ESAB M3® Plasma Precision Plasmarc Plasma Gas Box & Shield Gas Box User manual

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 qualied electrician.

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

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

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 inammable materials nearby.

NOISE - Excessive noise can damage hearing.

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

- Warn bystanders of the risk.

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

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

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 .•

simplied 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 specic 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 oset 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

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.

Unltered Gas Will Clog Proportional Valves

CAUTION

Dirt particles will clog small orices 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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ESAB M3® Plasma Precision Plasmarc Plasma Gas Box & Shield Gas Box User manual

ESAB M3® Plasma Precision Plasmarc Plasma Gas Box & Shield Gas Box User manual

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