ESAB IEFC-S PT-24 Precision Plasmarc System Installation guide

Category
Welding System
Type
Installation guide
F-15-754
Dec, 2010
Installation, Operation and Maintenance Manual for the
IEFC-S
PT-24 Precision Plasmarc System
With Integrated Flow Control (Separable)
Flow Console
Gas Bundle
Ignition Console
Power Console
Torch
Cutting Systems
411 South Ebenezer Road
Florence, South Carolina, U.S.A.
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 F15754
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.
© ESAB Cutting Systems, 2002
Printed in U.S.A.
Precision Plasma IEFC-S - CE Table of Contents
i
Section 1 Safety Page 1--(_)
1.1 Introduction ........................................................................................ 1
1.2 Safety Notations And Symbols ............................................................ 2
1.3 General Safety Information .................................................................. 3
1.4 Installation Precautions........................................................................ 4
1.5 Electrical Grounding ............................................................................ 5
1.6 Operating A Plasma Cutting Machine .................................................. 6-10
1.7 Service Precautions............................................................................. 11
1.8 Safety References............................................................................... 12-17
Section 2 Description Page 2--(_)
2.1 General............................................................................................... 1
2.2 Scope................................................................................................. 1
2.3 Package Options Available .................................................................. 2
2.4 Technical Specifications
2.4.1 Precision Plasma System ........................................................... 3
2.4.2 Plasma Gas ............................................................................... 4
2.4.3 Start Gas ................................................................................... 4
2.4.4 Secondary Gas .......................................................................... 4
2.4.5 Cut Gas ..................................................................................... 4
2.4.6 PT-24 Torch ............................................................................... 4
Precision Plasma IEFC-S - CE Table of Contents
ii
Section 3 Installation Page 3--(_)
3.1 General .............................................................................................. 1
3.2 Equipment Required........................................................................... 1
3.3 Location ............................................................................................. 1
3.4 Primary Electrical Input Connections ................................................... 2-3
3.5 Alternate Connection Locations for IFC ............................................... 4
3.6 IFC Basic Component Identification..................................................... 4
3.7 Ignition Console Basic Components and Connection Points ................ 5
3.8 Interconnecting Lines.......................................................................... 6
3.9 Joining Ignition and Gas Consoles....................................................... 7
3.10 Connection Separated Gas and Ignition Consoles ............................. 8
3.11 Power Console Connections............................................................. 9
3.12 Voltage Selector Switch .................................................................... 9
3.13 Separated Gas and Ignition Console Interconnection Diagram ........... 10-11
3.14 Combined Gas and Ignition Console Interconnection Diagram ........... 12-13
3.15 Input to Gas Console........................................................................ 14-15
3.16 Input to Power Console .................................................................... 16
3.17 Torch Mounting ................................................................................ 17
3.18 Torch Coolant................................................................................... 18
3.19 Inspection Of Gas And Coolant Lines ................................................. 18
3.20 Using the 5 Solenoid Torch Manifold ................................................. 19
3.21 Converting IEFC-S Gas Console Manifold to Accommodate a 4
Solenoid Torch Manifold....................................................................
19-20
Precision Plasma IEFC-S - CE Table of Contents
iii
Section 4 Operation Page 4--(_)
4.1 Power Supply Controls
4.1.1 Main Power Switch ..................................................................... 1
4.1.2 Pilot Arc Switch........................................................................... 1
4.1.3 Fault Indicator Lights ................................................................... 2
4.1.4 Meters ........................................................................................ 2
4.1.5 Current Control Switch ................................................................ 2
4.2 Cut Quality..........................................................................................
4.2.1 Introduction................................................................................. 3
4.2.2 Cut Angle.................................................................................... 4
4.2.3 Cut Flatness................................................................................ 5
4.2.4 Surface Finish ............................................................................. 6
4.2.5 Dross.......................................................................................... 7-8
4.2.6 Dimensional Accuracy ................................................................. 9
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction................................................................................. 10
4.3.2 Aluminum.................................................................................... 10
4.3.3 Carbon Steel............................................................................... 11
4.3.4 Stainless Steel............................................................................. 12-13
4.4 Process Data
4.4.1 Introduction................................................................................. 15
4.4.2 Process Data Settings................................................................. 16-61
Aluminum............................................................................. 16-23
Carbon Steel ........................................................................ 24-33
Stainless Steel...................................................................... 34-61
4.4.3 Relationship of Kerf Width to Amperes and Material Thickness ..... 62
4.4.3.1 Aluminum Kerf Values.......................................................... 62
4.4.3.2 Carbon Steel Kerf Values..................................................... 64
4.4.3.3 Stainless Steel Kerf Values O
2
/N
2
/O
2
.................................... 67
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH
4
................................. 68
4.4.3.5 Stainless Steel Kerf Values N
2
/N
2
/CH
4
.................................. 69
4.4.3.6 Stainless Steel Kerf Values N
2
/N
2
......................................... 70
4.4.3.7 Stainless Steel Kerf Values Air/Air........................................ 72
Plasma Marking Data........................................................... 74
Precision Plasma IEFC-S - CE Table of Contents
iv
Section 5 Maintenance Page 5--(_)
5.1 General .............................................................................................. 1
5.2 Inspection and Cleaning...................................................................... 1
5.3 PT-24 Torch Description..................................................................... 2-4
5.4 IEFC-S Fluid Schematic ...................................................................... 3
5.4 Torch Maintenance............................................................................. 5-6
5.5 PT-24 Consumable Disassembly and Inspection ................................. 7-10
5.6 PT-24 Torch Re-Assembly.................................................................. 11-12
5.7 Flow Control....................................................................................... 13
5.8 Proportional Valve Removal................................................................. 14
Section 6 Troubleshooting Page 6--(_)
6.1 General Safety.................................................................................... 1
6.2 Troubleshooting Guide........................................................................ 2
6.2.1 Reduced Consumable Life .......................................................... 2
6.2.2 Poor Cut Quality ......................................................................... 3
6.2.3 No Pilot Arc ................................................................................ 3
6.2.4 No Arc Transfer .......................................................................... 3
6.2.5 No Preflow.................................................................................. 3
6.2.6 Torch Fails to Fire ....................................................................... 3
6.2.7 Nozzle Life Extremely Short......................................................... 4
6.2.8 Short Electrode Life .................................................................... 4
6.2.9 Short Electrode AND Nozzle Life ................................................. 4
6.3 IEFC-S Fluid Schematic ...................................................................... 5
IEFC-S Manifold Valve Identification............................................. 5
6.4 IEFC-S Electrical Schematic................................................................ 6-7
6.5 Ignition Console Electrical Schematic .................................................. 8
6.6 Ignition Console Fluid Schematic......................................................... 8
6.7 Precision Plasma Power Source Electrical Schematic .......................... 10-11
6.8 Precision Plasma Power Source Wiring Diagram (includes CE Version) 12-16
6.7 Power Module Schematic – CE Version............................................... 18-19
6.8 Precision Plasma Power Module Wiring Diagram – CE Version ............ 20-21
6.9 Torch Manifold.................................................................................... 22
Precision Plasma IEFC-S - CE Table of Contents
v
Section 7 Replacement Parts Page 7--(_)
7.1 General............................................................................................... 1
7.2 Ordering ............................................................................................. 1
7.3 Plasmarc Power Source – Exterior Components .................................. 2-7
7.4 Plasmarc Power Source – Internal Components .................................. 8-17
7.5 Power Source Module......................................................................... 18-25
7.6 IEFC-S Gas Console ........................................................................... 26-27
7.7 IEFC-S Gas Manifold........................................................................... 28-29
7.8 IEFC-S Ignition Console...................................................................... 30-31
7.9 PT-24 Torch Assembly IFC Series ......................................................
32-33
7.10 Torch Manifold 5 solenoid .................................................................
34-35
7.11 Interface Cables and Hoses...............................................................
36-37
Customer/Technical Information Back Manual Cover
Precision Plasma IEFC-S - CE Table of Contents
vi
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SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-1
1.1 Introduction
The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. However, as with any
machine tool, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of usefulness.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain precautions
could result in serious personnel injury or severe
equipment damage. The following precautions are
general guidelines applicable when working with
cutting machines. More explicit precautions pertaining
to the basic machine and accessories are found in the
instruction literature. For a wide scope of safety
information on the field of cutting and welding
apparatus, obtain and read the publications listed in
the Recommended References.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-2
DANGER
!
WARNING
!
CAUTION
!
CAUTION
NOTICE
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.
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
Used to call attention to potential hazards that
could result in personal injury or loss of life.
Used to call attention to hazards that could result
in minor personal injury or equipment damage.
Used to call attention to minor hazards to
equipment.
Used to call attention to important installation,
operation or maintenance information not
directly related to safety hazards.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-3
1.3 General Safety Information
NOTICE
Some subjects listed are not related specifically to
the type of equipment covered in this manual.
However, the safety principles still apply. They are
offered as a reminder that this equipment or
related apparatus should be operated with
alertness and understanding. Safety of operators,
technicians, maintenance workers and observers
should not be taken for granted.
WARNING
!
Machinery may start automatically.
Equipment positioning mechanized plasma torches
moves in various directions and speeds.
· Moving machinery can crush.
· Only qualified personnel should operate or
service this power source.
· Keep all personnel, materials, and equipment
not involved in production process clear of
entire system area.
· Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.
· Post appropriate WARNING signs at every
work cell entrance.
· Follow lockout procedure before servicing any
equipment.
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.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-4
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.
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
PT-24 Precision Plasma System IEFC-S -
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
PT-24 Precision Plasma System IEFC-S -
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
PT-24 Precision Plasma System IEFC-S -
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 workpiece and electrical
ground.
· Keep gloves, shoes, clothing, work area, and
equipment dry.
· Replace worn or damaged cables.
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
PT-24 Precision Plasma System IEFC-S -
1-8
WARNING
!
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.
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.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-9
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.
CAUTION
Do Not Use this Torch Under Water.
The PT-24 is designed to be a dry cutting
process.
Cutting under water may result in:
· reduced consumable life
· degradation of cut quality
· possible damaged torch
Cutting under water may result in poor cutting
performance. Water vapor created when hot material
or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level
to provide maximum clearance between water and
material.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-10
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.
WARNING
!
Pinch hazard.
Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during operation.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-11
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.
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.
SECTION 1 SAFETY
PT-24 Precision Plasma System IEFC-S -
1-12
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.
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.
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ESAB IEFC-S PT-24 Precision Plasmarc System Installation guide

Category
Welding System
Type
Installation guide

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