ESAB Precision Plasmarc System Installation guide

Category
Welding System
Type
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.
©
©©
© ESAB Cutting Systems, 2000
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
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
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
N
I
T
R
O
G
E
N
A
I
R
O
X
Y
G
E
N
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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ESAB Precision Plasmarc System Installation guide

Category
Welding System
Type
Installation guide

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