ESAB PCC-14 Plumbing Box User manual

Page is loading ...

2

DECLARATION OF CONFORMITY

according to the Low Voltage Directive 2006/95/EC, according to the EMC Directive 2004/108/EC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

enligt Lågspänningsdirektivet 2006/95/EG, enligt EMC-Direktivet 2004/108/EG

Type of equipment Materialslag

Plumbing Box

Brand name or trade mark Fabrikatnamn eller varumärke

ESAB

Type designation etc. Typbeteckning etc.

PCC-14 (0558005840)

Manufacturer positioned outside the EEA

Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB Welding & Cutting Products

411 South Ebenezer Road, Florence, South Carolina 29501, USA

Phone: +1 843 669 4411, Fax: +1 843 664 4258

Manufacturer´s authorised representative established within the EEA

Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB AB, Welding Equipment

Esabvägen, SE-695 81 LAXÅ, Sweden

Phone: +46 584 81 000, Fax: +46 584 411 924

The following harmonised standards in force within the EEA have been used in the design:

Följande harmoniserande standarder har använts i konstruktionen:

EN 60974-8, Arc welding equipment – Part 8: Gas consoles for welding and cutting systems

EN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised

representative established within the EEA, that the equipment in question complies with the safety requirements

stated above.

Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom

EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Date / Datum

Laxå 2007-08-08

Signature / Underskrift Position / Befattning

Global Director

Equipment and Automation

Kent Eimbrodt

Clarification

Page is loading ...

4

TABLE OF CONTENTS

PCC-14

Plumbing Box

0558006579

Instruction Manual (EN)

This documentation is for ESAB equipment part number 0558005840

6

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!

7

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.0 Plumbing Box Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.1 Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.2 PCC-14 Plumbing Box Dimensions/ Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

2.3 Plumbing Box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.4 Spark Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.5 Plumbing Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.6 Adaptor for PCC-14 Plumbing Box use with ESP-150 or ESP-200 Power Supplies . . . . . . . . . . . . . . . . . . 20

2.7 PCC-14 Plumbing Box used with ESP-150 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

2.8 PCC-14 Plumbing Box use with ESP-200 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.9 PT-36R Torch Connections to Plumbing Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.10 ESP-150 Torch Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

2.10.a ESP150 DUECE PACK Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

2.11 ESP-200 Torch Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

2.12 Voltage Divider Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

8

TABLE OF CONTENTS

9

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

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

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

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

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

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

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

injury to the operator and damage to the equipment.

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

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

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

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

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

clothing, safety gloves.

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

trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

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

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

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

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or

water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and

against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-

tended to be used outside during precipitation unless sheltered.

Enclosure Class

Maximum

Tilt Allowed

15°

CAUTION

If equipment is placed on a surface that

slopes more than 15°, toppling over may oc-

cur. Personal injury and / or signicant dam-

age to equipment is possible.

10

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK - Can kill.

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

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

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

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

and the general area.

ARC RAYS - Can injure eyes and burn skin.

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

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

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

NOISE - Excessive noise can damage hearing.

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

- Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

This product is solely intended for plasma cutting. Any other

use may result in personal injury and / or equipment damage.

CAUTION

To avoid personal injury and/or equipment

damage, lift using method and attachment

points shown here.

11

SECTION 2 DESCRIPTION / INSTALLATION

2.0 Plumbing Box Description

The PCC-14 Plumbing Box is a Plasmarc Cutting Control used to connect PT-36R, PT-26,

PT-19XL, PT-19XLS, PT-600 or PT-251 torches to a remotely located ESP-150, ESP-200, or

Deucepack system. The PCC-14 includes high frequency starting circuits to eliminate

starting problems with long torches and to minimize high frequency interference with

other customer systems.

Weight: 41lbs. (18.6 kg)

Plasma and Start Gases:

The PCC-14 may be used with O2, N2, Air, or H-35 (35% H2/65% Ar) with a maximum input pressure of 110 psig (7.6 bar).

It is recommended, but not required, that N2 be used as the start gas when using H-35. The ow rate of gas will depend on

the pressure set, the torch connected to the plumbing box, and the parts installed in the torch. Without a torch attached,

the maximum ow rate for these gases at 100 psig (6.9 bar) is about 1000 scfh (28.3 cu-m/h). The minimum acceptable

pressure for the start gas is 19 psig (1.3 bar); for the plasma gas it is 24 psig (1.7 bar). Below these pressures the pressure

switches may not be satised.

Shield Gases:

The PCC-14 may be used with Air, N2, Ar, or CO2. The maximum pressure is 110 psig (7.6 bar). This will result in a ow of

250scfh (7.1 cu-m/h) N2. See Graph 2-1. There is no pressure interlock on the shield gas.

Coolant:

The PCC-14 is designed for use with water based coolants using either ethylene glycol or propylene glycol antifreeze (ESAB

P/N’s 156F05 or 0558004297). Maximum design pressure is 200 psig (13.8 bar). Flow rates depend on the torch but typically

vary from .9 to 2 gpm (4.1 to 9.1 l/m).

2.1 Specications

12

Install the PCC-14 Plumbing Box in an appropriate location so as to maintain adequate and unrestricted airow

into and out of the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions

in the base of this unit.

16.625"

(422.28 mm)

12.500"

(317.5 mm)

1.060"

(26.92 mm)

6.875"

(174.63 mm)

4.500"

(114.3 mm)

2.125"

(53.98 mm)

SECTION 2 DESCRIPTION / INSTALLATION

2.2 PCC-14 Plumbing Box Dimensions/ Mounting Hole Locations

13.0"

(330.2 mm)

15.4"

(391.2 mm)

18.8"

(477.5 mm)

13

SECTION 2 DESCRIPTION / INSTALLATION

Gas Purging:

When switching between H-35 and an oxidizing gas (air or oxygen) it is recommended that the following procedure be

followed:

1. Turn o the gas.

2. Put the system into plasma gas test until line pressure is exhausted. If the start gas is being switched to or from

H-35, switch to start gas test until that line is exhausted as well.

3. Disconnect the old gas and connect a relatively inert gas such as nitrogen, argon, carbon dioxide, C-25, etc. Set the

pressure to 50 psig (3.5 bar) and purge each aected line for 60 seconds.

4. Then shut o the gas and exhaust each line per Step 2.

5. Connect the gas to be used. Set the pressure to recommended values for the cutting condition to be used, and

purge each aected line for 15 seconds per 25 ft. (7.6 m) of line.

Note:

The expected life of the internal exible hoses is 10 years.

Replace them earlier if cracking or brittleness is noted.

Note:

See appropriate equipment literature for operating conditions and necessary gas purities.

Flashback arrestors are required to prevent re from propagating back

to the gas supply through lines carrying oxygen or fuel gases.

Use AWG 1/0 power cable to carry electrode current from the power

source to the PCC-14. See Table 2-2 for additional cables.

Avoid using the same supply lines for both oxygen and air if oil may

be mixed with the air. Oil in the presence of 100% oxygen can be

highly ammable.

Failure to observe above cautions may result in personal injury and /

or damage to the equipment.

CAUTION

ELECTRICITY CAN KILL!

HIGH VOLTAGE CAN BE PRESENT BEHIND COVER PLATE. DO NOT OP

ERATE WITHOUT COVER PLATE IN PLACE. BEFORE REMOVING COVER

PLATE OR PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS

EQUIPMENT, ENSURE THE POWER SOURCE IS TURNED OFF AND DIS

CONNECTED.

WARNING

Only qualied maintenance personnel should repair and maintain

this equipment.

Unit is NOT designed for use in rain or snow. Damage to equipment

may result.

Unit is to be lifted only by the handle provided . Failure to do so may

result in damage to the equipment.

CAUTION

2.3 Plumbing Box Installation

14

SECTION 2 DESCRIPTION / INSTALLATION

250 (7.1)

240 (6.8)

230 (6.5)

220 (6.2)

210 (5.9)

200 (5.7)

190 (5.4)

180 (5.1)

170 (4.8)

160 (4.5)

150 (4.2)

140 (4.0)

130 (3.7)

120 (3.4)

110 (3.1)

100 (2.8)

90 (2.5)

80 (2.3)

70 (2.0)

60 (1.7)

50 (1.4)

40 (1.1)

30 (0.8)

20 (0.6)

10 (0.3)

0

0 10 20 30 40 50 60 70 80 90 100 110 120 130

(0.7) (1.4) (2.1) (2.8) (3.5) (4.1) (4.8) (5.5) (6.2) (6.9) (7.6) (8.3) (9.0)

PSIG (BAR) Pressure Setting to 0.052 in. (1.32 mm) Diameter Orice

Shield Gas Flow SCFH (CU-M/H) N

2

Graph 2-1 - Gas Pressure / Flow

15

SECTION 2 DESCRIPTION / INSTALLATION

Table 2-2 - Hoses / Cables / Regulators

2.4 Spark Gap Adjustment

1. Disconnect input power to power source.

2. Remove access cover from spark gap opening.

3. Check / set to recommended spark gap of 0.040” (1 mm).

4. Replace cover.

Spark Gap

Access Cover

16

SECTION 2 DESCRIPTION / INSTALLATION

2.5 Plumbing Box Connections

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL

DISCONNECT BOX BEFORE MAKING ANY CONNECTIONS TO

THE POWER SUPPLY.

DISCONNECT CURRENT SUPPLY AT WALL DISCONNECT

BEFORE SERVICING PLUMBING BOX.

• DO NOT OPERATE PLUMBING BOX WITH ANY COVERS

REMOVED / OPEN.

• DO NOT TOUCH ANY TORCH FRONTEND PARTS WITH

POWER ON.

• DO NOT ATTEMPT TO SERVICE UNLESS POWER HAS BEEN

DISCONNECTED AT THE WALL.

WARNING

THIS EQUIPMENT CAN BE HAZARDOUS IF NOT PROPERLY

OPERATED AND MAINTAINED.

READ AND UNDERSTAND ALL EQUIPMENT LITERATURE AND

WARNING LABELS BEFORE OPERATING THIS EQUIPMENT.

FOLLOW THESE INSTRUCTIONS TO PREVENT INJURY OR

PROPERTY DAMAGE.

YOU MUST COMPLY WITH LOCAL, STATE AND NATIONAL

ELECTRICAL AND SAFETY CODES.

ONLY TR AINED PERSONNEL SHO ULD PERFORM

MAINTENANCE OR REPAIRS ON THIS EQUIPMENT.

17

SECTION 2 DESCRIPTION / INSTALLATION

Connection Locations Inside Plumbing Box

18

SECTION 2 DESCRIPTION / INSTALLATION

Plasma Gas Hose From Torch

Shield Gas Hose From Torch

Typical For All Torch Congurations

Pilot Arc Cable

From Power Supply

Plumbing Box Style Torches - PT-36R, PT-600 All, PT-19XLS 4.5 ft. (1.4 m) to 25 ft. (7.6 m)

Pilot Arc Cable From Torch

Power / Coolant Supply

Hose From Torch

Power / Coolant Return

Hose From Torch

Coolant Supply Hose

Power Cables

Coolant Return Hose

19

SECTION 2 DESCRIPTION / INSTALLATION

Shield Gas Hose From Torch

Plasma Gas Hose From Torch

Typical For All Torch Congurations

Pilot Arc Cable

From Power Supply

Direct Connect Style Torches - PT-26 All, PT-19XLS 25 ft. (7.6 m) and 50 ft. (15.2 m)

Pilot Arc Cable From Torch

Coolant Return

Hose From Torch

Coolant Supply Hose

Power Cables

Coolant Return Hose

Power / Coolant Supply

Hose From Torch

NOTE

This Fitting Must Be Removed To

Make Connection From Torch

NOTE

On all PT-26 Torches the Pilot Arc

Cable is included inside the Cool-

ant Return Hose Assembly and the

separate pilot arc cable connection

shown above is NOT used.

20

SECTION 2 DESCRIPTION / INSTALLATION

2.6 Adaptor for PCC-14 Plumbing Box use with ESP-150 or ESP-200 Power Supplies

P1P3

P2

Adaptor

0558006530

Note:

The ESP-150 and the ESP-200 are supplied from the factory connected for manual use. If the unit is to

be used with a PCC-14 Plumbing Box, Adaptor (0558006530) must be installed.

21

SECTION 2 DESCRIPTION / INSTALLATION

Remove Plug P45 from J4 Receptacle

P1P3

P2

Adaptor

0558006530

ESP-150 Power Supply

Reconnect Plug P45

into P1 Receptacle

Connect Plug P2 into J4 Receptacle

Connect Plug P3 into J5 Receptacle

Note:

The ESP-150 is supplied from the factory with Plug

P45 connected to the J4 Receptacle. If the unit is

to be used with a PCC-14 Plumbing Box, install

Adaptor (0558006530) as shown.

2.7 PCC-14 Plumbing Box used with ESP-150 Power Supply

22

SECTION 2 DESCRIPTION / INSTALLATION

Remove Plug P5 from J5 Receptacle

ESP-200 Power Supply

P1P3

P2

Adaptor

0558006530

Reconnect Plug P5

into P1 Receptacle

Connect Plug P2 into J5 Receptacle

Connect Plug P3 into J6 Receptacle

J5 J6

J5

J6

Note:

The ESP-200 is supplied from the factory with Plug

P5 connected to the J5 Receptacle. If the unit is

to be used with a PCC-14 Plumbing Box, install

Adaptor (0558006530) as shown.

2.8 PCC-14 Plumbing Box use with ESP-200 Power Supply

Page is loading ...

ESAB PCC-14 Plumbing Box User manual

ESAB PCC-14 Plumbing Box User manual

in other languages

Related papers

Other documents