ESAB Precision Plasmarc System Installation guide

CUTTING SYSTEMS

F-15-480-D

October, 2000

Installation, Operation and Maintenance Manual for the

PRECISION PLASMARC SYSTEM

with Electronic Flow Control

411 s. Ebenezer Road

Florence, SC 29501-0545

The equipment described in this manual is

potentially hazardous. Use caution when installing,

operating and maintaining this equipment.

Purchaser is solely responsible for the safe

operation and use of all products purchased,

including compliance with OSHA and other

government standards. ESAB Cutting

Systems has no liability for personal injury or

other damage arising out of the use of any

product manufactured or sold be ESAB. See

standard ESAB terms and conditions of sale

for a specific statement of ESAB’s

responsibilities and limitations on its liability.

Every effort was made to ensure the accuracy

and completeness of this manual. Information

in this document is subject to change without

notice.

This manual is ESAB Part Number F15480

This manual is ESAB Part Number F15480This manual is ESAB Part Number F15480

This manual is ESAB Part Number F15480

This manual is for the convenience and use of the

cutting machine purchaser. It is not a contract or

other obligation on the part of ESAB Cutting

Systems.

©

©©

Printed in U.S.A.

Precision Plasma Electronic Flow Control Table of Contents

i

Page

Section 1 Safety

1.1 Introduction 1

1.2 Safety Notations And Symbols 1

1.3 General Safety Information 2

1.4 Installation Precautions 3

1.5 Electrical Grounding 4

1.6 Operating A Plasma Cutting Machine 4

1.7 Service Precautions 8

1.8 Safety References 9

Section 2 Description

2.1 General 1

2.2 Scope 1

2.3 Package Options Available 1

2.4 Technical Specifications

2.4.1 Precision Plasma System 2

2.4.2 Plasma Gas 3

2.4.3 Start Gas 3

2.4.4 Secondary Gas 3

2.4.5 PT-24 Torch 3

Section 3 Installation

3.1 General 1

3.2 Equipment Required 1

3.3 Location 1

3.4 Primary Electrical Input Connections 2

3.5 Interconnecting Lines 4

Precision Plasmarc Component Interconnecting Diagram 8

3.6 Torch Mounting 10

3.7 Torch Coolant 11

3.8 Inspection of Gas and Coolant Lines 11

3.9 Replacement of EPROM in the Plasmarc Power Source

Programmable Logic Controller (PLC)

12

Precision Plasma Electronic Flow Control Table of Contents

ii

Section 4 Operation

4.1 Power Supply Controls

4.1.1 Main Power Switch 1

4.1.2 Pilot Arc Switch 1

4.1.3 Fault Indicator Lights 2

4.1.4 Meters 2

4.1.5 Current Control Switch 2

4.2 Cut Quality

4.2.1 Introduction 3

4.2.2 Cut Angle 3

4.2.3 Cut Flatness 4

4.2.4 Surface Finish 5

4.2.5 Dross 6

4.2.6 Dimensional Accuracy 8

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction 9

4.3.2 Aluminum 9

4.3.3 Carbon Steel 10

4.3.4 Stainless Steel 11

4.4 Process Data

4.4.1 Introduction 13

4.4.2 Process Data Settings 14

Plasma Marking Data 54

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness 76

4.4.3.1 Aluminum Kerf Values 76

4.4.3.2 Carbon Steel Kerf Values 78

4.4.3.3 Stainless Steel Kerf Values O

2

/N

2

/O

2

81

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4

82

4.4.3.5 Stainless Steel Kerf Values N

2

/N

2

/CH

4

83

4.4.3.6 Stainless Steel Kerf Values N

2

/N

2

84

4.4.3.7 Stainless Steel Kerf Values Air/Air 86

Precision Plasma Electronic Flow Control Table of Contents

iii

Section 5 Maintenance

5.1 General 1

5.2 Inspection and Cleaning 1

5.3 PT-24 Torch Description 2

5.4 Torch Maintenance 5

5.5 PT-24 Consumable Disassembly and Inspection 7

5.6 PT-24 Torch Re-Assembly 9

Section 6 Troubleshooting

6.1 General Safety 1

6.2 Programmable Logic Controller (PLC) 1

6.2.1 PLC LED Introduction 2

6.2.2 PLC LED Functions 2

6.3 Troubleshooting Guide

6.3.1 Reduced Consumable Life 3

6.3.2 Poor Cut Quality 4

6.3.3 No Pilot Arc 4

6.3.4 No Arc Transfer 4

6.3.5 No Preflow 4

6.3.6 Torch Fails to Fire 4

6.3.7 Nozzle Life Extremely Short 5

6.3.8 Short Electrode Life 5

6.3.9 Short Electrode AND Nozzle Life 5

6.4 Flow Control Schematic 6

6.5 Gas Flow Schematic 7

6.6 Junction Box Wiring Diagram 8

6.7 Junction Box Schematic 9

6.8 Precision Plasma Power Module Wiring Diagram 10-11

6.9 Power Module Schematic 12

6.10 Power Source Wiring Diagrams 13-17

6-11 Power Source Schematic 18-19

Precision Plasma Electronic Flow Control Table of Contents

iv

6.12 Technical Guide to Using/Understanding the Operation of the EFC 20

6.12.1 Precision Process Timers 21

6.12.2 Process Timer Values 22

6.12.3 Process Window Key Functions 23

6.12.4 Proportional Valve Analog Values for PARAM.CUT

PARAM.CUTPARAM.CUT

PARAM.CUT and DEF.TEC

DEF.TECDEF.TEC

DEF.TEC 24

6.12.5 Process Gas Selection Requirements 25

6.12.6 EFC Process Gas Flow Chart 26

6.12.7 Station On, Flush/Pressurize Cycle Timers 27

6.12.8 Solenoid/Proportional Valve Requirements and

Gas Error Monitoring

Carbon Steel PG-O

2

, SG-O

2

28

Carbon Steel PG-O

2

, SG-N

2

/O

2

30

Carbon Steel PG-O

2

, Sg-O

2

32

Stainless Steel PG-N

2

, SG-N

2

34

Stainless Steel PG-N

2

, SG-N

2

/CH

4

36

Stainless Steel PG-Air, SG-Air 38

Stainless Steel PG-Air, SG-Air/CH

4

40

Aluminum PG-N

2

, SG- N

2

42

Aluminum PG-N

2

, SG-N

2

/CH

4

44

Marking PG-Argon, SG-Air 46

Section 7 Replacement Parts

7.1 General 1

7.2 Ordering 2

7.3 Plasmarc Power Source – Exterior Components 3

7.4 Plasmarc Power Source – Internal Components 8

7.5 Power Source Module 18

7.6 EFC Junction Box 26

7.7 Electronic Flow Control Box 32

7.8 PT-24 Torch Assembly EFC Series A/M 36

7.9 T Gas Shut-off Valve Assembly - Series A/M Torch 38

7.10 PT-24 Torch Assembly – Version 1 40

7.11 Solenoid Assembly - EFC Torch – Version 1 42

Customer/Technical Information Back Manual Cover

SECTION 1 SAFETY

1-1

DANGER

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

1.1 Introduction

The process of cutting metals with plasma equipment

provides industry with a valuable and versatile tool.

ESAB cutting machines are designed to provide both

operation safety and efficiency. However, as with any

machine tool, sensible attention to operating

procedures, precautions, and safe practices is

necessary to achieve a full measure of usefulness.

Whether an individual is involved with operation,

servicing, or as an observer, compliance with

established precautions and safe practices must be

accomplished. Failure to observe certain precautions

could result in serious personnel injury or severe

equipment damage. The following precautions are

general guidelines applicable when working with

cutting machines. More explicit precautions pertaining

to the basic machine and accessories are found in the

instruction literature. For a wide scope of safety

information on the field of cutting and welding

apparatus, obtain and read the publications listed in

the Recommended References.

1.2 Safety Notations And Symbols

The following words and symbols are used throughout

this manual. They indicate different levels of required

safety involvement.

!

ALERT or ATTENTION. Your safety is involved

or potential equipment failure exists. Used in

concurrence 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

1-2

1.3 General Safety Information

WARNING

!

Machine starts automatically.

This equipment moves in various directions and

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

This equipment moves in various directions and

speeds.

speeds.speeds.

speeds.

• Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

Moving machinery can crush.

• Only qualified personnel should operate or service

Only qualified personnel should operate or serviceOnly qualified personnel should operate or service

Only qualified personnel should operate or service

equipment.

equipment.equipment.

equipment.

• Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment notKeep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not

involved in production process clear of entire

involved in production process clear of entireinvolved in production process clear of entire

involved in production process clear of entire

system area.

system area.system area.

system area.

• Keep gear racks and rails clear of debris or

Keep gear racks and rails clear of debris orKeep gear racks and rails clear of debris or

Keep gear racks and rails clear of debris or

obstructions, such as tools or clothing.

obstructions, such as tools or clothing.obstructions, such as tools or clothing.

obstructions, such as tools or clothing.

• Fence off entire work cell to prevent personnel

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

Fence off entire work cell to prevent personnel

from passing through area or standing in the

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

from passing through area or standing in the

working envelope of the equipment.

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

working envelope of the equipment.

• Post appropriate WARNING signs at every work

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

Post appropriate WARNING signs at every work

cell entrance.

cell entrance.cell entrance.

cell entrance.

• Follow lockout procedure before servicing.

Follow lockout procedure before servicing.Follow lockout procedure before servicing.

Follow lockout procedure before servicing.

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 beforeRead and understand this operator’s manual before

Read and understand this operator’s manual before

using machine.

using machine.using machine.

using machine.

• Read entire procedure before operating or

Read entire procedure before operating orRead entire procedure before operating or

Read entire procedure before operating or

performing any system maintenance.

performing any system maintenance.performing any system maintenance.

performing any system maintenance.

• Special attention must be given to all hazard

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

Special attention must be given to all hazard

warnings that provide essential information

warnings that provide essential informationwarnings that provide essential information

warnings that provide essential information

regarding personnel safety and/or possible

regarding personnel safety and/or possibleregarding personnel safety and/or possible

regarding personnel safety and/or possible

equipment damage.

equipment damage.equipment damage.

equipment damage.

• All safety precautions relevant to electrical

All safety precautions relevant to electricalAll safety precautions relevant to electrical

All safety precautions relevant to electrical

equipment and process operations must be

equipment and process operations must beequipment and process operations must be

equipment and process operations must be

strictly observed by all having system

strictly observed by all having systemstrictly 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 byRead all safety publications made available by

Read all safety publications made available by

your company.

your company.your company.

your company.

SECTION 1 SAFETY

1-3

WARNING

!

Failure to follow safety warning label

instructions could result in death or

serious injury.

Read and understand all safety warning labels on

Read and understand all safety warning labels onRead 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 safetyRefer to operator’s manual for additional safety

Refer to operator’s manual for additional safety

information.

information.information.

information.

1.4 Installation Precautions

WARNING

!

Improperly installed equipment can cause

injury or death.

Follow these guidelines while installing machine:

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

Follow these guidelines while installing machine:

Do not connect a cylinder directly to machine inlet. An

Do not connect a cylinder directly to machine inlet. AnDo not connect a cylinder directly to machine inlet. An

Do not connect a cylinder directly to machine inlet. An

appropriate cylinder regulator must be installed on a

appropriate cylinder regulator must be installed on aappropriate cylinder regulator must be installed on a

appropriate cylinder regulator must be installed on a

fuel gas cylinder to reduce pressure to a reasonable

fuel gas cylinder to reduce pressure to a reasonablefuel gas cylinder to reduce pressure to a reasonable

fuel gas cylinder to reduce pressure to a reasonable

inlet supply pressure. Machine regulator is then used

inlet supply pressure. Machine regulator is then usedinlet supply pressure. Machine regulator is then used

inlet supply pressure. Machine regulator is then used

to obtain pressure required by torches.

to obtain pressure required by torches.to obtain pressure required by torches.

to obtain pressure required by torches.

Contact your ESAB representative before installation.

Contact your ESAB representative before installation.Contact your ESAB representative before installation.

Contact your ESAB representative before installation.

He can suggest certain precautions regarding piping

He can suggest certain precautions regarding pipingHe can suggest certain precautions regarding piping

He can suggest certain precautions regarding piping

installation and machine lifting, etc. to ensure

installation and machine lifting, etc. to ensureinstallation and machine lifting, etc. to ensure

installation and machine lifting, etc. to ensure

maximum security.

maximum security.maximum security.

maximum security.

Never attempt any machine modifications or apparatus

Never attempt any machine modifications or apparatusNever attempt any machine modifications or apparatus

Never attempt any machine modifications or apparatus

additions without first consulting a qualified ESAB

additions without first consulting a qualified ESABadditions without first consulting a qualified ESAB

additions without first consulting a qualified ESAB

representative.

representative.representative.

representative.

Observe machine clearance requirements for proper

Observe machine clearance requirements for properObserve machine clearance requirements for proper

Observe machine clearance requirements for proper

operation and personnel safety.

operation and personnel safety.operation and personnel safety.

operation and personnel safety.

SECTION 1 SAFETY

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 intoMachine must be properly grounded before put into

Machine must be properly grounded before put into

service.

service.service.

service.

WARNING

!

Improper grounding can damage machine

and electrical components.

• Machine must be properly grounded before put

Machine must be properly grounded before putMachine must be properly grounded before put

Machine must be properly grounded 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 gooda 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. WearHot 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 flyinggoggles 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. Bystanders

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

Chipped slag may be hot and fly far. Bystanders

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.

• From plasma arc can damage hearing. Wear

From plasma arc can damage hearing. WearFrom plasma arc can damage hearing. Wear

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.

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 afterDo 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 withcutting. 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 afterDo not touch plasma torch immediately after

Do not touch plasma torch immediately after

cutting. Allow torch time to cool.

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

cutting. Allow torch time to cool.

SECTION 1 SAFETY

1-5

WARNING

!

Hazardous voltages. Electric shock

can kill.

• Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting 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 suppliesAlways 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 suppliesAlways turn power off to plasma power supplies

Always turn power off to plasma power supplies

before opening or servicing plasma plumbing or

before opening or servicing plasma plumbing orbefore opening or servicing plasma plumbing or

before opening or servicing plasma plumbing or

flow control box.

flow control box.flow control box.

flow control box.

• 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 machineKeep 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.

• Insulate yourself from

Insulate yourself from Insulate yourself from

Insulate yourself from workpiece and electrical

workpiece and electricalworkpiece and electrical

workpiece and electrical

ground: wear insulating gloves, shoes and

ground: wear insulating gloves, shoes andground: wear insulating gloves, shoes and

ground: wear insulating gloves, shoes and

clothing.

clothing.clothing.

clothing.

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

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

Keep gloves, shoes, clothing, work area, and

equipment dry.

equipment dry.equipment dry.

equipment dry.

WARNING

!

Pinch hazard.

Moving vertical slides can crush or pinch.

Moving vertical slides can crush or pinch.Moving vertical slides can crush or pinch.

Moving vertical slides can crush or pinch.

Keep hands clear of torch and slide during operation.

Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.

Keep hands clear of torch and slide during operation.

WARNING

!

Fume hazard.

Fumes and gases generated by the plasma cutting

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

Fumes and gases generated by the plasma cutting

process can be hazardous to your health.

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

process can be hazardous to your health.

• Do NOT breathe fumes.

Do NOT breathe fumes.Do NOT breathe fumes.

Do NOT breathe fumes.

• Do not operate plasma torch without fume removal

Do not operate plasma torch without fume removalDo 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 ifUse 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 notUse approved respirator if ventilation is not

Use approved respirator if ventilation is not

adequate.

adequate.adequate.

adequate.

SECTION 1 SAFETY

1-6

WARNING

!

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn

Arc rays can injure eyes and burn Arc rays can injure eyes and burn

Arc rays can injure eyes and burn skin.

skin.skin.

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

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

Wear dark safety glasses or goggles with side

sideside

side

shields. Refer to following chart for recommended

shields. Refer to following chart for recommendedshields. 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 Le

Le Le

Lens Shade

ns Shadens Shade

ns Shade

Up to 100 Amps

Up to 100 AmpsUp to 100 Amps

Up to 100 Amps Shade No. 8

Shade No. 8Shade No. 8

Shade No. 8

100-200 Amps

100-200 Amps100-200 Amps

100-200 AmpsShade No. 10

Shade No. 10Shade No. 10

Shade No. 10

200-400 Amps

200-400 Amps200-400 Amps

200-400 AmpsShade 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 orReplace 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 arcWarn 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 area to reduce reflection and

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

Prepare cutting area 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 colors to

Paint walls and other surfaces with dark colors toPaint walls and other surfaces with dark colors to

Paint walls and other surfaces with dark colors to

reduce reflections.

reduce reflections.reduce reflections.

reduce reflections.

• Install protective screens or curtains to reduce

Install protective screens or curtains to reduceInstall protective screens or curtains to reduce

Install protective screens or curtains to reduce

ultraviolet transmission.

ultraviolet transmission.ultraviolet transmission.

ultraviolet transmission.

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and violently

Mishandling gas cylinders can rupture and violentlyMishandling gas cylinders can rupture and violently

Mishandling 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 byAlways secure cylinders in an upright position by

Always secure cylinders in an upright position by

chain or strap to a suitable stable object not part of

chain or strap to a suitable stable object not part ofchain or strap to a suitable stable object not part of

chain or strap to a 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 andLocate 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.

• Refer to CGA Standard P-1, “Precautions for Safe

Refer to CGA Standard P-1, “Precautions for SafeRefer to CGA Standard P-1, “Precautions for Safe

Refer to CGA Standard P-1, “Precautions for Safe

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.

SECTION 1 SAFETY

1-7

CAUTION

WARNING

!

Spark 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 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.

• Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g.

Do not have on your person any 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 nozzlePilot 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 activatingaway 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-retardant clothing that covers all

Wear flame-retardant clothing that covers allWear flame-retardant clothing that covers all

Wear flame-retardant clothing that covers all

exposed areas.

exposed areas.exposed areas.

exposed areas.

• Wear

Wear Wear

Wear cuffless trousers to prevent entry of sparks

cuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparks

cuffless trousers to prevent entry of sparks

and slag.

and slag.and slag.

and slag.

POOR PERFORMANCE WILL RESULT

WHEN CUTTING ABOVE WATER.

The PT-24 is designed to be a dry cutting

process.

Cutting above water may result in:

Cutting above water may result in:Cutting above water may result in:

Cutting above water may result in:

• reduced consumable life

reduced consumable lifereduced consumable life

reduced consumable life

• degradation of cut quality

degradation of cut qualitydegradation of cut quality

degradation of cut quality

Cutting above water may result in poor cutting

Cutting above water may result in poor cuttingCutting above water may result in poor cutting

Cutting above water may result in poor cutting

performance. Water vapor created when hot material

performance. Water vapor created when hot materialperformance. Water vapor created when hot material

performance. Water vapor created when hot material

or sparks contact liquid may cause arcing inside torch.

or sparks contact liquid may cause arcing inside torch.or sparks contact liquid may cause arcing inside torch.

or sparks contact liquid may cause arcing inside torch.

When cutting on a water table, reduce the water level

When cutting on a water table, reduce the water levelWhen cutting on a water table, reduce the water level

When cutting on a water table, reduce the water level

to provide maximum clearance between water and

to provide maximum clearance between water andto provide maximum clearance between water and

to provide maximum clearance between water and

material.

material.material.

material.

SECTION 1 SAFETY

1-8

WARNING

!

Explosion hazard.

Certain molten aluminum-lithium (Al-

Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Al-

Certain molten aluminum-lithium (Al-Li) alloys can

Li) alloys canLi) 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.

Do not plasma cut the following Al-

Do not plasma cut the following Al-Do not plasma cut the following Al-

Do not plasma cut the following Al-Li alloys with

Li alloys withLi alloys with

Li alloys with

water:

water:water:

water:

Alithlite (Alcoa)

Alithlite (Alcoa)Alithlite (Alcoa)

Alithlite (Alcoa) X8192 (Alcoa)

X8192 (Alcoa)X8192 (Alcoa)

X8192 (Alcoa)

Alithally (Alcoa)

Alithally (Alcoa)Alithally (Alcoa)

Alithally (Alcoa) Navalite (US Navy)

Navalite (US Navy)Navalite (US Navy)

Navalite (US Navy)

2090 Alloy (Alcoa)

2090 Alloy (Alcoa)2090 Alloy (Alcoa)

2090 Alloy (Alcoa) Lockalite (Lockheed)

Lockalite (Lockheed)Lockalite (Lockheed)

Lockalite (Lockheed)

X8090A (Alcoa)

X8090A (Alcoa)X8090A (Alcoa)

X8090A (Alcoa) Kalite (Kaiser)

Kalite (Kaiser)Kalite (Kaiser)

Kalite (Kaiser)

X8092 (Alcoa)

X8092 (Alcoa)X8092 (Alcoa)

X8092 (Alcoa) 8091 (

8091 (8091 (

8091 (Alcan)

Alcan)Alcan)

Alcan)

• These alloys should only be dry cut on a dry table.

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

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

• DO NOT dry cut over water.

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

DO NOT dry cut over water.

• Contact your aluminum supplier for additional

Contact your aluminum supplier for additionalContact your aluminum supplier for additional

Contact your aluminum supplier for additional

safety information regarding hazards associated

safety information regarding hazards associatedsafety information regarding hazards associated

safety information regarding hazards associated

with these alloys

with these alloyswith these alloys

with these alloys

.

1.7 Service Precautions

CAUTION

Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. A

composite program can be established from

composite program can be established fromcomposite program can be established from

composite program can be established from

recommended schedules in the instruction literature.

recommended schedules in the instruction literature.recommended schedules in the instruction literature.

recommended schedules in the instruction literature.

Avoid leaving test equipment or hand tools on

Avoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools on

Avoid leaving test equipment or hand tools on

machine. Severe electrical or mechanical damage

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

machine. Severe electrical or mechanical damage

could occur to equipment or machine.

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

could occur to equipment or machine.

CAUTION

!

Extreme caution should be used when probing

Extreme caution should be used when probingExtreme 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. Integratedcircuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integrated

circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.

Power off before using test probes to prevent

Power off before using test probes to preventPower 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 cablesAll 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, allproperly 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 turnedguards and covers replaced before power is turned

guards and covers replaced before power is turned

on.

on.on.

on.

Never plug or unplug a printed circuit board while

Never plug or unplug a printed circuit board whileNever plug or unplug a printed circuit board while

Never plug or unplug a printed circuit board while

machine power is on. Instantaneous surges of voltage

machine power is on. Instantaneous surges of voltagemachine power is on. Instantaneous surges of voltage

machine power is on. Instantaneous surges of voltage

and current can damage electronic components.

and current can damage electronic components.and current can damage electronic components.

and current can damage electronic components.

SECTION 1 SAFETY

1-9

1.8 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.

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

Welding Society.

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

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

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

Batterymarch Street, Boston, Massachusetts, 02110.

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

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

Protection Association.

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

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

Systems. Obtainable through your ESAB representative or local

distributor.

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

ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed Gases in

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

Literature applicable to safe practices in welding and cutting with

gaseous materials is also available from the Compressed Gas

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

SECTION 1 SAFETY

1-10

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SECTION 2 DESCRIPTION

2-1

2.1 General

The Precision Plasmarc System consists of four

separate components. The power source, the

junction box, the flow control box, and the PT-24

torch. The power source provides power and

coolant to the PT-24 torch via the junction box.

2.2 Scope

The purpose of this manual is to provide the

operator with all the information required to install

and operate the Precision Plasmarc System.

Technical reference material is also provided to

assist in troubleshooting the cutting package.

2.3 Package Options Available

Precision Plasmarc package options available through your ESAB dealer

Precision Plasmarc Power Source (

200/230/380/415/460/575) 3-phase 50/60

Hz (required)

P/N 37357

Electronic Flow Control Box (required) P/N 22406

Junction Box (required) P/N 22407

4.5 ft. (1.4 m) P/N 0558001463

12 ft. (4.4 m) P/N 0558001877PT-24 Torch Electronic Flow Series A/M (one required)

17 ft. (5.2 m) P/N 0558001464

12 ft. (3.6 m) P/N 22428

25 ft. (7.6 m) P/N 21905

40 ft. (12.2 m) P/N 22504

60 ft. (18 m) P/N 21906

80 ft. (24.4 m) P/N 22505

Power Bundle (one required)

100 ft. (30 m) P/N 21907

10 ft. (3 m) P/N 37533

20 ft. (6 m) P/N 37534

30 ft. (9 m) P/N 37535

60 ft. (18 m) P/N 37536

Gas Line Bundle (one required)

100 ft. (30 m) P/N 37537

10 ft. (3 m) P/N 21917

20 ft. (6 m) P/N 21918

30 ft. (9 m) P/N 21919

60 ft. (18 m) P/N 21920

Control Lead Flow Console to Junction Box

(one required)

100 ft. (30 m) P/N 21921

Torch Coolant (one gallon (3.8 l) containers. four gallons (15 l) required) P/N 156F05

NOTES:

• Control lead from the power source to customer CNC is supplied based on customer order.

• Gas supply, hoses, work lead and input primary cable are all supplied by the customer.

• See Process Data Sheets for a list of torch consumable parts.

SECTION 2 DESCRIPTION

2-2

R

E

C

I

S

I

O

N

P

L

A

S

M

A

R

C

P

I

L

O

T

A

R

C

P

O

W

E

R

C

O

N

T

R

O

L

C

U

R

E

N

T

22" (559mm)

42" (1067mm)

44" (1118mm)

WEIGHT = 560 lbs. (254 kg)

WEIGHT = 560 lbs. (254 kg)WEIGHT = 560 lbs. (254 kg)

WEIGHT = 560 lbs. (254 kg)

POWER SUPPLY

POWER SUPPLYPOWER SUPPLY

POWER SUPPLY

N

I

T

R

O

G

E

N

O

2

A

I

R

M

E

T

H

-

3

5

O

2

N

2

A

I

R

N

2

N

2

P

L

A

S

M

A

G

A

S

N

O

.

1

P

L

A

S

M

A

G

A

S

N

O

.

2

S

H

I

E

L

D

G

A

S

N

O

.

1

S

H

I

E

L

D

G

A

S

N

O

.

2

A

R

G

O

N

A

I

R

O

X

Y

G

E

N

I

T

R

O

G

E

N

A

I

R

O

X

Y

G

E

N

I

T

R

O

G

E

N

H

Y

D

R

O

G

E

N

M

E

T

H

A

N

E

14.5" (1118mm)

12" (305mm)

12.25" (311mm)

WEIGHT = 51 lbs. (23 kg)

WEIGHT = 51 lbs. (23 kg)WEIGHT = 51 lbs. (23 kg)

WEIGHT = 51 lbs. (23 kg)

ELECTRONIC FLOW CONTROL BOX

ELECTRONIC FLOW CONTROL BOX ELECTRONIC FLOW CONTROL BOX

ELECTRONIC FLOW CONTROL BOX

6.75" (171mm)

10.62" (270mm)

19.75" (502mm)

WEIGHT = 26.5 lbs.(12 kg)

WEIGHT = 26.5 lbs.(12 kg)WEIGHT = 26.5 lbs.(12 kg)

WEIGHT = 26.5 lbs.(12 kg)

JUNCTION BOX

JUNCTION BOXJUNCTION BOX

JUNCTION BOX

2.4 Precision Plasma Technical Specifications

2.4.1 System

Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz

Input Current 65/60/50/40/30/25 amps per phase

Power Factor 0.95

Output Current Range 15-100 amps dc

Output Load Voltage 120 V dc

Duty Cycle 100%

Open Circuit Voltage 315 V dc

SECTION 2 DESCRIPTION

2-3

2.4.2 Plasma Gas Technical Specifications

Type O

2

, N

2

, Air

Pressure 125 psig (8.6 bars)

Flow

100 cfh (47 l/min) max. (varies with

application)

Purity Required*

O

2

-99.995%

N

2

-99.995%

Air-clean, dry and oil free

Recommended Liquid Cylinder Service

Regulators

Oxygen: R-76-150-540LC (P/N 19777)

Inert gas: R-76-150-580LC (P/N 19977)

Recommended Cylinder 2-Stage

Regulators

Oxygen: R-77-150-540 (P/N 998337

Hydrogen/Methane:R-77-150-350 (P/N

998342)

Nitrogen: R-77-150-580 (P/N 998344)

Industrial Air: R-77150=590 (P/N

998348)

Recommended Heavy –Duty Hi-flow

Station or Pipeline Regulators

Oxygen: R-76-150-024 (P/N 19151)

Recommended High-capacity Station

or Pipeline Regulators

R-6703 (P/N 22236)

Gas Filter Required 25 micron w/bowl guard (P/N 56998133)

2.4.3 Start Gas Technical Specifications

Type N

2

, Air

Pressure 125 psig (8.6 bar)

Flow

60 cfh (28 l/min) max (varies with

application)

Minimum Purity Required 99.995%

2.4.4 Secondary Gas Technical Specifications

Type N

2

, O

2

, H-35, Methane, Air

Pressure

100 psig (6.6 bar) H-35,

Methane; 125 psig (8.6 bar) N

2

,

O

2

, Air

Flow

60 cfh (28 l/min) max (varies with

application)

Minimum Purity Required 99.995%

2.4.5 Pt-24 Torch Technical Specifications

Type Water-Cooled, Dual Gas

Rating 100 amps @ 100 % duty cycle

Dimensions See Package Options (2.3)

SECTION 2 DESCRIPTION

2-4

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