ESAB SmartFlow 2.5 Plasma System Plumbing Box User manual

F-15-732

April 2007

Installation, Operation, and Maintenance for the

SmartFlow 2.5

Plasma System Plumbing Box

The equipment described in this manual is

potentially hazardous. Use caution when

installing, operating and maintaining this

equipment.

Purchaser is solely responsible for the safe

operation and use of all products purchased,

including compliance with OSHA and other

government standards. ESAB Cutting

Systems has no liability for personal injury or

other damage arising out of the use of any

product manufactured or sold be ESAB. See

standard ESAB terms and conditions of sale

for a specific statement of ESAB’s

responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total

customer satisfaction. We constantly look for

ways to improve our products, service and

documentation. As a result, we make

enhancements and/or design changes as

required. ESAB makes every possible effort to

ensure our documentation is current. We

cannot guarantee that each piece of

documentation received by our customers

reflects the latest design enhancements.

Therefore, the information contained in this

document is subject to change without notice.

This manual is ESAB Part Number F15732

This manual is for the convenience and use of the

cutting machine purchaser. It is not a contract or

other obligation on the part of ESAB Cutting

Systems.

Printed in U.S.A.

Table Of Contents

SmartFlow 2.5

Safety (Section 1)

1.1 Introduction.........................................................................................................1-1

1.2 Safety Notations And Symbols...........................................................................1-2

1.3 General Safety Information.................................................................................1-3

1.4 Installation Precautions ......................................................................................1-4

1.5 Electrical Grounding...........................................................................................1-5

1.6 Operating A Plasma Cutting Machine ................................................................1-6

1.8 Safety References............................................................................................1-13

1.8.1 USA Domestic............................................................................................1-14

1.8.2 International ...............................................................................................1-15

Description (Section 2)

2.1 Introduction.........................................................................................................2-1

2.2 SmartFlow II

V

and PT-15XL................................................................................2-1

2.3 SmartFlow II

V

and PT-19XLS/PT-600.................................................................2-2

2.4 SmartFlow II

V

Options ........................................................................................2-2

2.5 Gas Requirements..............................................................................................2-2

2.6 Water Supply Requirements...............................................................................2-3

2.7 Electrical Input Requirements.............................................................................2-3

2.8 Dimensions.........................................................................................................2-4

Installation (Section 3)

3.1 Introduction.........................................................................................................3-1

3.2 Box Mounting (Bottom View)..............................................................................3-1

3.3 Hose and Cable Connections.............................................................................3-2

3.3.1 Starter Box Connections..............................................................................3-4

3.3.2 PC Board Connections.................................................................................3-5

3.3.3 Torch Cooling Water Connections...............................................................3-6

3.3.4 Power Source To SMF II

V

Buss Connection................................................3-7

3.4 Nomex Insulation................................................................................................3-8

3.5 Gas Connections................................................................................................3-8

3.5.1 Gas Lines From Supply................................................................................3-8

3.5.2 Gas Pressure Setup...................................................................................3-10

3.6 Cut Water Setup (PT-15XL) .............................................................................3-10

3.7 Secondary Shield Gas Setup (PT-19XLS/PT-600)...........................................3-11

3.8 A Component Relationship Block Diagram ......................................................3-12

3.9 Fluid Schematic – SmartFlow II

V

Standard and H-35 Versions........................3-14

Table Of Contents

SmartFlow 2.5

Operation (Section 4)

4.1 Operation Introduction........................................................................................4-1

Maintenance (Section 5)

5.1 SmartFlow II

V

Maintenance Introduction.............................................................5-1

5.2 Pressure Switches...............................................................................................5-2

5.3 Spark Gap Of the Arc Starter..............................................................................5-3

5.4 Spark Adjustment Procedure ..............................................................................5-4

5.5 Gas Proportional Valves......................................................................................5-5

5.6 Cutwater/Secondary Shield Proportional Valve ..................................................5-5

5.7 Cooling Water Flow Switch .................................................................................5-6

5.8 Gas Filters...........................................................................................................5-7

Troubleshooting (Section 6)

6.1 Troubleshooting Introduction...............................................................................6-1

6.2 Cooling Water Circuit .........................................................................................6-2

6.3 Cut Water and Auxiliary Cut Water ....................................................................6-3

6.4 Plasma Gas........................................................................................................6-4

6.5 Secondary Shield...............................................................................................6-5

6.6 Arc Start .............................................................................................................6-6

6.6.1 Setting the Spark Gap..................................................................................6-6

6.6.2 Spark Gap Size Attributes............................................................................6-7

6.6.3 Spark Viewing..............................................................................................6-8

6.7 Fluid Schematic..................................................................................................6-9

6.8 SmartFlow II

V

Interface PCB Schematic (3 pages) ..........................................6-10

6.9 SmartFlow II Secondary Shield Gas Proportional Valve Calibration................6-13

Replacement Parts (Section 7)

7.1 General...............................................................................................................7-1

7.2 Ordering .............................................................................................................7-1

7.3 Inside Right View – SF 2.5 (without H-35 capability) DISCONTINUED.............7-2

7.4 Inside Right View – SF 2.5 (with H-35 capability) ..............................................7-4

7.5 Outside Front View.............................................................................................7-6

7.6 Inside Left View..................................................................................................7-8

7.7 Outside Back View...........................................................................................7-10

SECTION 1 SAFETY

SmartFlow 2.5

1-1

1.1 Introduction

ESAB cutting machines are designed to provide

both operational safety and efficiency. However,

as with any machine tool, sensible attention to

operating procedures, precautions, and safe

practices is necessary. Whether an individual is

involved with operation, servicing, or as an

observer, compliance with established

precautions and safe practices must be carried

out. Failure to observe warnings/ precautions

could result in death/serious personal injury or

severe equipment damage. The following are

general guidelines applicable when working with

cutting machines. Additional precautions

pertaining to this equipment are found throughout

this literature. For a wide scope of safety

information on the field of cutting and welding,

obtain and read the publications listed in the

Recommended References at the end of this

section.

SECTION 1 SAFETY

SmartFlow 2.5

1-2

1.2 Safety Notations and Symbols

The following words and symbols are used

throughout this manual. They indicate different

levels of required safety involvement.

ALERT or ATTENTION. Your safety is involved or

potential equipment failure exists. Used with

other symbols and information.

DANGER

Used to call attention to immediate hazards which,

if not avoided, will result in serious personal injury

or loss of life.

WARNING

Used to call attention to potential hazards that

could result in personal injury or loss of life.

CAUTION

Used to call attention to hazards that could result

in minor personal injury or equipment damage.

CAUTION

Used to call attention to minor hazards to

equipment.

NOTICE

Used to call attention to important installation,

operation or maintenance information not directly

related to safety hazards.

SECTION 1 SAFETY

SmartFlow 2.5

1-3

1.3 General Safety Information

WARNING

Failure to follow operating instructions

could result in death or serious injury.

Read and understand this operator’s manual

before using machine.

• Read entire procedure before operating or

performing any system maintenance.

• Special attention must be given to all

hazard warnings that provide essential

information regarding personnel safety

and/or possible equipment damage.

• All safety precautions relevant to electrical

equipment and process operations must

be strictly observed by all having system

responsibility or access.

• Read all safety publications made

available by your company.

WARNING

Failure to follow safety warning label

instructions could result in death or

serious injury.

Read and understand all safety warning labels

on machine.

Refer to operator’s manual for additional

safety information.

SECTION 1 SAFETY

SmartFlow 2.5

1-4

1.4 Installation Precautions

WARNING

Improperly Installed Equipment Can

Cause Injury Or Death.

Follow these guidelines while installing

machine:

• Do not connect a cylinder directly to

machine inlet. An appropriate cylinder

regulator must be installed on a fuel gas

cylinder to reduce pressure to a

reasonable inlet supply pressure.

Machine regulator is then used to obtain

pressure required by torches.

• Contact your ESAB representative before

installation. He can suggest certain

precautions regarding piping installation

and machine lifting, etc. to ensure

maximum security.

• Never attempt any machine modifications

or apparatus additions without first

consulting a qualified ESAB

representative.

• Observe machine clearance requirements

for proper operation and personnel safety.

• Always have qualified personnel perform

installation, troubleshooting and

maintenance of this equipment.

• Provide a wall mounted disconnect switch

with proper fuse sizes close to the power

supply.

SECTION 1 SAFETY

SmartFlow 2.5

1-5

1.5 Electrical Grounding

Electrical grounding is imperative for proper

machine operation and SAFETY. Refer to this

manual’s Installation section for detailed

grounding instructions.

WARNING

Electric shock hazard.

Improper grounding can cause severe injury

or death.

Machine must be properly grounded before

put into service.

WARNING

Improper Grounding Can Damage

Machine And Electrical

Components.

• Machine must be properly grounded

before put into service.

• Cutting table must be properly grounded

to

a good Earth ground rod.

SECTION 1 SAFETY

SmartFlow 2.5

1-6

1.6 Operating a Plasma Cutting Machine

WARNING

Flying debris and loud noise

hazards.

• Hot spatter can burn and injure eyes.

Wear goggles to protect eyes from burns

and flying debris generated during

operation.

• Chipped slag may be hot and fly far.

Bystanders should also wear goggles and

safety glasses.

• Noise from plasma arc can damage

hearing. Wear correct ear protection when

cutting above water.

WARNING

Burn hazard.

Hot metal can burn.

• Do not touch metal plate or parts

immediately after cutting. Allow metal time

to cool, or douse with water.

• Do not touch plasma torch immediately

after cutting. Allow torch time to cool.

SECTION 1 SAFETY

SmartFlow 2.5

1-7

WARNING

Hazardous voltages. Electric shock

can kill.

• Do NOT touch plasma torch, cutting table

or cable connections during plasma

cutting process.

• Always turn power off to plasma power

supplies before touching or servicing

plasma torch.

• Always turn power off to plasma power

supplies before servicing any system

component.

• Do not touch live electrical parts.

• Keep all panels and covers in place when

machine is connected to power source.

• Wear insulating gloves, shoes, and

clothing to insulate yourself from the

workpiece and electrical ground.

• Keep gloves, shoes, clothing, work area,

and equipment dry.

• Replace worn or damaged cables.

SECTION 1 SAFETY

SmartFlow 2.5

1-8

WARNING

Fume hazard.

Fumes and gases generated by the plasma

cutting process can be hazardous to your

health.

• Do NOT breathe fumes.

• Do not operate plasma torch without fume

removal system operating properly.

• Use additional ventilation to remove

fumes if necessary.

• Use approved respirator if ventilation is

not adequate.

• Provide positive mechanical ventilation

when cutting galvanized steel, stainless

steel, copper, zinc, beryllium, or cadmium.

Do not breathe these fumes.

• Do not operate near degreasing and

spraying operations. Heat or arc rays can

react with chlorinated hydrocarbon vapors

to form phosgene, a highly toxic gas and

other irritant gases.

SECTION 1 SAFETY

SmartFlow 2.5

1-9

WARNING

Radiation hazard.

Arc rays can injure eyes and burn skin.

• Wear correct eye and body protection.

• Wear dark safety glasses or goggles with

side shields. Refer to following chart for

recommended lens shades for plasma

cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

• Replace glasses/goggles when lenses are

pitted or broken

• Warn others in area not to look directly at

the arc unless wearing appropriate safety

glasses.

• Prepare cutting area to reduce reflection

and transmission of ultraviolet light.

 Paint walls and other surfaces with

dark colors to reduce reflections.

 Install protective screens or curtains

to reduce ultraviolet transmission.

SECTION 1 SAFETY

SmartFlow 2.5

1-10

WARNING

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and

violently release gas.

• Avoid rough handling of cylinders.

• Keep cylinder valves closed when not in

use.

• Maintain hoses and fittings in good

condition.

• Always secure cylinders in an upright

position by chain or strap to a suitable

stable object not part of an electrical

circuit.

• Locate cylinders away from heat, sparks

and flames. Never strike an arc on a

cylinder.

• Use approved pressure reducing regulator

for the specific gas.

• Refer to CGA Standard P-1, “Precautions

for Safe Handling of Compressed Gases in

Cylinders”, available from Compressed

Gas Association.

WARNING

Explosion hazard.

• Certain molten aluminum-lithium (Al-Li)

alloys can cause explosions when plasma

cut OVER water.

 These alloys should only be dry cut

on a dry table.

 DO NOT dry cut over water.

 Contact your aluminum supplier for

additional safety information

regarding hazards associated with

these alloys

.

• Do not cut in atmospheres containing

explosive dust or vapors.

• Do not carry any combustibles on your

person (e.g. butane lighter)

• Do not cut containers that have held

combustibles.

SECTION 1 SAFETY

SmartFlow 2.5

1-11

WARNING

Burn Hazard.

Heat, spatter, and sparks cause fire and

burns.

• Do not cut near combustible material.

• Do not have on your person any

combustibles (e.g. butane lighter).

• Pilot arc can cause burns. Keep torch

nozzle away from yourself and others

when activating plasma process.

• Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and

hat.

• Wear flame-retardant clothing covering all

exposed areas.

• Wear cuff-less trousers to prevent entry of

sparks and slag.

• Have fire extinguishing equipment

available for use.

SECTION 1 SAFETY

SmartFlow 2.5

1-12

1.7 Service Precautions

WARNING

Hazardous voltages. Electric shock

can kill.

• Do NOT touch plasma torch, cutting table

or cable connections during plasma

cutting process.

• Always turn power off to plasma power

supplies before touching or servicing

plasma torch.

• Always turn power off to plasma power

supplies before removing covers or

panels to service any system component.

• Do not touch live electrical parts.

• Keep all panels and covers in place when

machine is connected to power source.

• Keep gloves, shoes, clothing, work area,

and equipment dry.

• Inspect power and ground leads cables for

wear or cracking. Replace worn or

damaged cables. Do not use if damaged.

• Never bypass safety interlocks.

• Follow lock-out procedures.

CAUTION

Establish and adhere to preventive

maintenance. A composite program can be

established from recommended schedules.

Avoid leaving test equipment or hand tools on

machine. Severe electrical or mechanical

damage could occur to equipment or

machine.

SECTION 1 SAFETY

SmartFlow 2.5

1-13

CAUTION

Extreme caution should be used when

probing circuitry with an oscilloscope or

voltmeter. Integrated circuits are susceptible

to over voltage damage. Power off before

using test probes to prevent accidental

shorting of components.

All circuit boards securely seated in sockets,

all cables properly connected, all cabinets

closed and locked, all guards and covers

replaced before power is turned on.

1.8 Safety References

The following nationally recognized publications on

safety in welding and cutting operations are

recommended. These publications have been

prepared to protect persons from injury or illness and

to protect property from damage, which could result

from unsafe practices. Although some of these

publications are not related specifically to this type of

industrial cutting apparatus, the principles of safety

apply equally.

SECTION 1 SAFETY

SmartFlow 2.5

1-14

1.8.1 USA Domestic

• “Precautions and Safe Practices in Welding and

Cutting with Oxygen-Fuel Gas Equipment,” Form

2035. ESAB Cutting Systems.

• “Precautions and Safe Practices for Electric

Welding and Cutting,” Form 52-529. ESAB Cutting

Systems.

• “Safety in Welding and Cutting” - ANSI Z 49.1,

American Welding Society, 2501 NW 7th Street,

Miami, Florida, 33125.

• “Recommended Safe Practices for Shielded

Gases for Welding and Plasma Arc Cutting” - AWS

C5.10-94, American Welding Society.

• “Recommended Practices for Plasma Arc

Welding” - AWS C5.1, American Welding Society.

• “Recommended Practices for Arc Cutting” -

AWS C5.2, American Welding Society.

• “Safe Practices” - AWS SP, American Welding

Society.

• “Standard for Fire Protection in Use of Cutting

and Welding Procedures” - NFPA 51B, National

Fire Protection Association, 60 Batterymarch

Street, Boston, Massachusetts, 02110.

• “Standard for Installation and Operation of

Oxygen - Fuel Gas Systems for Welding and

Cutting” - NFPA 51, National Fire Protection

Association.

• “Safety Precautions for Oxygen, Nitrogen,

Argon, Helium, Carbon Dioxide, Hydrogen, and

Acetylene,” Form 3499. ESAB Cutting Systems.

Obtainable through your ESAB representative or

local distributor.

• "Design and Installation of Oxygen Piping

Systems," Form 5110. ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed

Gases in Cylinders”, CGA Standard P-1,

Compressed Gas Association.

• Literature applicable to safe practices in welding

and cutting with gaseous materials is also available

from the Compressed Gas Association, Inc., 500

Fifth Ave., New York, NY 10036.

SECTION 1 SAFETY

SmartFlow 2.5

1-15

1.8.2 International

Accident Prevention

VBG 1 General Provisions

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working

methods

VBG 48 Shot Blasting Works

VBG 61 Gases

VBG 62 Oxygen

VBG 87 Operating liquid jet cutting machines

VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE Regulations

VDE 0100 Erection of power installations with normal

voltages up to 1000 volts

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users

guide (DIN EN 60825)

VDE 0837-

50

Specification for laser guards

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-204 Acetylene lines

TRAC-206 Acetylene cylinder battery systems

TRAC-207 Safety devices

TRG Technical Rules for Pressure gases

TRG 100 General regulations for pressure gases

TRG 101 Pressure gases

TRG 102 Technical gas mixtures

TRG 104 Pressure gases; alterative use of

compressed gas tanks

SECTION 1 SAFETY

SmartFlow 2.5

1-16

DIN Standards

DIN 2310

Part 1

Thermal cutting; terminology and

nomenclature

DIN 2310

Part 2

Thermal cutting; determination of quality of cut

faces

DIN 2310

Part 4

Thermal cutting; arc plasma cutting; process

principles, quality, dimensional tolerances

DIN 2310

Part 5

Thermal cutting; laser beam cutting of metallic

materials; process principles

DIN 4844

Part 1

Safety markings (DIN EN 7287)

DIN EN ISO Harmonized Standards

DIN EN

292/1 and 2

Safety of machinery

DIN EN 559 Hoses for welding, cutting and allied

processes

DIN EN 560 Hose connections and hose couplings for

equipment for welding, cutting and allied

processes

DIN EN 561 Gas welding equipment hose couplings

DIN EN

626-1

Safety of machines, reduction of risks to

health

DIN EN

848-1

Single spindle vertical milling machines

DIN EN

1829

High pressure water jet machines

DIN EN

9013

Thermal cutting, oxygen cutting, process

principles, dimensional tolerances

DIN EN

12584

Imperfections in oxy/fuel flame cuts, laser

beam cuts and plasma

DIN EN

12626

Laser processing machines

DIN EN

28206

Acceptance testing for oxygen cutting

machines

DIN EN

31252

Laser Equipment

DIN EN

31553

Laser and laser related equipment

DIN EN

60204-1

Electrical equipment of machines

DIN EN

60825

Radiation safety of laser products

DIN EN 999 Arrangement of protection devices

VDI Guidelines

VDI 2906 Quality of cut faces on metallic workpieces;

abrasive water jet cutting and arc plasma

cutting

VDI 2084 Room air; Technical systems for welding

workshops

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