ESAB EtchArc®-1125 Plasma Marking System User manual

Category
Welding System
Type
User manual
F15-727
April, 2002
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.
©
©©
© ESAB Cutting Systems, 2002
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
manuals 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
This page intentionally left blank.
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
  • Page 1 1
  • Page 2 2
  • Page 3 3
  • Page 4 4
  • Page 5 5
  • Page 6 6
  • Page 7 7
  • Page 8 8
  • Page 9 9
  • Page 10 10
  • Page 11 11
  • Page 12 12
  • Page 13 13
  • Page 14 14
  • Page 15 15
  • Page 16 16
  • Page 17 17
  • Page 18 18
  • Page 19 19
  • Page 20 20
  • Page 21 21
  • Page 22 22
  • Page 23 23
  • Page 24 24
  • Page 25 25
  • Page 26 26
  • Page 27 27
  • Page 28 28
  • Page 29 29
  • Page 30 30
  • Page 31 31
  • Page 32 32
  • Page 33 33
  • Page 34 34
  • Page 35 35
  • Page 36 36
  • Page 37 37
  • Page 38 38
  • Page 39 39
  • Page 40 40
  • Page 41 41
  • Page 42 42
  • Page 43 43
  • Page 44 44
  • Page 45 45
  • Page 46 46
  • Page 47 47
  • Page 48 48
  • Page 49 49
  • Page 50 50
  • Page 51 51
  • Page 52 52
  • Page 53 53
  • Page 54 54
  • Page 55 55
  • Page 56 56
  • Page 57 57
  • Page 58 58
  • Page 59 59
  • Page 60 60
  • Page 61 61
  • Page 62 62
  • Page 63 63
  • Page 64 64
  • Page 65 65
  • Page 66 66
  • Page 67 67
  • Page 68 68
  • Page 69 69
  • Page 70 70
  • Page 71 71
  • Page 72 72
  • Page 73 73
  • Page 74 74
  • Page 75 75
  • Page 76 76
  • Page 77 77
  • Page 78 78
  • Page 79 79
  • Page 80 80
  • Page 81 81
  • Page 82 82
  • Page 83 83
  • Page 84 84
  • Page 85 85
  • Page 86 86
  • Page 87 87
  • Page 88 88
  • Page 89 89
  • Page 90 90
  • Page 91 91
  • Page 92 92
  • Page 93 93
  • Page 94 94
  • Page 95 95
  • Page 96 96
  • Page 97 97
  • Page 98 98
  • Page 99 99
  • Page 100 100
  • Page 101 101
  • Page 102 102
  • Page 103 103
  • Page 104 104
  • Page 105 105
  • Page 106 106
  • Page 107 107
  • Page 108 108
  • Page 109 109
  • Page 110 110

ESAB EtchArc®-1125 Plasma Marking System User manual

Category
Welding System
Type
User manual

Ask a question and I''ll find the answer in the document

Finding information in a document is now easier with AI