ESAB Precision Plasmarc System Installation guide

CUTTING SYSTEMS

F-15-480-E

July, 2007

Installation, Operation and Maintenance Manual for the

PRECISION PLASMARC SYSTEM

with Electronic Flow Control

411 s. Ebenezer Road

Florence, SC 29501-0545

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 F15480

March-01 date reflects added cable part nos. in

Sect 2. Corrected Pressure in Section 6.

Dec.-01 Replacement parts section updated

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.

Precision Plasma Electronic Flow Control Table of Contents

i

Page

Section 1 Safety

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

1.2 Safety Notations And Symbols ....................................................................... 1

1.3 General Safety Information............................................................................. 2

1.4 Installation Precautions................................................................................... 3

1.5 Electrical Grounding........................................................................................ 4

1.6 Operating A Plasma Cutting Machine............................................................. 4

1.7 Service Precautions........................................................................................ 8

1.8 Safety References .......................................................................................... 9

Section 2 Description

2.1 General........................................................................................................... 1

2.2 Scope.............................................................................................................. 1

2.3 Package Options Available............................................................................. 1-2

2.4 Technical Specifications .................................................................................

2.4.1 Precision Plasma System ...................................................................... 2-3

2.4.2 Plasma Gas ............................................................................................ 4

2.4.3 Start Gas ................................................................................................ 4

2.4.4 Secondary Gas....................................................................................... 4

2.4.5 PT-24 Torch............................................................................................ 4

Section 3 Installation

3.1 General........................................................................................................... 1

3.2 Equipment Required....................................................................................... 1

3.3 Location .......................................................................................................... 1

3.4 Primary Electrical Input Connections.............................................................. 2

3.5 Interconnecting Lines...................................................................................... 4

Precision Plasmarc Component Interconnecting Diagram ............................. 8

3.6 Torch Mounting............................................................................................... 10

3.7 Torch Coolant ................................................................................................. 11

3.8 Inspection of Gas and Coolant Lines.............................................................. 11

3.9 Replacement of EPROM in the Plasmarc Power Source Programmable

Logic Controller (PLC) ...........................................................................................

12

Precision Plasma Electronic Flow Control Table of Contents

ii

Section 4 Operation

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................................................................................................. 3

4.2.3 Cut Flatness............................................................................................. 4

4.2.4 Surface Finish.......................................................................................... 5

4.2.5 Dross ....................................................................................................... 6

4.2.6 Dimensional Accuracy............................................................................. 8

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction.............................................................................................. 9

4.3.2 Aluminum................................................................................................. 9

4.3.3 Carbon Steel............................................................................................ 10

4.3.4 Stainless Steel......................................................................................... 11

4.4 Process Data

4.4.1 Introduction.............................................................................................. 13

4.4.2 Process Data Settings............................................................................. 14

Plasma Marking Data ...................................................................... 54

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness.............. 76

4.4.3.1 Aluminum Kerf Values..................................................................... 76

4.4.3.2 Carbon Steel Kerf Values................................................................ 78

4.4.3.3 Stainless Steel Kerf Values O

2

/N

2

/O

2

............................................. 81

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4

.......................................... 82

4.4.3.5 Stainless Steel Kerf Values N

2

/N

2

/CH

4

........................................... 83

4.4.3.6 Stainless Steel Kerf Values N

2

/N

2

................................................... 84

4.4.3.7 Stainless Steel Kerf Values Air/Air.................................................. 86

Precision Plasma Electronic Flow Control Table of Contents

iii

Section 5 Maintenance

5.1 General........................................................................................................... 1

5.2 Inspection and Cleaning ................................................................................. 1

5.3 PT-24 Torch Description................................................................................. 2

5.4 Torch Maintenance......................................................................................... 5

5.5 PT-24 Consumable Disassembly and Inspection........................................... 7

5.6 PT-24 Torch Re-Assembly.............................................................................. 9

Section 6 Troubleshooting

6.1 General Safety................................................................................................ 1

6.2 Programmable Logic Controller (PLC)........................................................... 1

6.2.1 PLC LED Introduction............................................................................ 2

6.2.2 PLC LED Functions ............................................................................... 2

6.3 Troubleshooting Guide

6.3.1 Reduced Consumable Life...................................................................... 3

6.3.2 Poor Cut Quality...................................................................................... 4

6.3.3 No Pilot Arc............................................................................................. 4

6.3.4 No Arc Transfer....................................................................................... 4

6.3.5 No Preflow .............................................................................................. 4

6.3.6 Torch Fails to Fire................................................................................... 4

6.3.7 Nozzle Life Extremely Short.................................................................... 5

6.3.8 Short Electrode Life ................................................................................ 5

6.3.9 Short Electrode AND Nozzle Life............................................................ 5

6.4 Flow Control Schematic.................................................................................. 6

6.5 Gas Flow Schematic....................................................................................... 7

6.6 Junction Box Wiring Diagram.......................................................................... 8

6.7 Junction Box Schematic................................................................................... 9

6.8 Precision Plasma Power Module Wiring Diagram .......................................... 10-11

6.9 Power Module Schematic............................................................................... 12

6.10 Power Source Wiring Diagrams.................................................................... 13-17

6-11 Power Source Schematic ............................................................................. 18-19

Precision Plasma Electronic Flow Control Table of Contents

iv

6.12 Technical Guide to Using/Understanding the Operation of the EFC............. 20

6.12.1 Precision Process Timers...................................................................... 21

6.12.2 Process Timer Values............................................................................ 22

6.12.3 Process Window Key Functions 23

6.12.4 Proportional Valve Analog Values for PARAM.CUT and DEF.TEC .......... 24

6.12.5 Process Gas Selection Requirements................................................... 25

6.12.6 EFC Process Gas Flow Chart................................................................ 26

6.12.7 Station On, Flush/Pressurize Cycle Timers........................................... 27

6.12.8 Solenoid/Proportional Valve Requirements and

Gas Error Monitoring

Carbon Steel PG-O

2

, SG-O

2

................................................................. 28

Carbon Steel PG-O

2

, SG-N

2

/O

2

............................................................ 30

Carbon Steel PG-O

2

, Sg-O

2

.................................................................. 32

Stainless Steel PG-N

2

, SG-N

2

............................................................. 34

Stainless Steel PG-N

2

, SG-N

2

/CH

4

....................................................... 36

Stainless Steel PG-Air, SG-Air ............................................................. 38

Stainless Steel PG-Air, SG-Air/CH

4

...................................................... 40

Aluminum PG-N

2

, SG- N

2

..................................................................... 42

Aluminum PG-N

2

, SG-N

2

/CH

4

............................................................... 44

Marking PG-Argon, SG-Air................................................................... 46

Section 7 Replacement Parts

7.1 General............................................................................................................ 1

7.2 Ordering........................................................................................................... 2

7.3 Plasmarc Power Source – Exterior Components ............................................ 3

7.4 Plasmarc Power Source – Internal Components............................................. 8

7.5 Power Source Module ..................................................................................... 18

7.6 EFC Junction Box............................................................................................ 26

7.7 Electronic Flow Control Box............................................................................. 32

7.8 PT-24 Torch Assembly EFC Series A/M ........................................................ 36

7.9 T Gas Shut-off Valve Assembly - Series A/M Torch........................................ 38

7.10 PT-24 Torch Assembly – Version 1............................................................... 40

7.11 Solenoid Assembly - EFC Torch – Version 1 ................................................ 42

7.12 Interface Cables and Hoses .......................................................................... 44

Customer/Technical Information Resource Back Manual Cover

SECTION 1 SAFETY

1-1

DANGER

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

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.

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 in

concurrence 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

1-2

1.3 General Safety Information

WARNING

!

Machine starts automatically.

This equipment moves in various directions and

speeds.

• Moving machinery can crush.

• Only qualified personnel should operate or

service equipment.

• Keep all personnel, materials, and equipment

not involved in production process clear of

entire system area.

• Keep gear racks and rails clear of debris or

obstructions, such as tools or clothing.

• 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.

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

1-3

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.

SECTION 1 SAFETY

1-4

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.

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.

• 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

SECTION 1 SAFETY

1-5

cutting. Allow torch time to cool.

SECTION 1 SAFETY

1-6

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 opening or servicing plasma

plumbing or flow control box.

• Do not touch live electrical parts.

• Keep all panels and covers in place when

machine is connected to power source.

• Insulate yourself from workpiece and

electrical ground: wear insulating gloves,

shoes and clothing.

• Keep gloves, shoes, clothing, work area, and

equipment dry.

WARNING

!

Pinch hazard.

Moving vertical slides can crush or pinch.

Keep hands clear of torch and slide during

operation.

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

SECTION 1 SAFETY

1-7

adequate.

SECTION 1 SAFETY

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.

• Refer to CGA Standard P-1, “Precautions for

Safe Handling of Compressed Gases in

Cylinders”, available from Compressed Gas

Association.

SECTION 1 SAFETY

1-9

CAUTION

WARNING

!

Spark hazard.

Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

• Do not cut containers that have held

combustibles.

• 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 that covers all

exposed areas.

• Wear cuffless trousers to prevent entry of

sparks and slag.

POOR PERFORMANCE WILL RESULT

WHEN CUTTING ABOVE WATER.

The PT-24 is designed to be a dry cutting

process.

Cutting above water may result in:

• reduced consumable life

• degradation of cut quality

Cutting above 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

1-10

WARNING

!

Explosion hazard.

Certain molten aluminum-lithium (Al-Li) alloys

can cause explosions when plasma cut OVER

water.

Do not plasma cut the following Al-Li alloys

with water:

Alithlite (Alcoa) X8192 (Alcoa)

Alithally (Alcoa) Navalite (US Navy)

2090 Alloy (Alcoa) Lockalite (Lockheed)

X8090A (Alcoa) Kalite (Kaiser)

X8092 (Alcoa) 8091 (Alcan)

• 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

.

1.7 Service Precautions

CAUTION

Establish and adhere to preventive maintenance.

A composite program can be established from

recommended schedules in the instruction

literature.

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.

Never plug or unplug a printed circuit board

while machine power is on. Instantaneous

surges of voltage and current can damage

electronic components.

SECTION 1 SAFETY

1-11

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.

• “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

1-12

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SECTION 2 DESCRIPTION

2-1

2.1 General

The Precision Plasmarc System consists of four

separate components. The power source, the

junction box, the flow control box, and the PT-24

torch. The power source provides power and

coolant to the PT-24 torch via the junction box.

2.2 Scope

The purpose of this manual is to provide the

operator with all the information required to install

and operate the Precision Plasmarc System.

Technical reference material is also provided to

assist in troubleshooting the cutting package.

2.3 Package Options Available

Precision Plasmarc package options available through your ESAB dealer

Precision Plasmarc Power Source (

200/230/380/415/460/575) 3-phase 50/60 Hz

(required)

P/N 37357

Electronic Flow Control Box (required) P/N 22406

Junction Box (required) P/N 22407

4.5 ft. (1.4 m) P/N 0558001463

12 ft. (4.4 m) P/N 0558001877

PT-24 Torch Electronic Flow Series A/M (one required)

17 ft. (5.2 m) P/N 0558001464

12 ft. (3.6 m) P/N 22428

25 ft. (7.6 m) P/N 21905

40 ft. (12.2 m) P/N 22504

60 ft. (18 m) P/N 21906

80 ft. (24.4 m) P/N 22505

Power Bundle (one required)

100 ft. (30 m) P/N 21907

10 ft. (3 m) P/N 37533

20 ft. (6 m) P/N 37534

30 ft. (9 m) P/N 37535

60 ft. (18 m) P/N 37536

Gas Line Bundle (one required)

100 ft. (30 m) P/N 37537

10 ft. (3 m) P/N 21917

20 ft. (6 m) P/N 21918

Standard Cable 30 ft. (9 m) P/N 21919

60 ft. (18 m) P/N 21920

100 ft. (30 m) P/N 21921

10 ft. (3 m) P/N 56997111

20 ft. (6 m) P/N 56997112

30 ft. (9 m) P/N 56997113

40 ft. (12 m) P/N 0560986745

60 ft. (18 m) P/N 56997114

Flex cable (recommended

for power track applications)

100 ft. (30 m) P/N 56997115

Control Lead – Flow Console to Junction Box

(one required)

SECTION 2 DESCRIPTION

2-2

30 ft. (9.1 m ) P/N 57002248

50 ft. (15.2 m) P/N 57002249

75 ft. (22.8 m ) P/N 57002250

100 ft. (30.5 m) P/N 57002251

Control Lead – Power Source to Cutting Machine I/O

160 ft. (48.8 m) P/N 57002252

3 ft. (.9 m) P/N 57000419

50 ft. (15.2 m) P/N 57000420

75 ft. (22.8 m) P/N 57000421

100 ft. (30.5 m) P/N 57000422

125 ft. (38.1 m) P/N 57000423

150 ft. (45.7 m) P/N 57000424

175 ft. (53.3 m) P/N 57000425

High Frequency Power Cable – Power Supply to Junction

Box –or- Power Supply to Cutting Machine I/O, depending

on configuration

200 ft. (61 m) P/N 57000426

Torch Coolant (one gallon (3.8 l) containers. four gallons (15 l) required) P/N 156F05

NOTES:

• Control lead from the power source to customer CNC is supplied based on customer order.

• Gas supply, hoses, work lead and input primary cable are all supplied by the customer.

• See Process Data Sheets for a list of torch consumable parts.

2.4 Precision Plasma Technical Specifications

2.4.1 System

Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz

Input Current 65/60/50/40/30/25 amps per phase

Power Factor 0.95

Output Current Range 15-100 amps dc

Output Load Voltage 120 V dc

Duty Cycle 100%

Open Circuit Voltage 315 V dc

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