ESAB m3® plasma Water Injection Control User manual

Brand: ESAB

Model: m3® plasma Water Injection Control

Category: Welding System

Type: User manual

WATER INJECTION CONTROL

WIC

Instruction Manual

0558009491 08/2013

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 Description ............................................................................................19

2.1 Functions and Features ...........................................................................19

2.2 Functions and Features (Pump Module) .......................................................... 20

2.3 Technical Specications...........................................................................21

2.4 Connections, Controls and Indicators............................................................. 22

3.0 Installation............................................................................................ 23

3.1 Mounting Hole Locations ........................................................................ 23

3.2 Cut Water Requirements ......................................................................... 23

4.0 Operation............................................................................................. 25

4.1 Operation in CAN Communication Mode ......................................................... 25

4.2 Operation in Optional Control Mode ..............................................................27

4.3 Motor Precaution .................................................................................27

4.4 Anti-freezing Function ........................................................................... 28

4.4.1 Anti-freezing Procedure ........................................................................ 28

4.5 Back Pressure Regulator (BPR) Manifold Assembly................................................. 30

5.0 Maintenance...........................................................................................31

5.1 Troubleshooting with ESAB Vision 5x CNC .........................................................31

5.2 Troubleshooting of CAN Communication ..........................................................32

5.3 S1 and S2 Address ................................................................................33

5.4 Faults and Errors ................................................................................. 34

5.5 Power Requirement...............................................................................35

5.6 Flow Sensor Replacement........................................................................ 36

5.7 Pump Filter Replacement .........................................................................37

6.0 Replacement Parts .................................................................................... 39

6.1 General.......................................................................................... 39

6.2 Ordering ........................................................................................ 39

6.3 WIC Parts........................................................................................ 39

6.4 Hoses and Cables................................................................................ 40

6.5 Recommended Wall Mounted Filter Assembly .....................................................42

6.6 Back Pressure Regulator (BPR) Assembly ...........................................................42

TABLE OF CONTENTS

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.

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.

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"

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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POWER

DATA

LIQUID Optional

Phone 1-843-664-5550

Email: [email protected]

0558009782-OR

GAS

CC-IC

PS-IC

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Ext. E-Stop

Digital I/O

(Must be 230V

with

AHC)

Ext. 115/230V

IFH-IC

RAS-TC IN

Air

SGC-A/C OUT

SGC-SG

SGC-PWR

SGC-PG1

SGC-PG2

SGC-Air

SGC-N

SGC-O

SGC-CH

GFA-Air

GFA-N

GFA-O

GFA-CH

RAS-E-Stop

RAS-CAN

Power, Pilot Arc, Coolant

RAS -VDR

AHC- AC IN

AHC-CAN

WIC-H

OUT

AHC

Air Curtain

Hose

Shield Gas Hose

Plasma Gas

Hose

PGC-PG1

PGC-PG2

PGC-H

PGC-Ar

PGC-CAN

PN 05580 07515

IFH-RAS CAN

IFH-AC2

IFH-AHC CAN

IFH-WIC CAN

IFH-SGC CAN

IFH-PGC CAN

IFH-AC1

RAS-TC OUT

RAS-PA

RAS-E(

RAS-PSC

PS-PA

PS-E(

)

PS-PSC

Coolant Return Hose

MMI-IC

GFA-H

GFA-A

SGC-CAN

SGC-AC IN

SGC-A/C IN

CC-TC OUT

CC-TC IN

IFH-IC

IFH-AC IN

Manual

0558008526

Manual

0558008526

Manual

0558007823

Manual

0558008527

Manual

0558008527

Manual

0558008527

Manual

0558006404

PT-36 Torch

SGC

(Shield Gas Control)

RAS

(Remote Arc Starter)

PGC

(Plasma Gas Control)

(Coolant Circulator)

(Power Supply)

IFH

(Interface Hub)

MMI

(Vision 50P)

Manual

0560946014 (A6) or

0560946015 (B4)

PGC-PWR

Air Curtain

Customer

CNC

GFA

(Gas Filter

Assembly)

IFH-TDF

Remote -TDF

AHC-VDR

Water Injection System Interconnect Diagram

BPR

(Back Pressure

Regulator)

WIC

(Water Injection

Control)

230V AC

Manual

0558008527

Manual

0558009491

WIC-Air IN (optional)

WIC-H

2O IN

WIC-AC IN

WIC-CAN

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2.0 Description

SECTION 2 DESCRIPTION

15.0”

(381 mm)

18.3”

(465 mm)

8.6”

(218 mm)

18.3”

(465 mm)

6.4”

(163 mm)

6.4”

(163 mm)

12.1”

(307 mm)

Water Injection Control ..................................................................................................................................................................0558009370

The Water Injection Control (WIC) regulates the ow of cut water supplied to the plasma torch. This water is used

as a shield in the cutting process. This shield assists in forming the plasma arc and also cools the cut surface. The

selection and output of cut water is performed and controlled by the CNC. The WIC consists of a water regula-

tor, pump and a closed feedback loop between proportional valve and ow sensor. This is controlled by a local

Process Control Unit (PCU). When used with a cutting machine having ESAB Vision 5X CNC, it sends command

signals to the PCU through the CAN bus. If using other CNC’s, the WIC is used in Optional Control Mode (refer to

Optional Control Mode section). This controls the proportional and solenoid valves. Similar to the m3 Shield Gas

Control (SGC), the WIC is monitored and sends feedback signals through the CAN bus to the CNC for diagnostic

purposes by selecting dierent SDP les. The WIC can be used in conjunction with the SGC to select a wet cut

(cut water as shield) or dry cut (gas as a shield).

Option 1: Wet cut using the WIC and the Plasma Gas Control (PGC). The WIC provides 24 VDC and 24 VAC

power for the PGC.

Option 2: Wet or dry cut (SGC + PGC or WIC + PGC). The SGC provides the 24 VDC and 24 VAC power for the

PGC.

2.1 Functions and Features

2.2 Functions and Features (Pump Module)

The Pump Module of the WIC consists of a pressure regula-

tor (REG), a pump (P1), a pressure transducer (PT1), a propor-

tional valve (PV1), and a ow sensor (FS) connected in series

as shown below. The lter and the valves are optional and

are supplied by the customer.

The ltered and softened cut water is supplied to the H2O

IN connection at greater than 20 psi (1.4 bar). The pressure

regulator reduces the water pressure to 20 psi (1.4 bar) (fac-

tory set) and sends it to the pump. The pump can increase

the cut water pressure by 150 psi (10.4 bar) (factory set)

above the inlet pressure, thus water after pump should have

an approximate pressure of 170 psi (11.7 bar).

By monitoring the ow, the PCU inside the WIC can regulate

the water ow to a given value.

SECTION 2 DESCRIPTION

Water Injection Control Flow Diagram

Customer Supplied

Components

H2O

PR1

P1/

PT1

PV1/

PWM

FS1

AIR

H2O OUT

(OPTIONAL AIR SUPPLY)

(Valve open

during purge)

EXHAUST

VALVE

WATER

VALVE

FILTER

TO TORCH

CV1

CV2

SOL1

BPR

FILTER

Dimensions (Electrical module) 163 mm x 307 mm x 163 mm (6.4 in x 12.1 in x 6.4 in)

Dimensions (Pump Module) 465 mm x 465 mm x 218 mm (18.3 in x 18.3 in x 8.6 in)

Weight (Electrical module) 15 lb. dry (6.8 kg)

Weight (Pump Module) 60 lb. dry (27.2 kg)

Water Requirements

Soft tap water with an allowable water hardness of <10 ppm as CaCO3 or less, l-

tered at 5 microns, and a minimum ow rate 1 gpm (3.8 l/min) @ at 20 psi (1.4 bar).

Resistivity must be at least 15 k ohm per cm.

Air Supply (anti-freezing function) 250 CFH @ 80 psi (7.1 cmh @ 5.5 bar)

Pump

Positive displacement, rotary vane with adjustable bypass valve (250 psi / 17.2 bars

maximum), CW rotation, Capacity: 1.33 GPM @ 150 psi (5.04 l/min @ 10.3 bars),

Nominal speed: 1725 rpm, Temperature rating: 150

F (66

Motor

1/2 HP, 230 VAC single phase, 50/60 Hz, 1725/1425 RPM, 3.6A,

Temperature rating: 150

F (66

Pressure Regulator

Inlet water pressure: 100 psi (6.9 bar) maximum

Outlet water pressure: 20 psi (1.4 bar) factory set

Pressure Transducer

Maximum pressure range: 0 - 200 psi (0 - 13.8 bar)

Temperature range: -40 - 257

F (-40

- 125

Supply voltage: 24 VDC

Pressure signal output: 4 mA for 0 psi, 20 mA for 200 psi (13.8 bar). Regulated to 1

to 5 VDC with 250 ohm resistor.

Proportional Valve

Supply voltage: 24 VDC

Full load current: 500 mA, Input control signal: 0-10 VDC.

Coil: Standard Voltage: 24 VDC, Operating current: 100-500 mA,

Valve: Orice size: 3/32”, Cv:0.14 (fully open)

Operating dierential pressure: 115 psi (8.0 bar) ; Max. ow 1.5 gpm

Maximum uid temperature: 150

F (66

Flow Sensor

Maximum operating pressure: 200 psi (13.8 bar),

Operating temperature: -4 - 212

F (-20

- 100

C), Input power: 5 - 24 VDC @ 50 mA

maximum, Output signal: 58 - 575 Hz, Flow range: 0.13 - 1.3 gpm

Air Solenoid

Supply voltage: 24 VDC, Maximum operating pressure: 140 psi (9.7 bar) , Operating

temperature: 32 - 77

F (0 - 25

2.3 Technical Specications

SECTION 2 DESCRIPTION

2.4 Connections, Controls and Indicators

The following descriptions of connections, controls and indicators will be useful in operation.

A. On/O Switch – This switch controls the

input power on/o.

B. Power On Light - This light illuminates when

the input power to the unit is on.

C. Pressure Sensor - Pressure transducer signal

input and 24 VDC supply.

D. Proportional Valve – Proportional valve

control signal and 24 VDC supply.

E. Air Solenoid - 24 VDC supply to solenoid

to purge water out of hoses for anti-freeze

purposes.

F. Flow Sensor – Flow sensor signal input and

24 VDC supply.

G. Pump Power – Output 230 VAC to motor.

Power is turned on/o by the control pro-

gram.

C D E

H. *AIR – Air input for anti-freeze purposes only.

J. *Water OUT – Cut water output to the torch.

K. *Water IN – Cut water input from the supply.

L. **Optional Control – This is an auxiliary

control used only for Optional Control Mode, if

CAN is not available.

M. *CAN - CAN connection.

N. **24 VAC/DC - 24 VAC power output for

Plasma Gas Control, if Shield Gas Control is not

available.

This port is used only when the customer

wants to cut with water as shield all the

time, thus the shield gas control, (SGC) is not

required. In this case the WIC is required to

provide 24 VDC/AC power to the plasma gas

control (PGC).

O. Fuses – 10A, slow blow fuse for complete unit

protection. 1A, slow blow fuse is for 24 VAC

output only.

P. * AC In - Power supply (230 VAC) to the com-

plete unit.

Q. Ground Stud – Connect the machine chassis

to this stud.

Note:

Chassis must be connected to the machine ground.

WIC

WATER INJECTION CONTROL

PRESSURE

SENSOR

PROPORTIONAL

VALVE

AIR

SOLENOID

FLOW

SENSOR

OFF

PUMP

POWER

AIR

FREEZE PROTECTION

OPTIONAL

CONTROL

CAN

24 VAC/DC

AC IN

10A

FUSE

* Required connections

** Optional connections

SECTION 3 INSTALLATION

3.0 Installation

3.1 Mounting Hole Locations

Install the WIC in an appropriate location to maintain adequate and unrestricted airow into and out of the cabi-

netry. For permanent mounting, please refer to the gure below for mounting hole dimensions.

3.2 Cut Water Requirements

The customer must supply a clean water source to the WIC to maximize consumable life. Water must be ltered

to a low level of calcium carbonate (measured in water hardness). This is critical for the proper performance of

the nozzle in the torch. Excessive deposits of calcium carbonate on the nozzle will alter water ow and produce

an unstable arc. Hardness of the water at the torch must be less than 2 ppm. If using a conductivity meter to mea-

sure water purity, the recommended level is: Resistivity must be at least 200,000 ohm•cm, conductivity can be

no more than (5 µ S/cm). Source water may require a water softener, reverse osmosis system or other de-ionizing

equipment to obtain this low level of hardness. Consult a water specialist for detailed advice in this area.

16.75”

425.45 mm

10.28”

261.11 mm

.50”

12.7 mm

.281”

7.137 mm

SECTION 3 INSTALLATION

SECTION 4 OPERATION

4.0 Operation

In CAN Communication Mode, customer needs to select a water injection le (SDP) as shown in Figure 4.1. Make

sure to select the correct gas type with water as a shield. Table 4.1 shows all dierent gas types used in the m3

G2 plasma system. Gas type 13 and 14 are used for water injection.

Figure 4.1

Figure 4.2

4.1 Operation in CAN Communication Mode

If the selection is conrmed in the pa-

rameter screen, the recommended wa-

ter ow will be displayed (see gure 4.2).

After selecting the le, perform “shield

test” and water will then ow through

torch. If everything is correct, select

“cycle start” to start plasma.

Note:

In CAN Communication Mode only, wa-

ter ow command will increase by 25%

automatically during shield test and dry

run. Therefore, actual ow will be 25%

higher than the commanded ow from

the CNC during shield test and dry run.

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SECTION 4 OPERATION

4.2 Operation in Optional Control Mode

When CAN communications are not available, the

WIC can work in Optional Control Mode. This hap-

pens when retrotting an older system with PT-36

torch. In this mode, all commands come from the

external 10-pin connector labeled “OPTIONAL

CONTROL” on the back panel of the WIC. Signals

from this 10-pin connector are listed below:

PIN Function

A +24 VDC (OUT)

B External Anti-freeze

C CNC COM

D Fault

E External Reference COM

F External Flow Reference

G Water Flow Output

H Water Pressure Output

J +24 VDC (from Pin A)

K Chassis

Pin A (+24 VDC) is an output to customer. Customer needs to send +24

VDC through pin B to activate anti-freeze function. Pin D is the fault

signal, which is normal high and the signal level is from pin C. In case

of fault, pin D will reset to low. Customer needs to monitor pin D for

fault. Water ow is provided to the system via pin E and pin F. Every

one volt gives 0.2 gpm, for example: 5V = >1.0 gpm or 1V = >0.2 gpm.

The system can also provide the water ow and water pressure back to

customer. For these two signals, the mapping relationships are: 5V = >1

gpm for ow, 5V = >100 psi (6.9 bar) for pressure.

Outputs from pin D (Fault), pin G (Water Flow Output), and pin H (Wa-

ter Pressure Output) are available in both CAN Communication Mode

and Optional Control Mode.

To start the pump, a water ow command is needed. The minimum ow is 0.15 gpm. For Optional Control Mode,

every one volt will command a water ow of 0.2 gpm. However, the ow command must meet the minimum

requirement. If a water ow command from CAN is available and greater than the minimum ow requirement,

the WIC will ignore the water ow command from the 10-pin connector.

While the pump is running, the actual water ow and water pressure are always available from the 10-pin con-

nector. Customer can use them for troubleshooting purposes.

4.3 Motor Precaution

The pump used in this application has an adjustable by-pass to maintain the pressure at a certain level. With

factory settings, the pump can boost the pressure to a level 150 psi (10.4 bar) higher than the inlet pressure. If al-

lowed to run continuously, and the ow is blocked, the heat from the motor can increase the water temperature

to a high level. This will result in excessively high heat that will cause the motor to fail.

OPTIONAL

CONTROL

LAYOUT

OUTSIDE VIEW

    

   

   

   

   



  





  





  





  





  







  





  

 



  





  





   

   

  







   

  





  





  





   

  





   

  





  





  





  





  





  







  





   



   

   



   



   

   

   

   

   



   

   

   

   

   





   

   

   

   





For Optional Control Mode, Pin A and Pin J must be jumpered to sup-

ply 24 VDC to the PCUA.

4.4 Anti-freezing Function

Note:

During the purging process, the back pressure regulator setting should not be changed since

the proportional valve is very sensitive to dierential pressure (115 psi /8.0 bar). If the back pres-

sure regulator is changed to a dierent value, the proportional valve might operate in a noisy

manner as the dierential pressure might be greater than 115 psi (8.0 bar). This may happen

initially after starting the pump, resulting in high pressure surge through the proportional valve.

Anti-Freeze air input

SECTION 4 OPERATION

For customers in cold climate areas, purging water out

of the WIC, if the unit is not to be used for long periods

of time, is recommended. To prevent the WIC/hoses/

torch from freezing, the WIC is equipped with an op-

tional anti-freeze mechanism. Compressed air, at 80 psi

(5.5 bar), is introduced through the inlet to ush the cut

water trapped inside the WIC components, hoses and

torch. During purging, the water will come out from the

torch and exhaust valve.

WIC

WATER INJECTION CONTROL

PRESSURE

SENSOR

PROPORTIONAL

VALVE

AIR

SOLENOID

FLOW

SENSOR

OFF

PUMP

POWER

AIR

FREEZE PROTECTION

4.4.1 Anti-freezing Procedure

1. Close the water valve.

2. Open the exhaust valve. (refer to Water Injection Control Flow Diagram, next page)

3. On the CNC press the Anti-freeze button shown below.

4. The WIC will open the Air Solenoid.

5. The proportional valve will be turned on slowly up to a xed orice. (See the setup in the station

constant.)

6. Purge will last for 3 minutes while water comes from the torch and the exhaust valve.

7. When timer times out, or Anti-freeze button is pressed again, the air solenoid and the proportional

valve will be turned o.

8. Purge complete.

1. Close the exhaust valve.

2. Open the water valve.

3. On the CNC, press Shield Gas Test, then press Cut Gas Test.

4. Wait until water comes out from the torch.

5. On the CNC, press Cut Gas Test, then press Shield Gas Test. This will stop the water from the torch.

6. Ready for normal operation.

Back to normal operation

In Optional Control Mode, to purge the water out of the WIC/hoses/torch, customer needs to set pin B (External

Anti-freeze) to HIGH for at least 3 minutes. Once this signal is removed, purge will stop. However, purge will au-

tomatically stop after 3 minutes even if external anti-freeze is still high.

During purge, customer CNC ignore any ow error or pressure error. When ready to cut again, customer CNC

needs to send a 0.35 gpm command to the WIC, to allow the torch/hose to be lled with water again. Customer

CNC should also ignore ow/pressure errors at this time.

Anti-Freeze function

Cut Shield Test

SECTION 4 OPERATION

Water Injection Control Flow Diagram

Customer Supplied

Components

H2O

PR1

P1/

PT1

PV1/

PWM

FS1

AIR

H2O OUT

(OPTIONAL AIR SUPPLY)

(Valve open

during purge)

EXHAUST

VALVE

WATER

VALVE

FILTER

TO TORCH

CV1

CV2

SOL1

BPR

FILTER

SECTION 4 OPERATION

The Back Pressure Regulator (BPR) manifold assembly (factory set @

40 psi/2.8 bar) consists of a back pressure regulator and two check

valves. This is mounted on or near the Plasma Gas Control, as close to

the torch as possible. The function of the BPR is to maintain the water

pressure to the torch and provide a fast response of the cut water

ow to the torch. Additionally, the BPR prevents the reverse ow of

gas into the WIC or water into the shield gas supply. This is done by

the two check valves inside the manifold assembly.

There are three inputs to the BPR. Cut water from WIC, shield gas and

the air curtain from either the SGC or the CGC. If the system contains

an SGC, the shield gas and air curtain hoses will connect directly to

the input of the BPR. If the system does not contain an SGC, but uses

a CGC, the shield gas output of the CGC should be connected to the

input of the BPR using the short jumper hose included with the BPR

assembly. Two outputs from the BPR are the shield gas or water, and

air curtain to the torch. Depending on the input, the output can be

either water (H2O) or shield gas (SG).

4.5 Back Pressure Regulator (BPR) Manifold Assembly

H2O

A/C

SG/H2O

A/C

CV2CV1

REG

If the BPR setup was disturbed or changed for any reason, customer needs to follow the procedure below to set

pressure to 40 psi (2.8 bar):

(1) Do “Shield Test” for 5-10 seconds, then stop;

(2) Read the water pressure from Vision 50P.

(3) If the water pressure without water owing is not 40 psi (2.8 bar), slowly adjust the screw on the BPR manifold

assembly. Then repeat (1) to (3) until the pressure is 40 psi (2.8 bar).

For Optional Control Mode, instead of doing “Shield Test”, please send a 0.5gpm ow command, and the water

pressure can be read from the 10-pin connector.

ADJUSTMENT SCREW

Figure 4.3 Back Pressure Regulator Schematic

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ESAB m3® plasma Water Injection Control User manual

Brand: ESAB

Model: m3® plasma Water Injection Control

Category: Welding System

Type: User manual

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