ESAB Precision Plasmarc System Series "A" User manual

F-15-456-F

November, 2010

INSTRUCTION MANUAL

PRECISION PLASMARC SYSTEM

SERIES "A"

This manual provides installation and operation instructions for the following components of the Precision Plasmarc

System starting with Ser. No. PORI818001:

Precision Plasmarc Console/Power Source, 208/230/400/460/575 V ac, 50/60 Hz, 3-phase, P/N 37357

Precision Plasmarc Flow Control Box P/N 37416

Precision Plasmarc Junction Box with HF Unit P/N 37400

PT-24 Torch 4.5 FT. (1.4 m) P/N 22362

PT-24 Torch 17 FT. (5.2 m) P/N 22363

2

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!

3

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 UNPACKING/HOISTING ..............................................................................................17

1.1 Inspection ..................................................................................................................................................17

1.2 Hoisting ......................................................................................................................................................17

SECTION 2 DESCRIPTION .............................................................................................................19

2.1 General .......................................................................................................................................................19

2.2 Scope ..........................................................................................................................................................19

2.3 Package Options Available ..................................................................................................................19

SECTION 3 INSTALLATION........................................................................................................................................23

3.1 General .......................................................................................................................................................23

3.2 Equipment Required .............................................................................................................................23

3.3 Location .....................................................................................................................................................23

3.4 Primary Electrical Input Connections ..............................................................................................23

3.5 Interconnecting Lines ...........................................................................................................................24

SECTION 4 OPERATION .................................................................................................................33

4.1 Power Source Controls/Indicators ....................................................................................................33

4.2 Operation ..................................................................................................................................................34

4.3 Sample Procedure for Setting O

2

Gas Flow Rates on Flow Control Box ..............................35

4.4 Sample Procedure for Setting N

2

Gas Flow Rates on Flow Control Box ..............................35

Process Data Sheets ...............................................................................................................................37

SECTION 5 CUTTING QUALITY .....................................................................................................63

5.1 Cut Angle ...................................................................................................................................................63

5.2 Voltage and Cut Quality .......................................................................................................................64

5.3 Top Dross ...................................................................................................................................................66

5.4 Dross Formation ......................................................................................................................................66

5.5 Summary ...................................................................................................................................................67

SECTION 6 MAINTENANCE ...........................................................................................................69

6.1 General .......................................................................................................................................................69

6.2 Inspection and Cleaning ......................................................................................................................69

6.3 Torch Consumable Parts ......................................................................................................................69

6.4 Gas Pressure Switch ...............................................................................................................................69

6.5 PT-24 Torch Description .......................................................................................................................69

6.6 Torch Maintenance ................................................................................................................................70

6.7 PT-24 Consumable Removal, Inspection and Installation .......................................................70

SECTION 7 TROUBLESHOOTING ..................................................................................................73

7.1 Troubleshooting .....................................................................................................................................73

7.2 Process Troubleshooting ......................................................................................................................73

7.3 Troubleshooting Procedures ..............................................................................................................75

SECTION 8 REPLACEMENT PARTS ................................................................................................81

8.1 General .......................................................................................................................................................81

8.2 Ordering .....................................................................................................................................................81

4

TABLE OF CONTENTS

5

Safety Precautions

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 work piece has been completely cleaned so that

there are no substances on the work piece 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, Battery march 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.

SAFETY PRECAUTIONS

6

SAFETY PRECAUTIONS

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

nected to the ground system of the input power.

2. Connect the work piece to a good electrical

ground.

3. Connect the work cable to the work piece. 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 work piece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

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

gouge on materials such as galvanized steel, stain-

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

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

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

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

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

for specic ventilation recommendations.

7

SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

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

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

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

cylinders to work tables or xtures where they may

become part of an electrical circuit.

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

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

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

Never strike an arc on a cylinder.

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

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

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

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

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

Miami, FL 33126, are recommended to you:

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

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

Welding"

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

Cutting"

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

Arc Gouging and Cutting"

8

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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17

SECTION 1 UNPACKING/HOISTING

1.1 INSPECTION

A. The Precision Plasmarc System will be shipped in four

separate containers. The power source, the junction box,

the ow control box and the PT-24 torch components

will all have their own containers. Remove all packing

material and inspect for evidence of concealed damage

which may not have been apparent upon receipt of the

four containers. All four components, the power source,

ow control box, junction box and PT-24 torch are fully

assembled with the exception of the xed caster wheels

on the power source. Immediately notify the carrier of

any defects or damage.

B. Check each container for any loose parts prior to dispos-

ing of shipping materials.

C. Check air louvers on the power source and junction box

and any other opening to ensure that any obstructions

are removed.

1.2 HOISTING

The power source is equipped with one lifting eye that

enables the unit to be hoisted.

18

SECTION 1 UNPACKING/HOISTING

19

2.1 GENERAL

The Precision Plasmarc System consists of four separate

components: the power source, the junction box, the ow

control box, and the PT-24 torch. The power source pro-

vides power and coolant to the PT-24 torch via the junc-

tion box. The power source also provides control voltage

to the ow control box for precise control of the plasma

gas and shield gas to the PT-24 torch.

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

Table 2-1 lists Precision Plasmarc package options avail-

able through your ESAB dealer.

NOTE:

1. Control lead from the power source to customer CNC is supplied based on customer order. The gas supply hoses, work

lead and input primary cable are all supplied by the customer.

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

SECTION 2 DESCRIPTION

Table 2-1. Available Package Options

Precision Plasmarc Power Source (208/230/380/415/460/575) 3-phase 50/60 Hz (required) P/N 37357

Flow Control Box (required) P/N 37416

Junction Box with HF Unit (required) P/N 37400

PT-24 Torch (one required)

4.5 ft. (1.4 m)

17 ft (5.2 m)

P/N 22362

P/N 22363

Power Bundle (one required)

25 ft (7.6 m)

60 ft (18 m)

100 ft (30 m

P/N 21905

P/N 21906

P/N 21907

Gas Line Bundle (one required)

10 ft (3 m)

20 ft (6 m)

30 ft (9 m)

60 ft (18 m)

100 ft (30 m)

P/N 21902

P/N 21903

P/N 21904

P/N 22334

P/N 22335

Control Lead Flow Control to Junction Box and Power Source to Flow Control Box (two

required)

10 ft (3 m)

20 ft (6 m)

30 ft (9 m)

60 ft (18 m)

100 ft (30 m)

P/N 21917

P/N 21918

P/N 21919

P/N 21920

P/N 21921

Torch Coolant 1 gallon (3.8 l) containers (4 gallons (15 l) required) P/N 156F05

PT-24 Spare Parts Kit P/N 37609

20

Figure 2-1. Precision Plasma System

Power Source

Flow Control

Junction Box

Table 2-2. Technical Specications (Precision Plasma System)

Input Voltage 208/230/380/415/460/575 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 215 V dc

Duty Cycle 100%

Open Circuit Voltage 315 V dc

Power Source Size 22" (550 mm) W X 42" (1050 mm) D X 44" (1100 mm)

Power Source Weight 560 lbs. (254 kg)

Flow Control Box Size 11" (275 mm) W X 11" (275 mm) D X 16" (400 mm)

Flow Control Box Weight 35 lbs (16 kg)

Junction Box Size 17" (425 mm) L X 10" (250 mm) W X 7" (175 mm)

Junction Box Weight 27 Ibs (12 kg)

SECTION 2 DESCRIPTION

21

Table 2-3. Technical Specications

(Plasma Gas)

Type O

2

, N

2

, Air

Pressure 125 psig (8.6 bars)

Flow 100 cfh (47 I/min) max (varies with application)

Purity Required 0

2

-99.8%,N

2

-99.995%, Air-clean, dry, oil-free

Recommend Liquid Cylinder Oxygen: R-76-150-540LC (P/N 19777)

Service Regulators Inert Gas: R-76-150-580LC (P/N 19977)

Recommended Cylinder 2-Stage Oxygen: R-77-150-540 (P/N 998337)

Regulators Hydrogen, Methane: R-77-150-350 (P/N 998342)

Nitrogen: R-77-150-580 (P/N 998344)

Industrial Air: R-77-150-590 (P/N 998348)

Recommended Heavy-Duty Oxygen: R-76-150-024 (P/N 19151)

Hi-FIow Station or Pipeline

Regulators

Recommended High-Capacity R-6703 (P/N 22236)

Station or Pipeline Regulators

Table 2-4.Technical Specications

(Starting Gas)

Type N

2

, Air

Pressure 125 psig (8.6 bars)

Flow 60 cfh (28 I/min) max (varies with application)

Purity Required 99.995%, Dry, clean, free of oil and matter

Table 2-5. Technical Specications

(Secondary Gas)

Type N

2

O

2

H-35, Methane

Pressure 100 psig (6.9 bars) H-35, Methane; 125 psig

(8.6 bars) N

2

, O

2

, Air

Flow 60 cfh (28 I/min) max (varies with application)

Minimum Purity Required N

2

-99.995%; 0

2

, 99.8% H-35, Methane-99.8%

Table 2-6.Technical Specications

(PT-24 Torch)

Type Water-Cooled, Dual Gas

Rating 100 amps @ 100% duty cycle

Dimensions: See Figure 8-9

SECTION 2 DESCRIPTION

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23

SECTION 3 INSTALLATION

3.1 GENERAL

Proper installation can contribute materially to the satis-

factory and trouble-free operation of the Precision Plas-

marc System. It is suggested that each step in this section

be studied and carefully followed.

3.2 EQUIPMENT REQUIRED

A. Gas Supply and Hoses. Gas supply may be from a bulk

source or from a bank of manifold cylinders and regu-

lated to supply 125 psig (8.6 bars) to the Flow Control

(Gas Flowing).

B. Work Lead. No. 4 AWG (25 mm

2

) cable is recommended

for connecting workpiece to power source.

C. Primary Input Cable. See Section 3.4.

3.3 LOCATION

Adequate ventilation is necessary to provide proper

cooling of the power source. Minimize the amount of

dirt, dust, and excessive heat to which the equipment is

exposed. There should be at least 2 feet (0.6m) of clear-

ance between the power source and wall or any other

obstruction to allow freedom of air movement through

the power source.

Installing or placing any type of ltering device will restrict

the volume of intake air, thereby subjecting the power

source internal components to overheating. Use of any

type of lter device voids the warranty.

3.4 PRIMARY ELECTRICAL INPUT

CONNECTIONS Figure 31

ELECTRIC SHOCK CAN KILL! Precautionary measures

should be taken to provide maximum protection

against electrical shock. Be sure that all power is o

by opening the line (wall) disconnect switch and by

unplugging the power cord to the unit before any con-

nections are made inside of the power source.

Be sure that the power source is properly congured

for your input power supply. Do NOT connect a power

source congured for 230 V to a 460 V input power

supply. Damage to the machine may occur.

As shipped, the power source is congured for 575 V, 60

Hz input. If using 208, 230, 380, 415, or 460 V input, the

jumper input power cables located on the auto trans-

former must be repositioned to the desired input voltage

for safe operation. To gain access to the autotransformer,

remove the right side panel. (See Figure 3-1.)

A line (wall) disconnect switch with fuses or circuit break-

ers should be provided at the main power panel (see Table

3-1 for fuse rating). The input power cable of the power

source may be connected directly to the disconnect

switch or a proper plug and receptacle may be purchased

from a local electrical supplier. If using plug/receptacle

combination, see Table 3-1 for recommended input

conductors for connecting receptacle to line disconnect

switch.

The following procedure explains the proper installa-

tion steps for connecting primary electrical power to the

power source. (See Figure 3-1.)

A. Remove right side panel.

B. Ensure input power cable is disconnected from all elec-

trical sources.

C. Route input power cable through the strain relief located

at the rear panel.

D. Pull input power cable through the strain relief to allow

cable wires sucient length to connect to the main

contactor. Tighten strain relief to ensure input power

cable is secured.

Table 3-1. Recommended Sizes For

Input Conductors and Line Fuses

Input Requirements

Input & Gnd

Conductor

CU/AWG/mm

2

Fuse

Ratings/

Phase,

Amps

Volts Phase Amps

208

230

380

415

460

575

3

65

60

50

40

30

25

No. 4

No. 6

No. 8

No. 10

25

16

10

6

100

80

60

50

40

*Sizes per National Electric Code for 75 °C rated conductors @

30 °C ambient. Not more than three conductors in raceway or

cable. Follow local codes if they specify sizes other than those

listed above.

24

SECTION 3 INSTALLATION

Figure 3-1. Power Source Primary Power Connection Diagram

(Shown factory connected in 575 V position)

E. Connect input power cable ground wire to the ground

lug provided on the base of the power source.

F. Connect three power leads of the input power cable to

the terminals located atop the main contactor. Secure

the leads by tightening each screw.

G. Connect jumper power cables from the bottom of the

main contactor to the proper input voltage marked on

the auto transformer. The unit is factory set for 575 V.

Ensure each input power jumper cable is connected

to the proper input voltage to be used on auto trans-

former.

H. Connect jumper wire to the proper input voltage con-

nector located on the 7-position terminal block. (See

Figure 3-1.)

3.5 INTERCONNECTING LINES

(Refer to Figure 3-2 or Figure 3-3 for the appropriate ap-

plication.)

A. All interconnecting service lines supplied are numbered

on each end with corresponding numbers marked on

the cabinets next to the connection to be made.

B. Connect all ve lines in gas bundle (Figure 3-4) to Flow

Control Box and Junction Box (Figure 3-5).

C. Connect power and coolant lines in power bundle (Fig-

ure 3-6) to junction box (Figure 3-7) and power source

(Figure 3-2 or 3-3).

D. Remove panel from rear of console and attach the

pilot-arc, torch and work lead. See Figure 3-8 to replace

panel.

E. Connect control lead (Figure 3-9) between the console

and the ow control and from the ow control to the

junction box. See Figure 3-2 or Figure 3-3 for the instal-

lation location.

MAIN CONTACTOR

AUTO TRANSFORMER

Connect each jumper to

proper input voltage

7-POSITION

TERMINAL BLOCK

Connect jumper to

proper input voltage

INPUT POWER CABLE

(Customer Supplied)

GROUND CONNECTION

25

SECTION 3 INSTALLATION

Figure 3-2. Precision Plasmarc Cutting Machine Interconnecting Diagram

PRIMARY CABLE

(Customer Supplied)

CONTROL LEAD - 14 Pin Connector

(Power source to Flow Control Box)

POWER SOURCE

CONTROL

AUTO TRANS.

COOLER

W/4 Gal. (1.5L)

Tank

Control Lead P/N’s

10 ft. (3m) P/N-21917

20 ft. (6m) P/N-21918

30 ft. (9m) P/N-21919

60 ft. (18m)P/N-21920

100 ft. (30m) P/N-21921

Power Bundle P/N’s

25 ft. (7.6m) P/N-21905

60 ft. (18m) P/N-21906

100 ft. (30m) P/N-21907

Gas Bundle P/N’s

10 ft. (3m) P/N-21902

20 ft. (6m) P/N-21903

30 ft. (9m) P/N-21904

60 ft. (18m) P/N-22334

100 ft. (30m) P/N-22335

PT-24 TORCH

4.5ft.(1.4m)P/N22362

17 ft. (5.2m) P/N 22363

Gas Line Bundle

#1 Cut Gas O

2

Plasma

#2 Cut Gas N

2

Plasma

#3 Plasma Gas N

2

Start

#4 Shield Gas

#5 Shield Gas, Preow

Power Bundle

#6 Coolant to Torch

#7 Coolant Return from Torch

Torch Power Cable

Pilot Arc Lead

CONTROL LEAD

(Flow Control to Junction Box)

JUNCTION BOX

with H.F. Unit

P/N-37400

Note:

All service lines have identication numbers stamped on connections

BACK VIEW

O

2

N

2

X

Alternate Gas

(Shield Addition)

Supplied by Customer

See Fig.3-7

1

2

3 4 5

6

7

FLOW CONTROL BOX P/N-37416

1

2

3

4

5

O2

N2

Alt

ARC VOLTAGE REMOTE

(Customer Supplied)

HEIGHT CONTROL

(Customer Supplied)

CUTTING TABLE

(Customer Supplied)

CONTROL LEAD - 19 Pin Connector

(Power Source to CNC)

(Supplied based on Customer Order)

ARC VOLTAGE CONTROL

(Customer Supplied)

CNC

WORK LEAD

(Customer Supplied)

POWER SOURCE - P/N37357

26

SECTION 3 INSTALLATION

Figure 3-3. Precision Plasmarc Robotic Interconnecting Diagram

Note:

All service lines have identication

numbers stamped on connections

Control Lead P/N’s

10 ft. (3m) P/N-21917

20 ft. (6m) P/N-21918

30 ft. (9m) P/N-21919

60 ft. (18m) P/N-21920

100 ft. (30m)P/N-21921

Power Bundle P/N’s

25 ft. (7.6m) P/N-21905

60 ft. (18m) P/N-21906

100 ft. (30m) P/N-21907

Consists of:

#6 Coolant to Torch

#7 Coolant Return from Torch

Torch Power Cable

Pilot Arc Lead

Gas Bundle P/N’s

10 ft. (3m) P/N-21902

20 ft. (6m) P/N-21903

30 ft. (9m) P/N 21904

60 ft. (18m) P/N 22334

100 ft. (30m) P/N 22335

Consists of:

#1 Cut Gas O

2

Plasma

#2 Cut Gas N

2

Plasma

#3 Plasma Gas N

2

Start

#4 Shield Gas

#5 Shield Gas, Preow

FLOW CONTROL BOX P/N-37416

GAS LINE BUNDLE

CONTROL LEAD

(Flow Control to Junc-

tion Box)

POWER BUNDLE

PRIMARY CABLE

(Customer Supplied)

CONTROL LEAD - 19 Pin Connector

(Supplied based on Customer Order)

WORK LEAD

(Customer Supplied)

PT-24 TORCH

4.5 ft. (1.4m) P/N 22362

17 ft. (5.2m) P/N 22363

WORK

JUNCTION BOX

with H.F. Unit

P/N-37400

See Fig. 3-7

1

2

3

4

5

6

7

1

2

3

4

5

O2

N2

Alt

BACK VIEW

O

2

N

2

X

Alternate Gas

(Shield Addition)

Supplied by Customer

CONTROL LEAD - 14 Pin Connector

(Power source to Flow Control Box)

POWER SOURCE

CONTROL

AUTO TRANS.

COOLER

W/4 Gal. (1.5L)

Tank

POWER SOURCE P/N-37357

27

SECTION 3 INSTALLATION

1

2

3

4 5

Junction Box

with H.F. Unit

Figure 3-5. Gas Bundle Installation

Figure 3-4. Gas Line Bundle

(2) adapters supplied

with bundle

BUNDLE P/N #1 #2 #3 #4 #5 SHEATH

10 FT. (3m) 21902 21884 21875 21878 21887 21881 995832

20 FT. (6m) 21903 21885 21876 21879 21888 21882 995832

30 FT. (9m) 21904 21886 21877 21880 21889 21883 995826

60 FT. (18m) 22334 22337 22343 22345 22340 22347 995826

100 FT. (30m) 22335 22338 22344 22346 22341 22348 995826*

*2 required

28

SECTION 3 INSTALLATION

Figure 3-7. Power Bundle/Junction Box Connections

6

7

6

POWER CABLE#3 AWG

No. 6 and No. 7

5/8-18 L.H.

No. 6 and No. 7

5/8-18 L.H.

PILOT ARC #16 AWG(YELLOW)

POWER BUNDLE #6

#7

25 FT. (7.6m) P/N-21905

21911 21914

60 FT. (18m) P/N-21906

100 FT. (30m) P/N-21907

21912 21915

21913 21916

(B-A/W) (B-A/W)

SHEATH

995832 (1)

995832 (2)

Figure 3-6. Power Bundle

Gas Tubing Bundle Connections:

Cut Gas (Yellow)

Shield Gas (Org. or Red)

Pre-Cut Gas (Black)

Start Gas (Blue)

Power

Cable

Gas Tubing

Bundle

Torch Assembly

Pilot Arc Cable

Hose No. 7

Hose No. 6

Power Bundle Assembly

Torch Pilot Arc

Torch Electrical

(J2) Cable

Torch Negative

29

SECTION 3 INSTALLATION

Figure 3-8. Power Bundle/Power Source Rear Panel

Connection

CONTROL LEADS P/N’S

10 FT.(3m) P/N-21917

20 FT.(6m) P/N-21918

30 FT.(9m) P/N-21919

60 FT.(18m) P/N-21920

100 FT.(30m) P/N-21921

Figure 3-9. Available Control Leads

F. Torch Mounting Options.

1. The torch is normally mounted by the sleeve.

2. For more precise mounting, the torch can be

mounted by the 1.812" (46 mm) dia collar shown

(see Figure 3-10). This insulated collar and its shoul-

der are machined relative to the nozzle retainer

thread on the torch body and is held concentric

to the cutting nozzle within a total indicator read-

ing of 0.010 inches (0.25 mm) or the nozzle bore

is within 0.005 inches of any point on the 1.812

dia.

NOTE

When mounting, be sure not to cover the small vent hole

in the side of the sleeve. This hole prevents coolant from

building inside the sleeve should a leak occur in a service

line.

Figure 3-10. Torch Mounting Options

F. Connect control lead (Figure 3-9) between the power

source and the ow control and from the ow control

to the junction box. See Figure 3-2 or Figure 3-3 for the

installation location.

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ESAB Precision Plasmarc System Series "A" User manual

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