ESAB PMC-91 Plasmarc System User manual

Brand: ESAB

Model: PMC-91 Plasmarc System

Category: Welding System

Type: User manual

PMC-91 PlasMarC systeM

Mechanized Plasma Cutting and Marking

with PT-600, PT-19XLS or PT-36

Instruction Manual

0558008059 05 / 2008

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

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

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

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

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

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

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

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

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

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

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

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

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

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

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

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

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

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

1.0 Safety Precautions ....................................................................................5

1.1 Safety - English .................................................................................5

1.2 Safety - Spanish.................................................................................9

1.3 Safety - French.................................................................................13

2.0 Introduction .........................................................................................17

2.1 General ........................................................................................17

2.2 Features .......................................................................................17

2.3 Component Description........................................................................18

3.0 Installation.......................................................................................... 25

3.1 System Component Locations.................................................................. 25

3.2 System Connections ........................................................................... 26

3.3 Torch Components ............................................................................ 34

3.4 Installing Air Curtain ........................................................................... 38

3.5 Water Muer Installation ...................................................................... 39

3.6 Air Curtain / Water Muer Control Box Installation..............................................40

4.0 Operation - Cutting ..................................................................................41

4.1 Controls and Indicators .........................................................................41

4.2 Pre-Operation Test / Checkout ................................................................. 46

4.3 Operating Techniques ......................................................................... 50

5.0 Operation - Marking..................................................................................55

5.1 Pre-Operation Test and Checkout ...............................................................55

5.2 Marking and Cutting Procedure ................................................................ 56

6.0 Troubleshooting .................................................................................... 57

6.1 Programmable Logic Controller (PLC)........................................................... 57

6.2 Sequence Description.......................................................................... 58

6.3 Operating Information ......................................................................... 60

6.4 Troubleshooting Guide .........................................................................61

Section / Title Page

PLASMA CUTTING WITH GAS MIXTURES CONTAINING HYDROGEN (H) OR METHANE (CH4)

CAN RESULT IN AN EXPLOSION.

FAILURE TO COMPLY WITH THE INFORMATION LISTED BELOW CAN RESULT IN DEATH, SEVERE

PERSONAL INJURY OR SERIOUS EQUIPMENT DAMAGE.

HYDROGEN OR METHANE GAS MIXTURES SHOULD NEVER BE USED FOR PLASMA CUTTING

UNDERWATER.

CUTTING WITH COMBUSTIBLE GAS MIXTURES OVER A WATER TABLE CAN RESULT IN THE AC-

CUMULATION OF EXPLOSIVE GAS POCKETS BETWEEN THE CUTTING TABLE AND THE WORK

PIECE. THESE POCKETS WILL EXPLODE WHEN IGNITED BY SPARKS FROM THE PLASMA ARC.

TO REDUCE, BUT NOT ELIMINATE, THE POSSIBILITY OF AN EXPLOSION THE FOLLOWING PRE-

CAUTIONS SHOULD BE TAKEN:

LOWER WATER LEVEL IN THE WATER TABLE 4 TO 6 INCHES (100 TO 150MM) BELOW THE •

WORK PIECE.

BEFORE CUTTING, BE AWARE OF POSSIBLE EXPLOSIVE GAS SOURCES IN THE WATER TA-•

BLE SUCH AS MOLTEN METAL REACTION, SLOW CHEMICAL REACTION AND SOME PLAS-

MA GASES.

CLEAN SLAG (ESPECIALLY FINE PARTICLES) FROM BOTTOM OF TABLE FREQUENTLY. RE-•

FILL TABLE WITH CLEAN WATER.

DO NOT LEAVE WORK PIECE ON TABLE OVERNIGHT.•

IF WATER TABLE HAS NOT BEEN USED FOR SEVERAL HOURS, VIBRATE OR JOLT IT TO •

BREAK UP GAS POCKETS BEFORE LAYING WORK PIECE ON THE TABLE.

IF POSSIBLE, CHANGE WATER LEVEL BETWEEN CUTS TO BREAK UP GAS POCKETS.•

MAINTAIN WATER PH LEVEL NEAR 7 (NEUTRAL).•

PROGRAMMED PART SPACING SHOULD BE A MINIMUM OF TWICE THE KERF WIDTH TO •

ENSURE MATERIAL IS ALWAYS UNDER THE KERF.

FANS SHOULD BE USED TO CIRCULATE AIR BETWEEN WORK PIECE AND WATER SURFACE. •

A TABLE WATER AERATION SYSTEM SHOULD ALSO BE USED.

WARNING

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety precau-

tions listed below as well as all other manuals, material

safety data sheets, labels, etc. Failure to observe Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operating

or observing operations. Warn bystanders not to

watch the arc and not to expose themselves to the

rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, Thick long-

sleeve shirt, cuess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

which could cause a later re. Use re watchers when

necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

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SECTION 2 INTRODUCTION

2.1 General

The PMC-91 Plasmarc System is a full capability plasmarc cutting and marking system that oers a wide variety of plasma

cutting and marking processes and applications. The system is designed specically for computer controlled mechanized

applications with expanded interfacing, exible conguration from a selection of packages and versatile ease of operation. By

selecting the components that best suit your needs the PMC-91 Plasmarc System can fully automate your cutting process.

The system is capable of water injection cutting and gas shielded underwater cutting can be accomplished at most •

current levels with appropriate torch and accessories.

The PMC-91 Plasmarc System can accommodate all major cutting gases including; oxygen, air, nitrogen, methane (CH•

)

or argon/hydrogen mixture.

The separate component design, ow control, plumbing box, power source provides maximum exibility for system •

layout tailored to your needs.

Selection from a variety of power sources and the paralleling capability allows a wide range of available cutting power •

to meet virtually any cutting condition.

Patented ESAB technology allows underwater cutting and beveling with excellent results.•

The PMC-91 Plasmarc System uses simple switch settings to setup process parameters for ow control and cutting •

power eliminating the diculty of adjustment associated with needle valves.

The shielded construction of the plasma torches and versatility of component location minimizes electrical interference •

with surrounding equipment.

The PMC-91 Plasmarc System can have marking capabilities through the marking box.•

Marking and cutting can be alternated in real-time by controlling the mark mode signal.•

Dierent power supplies can be controlled through the marking box, such as current, range selection.•

The PMC-91 system uses advanced technology for high quality cutting for a variety of common metals while keeping •

the operating costs at a minimum.

2.2 Features

Figure 2-1 Major Components

Coolant

Circulator

Flow

Control

Plumbing

Box

Power Source

Torch (PT-600, PT-19XLS or PT-36)

SECTION 2 INTRODUCTION

2.3 Component Description

The components that make up a PMC-91 Plasmarc System are designed specically for use in automated plasma cutting

and marking applications.

Refer to the specic equipment manual for detailed information.

EPP-401/450 Power Source EPP-601 Power Source

Figure 2-2 EPP-201 Power Source Figure 2-3 EPP-360 Power Source

The EPP power sources are de-

signed for marking and high speed

plasma mechanized cutting ap-

plications. They can be used with

other ESAB products such as the

PT-15, PT-19XLS, PT-600 and PT-36

torches along with the Smart Flow

II, a computerized gas regulation

and switching system.

EPP-360 Power Source

EPP-201 Power Source

Forced air cooled•

Solid state DC power•

Input voltage protection•

Remote or local front panel control•

Thermal switch protection for main transformer and power semiconductor com-•

ponents

Top lifting eyes or base forklift clearance for transport•

Parallel supplemental power source capabilities to extend current output range.•

10 to 36 amperes for marking•

25 to 200 amperes cutting current range•

10 to 36 amperes for marking•

30 to 360 amperes cutting current range•

10 to 100 amperes for marking in low current range•

50 to 450 amperes cutting in high current range•

35 to 100 amperes cutting in low current range•

10 to 100 amperes for marking in low current range•

50 to 600 amperes cutting in high current range•

35 to 100 amperes cutting in low current range•

SECTION 2 INTRODUCTION

Figure 2-4 EPP-401/450 Power Source

2.3 Component Description (con’t.)

Flow Control

The Flow Control is a programmable Logic Control (PLC) based unit. This device provides all the necessary control functions

for various uids and signals to and from other components of the system. Control Inputs/Outputs are connected to the

power source, marking box, coolant circulator, air curtain and the cutting machine control.

Connections to the ow control are Oxygen In, Air In, Alternate Gas In, Nitrogen In, Start Gas Out, Cut Gas Out, Shield Gas

Out.

Figure 2-6 Flow Control and PMC-91 Plasma Marking Control

Figure 2-5 EPP-601 Power Source

Coolant Circulator

The CC-11 coolant circulator is a radiator type cooler for circulating a coolant uid through the plasma torch providing heat

exchanger action for the internal parts of the torch. Though the system refers to water, it is not recommended that water be

used. For the protection of internal parts and lines a specially formulated coolant liquid is available that prevents production

of corrosion and mineral buildup. Refer to the power source manual for installation instructions.

PT-19XLS Plasma Torch

The PT-19XLS Torch is designed with all the quality standards and feature characteristics of the PT-15XL. The dierences are

primarily in applications and conditions for which the PT-19XLS is to be used. The PT-19XLS is a mechanized torch designed

for high speed, high current cutting using gas shielding instead of water injection.

The PT-19XLS is intended for applications of dry cutting using air (clean & dry) for the cut gas at current levels up to 200

amps. Oxygen (to 360A) or H-35 (to 600A) can be used with the PT-19XLS, however these gases are not recommended for

some materials. Use of an air curtain kit permits the PT-19XLS to be used for underwater cutting. Refer to the torch manual

for further details.

Plumbing Box

The Plumbing Box is an interconnecting device between the torch and other system components. It also contains the arc

starting high frequency generator. Connection of functions through the plumbing box include; cut gas, start gas, shield

gas, marking gas (argon), torch coolant, pilot arc, cutting current and height control.

Figure 2-7 Plumbing Box Assembly

SECTION 2 INTRODUCTION

2.3 Component Description (con’t.)

SECTION 2 INTRODUCTION

2.3 Component Description (con’t.)

PT-600 Plasma Torch

The PT-600 torch is a PT-19XLS with reduced manufacturing tolerances. The result is improved torch component concen-

tricity and cut accuracy.

F15-646

November, 2005

Installation, Operation, and Maintenance for the

PT-600 Mechanized

Plasma Cutting Torch

Figure 2-8 PT-19XLS and PT-600 Torches Figure 2-9 PT-36 Torch

PT-36 Plasma Torch

The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch compo-

nent concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the eld.

Only the torch front-end has replaceable parts.

SECTION 2 INTRODUCTION

2.3 Component Description (con’t.)

Air Curtain

The Air Curtain assembly provides improved cutting performance of the plasma torches when cutting underwater. A source

of oil free air at 80 psig is required to the air curtain control box. A curtain (wall) of air is created around the plasma arc area

allowing operation in a relatively dry zone, even with the end of the torch submerged 2 - 3 inches.

Underwater cut quality and speed are enhanced when using the air curtain for all plasma torch cutting applications.

Water Muer

The Water Muer system creates a bubble of air surrounded by water that allows the torch to be used underwater with

oxygen cut gas and water injection cutting without signicant loss of cut quality.

This device also allows above water cutting with reduced fume, noise and UV radiation from the arc by the ow of water

through the water muer. A separate water pump recycles ltered water from the water cutting table through the water

muer.

SECTION 1 INTRODUCTION

Figure 1-11. Bubble Muffler Assembly

Figure 1-12. PT-19XLS Water Muffler Assembly

The PT-19XLS is intended for applications of dry cut-

ting using air (clean & dry) for the cut gas at current

levels up to 200 amps. Oxygen (to 360A) or H-35 (to

600A) can be used with the PT-19XLS, however these

gases are not recommended for some materials. Use

of an air curtain kit permits the PT-19XLS to be used

for underwater cutting. Further details of the PT-19XLS

are contained in Form F-15-430.

Water Pump

The Water Pump is used to supply de-ionized cut wa-

ter to the PT-15XL torch for water injected cutting.

Air Curtain

The Air Curtain assembly provides improved cutting

performance of the PT-15XL and PT-19XLS plasma

torches when cutting underwater. A source of oil free

air at 80 psig is required to the air curtain control box.

A curtain (wall) of air is created around the plasma

arc area allowing operation in a relatively dry zone,

even with the end of the torch submerged 2 - 3 inches.

Underwater Cut quality and speed are enhanced when

using the air curtain for all PT-19XLS cutting applica-

tions and PT-15XL O

/water injection cutting.

Bubble Muffler

The Bubble Muffler system creates a bubble of air sur-

rounded by water that allows the PT-15XL torch to be

used underwater with oxygen cut gas and water injec-

tion cutting without significant loss of cut quality.

PT15XL H.D.

AIR CURTAIN

PT-19XLS

AIR CURTAIN

Figure 1-10. Air Curtain Assembly

This device also allows above water cutting with re-

duced fume, noise and UV radiation from the arc by

the flow of water through the bubble muffler. A sepa-

rate water pump recycles filtered water from the water

cutting table through the bubble muffler.

PT-19XLS Water Muffler

The PT-19XLS water muffler works much as the bubble

muffler described above.

SECTION 1 INTRODUCTION

Figure 1-11. Bubble Muffler Assembly

Figure 1-12. PT-19XLS Water Muffler Assembly

The PT-19XLS is intended for applications of dry cut-

ting using air (clean & dry) for the cut gas at current

levels up to 200 amps. Oxygen (to 360A) or H-35 (to

600A) can be used with the PT-19XLS, however these

gases are not recommended for some materials. Use

of an air curtain kit permits the PT-19XLS to be used

for underwater cutting. Further details of the PT-19XLS

are contained in Form F-15-430.

Water Pump

The Water Pump is used to supply de-ionized cut wa-

ter to the PT-15XL torch for water injected cutting.

Air Curtain

The Air Curtain assembly provides improved cutting

performance of the PT-15XL and PT-19XLS plasma

torches when cutting underwater. A source of oil free

air at 80 psig is required to the air curtain control box.

A curtain (wall) of air is created around the plasma

arc area allowing operation in a relatively dry zone,

even with the end of the torch submerged 2 - 3 inches.

Underwater Cut quality and speed are enhanced when

using the air curtain for all PT-19XLS cutting applica-

tions and PT-15XL O

/water injection cutting.

Bubble Muffler

The Bubble Muffler system creates a bubble of air sur-

rounded by water that allows the PT-15XL torch to be

used underwater with oxygen cut gas and water injec-

tion cutting without significant loss of cut quality.

PT15XL H.D.

AIR CURTAIN

PT-19XLS

AIR CURTAIN

Figure 1-10. Air Curtain Assembly

This device also allows above water cutting with re-

duced fume, noise and UV radiation from the arc by

the flow of water through the bubble muffler. A sepa-

rate water pump recycles filtered water from the water

cutting table through the bubble muffler.

PT-19XLS Water Muffler

The PT-19XLS water muffler works much as the bubble

muffler described above.

Figure 2-10 Air Curtain Assembly Figure 2-11 Water Muer Assembly

SECTION 2 INTRODUCTION

2.3 Component Description (con’t.)

Plasma Torches:

The basic torch body can be supplied in seven lead lengths between the plumbing box and torch.

The replaceable torch components are selected for the type of cut gas and current level used.

PT-19XLS - 4.5 ft. 37086

PT-19XLS - 6 ft. 37087

PT-19XLS - 12 ft. 37088

PT-19XLS - 15 ft. 37089

PT-19XLS - 17 ft. 37090

PT-19XLS - 20 ft. 37091

PT-19XLS - 25 ft. 37092

PT-600 - 4.5 ft. 0558001827

PT-600 - 6 ft. 0558001828

PT-600 - 12 ft. 0558001829

PT-600 - 15 ft. 0558001830

PT-600 - 17 ft. 0558001831

PT-600 - 20 ft. 0558001832

PT-600 - 25 ft. 0558001833

PT-36 - 4.5 ft. 0558003849

PT-36 - 6 ft. 0558003850

PT-36 - 12 ft. 0558003852

PT-36 - 25 ft. 0558003856

Flow Control: Provides interface for gases and power 0558005760

PMC-91 Marking

Control:

Provides interface for gases and power

Remote current control

Pilot arc Hi / Lo control

0558007858

Plumbing Box:

Provides interconnection between torch and

rest of system.

0558008045

CC-11 Water

Recirculator:

Circulates coolant for the torch 0558007515

Air Curtain:

PT-19XLS, PT-600 and PT-36

PT-19XLS, PT-600 and PT-36 Beveling

37440

34752

Water Muer: PT-19XLS, PT-600 and PT-36 37439

DESCRIPTION PART NUMBER

EPP-201

460 V, 3-Phase, 60 Hz 0558007801

575 V, 3-Phase, 60 Hz 0558007802

EPP-360

460 V, 3-Phase, 60 Hz 0558006832

575 V, 3-Phase, 60 Hz 0558006833

EPP-401/450

380/400V, 3-Phase, 50/60 Hz 0558007730

460 V, 3-Phase, 60 Hz 0558007731

575 V, 3-Phase, 60 Hz 0558007732

EPP-601

380/400V, 3-Phase, 50/60 Hz 0558007733

460 V, 3-Phase, 60 Hz 0558007734

575 V, 3-Phase, 60 Hz 0558007735

SECTION 2 INTRODUCTION

SECTION 3 INSTALLATION

General

Proper installation substantially contributes to the satisfactory and trouble-free operation of the PMC-91 System compo-

nents. Each step in this section should be studied carefully and followed as closely as possible. Immediately upon receipt

of the components, each should be inspected closely for damage which may have occurred in transit. Notify the carrier of

any damage or defects immediately. Instruction manuals for each component of the system are included in the package.

It is recommended that these manuals be collected and compiled in a common location.

Note

If the components are not to be immediately installed, store them in a clean, dry and well ventilated area.

3.1 System Component Locations

Power Source

CAUTION

When lifting the Power Source using the lifting lugs, ensure the lifting

means is securely connected to BOTH lifting lugs to prevent damage to the

unit or injury to personnel. DO NOT USE ANY LEVER DEVICE WHICH COULD

DAMAGE THE UNIT.

The location of the Power Source should be carefully selected to ensure satisfactory and dependable service. The Power

Source components are maintained at the proper operating temperatures by forced air that is drawn through the cabinet by

the fan units. For this reason, it is important that the Power Source be located in an indoor-open area where air can circulate

freely at the front, bottom, and rear openings of the cabinet. If space is a premium, leave at least two feet of clearance at

the rear of the cabinet.

The location should be such that a minimum of dirt, dust, or moisture will be drawn into the air stream. It is desirable to

locate the unit so that the top and side panels can be removed for cleaning and troubleshooting. In relationship to a cutting

machine, the power source can be positioned virtually anywhere that will not interfere with machine travel. Accessories on

the cutting machine are available to carry hoses and cables without interference with machine travel.

Flow Control

The Flow Control can be placed on the Power Source or mounted onto the cutting machine. The Flow Control needs to

be accessible for setting various cutting parameters. After setting the cutting conditions, access to the Flow Control is not

required during the cutting operation.

SECTION 3 INSTALLATION

Plumbing Box

The Plumbing Box is normally located on the cutting machine in close proximity to the torch station. Since the torch can

be equipped with various standard lengths of cable and hose, the exact location is determined by the conguration and

station load capacity of the machine.

Access to the Plumbing Box is not required during the standard operating procedures, location near the operator is not

required. Two important considerations pertain to the location of the plumbing box:

There should be space for the box door to be opened fully.1.

Sucient space should be provided on all sides to permit easy connection of gas/water hoses and electrical cables to the box.2.

3.1 System Component Locations (con’t.)

3.2 System Connections

WARNING

BEFORE MAKING ANY CONNECTIONS TO THE OUTPUT BUS BARS, MAKE SURE

THE POWER SOURCE IS DEENERGIZED BY OPENING THE LINE WALL DIS

CONNECT SWITCH. TO BE DOUBLY SAFE, HAVE A QUALIFIED PERSON CHECK

THE OUTPUT BUS BARS WITH A VOLTMETER TO BE SURE ALL POWER IS OFF.

Note

Input Power Connections

The power sources (EPP-201, EPP-360, EPP-401/450 or EPP-601) used with the system are 3-phase units and must be con-

nected to a 3-phase power line. Although designed with line voltage compensation, it is suggested that the unit be operated

on a separate line to ensure the performance of the power source is not impaired due to an overloaded circuit.

A line (wall) disconnect switch, with fuses or circuit breakers, shall be used at the main power panel. The primary power input

must have four insulated power leads (three power leads and one ground wire). The wires may be a thick rubber covered

cable or may run in a solid or exible conduit.

The ground wire must be approximately six inches longer than the power leads. This is a safety measure to

ensure that in the event the power lines are accidently pulled out the ground wire will remain connected.

Input conductors must be terminated with ring terminals sized for 1/2 inch hardware before being connected.

Note

Refer to the specic equipment manual for detailed installation instructions.

Flow Control Connections

The Flow Control serves as a form of interface between the various process utilities to enable a central location for setup

adjustments. Connections are made to receptacles on the rear panel and are grouped into two sections, the bottom row is

for gas connections while the top row is for electrical connections. The gas connections should be made rst.

Marking Box

Marking Box provides marking capability for PMC-91 Plasmarc System. The marking box should be under the ow control

box. Connections between the two boxes should be made with the cables provided. A hose assembly should also be used

for shield gas connection. Access to marking box is not required during normal, standard operation after the current and

gases are set up.

SECTION 3 INSTALLATION

3.2 System Connections (con’t.)

Fluid Hookups (See Table 3-1 for hose assemblies)

OXYGEN (O2) IN - This is a “B” size CGA oxygen tting. Connect the supply hose from the oxygen regulator to this 1.

point.

NITROGEN (N2) IN - This is a “B” size IAA tting. Connect the supply hose from the nitrogen regulator to this point.2.

AIR IN - This is a “B” size air tting. Connect the supply hose from the air regulator to this point.3.

ALTERNATE GAS IN - This is a “B” size CGA fuel gas tting. Connect the supply hose from the alternate gas regulator to 4.

this point.

START GAS OUT - This is a “B” size IAA tting. From this point connect the hose to Start Gas INPUT on the Plumbing 5.

Box.

CUT GAS OUT - This is a “B” size oxygen tting. The hose is connected from this point to the Cut Gas INPUT on the 6.

Plumbing Box.

SHIELD GAS OUT - This is a “B” size air / water tting. The hose is connected from this point to the shield gas input on 7.

the Plumbing Box. If the Marking Box is used, a tee hose assembly (0558008044) should be connected to Shield Gas

Out rst. The shield gas is then connected both to the Plumbing Box and the Marking Box.

Electrical Hookups (See Table 3-3 for cables)

POWER SOURCE - The power source plug should connect to Marking Box. Through Marking Box, Flow Control Box is 1.

powered and commanded.

PARALLELED POWER SOURCE - A cable from a second power source connects to this receptacle whenever two power 2.

sources are used in parallel. It parallels all control connections between the power source and ow control. The parallel

power supply is used only for cutting.

AIR CURTAIN - This is used to connect the coil of a solenoid valve in the air curtain control (when used) or to control a 3.

relay coil in the water muer pump unit.

WATER COOLER - This point is used to connect to the relay coil in the water cooler.4.

PLUMBING BOX - This cable connection goes to the Plumbing Box in the Marking Box, then through the Marking Box. 5.

It is connected to Plumbing Box.

CUTTING MACHINE NUMERICAL CONTROL (CNC) - This connection provides a current reference signal to the plasma 6.

power source and provides control signals to and from the ow control circuits, Start Process Command, Arc On, Process

Fault, and E-stop Interlock. This cable connection goes to the Marking Box CNC.

115 VAC AUXILIARY POWER - This optional connection allows the Flow Control to be energized without powering up 7.

the system. Disconnect after test function is completed.

SECTION 3 INSTALLATION

3.2 System Connections (con’t.)

Figure 3-1 Interface Block Diagram

Gas Regulators

Air

Oxygen

Nitrogen

Alternate

Wall Box

Input

Power

Power Source

Cooler and

Pump

Coolant Return

Coolant to Torch

(+) Work

(-) Electrode

Pilot Arc

Plumbing Box

Start Gas Solenoid

Cut Gas Solenoid

High Freq. On-O

Interlocks

Shield Gas

Start Gas

Cut Gas

Flow Control

Voltage

Feedback

Process OK

Interlocks

Current Ref.

E-Stop

Process O

Cutting Machine Control

Height

Reference

Height

Control

Shield Gas

Plasma Gas

Pilot Arc High Freq.

Coolant Return

Coolant to

Torch

Workpiece

Electrical Connections

Fluid Lines

Torch

PT-19XLS,

PT-600 or

PT-36

Legend

Marking Box

Shield Gas

Argon

(-) Electrode

Argon

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ESAB PMC-91 Plasmarc System User manual

Brand: ESAB

Model: PMC-91 Plasmarc System

Category: Welding System

Type: User manual

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ESAB PMC-91 Plasmarc System User manual

ESAB PMC-91 Plasmarc System User manual

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