ESAB m3® Plasma User manual

Manual Gas Control Plasma System

Instruction Manual

0558009496 02/2010

This documentation is for ESAB equipment:

PCC-14 Plumbing Box part number 0558005840

Plasma Control Interface part number 0560948696 (serial #’s AORJ951005, AORJ951004, AORJ951003)

PCC-14 Plumbing Box

Plasma Control Interface

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!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Safety - Spanish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.0 ESAB m3 Manual Gas Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PCC-14 Plumbing Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.2 Plumbing Box Spark Gap Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.3 Plumbing Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3.4 EPP-201 / EPP-360 Torch Connections to Plumbing Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3.5 PCC-14 Plumbing Box Mounting Hole Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Plasma Control Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

3.7 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

3.8 Plasma Control Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3.9 Typical / Recommended E-stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

3.10 Control Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.11 Plasma Control Interface Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

3.12 Plasma Control Interface STATUS Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.0 Marking Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.1 Marking Module Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.0 PT-36R Plasma Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

6.1 PT-36R Technical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

6.2 Gas Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

6.3 Recommended Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

6.4 PT-36R Torch Technical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.0 Coolant Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

7.1 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

7.2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.3 Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

8.0 EPP-201 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

8.1 Dimensions and Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

8.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

9.0 EPP-360 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

9.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

9.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4

TABLE OF CONTENTS

10.0 HOSES AND CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

10.1 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

10.2 Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

11.0 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

11.2 Ordering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Diagrams and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . attached packet

5

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety precau-

tions listed below as well as all other manuals, material

safety data sheets, labels, etc. Failure to observe Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operating

or observing operations. Warn bystanders not to

watch the arc and not to expose themselves to the

rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

which could cause a later re. Use re watchers when

necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

6

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

7

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

8

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

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SECTION 2 INTERCONNECT DIAGRAM

2.0 ESAB m3 Manual Gas Control System

The Manual Gas Control System consists of several components: Plasma Control Interface (PCI), PCC-14 Plumbing Box, Power Supply (PS), Coolant Circulator (CC), Torch and customer CNC.

Dotted line denotes optional

PCC-OUT

PCC-IN

PCC-PA

PCC-PWR

PS-PA

PS-IC

CC-IC

PS-PWR

PCC-SHG

PCC-STG

PCC-VDR

PCC-CTL

PCI-CTL

PCI-VDR

PCC-CG

CC-IN

CC-OUT

PS-ES

PS-CC

PCI-ES

PCI-EP

PCI-CI

PCI-CC

SM-AS

PCI-AS

PT-36R

POWER

DATA

LIQUID Optional

GAS

PCC-AR

REG-AR

REG-CG

REG-STG

REG-SHG

(optional)

Customer CNC

Ext. 115/230VAC

Control Interface

PS Contol Cable

E-Stop

ESAB m Manual Gas Control System

Ar

Cut Gas

Start Gas

Shield Gas

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Coolant Return Hose

Argon Select

PCI

Mark / Cut

Switching

Module

PS

CC

PCC-14

Plasma Gas

Shield Gas

Power, Pilot Arc, Coolant

Air Curtain

Torch

Bubble Muffler

VDR

Bubble Muffler / Air Curtain Control

PCC-14 Control

CC-11 Control Cable

3

Regulated

Gas Supply

(optional)

18

SECTION 2 INTERCONNECT DIAGRAM

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21

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

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

Plasma Torch to a remotely located EPP-201 or EPP-360 power supply system. The

PCC-14 includes high frequency starting circuits to eliminate starting problems

with long torches and to minimize high frequency interference with other customer

systems.

Weight: 41 lbs. (18.6 kg)

WARNING

THIS EQUIPMENT CAN BE HAZARDOUS IF NOT PROPERLY

OPERATED AND MAINTAINED.

READ AND UNDERSTAND ALL EQUIPMENT LITERATURE AND

WARNING LABELS BEFORE OPERATING THIS EQUIPMENT.

FOLLOW THESE INSTRUCTIONS TO PREVENT INJURY OR

PROPERTY DAMAGE.

YOU MUST COMPLY WITH LOCAL, STATE AND NATIONAL

ELECTRICAL AND SAFETY CODES.

ONLY TRAINED PERSONNEL SHOULD PERFORM MAINTENANCE

OR REPAIRS ON THIS EQUIPMENT.

3.0 General

3.1 Scope

The purpose of this manual is to provide the operator with all the information re-

quired to install and operate the Plumbing Box & Plasma Control Interface. Technical

reference material is also provided to assist in troubleshooting.

Specications: PCC-14 Plumbing Box

Plasma and Start Gases:

The PCC-14 may be used with O2, N2, Air or H-35 (35% H2/65% Ar) at a maximum input pressure of 125 psig (8.6 bar).

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

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

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

pressure for the start gas is 15 psig (1.0 bar); for the cut gas it is 24 psig (1.7 bar). Below these pressures the pressure switches

may not be satised.

Shield Gases:

The PCC-14 may be used with Air, N2, Ar, or CO2. The maximum pressure is for N2, Ar, Air or CO2 is 125 psig (8.6 bar). This

will result in a ow of 250 scfh (7.1 cu-m/h) N2. See Graph 3-1. There is no pressure interlock on the shield gas.

Coolant:

The PCC-14 is designed for use with plasma torch coolant (ESAB P/N’s 156F05 or 0558004297). Maximum design pressure

is 200 psig (13.8 bar). Flow rates depend on the torch but typically vary from 0.9 to 2 gpm (4.1 to 9.1 l/m).

22

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Gas Purging:

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

followed:

1. Turn o the gas.

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

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

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

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

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

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

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

Flashback arrestors are required to prevent re from propagating

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

Use AWG 2/0 power cable to carry electrode current from the power

source to the PCC-14. See section 9.0 for additional cables.

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

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

highly ammable.

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

or damage to the equipment.

CAUTION

Note:

The expected life of the internal exible hoses is 10 years. Replace them earlier if cracking or brittleness is noted.

Note:

When marking, ensure the start gas line is pressurized to avoid pressure switch errors.

Marking option

With the optional Marking Module installed, the PCC-14 will allow you to switch the cut gas to Argon for plate marking. With

the Marking Module installed, Argon gas input to the Marking Module is 125 psig (8.6 Bar).

23

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

250 (7.1)

240 (6.8)

230 (6.5)

220 (6.2)

210 (5.9)

200 (5.7)

190 (5.4)

180 (5.1)

170 (4.8)

160 (4.5)

150 (4.2)

140 (4.0)

130 (3.7)

120 (3.4)

110 (3.1)

100 (2.8)

90 (2.5)

80 (2.3)

70 (2.0)

60 (1.7)

50 (1.4)

40 (1.1)

30 (0.8)

20 (0.6)

10 (0.3)

0

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

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

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

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

2

Graph 3-1 - Gas Pressure / Flow

24

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

3.2 Plumbing Box Spark Gap Adjustment

1. Disconnect input power to power source.

2. Remove access cover from spark gap opening.

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

4. Replace cover.

Spark Gap

Access Cover

Spark Gap

ELECTRICITY CAN KILL!

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

ERATE WITHOUT COVER PLATE IN PLACE. BEFORE REMOVING COVER

PLATE OR PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS

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

CONNECTED.

WARNING

Only qualied maintenance personnel should repair and maintain

this equipment.

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

may result.

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

result in damage to the equipment.

CAUTION

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX

BEFORE MAKING ANY CONNECTIONS TO THE PCC14.

WARNING

25

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Connection Locations

Inside Plumbing Box

3.3 Plumbing Box Connections

26

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Plasma Gas Hose From Torch

Shield Gas Hose From Torch

Pilot Arc Cable

From Power Supply

Pilot Arc Cable From Torch

Power / Coolant Supply

Hose From Torch

Power / Coolant Return

Hose From Torch

Coolant Supply Hose

Power Cables

Coolant Return Hose

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX BEFORE

MAKING ANY CONNECTIONS TO THE POWER SUPPLY.

DISCONNECT CURRENT SUPPLY AT WALL DISCONNECT BEFORE SERVICING

PLUMBING BOX.

• DO NOT OPERATE PLUMBING BOX WITH ANY COVERS REMOVED / OPEN.

• DO NOT TOUCH ANY TORCH FRONTEND PARTS WITH POWER ON.

• DO NOT ATTEMPT TO SERVICE UNLESS POWER HAS BEEN DISCONNECTED

AT THE WALL.

WARNING

27

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

1. Torch connections are rst made in the PCC-14 plumbing box. Remove the cover of the plumbing box to access input

and output connections . For both manual and mechanized torch applications, pass the torch lines through the

openings in the front of plumbing box and make connections as shown.

2

3

4

5

3.4 EPP-201 / EPP-360 Torch Connections to Plumbing Box

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX

BEFORE MAKING ANY CONNECTIONS TO THE PCC14.

WARNING

Coolant Supply

(Electrode Cable)

Coolant Return

(Electrode Cable)

Plasma Gas

Pilot Arc

Shield Gas

4

2

3

5

1

1 Shield Gas Hose

2 Electrode Cable / Coolant Return Hose

3 Plasma Gas Hose

4 Electrode Cable / Coolant Supply Hose

5 Pilot Arc Cable

1

Lines from torch

4

2

3

5

1

28

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Chassis Ground

Note:

Chassis ground to be connected from PCC-14 Plumbing Box to either the cutting machine or to the chassis

of the power supply using the supplied ground wire.

(Ensure star washer is installed on the ground stud for the PCC-14 connections).

Hose connections should be wrench-tight.

Ensure plug of the switch lead is rmly locked in place. Then close hinged cover.

Interconnection Diagram - EPP-201/360

Electrode (-)

Pilot Arc (+)

Electrode (-)

Pilot Arc (+)

29

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Connections to the Power Supply

1. A power output cable attaches to a large bolted connection labeled “Electrode”.

2. The Pilot Arc cable connects to a small threaded stud labeled “Pilot Arc”.

3. The Plasma Control Interface connects to the power supply. The PCC-14 Plumbing Box control cable connects to the

Plasma Control Interface.

4. A work cable connects to the "Work" terminal on the front-lower-left of the console. The other end is attached to the

cutting table or work piece.

Connections to the rear of the Plumbing Box

1. The Start, Cut & Shield gas hoses from the regulator panel attach to the rear of the plumbing box.

2. The Plumbing Box Control cable from the Plasma Control Interface connects to the amphenol receptacle labeled

"CONTROL CABLE FROM POWER SOURCE".

Both power cables, the pilot arc cable and both coolant hoses enter the plumbing box from the rear and are connected

internally.

Connections to the Coolant Circulator

1. The coolant supply and return lines connect to the supply and return ttings on the coolant circulator.

3.5 PCC-14 Plumbing Box Mounting Hole Locations

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

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

in the base of this unit.

16.625"

(422.28 mm)

12.500"

(317.5 mm)

1.060"

(26.92 mm)

6.875"

(174.63 mm)

4.500"

(114.3 mm)

2.125"

(53.98 mm)

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33

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

Weight : 17.0 lbs. (7.7 kg)

This unit is an integral component of the m3 Manual Gas Control Plasma

system used by an external controller (e.g. CNC) to interface with the PCC-

14 Plumbing Box. It controls all the sequencing required for handling the

plasma cutting/marking operation leaving the external controller with a

simple interface to the Plasma Control Interface (PCI).

3.6 General

3.7 Scope

The purpose of this manual is to provide the operator with all the informa-

tion required to install and operate the Plumbing Box & Plasma Control

Interface. Technical reference material is also provided to assist in trouble-

shooting.

Specications: Plasma Control Interface

15.50”

(393.7 mm)

6.59”

(167.4 mm)

13.67”

(347.2 mm)

PS-1 PS-2

CNC PCC-14

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