Precision Plasmarc
Plasma Gas Box & Shield Gas Box
Instruction Manual (EN)
0558007535
Plasma Gas Box
Shield Gas Box
114
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!
115
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ..................................................................................117
2.0 Description...........................................................................................119
2.1 System Introduction ...........................................................................119
2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36 ...................................119
2.3 System Gas Requirements..................................................................... 120
2.4 Plasma Gas Box Water Supply Requirements ................................................... 120
2.5 Plasma Gas Box Electrical Input Requirements ................................................. 120
2.6 Shield Gas Box Electrical Input Requirements .................................................. 120
2.7 System Accessories ........................................................................... 120
2.8 Plasma Gas Box Dimensions....................................................................121
2.9 Shield Gas Box Dimensions.................................................................... 122
3.0 Installation .......................................................................................... 123
3.1 Plasma Gas Box Introduction .................................................................. 123
3.2 Plasma Gas Box Mounting (Bottom View) ...................................................... 123
3.3 Plasma Gas Box Connections .................................................................. 124
3.4 Plasma Gas Box Nomex Insulation ............................................................ 130
3.5 Plasma Gas Box Gas Connections...............................................................131
3.6 Shield Gas Box Introduction................................................................... 133
3.7 Shield Gas Box Mounting (Bottom View)....................................................... 133
3.8 Shield Gas Box Connections................................................................... 134
3.9 Component Relationship Block Diagram....................................................... 136
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
4.1 Plasma Gas Box Operation .................................................................... 143
4.2 Plasma Gas Box Pressure Gauges .............................................................. 143
4.3 Plasma Gas Box Pressure Switches .............................................................144
4.4 Shield Gas Box Operation ..................................................................... 145
4.5 Shield Gas Box Air Regulator for Air Curtain .................................................... 146
4.6 Shield Gas Box Check Valves .................................................................. 147
116
TABLE OF CONTENTS
117
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 qualied 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.
118
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 inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus 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
119
SECTION 2 DESCRIPTION
2.1 System Introduction
The m3 Plasma System is a streamlined, high performance-cutting package designed for use exclusively with the
ESAB CNC. This advanced technology integrates gas and water control into the machine CNC.
Using a system of electronic valves driven by CNC outputs, this system:
dramatically reduces the amount of Plasma Gas hardware necessary to control the plasma torch.•
reduced purge time/increased part throughput .•
simplied operation with gas and water ow rates are controlled by the ESAB CNC process parameter •
screen.
allows for programmed/automated control of uid and water ow rates using SDP Files (SchneidDaten-•
Paket = Cutting Data Package, see Vision control and programming manuals for details on SDP Files.
Data used to generate SDP les can be found in your model specic torch manual.) SDP les can also
be referred to as TDF les (Technology Data Files).
to be used with the PT-36 cutting torch. •
2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36
The complete m3 cutting system requires a variety of components. See section 3.9, Component Relationship
Block Diagram for components and hook-up.
Plasma Gas Box
Shield Gas Box
2.0 Description
120
SECTION 2 DESCRIPTION
2.4 Plasma Gas Box Water Supply Requirements
Cooling Water ......................................................................................175 PSI (12,1 bar), 1.5 gallons per minute (5.68 liters/minute)
2.5 Plasma Gas Box Electrical Input Requirements
Voltage Supply +24 VDC for proportional valves, mfc
+15 VDC for pressure switch
Voltage Signals 24 VAC input to start gas solenoid valve
120 VAC input to arc starter
0-10 VDC input to proportional valves
0-10 VDC for mass ow valve
2.6 Shield Gas Box Electrical Input Requirements
Voltage Supply +24 VDC for 120/230 transformer and I/O board
+24 VDC for proportional valves and mfc’s
2.7 System Accessories
Adapter Coolant EPP-200 ..............................................................................................0558006162
Coolant Hose Adaptor Kit ............................................................................................ 0558006698
2.3 System Gas Requirements
Argon 125 PSI (8,6 bar) with 0.25” NPT, 99.995% purity, Filtered to 25 microns
Nitrogen 125 PSI (8,6 bar) with 0.25” NPT, 99.99% purity, Filtered to 25 microns
Oxygen 125 PSI (8,6 bar) with 0.25” NPT, 99.5% purity, Filtered to 25 microns
H-35 (Argon/Hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns
Methane 75 PSI (5,2 bar) with 0.25” NPT, 93% purity, Filtered to 25 microns
Compressed Air
(Air Curtain )
80 PSI (5,5 bar) with 0.25” NPT, clean, dry, oil-free and ltered to 25 microns
Compressed Air
(Process)
80 PSI @ 1200cfh (5,5 bar @ 35 m
3
h) ltered to 25 microns
DIN Quality ISO 8573-1
Oil quality mg/m3 = 0.1 class 2
Particle Size 0.1um class 1
Temparature +3 C class 4
121
SECTION 2 DESCRIPTION
2.8 Plasma Gas Box Dimensions
11. 2 8 ”
286.5 mm
7. 2 5”
184.2 mm
17.13 ”
435.1 mm
122
SECTION 2 DESCRIPTION
2.9 Shield Gas Box Dimensions
20.00”
508.0 mm
12.0 0”
304.8 mm
8.00”
203.2 mm
123
SECTION 3 INSTALLATION
3.1 Plasma Gas Box Introduction
ELECTRICITY CAN KILL!
BEFORE PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS
EQUIPMENT, ENSURE THE POWER SOURCE EPP IS TURNED OFF AND
DISCONNECTED.
WARNING
The m3 Plasma System Plasma Gas Box interfaces with the ESAB Vision machine controls and the EPP product
line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control
electronic valves. The result is CNC management of gas or shield gas delivery to the plasma torch. Analog signal
feedback is sent back to the CNC, creating a control loop.
3.2 Plasma Gas Box Mounting (Bottom View)
If mounting the box is required:
The box has four (1.10”) 28 mm threaded mounting holes in a pattern oset from longitudinal center. Note rela-
tionship of hole pattern to gauges and cable clamp.
.75”
19.1 mm
4.50”
114.3 mm
2.00”
50.8 mm
11. 0 0 ”
279.4 mm
4.13”
104.9 mm
2.00”
50.8 mm
3.0 Installation
front
back
124
3.3 Plasma Gas Box Connections
1. To access the inside of the box: remove or unlock screws
and lift the box cover o to expose internal components.
SECTION 3 INSTALLATION
2. Disassemble the strain relief/clamp block. (When apart,
this strain relief will allow placement of cables and hoses
without removing plugs and ttings.)
A. Remove two screws holding block together.
B. Insert cables for making connections inside box.
C. Reattach block.
Strain Relief / Clamp Block
Note:
Wires can be inserted in any of the three holes,
only one cable is used in picture below.
Pilot Arc Cable
Power Source Cable
125
3.3.1 Plasma Gas Box Starter Box Connections
TB1 – Pilot arc cable from the plasma power source.
TB4 – Connected to buss bar (lower back right hand
corner).
TB2 – Pilot Arc Torch cable from the torch leads.
Black Lead - 120 vdc input
SECTION 3 INSTALLATION
View from underneath the Arc Starter Box
TB1 TB4 TB2 Black Lead
Arc Starter Box
Pilot Arc Cable
Buss Bar
126
SECTION 3 INSTALLATION
3.3.2 Plasma Gas Box Torch Connections
To connect the torch see the following illustrations. Hook-up requires connection of the cut and start gas hoses,
shield gas hose, coolant hoses, air curtain hose, the pilot arc cable (TB2) and the Torch Tip / Electrical soft touch
wire on the PC board X4 terminal.
6
2
1
5
1 - Female old-style air water nut for Shield Gas connection
2 - B-IG ttings for Plasma Start gas and Plasma Cut gas. Ei-
ther hose can be attached in either location.
3 - Cooling Water Connections.
4 - Pilot Arc Cable - connects to TB2 underneath Arc Starter
Box.
5 - Torch Tip / Electrical soft touch wire - connects to PC
board at X4 terminal.
6 - Air Curtain Hose - to air curtain at torch tip
7 - Ground Wires (yellow/green) - to be connected to ground
stud beneath torch connection inside box.
3
3
4
2
1
5
7
Torch Bundle Hose Connections
127
3.3.3 Plasma Gas Box Torch Cooling Water Connections
SECTION 3 INSTALLATION
Coolant Connections To and From Power Source
When packaged with a torch and power supply at the factory,
connections are labeled. Additional labels are available if re-
labeling becomes necessary. Tracing the Plasma Gas boxes in-
terior lines can identify the proper connections. Flow switch is
located on the “IN” line.
Coolant Connections To And From Torch
Note arrows on ttings indicating coolant ow direction.
Coolant Out has right-hand threads.
Coolant In has left-hand threads.
Plasma Gas Box Rear View
H
2
O IN
H
2
O OUT
Note:
Coolant hoses connect as shown from the
water cooler to the Plasma Gas box.
Plasma Gas Box
Rear View
128
3.3.4 Power Source To Plasma Gas Box Buss Connection
1. Strip 4/0 (95 mm
2
) insulation, approximately 38 mm.
2. Insert 4/0 (95 mm
2
) cable in buss bar hole until copper
extends to the edge of the buss block.
3. Tighten locking screw(s) on cable.
Note:
The buss will accommodate these cables.
(1) 4/0 (95 mm
2
) - 400 amps
(2) 4/0 (95 mm
2
) - 800 amps
(3) 4/0 (95 mm
2
) - 1000 amps
Careful attention while stripping insulation will make installation of
the power source cable in the buss easier. Do not spread or are the
copper conductors.
NOTICE
SECTION 3 INSTALLATION
Buss Block
Pilot Arc Cable
Power Source Cable
X1-10 - +24 vdc Input
X1-9 - Sensor Input
X1-2 - Common / Chassis Ground
X4 - Torch Tip / Electrical soft touch wire
PE - Chassis Ground
Note:
For more detailed information, refer to PC
board schematic next page.
3.3.5 Plasma Gas Box PC Board Connections
129
SECTION 3 INSTALLATION
PC Board Schematic
25.07.2005 12:51:42 C:\Programme\EAGLE_V4-11\projects\2256510\2256510.sch (Sheet: 1/1)
130
3.4 Plasma Gas Box Nomex Insulation
SECTION 3 INSTALLATION
Nomex Insulation
1. To access the inside of the box: remove or
unlock screws and lift the box cover o to
expose internal components.
2. Position Nomex insulation to prevent any
possible arcing between the buss and arc
start box terminals.
3. Replace enclosure of m3 Plasma System Plas-
ma Gas Box.
131
SECTION 3 INSTALLATION
3.5 Plasma Gas Box Gas Connections
Gas Connections are made on the exterior of the box. Gas lines are connected to the back of the plasma gas box
from supply sources. Gas lines are connected to the front of the plasma gas box from the torch.
Unltered Gas Will Clog Proportional Valves
CAUTION
Dirt particles will clog small orices in proportional valves. All gas
supplies must have a 25 micron lter installed between supply and
gas regulator panel. ESAB Filter P/N 56998133 (replacement lter
element P/N 0560988406). Proportional valves contain no service-
able parts. Replace valve assembly with factory parts.
Plasma Gas Box Front Gas Connections
Plasma Gas Box Rear Gas Connections
132
Gas Line Contamination Will Damage Proportional Valves.
Purge Gas Lines.
CAUTION
Before connecting gas delivery lines to the m3 Plasma System
Plasma Gas Box, purge all lines thoroughly. Residue from the hose
manufacturing process may clog/damage the proportional valves in
your m3 Plasma System Plasma Gas Box.
SECTION 3 INSTALLATION
1. Purge gas and air lines completely before connecting
to 25 micron gas lters.
2. Connect oxygen, H-35, nitrogen and air lines to gas
lters.
3. Purge gas/air lines between shield gas box and m3
Plasma System Plasma Gas Box.
4. Connect gas/air lines to back of Plasma Gas box.
1 PG1
2 PG2
3 Air Curtain
4 PG2 Out
5 PG1 Out
6 Shield
7 Torch
8 14 Pin To B3 Lifter
9 8 Pin to Shield Box
10 10 Pin To B3 Lifter
11 H-35
12 Start Gas Selection (O2 N2 AIR)
13 Argon
14 H
2
O IN
15 Shield
16 Air Curtain
17 Cut Gas Selection (O2 N2 AIR)
18 H
2
O OUT
19 LED Volt Meter
20 Torch Cable Leads Grounding stud
4
1
2
3
5
6
7
8
9
11
10
13
15
12
14
17
18
16
19
20
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