ESAB M3® Plasma Precision Plasmarc Plasma Gas Box & Shield Gas Box User manual

Precision Plasmarc

Plasma Gas Box & Shield Gas Box

0558007535 10/2008

Plasma Gas Box

Shield Gas Box

Uživatelská příručka (CS)

Instruktionsbog (DA)

Instructiehandleiding (NL)

Instruction Manual (EN)

Kasutusjuhend (ET)

Käyttöohje (FI)

Manuel d'instruction (FR)

Bedienungsanleitung (DE)

Használati útmutató (HU)

Manuale di istruzioni (IT)

2

DECLARATION OF CONFORMITY

according to the Low Voltage Directive 2006/95/EC, according to the EMC Directive 2004/108/EC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

enligt Lågspänningsdirektivet 2006/95/EG, enligt EMC-Direktivet 2004/108/EG

Type of equipment Materialslag

Plumbing Box

Brand name or trade mark Fabrikatnamn eller varumärke

ESAB

Type designation etc. Typbeteckning etc.

M3 Precision Plasmarc Plasma Gas Box (0560941491)

Manufacturer positioned outside the EEA

Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB Welding & Cutting Products

411 South Ebenezer Road, Florence, South Carolina 29501, USA

Phone: +1 843 669 4411, Fax: +1 843 664 4258

Manufacturer´s authorised representative established within the EEA

Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB AB, Welding Equipment

Esabvägen, SE-695 81 LAXÅ, Sweden

Phone: +46 584 81 000, Fax: +46 584 411 924

The following harmonised standards in force within the EEA have been used in the design:

Följande harmoniserande standarder har använts i konstruktionen:

EN 60974-8, Arc welding equipment – Part 8: Gas consoles for welding and cutting systems

EN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised

representative established within the EEA, that the equipment in question complies with the safety requirements

stated above.

Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom

EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Date / Datum

Laxå 2007-08-14

Signature / Underskrift Position / Befattning

Global Director

Equipment and Automation

Kent Eimbrodt

Clarification

3

TABLE OF CONTENTS

Section 5 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

Section 6 Replacement Parts .....................................................................................381

Language / Section Page

Czech (CS)............................................................................................................5

Danish (DA) .........................................................................................................41

Dutch (NL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

English (EN) ........................................................................................................113

Estonian (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

Finnish (FI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185

French (FR) .........................................................................................................221

German (DE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Hungarian (HU).....................................................................................................293

Italian (IT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329

4

DECLARATION OF CONFORMITY

according to the Low Voltage Directive 2006/95/EC, according to the EMC Directive 2004/108/EC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

enligt Lågspänningsdirektivet 2006/95/EG, enligt EMC-Direktivet 2004/108/EG

Type of equipment Materialslag

Plumbing Box

Brand name or trade mark Fabrikatnamn eller varumärke

ESAB

Type designation etc. Typbeteckning etc.

M3 Precision Plasmarc Shield Gas Box (0560941536, 0560942312)

Manufacturer positioned outside the EEA

Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB Welding & Cutting Products

411 South Ebenezer Road, Florence, South Carolina 29501, USA

Phone: +1 843 669 4411, Fax: +1 843 664 4258

Manufacturer´s authorised representative established within the EEA

Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB AB, Welding Equipment

Esabvägen, SE-695 81 LAXÅ, Sweden

Phone: +46 584 81 000, Fax: +46 584 411 924

The following harmonised standards in force within the EEA have been used in the design:

Följande harmoniserande standarder har använts i konstruktionen:

EN 60974-8, Arc welding equipment – Part 8: Gas consoles for welding and cutting systems

EN 60974-10, Arc welding equipment – Part 10: Electromagnetic compatibility (EMC) requirements

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised

representative established within the EEA, that the equipment in question complies with the safety requirements

stated above.

Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom

EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Date / Datum

Laxå 2007-08-14

Signature / Underskrift Position / Befattning

Global Director

Equipment and Automation

Kent Eimbrodt

Clarification

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21

ODDÍL 3 INSTALACE

Schéma počítačové desky

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57

SEKTION 3 INSTALLATION

PC-tavlens skema

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63

3.8.2 Beskyttelsesgasboks bagerste tilslutninger

SEKTION 3 INSTALLATION

1 Beskyttelsesgas ud

2 Lufttæppeindgang

3 Oxygen-indgang

4 N2 indgang

5 Luftindgang

6 Kontrolventiler (typiske)

7 CH4 indgang

m3 gastilslutningssæt (0558005229, inkluderet i/m3 systemet). Består af følgende:

BEST.NR. Beskrivelse Antal

36Z40 MØTRIKSLANGE B-A/W .63-18F RH 2

136Z08 MØTRIKSLANGE B-I/G .63-18M RH 1

3380 MØTRIKSLANGE B-OXY .56-18F RH 1

3381 MØTRIKSLANGE B/ACET .56-18F LH 2

136Z07 MØTRIKSLANGE A-I/G .38-24M RH 1

2064114 NPL SKUB A/A-W 3/16 ID SLANGE 1

03Z74 NPL SKUB B/STR. 3/8 SLANGE 5

347995 NPL SKUB B/A-W 3/8 ID SLANGE 1

0558006336 m3 PLASMAFILTERMONTERING 1

20373 LYSBUESPÆRREAGGREGAT 1

4

3

5

2

7

1

6

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Precisie plasmaboog

plasmagasbox en schildgasbox

Instructiehandleiding (NL)

0558007535

Plasmagasbox

Schildgasbox

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80

TABLE OF CONTENTS

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93

HOOFDSTUK 3 INSTALLATIE

Schema van printplaat

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Precision Plasmarc

Plasma Gas Box & Shield Gas Box

Instruction Manual (EN)

0558007535

Plasma Gas Box

Shield Gas Box

114

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!

115

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions ..................................................................................117

2.0 Description...........................................................................................119

2.1 System Introduction ...........................................................................119

2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36 ...................................119

2.3 System Gas Requirements..................................................................... 120

2.4 Plasma Gas Box Water Supply Requirements................................................... 120

2.5 Plasma Gas Box Electrical Input Requirements ................................................. 120

2.6 Shield Gas Box Electrical Input Requirements .................................................. 120

2.7 System Accessories ........................................................................... 120

2.8 Plasma Gas Box Dimensions....................................................................121

2.9 Shield Gas Box Dimensions.................................................................... 122

3.0 Installation .......................................................................................... 123

3.1 Plasma Gas Box Introduction .................................................................. 123

3.2 Plasma Gas Box Mounting (Bottom View) ...................................................... 123

3.3 Plasma Gas Box Connections .................................................................. 124

3.4 Plasma Gas Box Nomex Insulation ............................................................ 130

3.5 Plasma Gas Box Gas Connections...............................................................131

3.6 Shield Gas Box Introduction................................................................... 133

3.7 Shield Gas Box Mounting (Bottom View)....................................................... 133

3.8 Shield Gas Box Connections................................................................... 134

3.9 Component Relationship Block Diagram....................................................... 136

4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

4.1 Plasma Gas Box Operation .................................................................... 143

4.2 Plasma Gas Box Pressure Gauges .............................................................. 143

4.3 Plasma Gas Box Pressure Switches ............................................................. 144

4.4 Shield Gas Box Operation ..................................................................... 145

4.5 Shield Gas Box Air Regulator for Air Curtain ....................................................146

4.6 Shield Gas Box Check Valves .................................................................. 147

116

TABLE OF CONTENTS

117

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone

who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet

the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations

should be observed in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma

cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in

injury to the operator and damage to the equipment.

1. Anyone who uses welding or plasma cutting equipment must be familiar with:

- its operation

- location of emergency stops

- its function

- relevant safety precautions

- welding and / or plasma cutting

2. The operator must ensure that:

- no unauthorized person stationed within the working area of the equipment when it is started up.

- no one is unprotected when the arc is struck.

3. The workplace must:

- be suitable for the purpose

- be free from drafts

4. Personal safety equipment:

- Always wear recommended personal safety equipment, such as safety glasses, ame proof

clothing, safety gloves.

- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions:

- Make sure the return cable is connected securely.

- Work on high voltage equipment may only be carried out by a qualied electrician.

- Appropriate re extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

118

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND

OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON

MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK - Can kill.

- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

- Insulate yourself from earth and the workpiece.

- Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health.

- Keep your head out of the fumes.

- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

WARNING

119

SECTION 2 DESCRIPTION

2.1 System Introduction

The m3 Plasma System is a streamlined, high performance-cutting package designed for use exclusively with the

ESAB CNC. This advanced technology integrates gas and water control into the machine CNC.

Using a system of electronic valves driven by CNC outputs, this system:

dramatically reduces the amount of Plasma Gas hardware necessary to control the plasma torch.•

reduced purge time/increased part throughput .•

simplied operation with gas and water ow rates are controlled by the ESAB CNC process parameter •

screen.

allows for programmed/automated control of uid and water ow rates using SDP Files (SchneidDaten-•

Paket = Cutting Data Package, see Vision control and programming manuals for details on SDP Files.

Data used to generate SDP les can be found in your model specic torch manual.) SDP les can also

be referred to as TDF les (Technology Data Files).

to be used with the PT-36 cutting torch. •

2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36

The complete m3 cutting system requires a variety of components. See section 3.9, Component Relationship

Block Diagram for components and hook-up.

Plasma Gas Box

Shield Gas Box

2.0 Description

120

SECTION 2 DESCRIPTION

2.4 Plasma Gas Box Water Supply Requirements

Cooling Water ......................................................................................175 PSI (12,1 bar), 1.5 gallons per minute (5.68 liters/minute)

2.5 Plasma Gas Box Electrical Input Requirements

Voltage Supply +24 VDC for proportional valves, mfc

+15 VDC for pressure switch

Voltage Signals 24 VAC input to start gas solenoid valve

120 VAC input to arc starter

0-10 VDC input to proportional valves

0-10 VDC for mass ow valve

2.6 Shield Gas Box Electrical Input Requirements

Voltage Supply +24 VDC for 120/230 transformer and I/O board

+24 VDC for proportional valves and mfc’s

2.7 System Accessories

Adapter Coolant EPP-200 ..............................................................................................0558006162

Coolant Hose Adaptor Kit ............................................................................................ 0558006698

2.3 System Gas Requirements

Argon 125 PSI (8,6 bar) with 0.25” NPT, 99.995% purity, Filtered to 25 microns

Nitrogen 125 PSI (8,6 bar) with 0.25” NPT, 99.99% purity, Filtered to 25 microns

Oxygen 125 PSI (8,6 bar) with 0.25” NPT, 99.5% purity, Filtered to 25 microns

H-35 (Argon/Hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns

Methane 75 PSI (5,2 bar) with 0.25” NPT, 93% purity, Filtered to 25 microns

Compressed Air

(Air Curtain )

80 PSI (5,5 bar) with 0.25” NPT, clean, dry, oil-free and ltered to 25 microns

Compressed Air

(Process)

80 PSI @ 1200cfh (5,5 bar @ 35 m

3

h) ltered to 25 microns

DIN Quality ISO 8573-1

Oil quality mg/m3 = 0.1 class 2

Particle Size 0.1um class 1

Temparature +3 C class 4

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122

SECTION 2 DESCRIPTION

2.9 Shield Gas Box Dimensions

20.00”

508.0 mm

12.0 0”

304.8 mm

8.00”

203.2 mm

123

SECTION 3 INSTALLATION

3.1 Plasma Gas Box Introduction

ELECTRICITY CAN KILL!

BEFORE PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS

EQUIPMENT, ENSURE THE POWER SOURCE EPP IS TURNED OFF AND

DISCONNECTED.

WARNING

The m3 Plasma System Plasma Gas Box interfaces with the ESAB Vision machine controls and the EPP product

line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control

electronic valves. The result is CNC management of gas or shield gas delivery to the plasma torch. Analog signal

feedback is sent back to the CNC, creating a control loop.

3.2 Plasma Gas Box Mounting (Bottom View)

If mounting the box is required:

The box has four (1.10”) 28 mm threaded mounting holes in a pattern oset from longitudinal center. Note rela-

tionship of hole pattern to gauges and cable clamp.

.75”

19.1 mm

4.50”

114.3 mm

2.00”

50.8 mm

11. 0 0 ”

279.4 mm

4.13”

104.9 mm

2.00”

50.8 mm

3.0 Installation

front

back

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ESAB M3® Plasma Precision Plasmarc Plasma Gas Box & Shield Gas Box User manual

ESAB M3® Plasma Precision Plasmarc Plasma Gas Box & Shield Gas Box User manual

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