F-15-487
July, 2001
Installation, Operation, and Maintenance for the
SmartFlow II
Plasma System Plumbing Box
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 to
ESAB Cutting Systems first priority is toESAB Cutting Systems first priority is to
ESAB Cutting Systems first priority is total customer
tal customer tal customer
tal customer
satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to
improve our products, service and documentation.
improve our products, service and documentation. improve our products, service and documentation.
improve our products, service and documentation.
As a result, we make e
As a result, we make eAs a result, we make e
As a result, we make en
nn
nhancements and/or design
hancements and/or design hancements and/or design
hancements and/or design
changes as r
changes as rchanges as r
changes as re
ee
equired. ESAB makes every possible
quired. ESAB makes every possible quired. ESAB makes every possible
quired. ESAB makes every possible
effort to ensure our documentation is current. We
effort to ensure our documentation is current. We effort to ensure our documentation is current. We
effort to ensure our documentation is current. We
cannot guarantee that each piece of docume
cannot guarantee that each piece of documecannot guarantee that each piece of docume
cannot guarantee that each piece of documen
nn
ntation
tation tation
tation
received by our customers reflects the latest design
received by our customers reflects the latest design received by our customers reflects the latest design
received by our customers reflects the latest design
enhancements. Therefore, the information
enhancements. Therefore, the information enhancements. Therefore, the information
enhancements. Therefore, the information
contained in this document is subject to change
contained in this document is subject to change contained in this document is subject to change
contained in this document is subject to change
without n
without nwithout n
without no
oo
otice.
tice.tice.
tice.
This manual is ESAB Part Number F15487
This manual is ESAB Part Number F15487This manual is ESAB Part Number F15487
This manual is ESAB Part Number F15487
Date reflects rewritten and updated.
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, 2001
Printed in U.S.A.
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 Service Precautions............................................................................. 8
1.7 Safety References ............................................................................... 10
Section 2 Description
2.1 Introduction......................................................................................... 1
2.2 SmartFlow II and PT-15XL Plasma Torch ............................................. 1
2.3 SmartFlow II and PT-19XLS/PT-600 Plasma Torch .............................. 2
2.4 SmartFlow II Options ........................................................................... 2
2.5 Gas Requirements................................................................................ 2
2.6 Water Supply Requirements ................................................................ 3
2.7 Electrical Input Requirements............................................................... 3
2.8 Physical Dimensions............................................................................ 4
Section 3 Installation
3.1 Introduction......................................................................................... 1
3.2 Mounting............................................................................................. 1
3.3 Hose and Cable Connections .............................................................. 2
3.3.1 Starter Box Connections.............................................................. 3
3.3.2 PC Board Connections................................................................ 3
3.3.3 Torch Cooling Water Connections................................................ 4
3.3.4 Power Source (ESP) to SmartFlow II Buss Connections................ 4
3.4 Nomex Insulation................................................................................. 5
3.5 Gas Connections................................................................................. 5
3.5.1 Gas Lines From Supply................................................................ 5
3.5.2 Gas Pressure Setup..................................................................... 7
3.6 Cutwater Setup (PT-15XL only)............................................................ 7
3.7 Secondary Shield Gas Setup (PT-19XLS and PT-600)......................... 7
3.8 System Component Block Diagram ..................................................... 8
3.9 Fluid Schematic – SF II ........................................................................ 9
Table of Contents
ii
Page
Section 4 Operation
4.1 Introduction ........................................................................................ 1
4.2 Pressure Gages.................................................................................. 1
4.3 Pressure Switches .............................................................................. 1
Section 5 Maintenance
5.1 Introduction ........................................................................................ 1
5.2 Pressure Switches .............................................................................. 2
5.3 Arc Starter Spark Gap......................................................................... 3
5.4 Spark Gap Adjustment Procedure....................................................... 4
5.5 Gas Proportional Valves...................................................................... 5
5.6 Cutwater/ Secondary Shield Proportional Valve ................................... 5
5.7 Cooling Water Flow Switch.................................................................. 6
5.8 Gas Filters .......................................................................................... 7
Section 6 Troubleshooting
6.1 Introduction ........................................................................................ 1
6.2 Cooling Water Circuit .......................................................................... 2
6.3 Cutwater and Auxiliary Cutwater.......................................................... 3
6.4 Plasma Gas Circuit ............................................................................. 4
6.5 Secondary Shield................................................................................ 5
6.6 Arc Start
6.6.1 Setting the Spark Gap................................................................. 6
6.6.2 Spark Gap Size Attributes ........................................................... 7
6.6.3 Spark Viewing............................................................................. 8
6.7 Fluid Schematic .................................................................................. 9
6.8 SM II Interface PCB Schematic............................................................ 10
6.9 Technical Guide to SmartFlow II Process Diagnostics
6.9.1 Plasma Process Timer Values for Vision Cutting Record File
PARAM.CUT and Interpretation Data File DEF.TEC................................
11
6.9.2 Vision Keyboard Functions for Plasma System Test .....................
12
6.9.3 Proportional Valve Analog Flow Values for Vision Cutting Record
File PARAM.CUT and Interpretation File DEF.TEC.................................. 13
6.9.4 Gas Selection Requirements .......................................................
13
6.9.5 Plasma Process Gas Flowchart ...................................................
14
6.9.6 Solenoid and Proportional Valve Requirements – Station ON
Flush Cycle...........................................................................................
15
Table of Contents
iii
6.9.7 Solenoid and Proportional Valve Requirements –
PT-19XLS/PT-600 Start Gas N
2
, Cut Gas N
2
..........................................
16
Error Monitoring Requirements SFII— N
2
— N
2
..................................... 16
6.9.8 Solenoid and Proportional Valve Requirements –
PT-19XLS/PT-600 Start Gas H-35, Cut Gas H-35 ................................. 18
Error Monitoring Requirements SFII— H-35— H-35............................ 18
6.9.9 Solenoid and Proportional Valve Requirements –
PT-19XLS/PT-600 Start Gas N
2
, Cut Gas H-35...................................... 20
Error Monitoring Requirements SFII— N
2
— H-35 ................................ 20
6.9.10 Solenoid and Proportional Valve Requirements –
PT-19XLS/PT-600 Start Gas N
2
, Cut Gas O
2
.......................................... 22
Error Monitoring Requirements SFII— N
2
— O
2
.................................... 22
6.9.11 Solenoid and Proportional Valve Requirements –
PT-15XL Start Gas N
2
, Cut Gas N
2
....................................................... 24
Error Monitoring Requirements SFII— N
2
— N
2
..................................... 24
6.9.12 Solenoid and Proportional Valve Requirements –
PT-15XL Start Gas N
2
, Cut Gas O
2
...................................................... 26
Error Monitoring Requirements SFII— N
2
— O
2
.................................... 26
6.9.13 Solenoid and Proportional Valve Requirements –
PT-15XL Start Gas H-35, Cut Gas H-35.............................................. 28
Error Monitoring Requirements SFII— H-35— H-35............................ 28
6.9.14 Solenoid and Proportional Valve Requirements –
PT-15XL Start Gas N
2
, Cut Gas H-35 .................................................. 30
Error Monitoring Requirements SFII— N
2
— H-35 ................................ 30
6.9.15 SmartFlow II Test Files............................................................... 32
6.10 Secondary Shield Proportional Valve Calibration Procedure................ 38
Section 7 Replacement Parts
7.1 General............................................................................................... 1
7.2 Ordering ............................................................................................. 1
7.3 Right Inside without H-35 Option......................................................... 2
7.4 Right Inside with H-35 Option.............................................................. 4
7.5 Front Outside...................................................................................... 6
7.6 Left Inside........................................................................................... 8
7.7 Back Outside...................................................................................... 10
Customer/Technical Information Back Manual Cover
Table of Contents
iv
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SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-1
DANGER
!
WARNING
!
CAUTION
!
CAUTION
NOTICE
1.1 Introduction
ESAB cutting machines are designed to provide both
operational safety and efficiency. However, as with
any machine tool, sensible attention to operating
procedures, precautions, and safe practices is
necessary. Whether an individual is involved with
operation, servicing, or as an observer, compliance
with established precautions and safe practices must
be carried out. Failure to observe warnings/
precautions could result in death/serious personal
injury or severe equipment damage. The following are
general guidelines applicable when working with
cutting machines. Additional precautions pertaining to
this equipment are found throughout this literature.
For a wide scope of safety information on the field of
cutting and welding, obtain and read the publications
listed in the Recommended References at the end of
this section.
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.
Used to call attention to immediate hazards which, if
not avoided, will result in serious personal injury or
loss of life.
Used to call attention to potential hazards that could
result in personal injury or loss of life.
Used to call attention to hazards that could result in
minor personal injury or equipment damage.
Used to call attention to minor hazards to equipment.
Used to call attention to important installation,
operation or maintenance information not directly
related to safety hazards.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-2
1.3 General Safety Information
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 p
Read entire pRead entire p
Read entire procedure before operating or
rocedure before operating or rocedure before operating or
rocedure 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
regarding personnel safety and/or possible
regarding personnel safety and/or possible regarding personnel safety and/or possible
regarding personnel safety and/or possible
equipment damage.
equipment damage.equipment damage.
equipment damage.
• All safety precautions relevant to elect
All safety precautions relevant to electAll safety precautions relevant to elect
All safety precautions relevant to electrical
rical rical
rical
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 by
Read all safety publications made available by Read all safety publications made available by
Read all safety publications made available by
your company.
your company.your company.
your company.
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 additional safety
Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety
information.
information.information.
information.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-3
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:
• Do not connect a cylinder directl
Do not connect a cylinder directlDo not connect a cylinder directl
Do not connect a cylinder directly to machine inlet.
y to machine inlet. y to machine inlet.
y to machine inlet.
An appropriate cylinder regulator must be installed
An appropriate cylinder regulator must be installed An appropriate cylinder regulator must be installed
An appropriate cylinder regulator must be installed
on a fuel gas cylinder to reduce pressure to a
on a fuel gas cylinder to reduce pressure to a on a fuel gas cylinder to reduce pressure to a
on a fuel gas cylinder to reduce pressure to a
reasonable inlet supply pressure. Machine
reasonable inlet supply pressure. Machine reasonable inlet supply pressure. Machine
reasonable inlet supply pressure. Machine
regulator is then used to obtain pressure required
regulator is then used to obtain pressure required regulator is then used to obtain pressure required
regulator is then used to obtain pressure required
by torches.
by torches.by torches.
by torches.
• Contact your ESAB representati
Contact your ESAB representatiContact your ESAB representati
Contact your ESAB representative before
ve before ve before
ve before
installation. He can suggest certain precautions
installation. He can suggest certain precautions installation. He can suggest certain precautions
installation. He can suggest certain precautions
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 represe
qualified ESAB represequalified ESAB represe
qualified ESAB representative.
ntative.ntative.
ntative.
• Observe machine clearance requirements for
Observe machine clearance requirements for Observe machine clearance requirements for
Observe machine clearance requirements for
proper operation and personnel safety.
proper operation and personnel safety. proper operation and personnel safety.
proper 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 s
proper fuse sproper fuse s
proper fuse sizes close to the power supply.
izes close to the power supply.izes close to the power supply.
izes close to the power supply.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
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 death.
Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.
Improper grounding can cause severe injury or death.
Machine must be properly grounded before put into
Machine must be properly grounded before put into Machine must be properly grounded before put into
Machine must be properly grounded before put into
serv
servserv
service.
ice.ice.
ice.
WARNING
!
Improper Grounding Can Damage
Machine And Electrical Components.
• Machine must be properly gr
Machine must be properly grMachine must be properly gr
Machine must be properly grounded before put
ounded before put ounded before put
ounded before put
into service.
into service. into service.
into service.
• Cutting table must be properly grounded to
Cutting table must be properly grounded toCutting table must be properly grounded to
Cutting table must be properly grounded to a good
a good a good
a good
Earth ground rod.
Earth ground rod.Earth ground rod.
Earth ground rod.
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 operation.
debris generated during operation.debris generated during operation.
debris generated during operation.
• Chipped slag may be hot and fly far. Bystand
Chipped slag may be hot and fly far. BystandChipped slag may be hot and fly far. Bystand
Chipped slag may be hot and fly far. Bystanders
ers ers
ers
should also wear goggles and safety glasses.
should also wear goggles and safety glasses.should also wear goggles and safety glasses.
should also wear goggles and safety glasses.
• Noise from plasma arc can damage hearing. Wear
Noise from plasma arc can damage hearing. Wear Noise from plasma arc can damage hearing. Wear
Noise from plasma arc can damage hearing. Wear
correct ear protection when cutting above water.
correct ear protection when cutting above water. correct ear protection when cutting above water.
correct ear protection when cutting above water.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-5
WARNING
!
Burn hazard.
Hot metal can burn.
Hot metal can burn.Hot metal can burn.
Hot metal can burn.
• Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after
cutting. Allow metal time to cool, or douse with
cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with
cutting. Allow metal time to cool, or douse with
water.
water.water.
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 ti
cutting. Allow torch ticutting. Allow torch ti
cutting. Allow torch time to cool.
me to cool.me to cool.
me to cool.
WARNING
!
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table o
Do NOT touch plasma torch, cutting table oDo NOT touch plasma torch, cutting table o
Do NOT touch plasma torch, cutting table or cable
r cable r cable
r cable
connections during plasma cutting process.
connections during plasma cutting process.connections during plasma cutting process.
connections during plasma cutting process.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before touching or servicing plasma torch.
before touching or servicing plasma torch. before touching or servicing plasma torch.
before touching or servicing plasma torch.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before servicing any system component.
before servicing any system component.before servicing any system component.
before servicing any system component.
• Do not touch live electrica
Do not touch live electricaDo not touch live electrica
Do not touch live electrical parts.
l parts.l parts.
l parts.
• Keep all panels and covers in place when machine
Keep all panels and covers in place when machine Keep all panels and covers in place when machine
Keep all panels and covers in place when machine
is connected to power source.
is connected to power source.is connected to power source.
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 dry.
equipment dry.equipment dry.
equipment dry.
• Replac
ReplacReplac
Replace worn or damaged cables.
e worn or damaged cables.e worn or damaged cables.
e worn or damaged cables.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-6
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 ca
process caprocess ca
process can be hazardous to your health.
n be hazardous to your health.n be hazardous to your health.
n 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 removal
Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal
system operating properly.
system operating properly. system operating properly.
system operating properly.
• Use additional ventilation to remove fumes if
Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if
Use additional 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 posit
Provide positProvide posit
Provide positive mechanical ventilation when
ive mechanical ventilation when ive mechanical ventilation when
ive 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 not operate near degreasing and spraying
Do not operate near degreasing and spraying Do not operate near degreasing and spraying
Do 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 v
chlorinated hydrocarbon vchlorinated hydrocarbon v
chlorinated hydrocarbon vapors to form phosgene,
apors to form phosgene, apors to form phosgene,
apors 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
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-7
WARNING
!
Radiation hazard.
Arc rays
Arc rays Arc rays
Arc rays can injure eyes and burn skin.
can injure eyes and burn skin.can injure eyes and burn skin.
can injure eyes and burn skin.
• 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 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 N
Shade NShade N
Shade No. 8
o. 8o. 8
o. 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 Amps
400 Amps400 Amps
400 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 pitted or
Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or
broken
brokenbroken
broken
• Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses.
unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.
unless wearing appropriate safety glasses.
• Prepare cutting a
Prepare cutting aPrepare cutting a
Prepare cutting area to reduce reflection and
rea to reduce reflection and rea to reduce reflection and
rea to reduce reflection and
transmission of ultraviolet light.
transmission of ultraviolet light.transmission of ultraviolet light.
transmission of ultraviolet light.
§ Paint walls and other surfaces with dark
Paint walls and other surfaces with dark Paint walls and other surfaces with dark
Paint walls and other surfaces with dark
colors to reduce reflections.
colors to reduce reflections.colors to reduce reflections.
colors to reduce reflections.
§ 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
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-8
WARNING
!
Ruptured Gas Cylinders Can Kill
Mishandl
MishandlMishandl
Mishandling gas cylinders can rupture and violently
ing gas cylinders can rupture and violently ing gas cylinders can rupture and violently
ing gas cylinders can rupture and violently
release gas.
release gas. release gas.
release gas.
• Avoid rough handling of cylinders.
Avoid rough handling of cylinders.Avoid rough handling of cylinders.
Avoid rough handling of cylinders.
• Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.
• Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.
• Always secure cylinders in an upright position by
Always secure cylinders in an upright position by Always secure cylinders in an upright position by
Always secure cylinders in an upright position by
chain or strap to a
chain or strap to a chain or strap to a
chain or strap to a suitable stable object not part of
suitable stable object not part of suitable stable object not part of
suitable stable object not part of
an electrical circuit.
an electrical circuit.an electrical circuit.
an electrical circuit.
• Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.
• Use approved pressure reducing regulator for the
Use approved pressure reducing regulator for the Use approved pressure reducing regulator for the
Use approved pressure reducing regulator for the
specific gas.
specific gas.specific gas.
specific gas.
• Refer to CGA Standard P
Refer to CGA Standard PRefer to CGA Standard P
Refer to CGA Standard P-
--
-1, “Precautions for Saf
1, “Precautions for Saf1, “Precautions for Saf
1, “Precautions for Safe
e e
e
Handling of Compressed Gases in Cylinders”,
Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”,
Handling of Compressed Gases in Cylinders”,
available from Compressed Gas Association.
available from Compressed Gas Association.available from Compressed Gas Association.
available from Compressed Gas Association.
WARNING
!
Explosion hazard.
• Certain molten aluminum
Certain molten aluminumCertain molten aluminum
Certain molten aluminum-
--
-lithium (Al
lithium (Allithium (Al
lithium (Al-
--
-Li) alloys can
Li) alloys can Li) alloys can
Li) alloys can
cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water.
§ These alloys should only be dry cut on a dry
These alloys should only be dry cut on a dry These alloys should only be dry cut on a dry
These alloys should only be dry cut on a dry
table.
table.table.
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 rega
additional safety information regaadditional safety information rega
additional safety information regarding
rding rding
rding
hazards associated with these alloys
hazards associated with these alloyshazards associated with these alloys
hazards associated with these alloys
.
• Do not cut in atmospheres containing explosive
Do not cut in atmospheres containing explosive Do not cut in atmospheres containing explosive
Do not cut in atmospheres containing explosive
dust or vapors.
dust or vapors.dust or vapors.
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 combustibles.
Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-9
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 not have on your person a
Do not have on your person aDo not have on your person a
Do not have on your person any combustibles (e.g.
ny combustibles (e.g. ny combustibles (e.g.
ny combustibles (e.g.
butane lighter).
butane lighter).butane lighter).
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.
• Wear flame
Wear flameWear flame
Wear flame-
--
-retardant clothi
retardant clothiretardant clothi
retardant clothing covering all exposed
ng covering all exposed ng covering all exposed
ng covering all exposed
areas.
areas.areas.
areas.
• Wear cuff
Wear cuffWear cuff
Wear cuff-
--
-less trousers to prevent entry of sparks
less trousers to prevent entry of sparks less trousers to prevent entry of sparks
less trousers to prevent entry of sparks
and slag.
and slag.and slag.
and slag.
• Have fire extinguishing equipment available for use.
Have fire extinguishing equipment available for use.Have fire extinguishing equipment available for use.
Have fire extinguishing equipment available for use.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-10
1.6 Service Precautions
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 cable
ng table or cable ng table or cable
ng table or cable
connections during plasma cutting process.
connections during plasma cutting process.connections during plasma cutting process.
connections during plasma cutting process.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before touching or servicing plasma torch.
before touching or servicing plasma torch. before touching or servicing plasma torch.
before touching or servicing plasma torch.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before removing covers or panels to service any
before removing covers or panels to service any before removing covers or panels to service any
before removing covers or panels to service any
system c
system csystem c
system component.
omponent.omponent.
omponent.
• 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 machine
Keep all panels and covers in place when machine Keep all panels and covers in place when machine
Keep all panels and covers in place when machine
is connected to power source.
is connected to power source.is connected to power source.
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 wear or
Inspect power and ground leads cables for wear or Inspect power and ground leads cables for wear or
Inspect power and ground leads cables for wear or
cracking. Replace wor
cracking. Replace worcracking. Replace wor
cracking. Replace worn or damaged cables. Do
n or damaged cables. Do n or damaged cables. Do
n or damaged cables. Do
not use if damaged.
not use if damaged.not use if damaged.
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. A
Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A
Establish and adhere to preventive maintenance. A
composite program can be established from
composite program can be established from composite program can be established from
composite program can be established from
recommended schedules.
recommended schedules.recommended schedules.
recommended schedules.
Avoid leaving test equipment
Avoid leaving test equipment Avoid leaving test equipment
Avoid leaving test equipment or hand tools on
or hand tools on or hand tools on
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.
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-11
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. Integrated
circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated
circuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damag
circuits are susceptible to over voltage damagcircuits are susceptible to over voltage damag
circuits are susceptible to over voltage damage.
e. e.
e.
Power off before using test probes to prevent
Power off before using test probes to prevent Power off before using test probes to prevent
Power off before using test probes to prevent
accidental shorting of components.
accidental shorting of components.accidental shorting of components.
accidental shorting of components.
All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned
guards and covers replaced before power is turned guards and covers replaced before power is turned
guards and covers replaced before power is turned
on.
on.on.
on.
1.9 Safety References
The following nationally 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.
• “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.
Continued next page
SECTION 1 SAFETY
Smart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System
Smart Flow II Plasma Cutting System
1-12
• “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 2 DESCRIPTION
SmartFlow II Plasma Cutting System
SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System
SmartFlow II Plasma Cutting System
2-1
2.1 Introduction
The SmartFlow II Cutting System is a streamlined,
high performance-cutting package designed for use
exclusively with the ESAB Vision CNC. This
advanced technology integrates gas and water
control into the machine CNC.
Using a system of proportional valves driven by
CNC outputs, this system:
• dramatically reduces the amount of plumbing
hardware necessary to control the plasma torch
• reduced purge time/increased part throughput
• simplified operation with gas and water flow
rates manually controlled at the Vision CNC
process parameter screen
• allows for programmed/automated control of
gas and water flow rates using SDP Files
(S
SS
SchneidD
DD
DatenP
PP
Paket = Cutting Data Package,
see Vision control and programming manuals
for details on SDP Files. Data used to generate
SDP files can be found in your model specific
torch manual.)
• can be used with either a PT-15XL water
injection torch or a PT-600/PT-19XLS dry
cutting torch with secondary shield gas. (The
PT-600 and the PT-19XLS are both dry cutting
torches of similar design.)
2.2 SmartFlow II and PT-15XL
When the PT-15XL water injection torch is used, the
complete cutting system also requires the following
components:
• PT-15XL plasma torch
• a plasma power supply
• a recirculating water cooler
• coolant pump
• cut water pump
• air curtain regulator
• Vision CNC.
SECTION 2 DESCRIPTION
SmartFlow II Plasma Cutting System
SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System
SmartFlow II Plasma Cutting System
2-2
2.3 SmartFlow II and PT-19XLS/PT-600
When a dry torch (no water injection) is used, the
SmartFlow II water injection components are used
to control the secondary shield pressure. The
components of The SmartFlow II Cutting System
with dry torch requires the following components:
• Vision CNC,
• PT-19XLS or PT-600 plasma torch,
• power supply,
• a recirculating water cooler,
• and coolant pump.
2.4 SmartFlow II Options
SmartFlow II with H-35 capability
(H-35 is industry accepted nomenclature for a gas
mixture of 65% argon and 35% hydrogen)
SmartFlow II without H-35 capability
P/N 37538
P/N 37538P/N 37538
P/N 37538
P/N 37540
P/N 37540P/N 37540
P/N 37540
2.5 Gas Requirements
Nitrogen
• 125 PSI (8,63 bar) with 0.5” NPT
• 99.999% purity
• Filtered to 25 microns
Oxygen
• 125 PSI (8,63 bar) with 0.5” NPT
• 99.999% purity
• Filtered to 25 microns
Compressed Air
• 100 PSI (6,9 bar) with 0.5” NPT
• Clean, dry and filtered to 25
microns
H-35 (argon/hydrogen)
• 150 PSI (10,4 bar)
• Filtered to 25 microns
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