards that could result

in minor personal injury or equipment damage.

CAUTION

Used to call attention to minor hazards to

equipment.

NOTICE

Used to call attention to important installation,

operation or maintenance information not

directly related to safety hazards.

SECTION 1 Safety

EtchArc-1125 Power Source 1-2

1.3 General Safety Information

WARNING

!

Machinery often starts automatically.

This equipment moves in various directions and

This equipment moves in various directions and This equipment moves in various directions and

This equipment moves in various directions and

speeds.

speeds.speeds.

speeds.

• Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

Moving machinery can crush.

• Only qualified personnel should operate or

Only qualified personnel should operate or Only qualified personnel should operate or

Only qualified personnel should operate or

service this power source.

service this power source.service this power source.

service this power source.

• Keep all personnel, materials, and equipment

Keep all personnel, materials, and equipment Keep all personnel, materials, and equipment

Keep all personnel, materials, and equipment

not involved in prod

not involved in prodnot involved in prod

not involved in production process clear of

uction process clear of uction process clear of

uction process clear of

entire system area.

entire system area.entire system area.

entire system area.

• Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel

from passing through area or standing in the

from passing through area or standing in the from passing through area or standing in the

from passing through area or standing in the

working envelope of the equipment.

working envelope of the equipment. working envelope of the equipment.

working envelope of the equipment.

• Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every work Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every work

cell entrance.

cell entrance. cell entrance.

cell entrance.

• Follow lockout proced

Follow lockout procedFollow lockout proced

Follow lockout procedure before servicing any

ure before servicing any ure before servicing any

ure before servicing any

equipment.

equipment.equipment.

equipment.

WARNING

!

Failure to follow operating instructions

could result in death or serious injury.

Read and understand this operator’s manual before

Read and understand this operator’s manual before Read and understand this operator’s manual before

Read and understand this operator’s manual before

using machine.

using machine.using machine.

using machine.

• Read entire procedure before operating or

Read entire procedure before operating or Read entire procedure before operating or

Read entire procedure before operating or

performing any system maintenance.

performing any system maintenance. performing any system maintenance.

performing any system maintenance.

• Special attention must be given to all hazard

Special attention must be given to all hazard Special attention must be given to all hazard

Special attention must be given to all hazard

warnings that provide essential information

warnings that provide essential information warnings that provide essential information

warnings that provide essential information

re

rere

regarding personnel safety and/or possible

garding personnel safety and/or possible garding personnel safety and/or possible

garding personnel safety and/or possible

equipment damage.

equipment damage.equipment damage.

equipment damage.

• All safety precautions relevant to electrical

All safety precautions relevant to electrical All safety precautions relevant to electrical

All safety precautions relevant to electrical

equipment and process operations must be

equipment and process operations must be equipment and process operations must be

equipment and process operations must be

strictly observed by all having system

strictly observed by all having system strictly observed by all having system

strictly observed by all having system

responsibility or access.

responsibility or access. responsibility or access.

responsibility or access.

• Read all safety publications made available

Read all safety publications made availableRead all safety publications made available

Read all safety publications made available by

by by

by

your company.

your company.your company.

your company.

SECTION 1 Safety

EtchArc-1125 Power Source 1-3

WARNING

!

Failure to follow safety warning label

instructions could result in death or

serious injury.

Read and understand all safety warning labels on

Read and understand all safety warning labels on Read and understand all safety warning labels on

Read and understand all safety warning labels on

machine.

machine.machine.

machine.

Refer to operator’s manual for additiona

Refer to operator’s manual for additionaRefer to operator’s manual for additiona

Refer to operator’s manual for additional safety

l safety l safety

l safety

information.

information.information.

information.

1.4 Installation Precautions

WARNING

!

Improperly Installed Equipment Can Cause

Injury Or Death.

Follow these guidelines while installing machine:

Follow these guidelines while installing machine:Follow these guidelines while installing machine:

Follow these guidelines while installing machine:

• Contact your ESAB representative before

Contact your ESAB representative before Contact your ESAB representative before

Contact your ESAB representative before

installation. He can suggest certain precautio

installation. He can suggest certain precautioinstallation. He can suggest certain precautio

installation. He can suggest certain precautions

ns ns

ns

regarding piping installation and machine lifting,

regarding piping installation and machine lifting, regarding piping installation and machine lifting,

regarding piping installation and machine lifting,

etc. to ensure maximum security.

etc. to ensure maximum security.etc. to ensure maximum security.

etc. to ensure maximum security.

• Never attempt any machine modifications or

Never attempt any machine modifications or Never attempt any machine modifications or

Never attempt any machine modifications or

apparatus additions without first consulting a

apparatus additions without first consulting a apparatus additions without first consulting a

apparatus additions without first consulting a

qualified ESAB representative.

qualified ESAB representative.qualified ESAB representative.

qualified ESAB representative.

• Observe machine clearance requirements for

Observe machine clearance requirements for Observe machine clearance requirements for

Observe machine clearance requirements for

prope

propeprope

proper operation and personnel safety.

r operation and personnel safety. r operation and personnel safety.

r operation and personnel safety.

• Always have qualified personnel perform

Always have qualified personnel perform Always have qualified personnel perform

Always have qualified personnel perform

installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of

this equipment.

this equipment.this equipment.

this equipment.

• Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

proper fuse sizes close to the power supply.proper fuse sizes close to the power supply.

proper fuse sizes close to the power supply.

SECTION 1 Safety

EtchArc-1125 Power Source 1-4

1.5 Electrical Grounding

Electrical grounding is imperative for proper

machine operation and SAFETY. Refer to this

manual’s Installation section for detailed grounding

instructions.

WARNING

!

Electric shock hazard.

Improper grounding can cause severe injury or

Improper grounding can cause severe injury or Improper grounding can cause severe injury or

Improper grounding can cause severe injury or

death.

death.death.

death.

Machine

MachineMachine

Machine must be properly grounded before put into

must be properly grounded before put into must be properly grounded before put into

must be properly grounded before put into

service.

service.service.

service.

1.6 Operating A Plasma Cutting Machine

WARNING

!

Flying debris and loud noise

hazards.

• Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear

goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying

debris generated during

debris generated during debris generated during

debris generated during operation.

operation.operation.

operation.

• Chipped slag may be hot and fly far.

Chipped slag may be hot and fly far. Chipped slag may be hot and fly far.

Chipped slag may be hot and fly far.

Bystanders should also wear goggles and

Bystanders should also wear goggles and Bystanders should also wear goggles and

Bystanders should also wear goggles and

safety glasses.

safety glasses.safety glasses.

safety glasses.

• Noise from plasma arc can damage hearing.

Noise from plasma arc can damage hearing. Noise from plasma arc can damage hearing.

Noise from plasma arc can damage hearing.

Wear correct ear protection when cutting above

Wear correct ear protection when cutting above Wear correct ear protection when cutting above

Wear correct ear protection when cutting above

water.

water. water.

water.

WARNING

!

Burn hazard.

Hot metal can burn.

Hot metal can burn.Hot metal can burn.

Hot metal can burn.

• Do not touch m

Do not touch mDo not touch m

Do not touch metal plate or parts immediately

etal plate or parts immediately etal plate or parts immediately

etal plate or parts immediately

after cutting. Allow metal time to cool, or douse

after cutting. Allow metal time to cool, or douse after cutting. Allow metal time to cool, or douse

after cutting. Allow metal time to cool, or douse

with water.

with water.with water.

with water.

• Do not touch plasma torch immediately after

Do not touch plasma torch immediately after Do not touch plasma torch immediately after

Do not touch plasma torch immediately after

cutting. Allow torch time to cool.

cutting. Allow torch time to cool.cutting. Allow torch time to cool.

cutting. Allow torch time to cool.

SECTION 1 Safety

EtchArc-1125 Power Source 1-5

WARNING

!

Hazardous voltages. Electric shock

can kill.

• Do NOT touch plasma torch, cutti

Do NOT touch plasma torch, cuttiDo NOT touch plasma torch, cutti

Do NOT touch plasma torch, cutting table or

ng table or ng table or

ng table or

cable connections during plasma cutting process.

cable connections during plasma cutting process.cable connections during plasma cutting process.

cable connections during plasma cutting process.

• Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

Always turn power off to plasma power

supplies before touching or servicing plasma torch.

supplies before touchin

g

or servicin

g

plasma torch. supplies before touchin

g

or servicin

g

plasma torch.

supplies before touching or servicing plasma torch.

• Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

Always turn power off to plasma power

supplies before servicing any system component.

supplies before servicing any system component.supplies before servicing any system component.

supplies before servicing any system component.

• Do not touch live

Do not touch liveDo not touch live

Do not touch live electrical parts.

electrical parts. electrical parts.

electrical parts.

• Keep all panels and covers in place when

Keep all panels and covers in place when Keep all panels and covers in place when

Keep all panels and covers in place when

machine is connected to power source.

machine is connected to power source.machine is connected to power source.

machine is connected to power source.

• Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to

insulate yourself from workpiece and electrical

insulate yourself from workpiece and electrical insulate yourself from workpiece and electrical

insulate yourself from workpiece and electrical

ground.

ground.ground.

ground.

• Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

equipment d

equipment dequipment d

equipment dry.

ry.ry.

ry.

• Replace worn or damaged cables.

Replace worn or damaged cables.Replace worn or damaged cables.

Replace worn or damaged cables.

WARNING

!

Fume hazard.

Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cutting

process can be hazardous to your health.

process can be hazardous to your health.process can be hazardous to your health.

process can be hazardous to your health.

• Do NOT breathe fumes.

Do NOT breathe fumes.Do NOT breathe fumes.

Do NOT breathe fumes.

• Do not operate plasma torch without fume

Do not operate plasma torch without fume Do not operate plasma torch without fume

Do not operate plasma torch without fume

removal system operating properly.

removal system operating properly. removal system operating properly.

removal system operating properly.

• Use additional

Use additionalUse additional

Use additional ventilation to remove fumes if

ventilation to remove fumes if ventilation to remove fumes if

ventilation to remove fumes if

necessary.

necessary.necessary.

necessary.

• Use approved respirator if ventilation is not

Use approved respirator if ventilation is not Use approved respirator if ventilation is not

Use approved respirator if ventilation is not

adequate.

adequate.adequate.

adequate.

• Provide positive mechanical ventilation when

Provide positive mechanical ventilation when Provide positive mechanical ventilation when

Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper,

cutting galvanized steel, stainless steel, copper, cutting galvanized steel, stainless steel, copper,

cutting galvanized steel, stainless steel, copper,

zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe these zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe these

fumes.

fumes.fumes.

fumes.

•

Do

Do Do

Do not operate near degreasing and spraying

not operate near degreasing and spraying not operate near degreasing and spraying

not operate near degreasing and spraying

operations. Heat or arc rays can react with

operations. Heat or arc rays can react with operations. Heat or arc rays can react with

operations. Heat or arc rays can react with

chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vapors to form phosgene, chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vapors to form phosgene,

a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases. a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases.

SECTION 1 Safety

EtchArc-1125 Power Source 1-6

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn skin.Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn skin.

• Wear corre

Wear correWear corre

Wear correct eye and body protection.

ct eye and body protection.ct eye and body protection.

ct eye and body protection.

• Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with side

shields. Refer to following chart for recommended

shields. Refer to following chart for recommended shields. Refer to following chart for recommended

shields. Refer to following chart for recommended

lens shades for plasma cutting:

lens shades for plasma cutting:lens shades for plasma cutting:

lens shades for plasma cutting:

Arc Current

Arc CurrentArc Current

Arc Current

Lens Shade

Lens Shade Lens Shade

Lens Shade

Up to 100 Amps

Up to 100 AmpsUp to 100 Amps

Up to 100 Amps

Shade No. 8

Shade No. 8Shade No. 8

Shade No. 8

100

100100

100-

--

-200 Amps

200 Amps200 Amps

200 Amps

Shade No. 10

Shade No. 10Shade No. 10

Shade No. 10

200

200200

200-

--

-400

400 400

400 Amps

AmpsAmps

Amps

Shade No. 12

Shade No. 12Shade No. 12

Shade No. 12

Over 400 Amps

Over 400 AmpsOver 400 Amps

Over 400 Amps

Shade No. 14

Shade No. 14Shade No. 14

Shade No. 14

• Replace glasses/goggles when lenses are

Replace glasses/goggles when lenses are Replace glasses/goggles when lenses are

Replace glasses/goggles when lenses are

pitted or broken

pitted or brokenpitted or broken

pitted or broken

• Warn others in area not to look directly at the

Warn others in area not to look directly at the Warn others in area not to look directly at the

Warn others in area not to look directly at the

arc unless wearing appropriate safety glasses.

arc unless wearing appropriate safety glasses.arc unless wearing appropriate safety glasses.

arc unless wearing appropriate safety glasses.

• Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection and Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection and

transmission

transmissiontransmission

transmission of ultraviolet light.

of ultraviolet light. of ultraviolet light.

of ultraviolet light.

§ Use special paint on walls to absorb UV

Use special paint on walls to absorb UV Use special paint on walls to absorb UV

Use special paint on walls to absorb UV

light.

light.light.

light.

§ Install protective screens or curtains to

Install protective screens or curtains to Install protective screens or curtains to

Install protective screens or curtains to

reduce ultraviolet transmission.

reduce ultraviolet transmission.reduce ultraviolet transmission.

reduce ultraviolet transmission.

SECTION 1 Safety

EtchArc-1125 Power Source 1-7

WARNING

!

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

Do not cut near combustible material.Do not cut near combustible material.

Do not cut near combustible material.

• Do

DoDo

Do not have on your person any combustibles

not have on your person any combustibles not have on your person any combustibles

not have on your person any combustibles

(e.g. butane lighter).

(e.g. butane lighter).(e.g. butane lighter).

(e.g. butane lighter).

• Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle

away from yourself and others when activating

away from yourself and others when activating away from yourself and others when activating

away from yourself and others when activating

plasma process.

plasma process.plasma process.

plasma process.

• Wear correct eye and body protection.

Wear correct eye and body protection.Wear correct eye and body protection.

Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.

• W

WW

Wear flame

ear flameear flame

ear flame-

--

-retardant clothing covering all

retardant clothing covering all retardant clothing covering all

retardant clothing covering all

exposed areas.

exposed areas.exposed areas.

exposed areas.

• Wear cuffless trousers to prevent entry of

Wear cuffless trousers to prevent entry of Wear cuffless trousers to prevent entry of

Wear cuffless trousers to prevent entry of

sparks and slag.

sparks and slag.sparks and slag.

sparks and slag.

• Have fire extinguishing equipment available for

Have fire extinguishing equipment available for Have fire extinguishing equipment available for

Have fire extinguishing equipment available for

use.

use.use.

use.

WARNING

!

Explosion hazard.

• Certain molten aluminum

Certain molten aluminumCertain molten aluminum

Certain molten aluminum-

--

-lithium (Al

lithium (Allithium (Al

lithium (Al-

--

-Li) alloys

Li) alloys Li) alloys

Li) alloys

can cause explos

can cause exploscan cause explos

can cause explosions when plasma cut OVER

ions when plasma cut OVER ions when plasma cut OVER

ions when plasma cut OVER

water.

water. water.

water.

§ These alloys should only be dry cut on a

These alloys should only be dry cut on a These alloys should only be dry cut on a

These alloys should only be dry cut on a

dry table.

dry table.dry table.

dry table.

§ DO NOT dry cut over water.

DO NOT dry cut over water.DO NOT dry cut over water.

DO NOT dry cut over water.

§ Contact your aluminum supplier for

Contact your aluminum supplier for Contact your aluminum supplier for

Contact your aluminum supplier for

additional safety information regarding

additional safety information regarding additional safety information regarding

additional safety information regarding

hazards associated with these alloys

hazards associated with these alloyshazards associated with these alloys

hazards associated with these alloys

.

•

Do not cut in atmospheres con

Do not cut in atmospheres conDo not cut in atmospheres con

Do not cut in atmospheres containing

taining taining

taining

explosive dust or vapors.

explosive dust or vapors.explosive dust or vapors.

explosive dust or vapors.

•

Do not carry any combustibles on your person

Do not carry any combustibles on your person Do not carry any combustibles on your person

Do not carry any combustibles on your person

(e.g. butane lighter)

(e.g. butane lighter)(e.g. butane lighter)

(e.g. butane lighter)

• Do not cut containers that have held

Do not cut containers that have held Do not cut containers that have held

Do not cut containers that have held

combustibles.

combustibles.combustibles.

combustibles.

SECTION 1 Safety

EtchArc-1125 Power Source 1-8

1.7 Service Precautions

WARNING

!

Hazardous voltages. Electric shock

can kill.

• Do NOT touch plasma torch

Do NOT touch plasma torchDo NOT touch plasma torch

Do NOT touch plasma torch, cutting table or

, cutting table or , cutting table or

, cutting table or

cable connections during plasma cutting process.

cable connections during plasma cutting process.cable connections during plasma cutting process.

cable connections during plasma cutting process.

• Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

Always turn power off to plasma power

supplies before touching or servicing plasma torch.

supplies before touchin

g

or servicin

g

plasma torch. supplies before touchin

g

or servicin

g

plasma torch.

supplies before touching or servicing plasma torch.

• Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

Always turn power off to plasma power

supplies before removing covers or panels to

supplies before removing covers or panels to supplies before removing covers or panels to

supplies before removing covers or panels to

service any s

service any sservice any s

service any system component.

ystem component.ystem component.

ystem component.

• Do not touch live electrical parts.

Do not touch live electrical parts.Do not touch live electrical parts.

Do not touch live electrical parts.

• Keep all panels and covers in place when

Keep all panels and covers in place when Keep all panels and covers in place when

Keep all panels and covers in place when

machine is connected to power source.

machine is connected to power source.machine is connected to power source.

machine is connected to power source.

• Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

equipment dry.

equipment dry.equipment dry.

equipment dry.

• Inspect power and ground leads cables for

Inspect power and ground leads cables for Inspect power and ground leads cables for

Inspect power and ground leads cables for

wear or cracking. Repl

wear or cracking. Replwear or cracking. Repl

wear or cracking. Replace worn or damaged

ace worn or damaged ace worn or damaged

ace worn or damaged

cables. Do not use if damaged.

cables. Do not use if damaged.cables. Do not use if damaged.

cables. Do not use if damaged.

• Never bypass safety interlocks.

Never bypass safety interlocks.Never bypass safety interlocks.

Never bypass safety interlocks.

• Follow lock

Follow lockFollow lock

Follow lock-

--

-out procedures.

out procedures.out procedures.

out procedures.

CAUTION

Establish and adhere to preventive maintenance.

Establish and adhere to preventive maintenance. Establish and adhere to preventive maintenance.

Establish and adhere to preventive maintenance.

A composite program can be established from

A composite program can be established from A composite program can be established from

A composite program can be established from

recommended schedules.

recommended schedules.recommended schedules.

recommended schedules.

Avoid leaving test equ

Avoid leaving test equAvoid leaving test equ

Avoid leaving test equipment or hand tools on

ipment or hand tools on ipment or hand tools on

ipment or hand tools on

machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damage

could occur to equipment or machine.

could occur to equipment or machine.could occur to equipment or machine.

could occur to equipment or machine.

CAUTION

!

Extreme caution should be used when probing

Extreme caution should be used when probing Extreme caution should be used when probing

Extreme caution should be used when probing

circuitry with an oscilloscope or voltmeter.

circuitry with an oscilloscope or voltmeter. circuitry with an oscilloscope or voltmeter.

circuitry with an oscilloscope or voltmeter.

Integrated circuits are susceptible to over volta

Integrated circuits are susceptible to over voltaIntegrated circuits are susceptible to over volta

Integrated circuits are susceptible to over voltage

ge ge

ge

damage. Power off before using test probes to

damage. Power off before using test probes to damage. Power off before using test probes to

damage. Power off before using test probes to

prevent accidental shorting of components.

prevent accidental shorting of components.prevent accidental shorting of components.

prevent accidental shorting of components.

All circuit boards securely seated in sockets, all

All circuit boards securely seated in sockets, all All circuit boards securely seated in sockets, all

All circuit boards securely seated in sockets, all

cables properly connected, all cabinets closed and

cables properly connected, all cabinets closed and cables properly connected, all cabinets closed and

cables properly connected, all cabinets closed and

locked, all guards and covers replaced before

locked, all guards and covers replaced before locked, all guards and covers replaced before

locked, all guards and covers replaced before

power is turned

power is turnedpower is turned

power is turned on.

on. on.

on.

SECTION 1 Safety

EtchArc-1125 Power Source 1-9

1.8 Safety References -- Regulations, Standards, Guidelines

The following recognized publications on safety in welding and cutting

operations are recommended. These publications have been prepared

to protect persons from injury or illness and to protect property from

damage, which could result from unsafe practices. Although some of

these publications are not related specifically to this type of industrial

cutting apparatus, the principles of safety apply equally.

1.8.1 Domestic

• “Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting

Systems.

• “Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529. ESAB Cutting Systems.

• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

• “Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

• “Recommended Practices for Arc Cutting” - AWS C5.2, American

Welding Society.

• “Safe Practices” - AWS SP, American Welding Society.

• “Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B, National Fire Protection Association, 60

Batterymarch Street, Boston, Massachusetts, 02110.

• “Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51, National Fire

Protection Association.

• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting

Systems. Obtainable through your ESAB representative or local

distributor.

• "Design and Installation of Oxygen Piping Systems," Form 5110.

ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed Gases in

Cylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with

gaseous materials is also available from the Compressed Gas

Association, Inc., 500 Fifth Ave., New York, NY 10036.

SECTION 1 Safety

EtchArc-1125 Power Source 1-10

1.8.2 International

Accident Prevention

VBG 1 General Provisions

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working

methods

VBG 48 Shot Blasting Works

VBG 61 Gases

VBG 62 Oxygen

VBG 87 Operating liquid jet cutting machines

VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE Regulations

VDE 0100 Erection of power installations with normal

voltages up to 1000 volts

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users

guide (DIN EN 60825)

VDE 0837-

50

Specification for laser guards

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-204 Acetylene lines

TRAC-206 Acetylene cylinder battery systems

TRAC-207 Safety devices

TRG Technical Rules for Pressure gases

TRG 100 General regulations for pressure gases

TRG 101 Pressure gases

TRG 102 Technical gas mixtures

TRG 104 Pressure gases; alterative use of

compressed gas tanks

SECTION 1 Safety

EtchArc-1125 Power Source 1-11

DIN Standards

DIN 2310

Part 1

Thermal cutting; terminology and

nomenclature

DIN 2310

Part 2

Thermal cutting; determination of quality of cut

faces

DIN 2310

Part 4

Thermal cutting; arc plasma cutting; process

principles, quality, dimensional tolerances

DIN 2310

Part 5

Thermal cutting; laser beam cutting of metallic

materials; process principles

DIN 4844

Part 1

Safety markings (DIN EN 7287)

DIN EN ISO Harmonized Standards

DIN EN

292/1 and 2

Safety of machinery

DIN EN 559 Hoses for welding, cutting and allied

processes

DIN EN 560 Hose connections and hose couplings for

equipment for welding, cutting and allied

processes

DIN EN 561 Gas welding equipment hose couplings

DIN EN

626-1

Safety of machines, reduction of risks to

health

DIN EN

848-1

Single spindle vertical milling machines

DIN EN

1829

High pressure water jet machines

DIN EN

9013

Thermal cutting, oxygen cutting, process

principles, dimensional tolerances

DIN EN

12584

Imperfections in oxy/fuel flame cuts, laser

beam cuts and plasma

DIN EN

12626

Laser processing machines

DIN EN

28206

Acceptance testing for oxygen cutting

machines

DIN EN

31252

Laser Equipment

DIN EN

31553

Laser and laser related equipment

DIN EN

60204-1

Electrical equipment of machines

DIN EN

60825

Radiation safety of laser products

DIN EN 999 Arrangement of protection devices

VDI Guidelines

VDI 2906 Quality of cut faces on metallic workpieces;

abrasive water jet cutting and arc plasma

cutting

VDI 2084 Room air; Technical systems for welding

workshops

SECTION 1 Safety

EtchArc-1125 Power Source 1-12

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SECTION 2 System Description

EtchArc-1125 Plasma Marking System 2-1

2 Introduction

2.1 Overview

The EtchArc Plasma Marker is a constricted arc low

amperage plasma marking torch. It marks at

speeds between 100 and 500 ipm.

The plasma marking process is similar to the

plasma cutting process. However, rather than

piercing through the plate, the low amperage

plasma arc merely cuts the surface of the plate

material between .0002 and .005 deep. Voltage

height control maintains a constant torch standoff

for consistent, high speed, accurate pattern layout.

When the EtchArc Plasma Marker is used in

conjunction with ESAB’s Vision CNC, Dynamic

Current Control is used to precisely control width

and depth of marks by proportionally ramping

current up and down as the machine accelerates

and decelerates. This minimizes pitting at the

beginning, corners, and end of the mark.

Accurate positioning of the layout lines and marks

depends on using the automatic marker offsets

executed by the CNC during Automatic Mode.

However, the marker can be used manually for

testing and setup.

In automatic operation, the part program controls:

• machine motion

• offsets torch

• turns on automatic height control

• fires the torch and begins marking.

All of these steps can be performed by the operator

for manual operation.

The EtchArc-1125 Plasma Marking Power Supply

consists of a modified PCM-1125 capable of

supplying up to 35 amperes. Modifications include

an added argon solenoid, pressure switch, gas

connections, marker control board and cable

connection. Unused manual controls were

removed or disconnected from the PCM-1125.

The marking torch has only three consumable parts:

the electrode, nozzle and shield cup. Argon cut gas

provides long electrode and nozzle life.

SECTION 2 System Description

EtchArc-1125 Plasma Marking System 2-2

2.1.1 Interconnecting Diagram

2

1

3

5

6

7

9

10

12

13

14

15

16

8

B

11

E

EE

E

t

tt

tc

cc

c

h

hh

h

A

AA

A

r

rr

r

c

cc

c

F

4

F

EtchArc

EtchArcEtchArc

EtchArc-

--

-1125 Front Connections

1125 Front Connections1125 Front Connections

1125 Front Connections

B

EtchArc

EtchArcEtchArc

EtchArc-

--

-1125 Back Connections

1125 Back Connections1125 Back Connections

1125 Back Connections

1 Vision CNC (relay box) 9 Air Regulator

2 CNC Control Cable 10 Air Supply Hose

3 Argon Gas Hose to torch 11 Argon Supply Hose

4 Work Cable 12 Primary Power Cable

5 Torch Bundle 13 Argon Gas Supply

6 Marking Torch 14 Compressed Air Supply

7 Work Piece

8 Earth Ground

15

Fused Disconnect (mounted on

machine, used when EtchArc-1125

has been mounted on the machine)

16 Wall disconnect

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ESAB EtchArc®-1125 Plasma Marking System User manual

ESAB EtchArc®-1125 Plasma Marking System User manual

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