ESAB Standoff Control Model SC11 User manual

Brand: ESAB

Model: Standoff Control Model SC11

Category: Welding System

Type: User manual

November 30, 2001 Manual No. 0-2556

STANDOFF CONTROL

Model SC11

Instruction Manual

A-00686

ARC VOLTS

(

)

(

)

TORCH

MODE

LIFTER

SPEED

(

)

AUTO

FIND

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Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operat-

ing, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

Standoff Control

Model SC11

Instruction Manual No. 0-2556

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written permis-

sion of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to

any party for any loss or damage caused by any error or omission in this

Manual, whether such error results from negligence, accident, or any

other cause.

Printed in the United States of America

Publication Date: November 30, 2001

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications.................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference ............................................................................ 1-5

1.07 Declaration of Conformity............................................................................. 1-7

1.08 Statement of Warranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION & DESCRIPTION.................................................................................. 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 General Description ..................................................................................... 2-1

2.03 Specifications & Design Features................................................................. 2-1

SECTION 3:

INSTALLATION PROCEDURES ....................................................................................... 3-1

3.01 Introduction .................................................................................................. 3-1

3.02 Site Location ................................................................................................ 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Installation - General .................................................................................... 3-1

3.05 Mounting Bracket Assembly Installation ....................................................... 3-2

3.06 Standoff Control Assembly Installation ......................................................... 3-2

3.07 Installation With Automated Systems ........................................................... 3-3

3.08 Internal Selections........................................................................................ 3-3

3.09 External Cable Connections......................................................................... 3-5

3.10 Lifter Motor Installation ................................................................................. 3-6

SECTION 4:

OPERATION ..................................................................................................................... 4-1

4.01 Introduction .................................................................................................. 4-1

4.02 Functional Overview..................................................................................... 4-1

4.03 Operating Controls ....................................................................................... 4-1

4.04 Sequence Of Operations.............................................................................. 4-3

SECTION 5:

CUSTOMER/OPERATOR SERVICE................................................................................. 5-1

5.01 Introduction .................................................................................................. 5-1

5.02 Routine Maintenance ................................................................................... 5-1

5.03 Troubleshooting Guide ................................................................................. 5-1

5.04 Troubleshooting Specific Problems............................................................... 5-2

5.05 Test Procedures ........................................................................................... 5-3

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction .................................................................................................. 6-1

6.02 Ordering Information .................................................................................... 6-1

6.03 Standoff Control Assembly Parts.................................................................. 6-2

6.04 Replacement External Control Cables ......................................................... 6-3

6.05 Lifter Motor Assembly Parts ......................................................................... 6-4

APPENDIX 1: STANDOFF CONTROL ACCESSORY - WIRING DIAGRAM.............................A-1

APPENDIX 2: STANDOFF CONTROL PC BOARD PARTS LOCATION ..................................A-2

APPENDIX 3: START CIRCUIT SCHEMATICS ........................................................................A-3

APPENDIX 4: MOTION (OK-TO-MOVE) CIRCUIT SCHEMATICS ...........................................A-4

APPENDIX 5: CNC CONTROL CABLE INTERFACE DIAGRAM..............................................A-5

APPENDIX 6: SYSTEM INTERCONNECTION DIAGRAM .......................................................A-6

APPENDIX 7: LIFTER MOTOR ASSEMBLY DETAILED DIMENSIONS ...................................A-7

MOUNTING HOLE TEMPLATE .................................................................................................A-9

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Date: November 15, 2001 1-1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formation regarding the kind and amount of fumes

and gases that may be dangerous to your health.

• For information on how to test for fumes and gases

in your workplace, refer to item 1 in Subsection 1.03,

Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects and, in some cases, cancer. (California Health

& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

GENERAL INFORMATION 1-2 Date: November 15, 2001

• Wear dry gloves and clothing. Insulate yourself

from the work piece or other parts of the welding

circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publica-

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable ma-

terial in the workplace. Any material that cannot

be removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have

held combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.

The plasma arc process produces very bright ultra violet

and infra red light. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

ments, U.S. Government Printing Office, Washington,

D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding So-

ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable

from the Superintendent of Documents, U.S. Govern-

ment Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 1-3 GENERAL INFORMATION

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE

OF CUTTING AND WELDING PROCESSES, obtain-

able from American National Standards Institute, 1430

Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-

TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-

tainable from American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.05 Precautions De Securite

Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

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GENERAL INFORMATION 1-6 Date: November 15, 2001

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE

COUPE ET DE SOUDAGE, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA

SÉCURITÉ DU SOUDAGE, disponible auprès de

l’Association Nationale de Fournitures de Soudage

(National Welding Supply Association), 1900 Arch

Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRATIQUES

SURES POUR LA PRÉPARATION À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION

RESPIRATOIRE, disponible auprès de l’American

National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 1-7 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’

(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for

the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit

and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-

turing process. This is to ensure the product is safe, when used according to instructions in this manual and related

industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure

the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our

area of manufacture.

Manufacturers responsible representative: Giorgio Bassi

Managing Director

Thermal Dynamics Europe

Via rio Fabbiani 8A

40067 Rastignano (BO)

Italy

GENERAL INFORMATION 1-8 Date: November 15, 2001

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics

Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in

workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges

to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the

customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 6, 2001

Manual 0-2556 2-1 INTRODUCTION & DESCRIPTION

SECTION 2:

INTRODUCTION &

DESCRIPTION

2.01 Scope of Manual

This manual contains descriptions, operating instructions

and maintenance procedures for the SC11 Standoff Con-

trol Accessory. Service of this equipment is restricted to

properly trained personnel; unqualified personnel are

strictly cautioned against attempting repairs or adjust-

ments not covered in this manual, at the risk of voiding

the Warranty.

Read this manual thoroughly. A complete understand-

ing of the characteristics and capabilities of this equip-

ment will assure the dependable operation for which it

was designed.

2.02 General Description

The SC11 Standoff Control Accessory extends the neces-

sary system controls away from the power supply and is

an accessory for use with standard machine torch sys-

tems.

NOTE

The SC11 Standoff Control functions without con-

nection to the Remote Control Accessory RC6010.

The SC11 Standoff Control has all the connections re-

quired at the rear panel. The connections are for CNC

Control, External Power, Lifter Motor, and Plasma Power

Supply. The inputs and outputs at these connections al-

low the various parts of the system to be operated at one

station.

The Standoff Control receives bias power (+48 vdc), torch

voltage signal (0-12 vdc = 0-200 arc volts) and sends and

receives power supply and CNC control signals such as

start, arc transfer (OK-To-Move) and standoff inhibit

(CSD).

The Standoff Control operates the torch lifter motor as-

sembly to find height, regulate height and retract at end

of cut. Height is regulated by comparing the torch arc

voltage with a preset reference voltage (ARC VOLTS con-

trol) and using the resulting error voltage to raise and

lower the torch lifter motor.

A-00686

ARC VOLTS

(

)

(

)

TORCH

MODE

LIFTER

SPEED

(

)

AUTO

FIND

Figure 2-1 SC11 Standoff Control

All necessary cables are supplied for the type system or-

dered. If the SC11 Standoff Control Accessory is not pur-

chased as part of a system, the appropriate remote con-

trol cable and a CNC cable (if required) must be ordered

separately. Some systems may require an external 48 volt

power source. Refer to Section 6, Parts Lists, for order-

ing information.

A-00700

Standoff

Control Accessory

CNC

Lifter Motor

Control Cable

Power Supply

Control Cable

Plasma Power

Supply

CNC

Control Cable

Input Power

Figure 2-2 System Configuration With SC11

2.03 Specifications & Design

Features

A. Standoff Control

The following applies to the Standoff Control Assembly

only.

1. System Compatiblility

The Standoff Control Accessory was designed to be

used with various Plasma Cutting Systems

INTRODUCTION & DESCRIPTION 2-2 Manual 0-2556

2. Input Power

48 vdc supplied from the Plasma Cutting Power Sup-

ply or an external 48 volt power source

3. Front Panel Controls

MODE, LIFTER SPEED, TORCH, ARC VOLTS,

PIERCE HT, PIERCE DELAY, and END OF CUT RE-

TRACT

4. Front Panel Indicators

Arc Volts Display, PLASMA ON, AUTO HT, FIND

HT, HI, LO, T.H.C. ACTIVE, UP, and DN indicators

5. Rear Panel Connections

Connections for MOTOR, PLASMA, EXTERNAL

POWER, CNC, and CNC Cable Strain Relief

6. Dimensions (H x W x L)

2.62 x 12.12 x 10 inches (66 x 308 x 254 mm)

7. Weight

5 lbs (2.5 kg)

B. Lifter Motor

The following applies to the Lifter Motor Assembly only.

1. Dimensions (H x W x D)

29 x 10 x 8 inches (737 x 254 x 203 mm)

Refer to Appendix 7 for detailed dimensions.

2. Weight (Approximately)

20 lbs (9.07 kg)

Manual 0-2556 3-1 INSTALLATION PROCEDURES

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

This Section describes installation of the Standoff Con-

trol Accessory. These instructions apply to the Standoff

Control Accessory only; installation procedures for the

Plasma Power Supply and Torches are given in Manuals

specifically provided for those units.

The complete installation consists of:

1. Site Selection

2. Unpacking

3. Installing Standoff Control Assembly

4. External Cable Connections

5. Lifter Motor Installation

6. Operator Training

3.02 Site Location

Select a clean, dry location with good ventilation and ad-

equate working space around all components.

Review the safety precautions in the front of this manual

to be sure that the location meets all safety requirements.

3.03 Unpacking

Each component of the system is packaged separately and

protected with a carton and packing material to prevent

damage during shipping. Components are packaged as

follows:

A. Standoff Control Components

The components supplied with the Standoff Control Ac-

cessory depends on the Cutting System. The Standoff

Control Accessory components are packaged separately

and include:

For Automated Cutting Systems:

• Standoff Control Assembly

• Lifter Motor Assembly

• External Power Supply and Cables

• Instruction Manual

For Other Cutting Systems:

• Standoff Control Assembly

• Lifter Motor Assembly

• Voltage Divider PC Board, Ribbon Cable, and Wire

Harness Assembly

• Instruction Manual

NOTE

The Voltage Divider PC Board, Ribbon Cable and

Wire Harness Assembly will be factory installed if

ordered as part of a Plasma Cutting System.

B. Other Equipment and Accessories

Items such as Lifter Motor Control Cable, CNC Cable,

Remote Cable, Plasma Cutting Power Supply and Torch

are ordered and packaged separately from the Standoff

Control components.

C. Unpacking Procedure

1. Unpack each item and remove all packing material.

2. Locate the packing list(s) and use the list to identify

and account for each item.

3. Inspect each item for possible shipping damage. If

damage is evident, contact your distributor and/or

shipping company before proceeding with system

installation.

3.04 Installation - General

WARNING

Disconnect primary power to the plasma cutting

system before installating the Standoff Control.

The installation of the Standoff Control Accessory requires

mounting the Standoff Control and connecting all re-

quired cables.

The installation instructions are divided into Sub-Sections

for the component to be installed. The Sub-Sections are

as follows:

Section 3.05 Mounting Bracket Assembly Installa-

tion

Section 3.06 Standoff Control Assembly Installa-

tion

Section 3.07 Installation With Automated Systems

Section 3.08 Internal Switch/Jumper Selections

Section 3.09 External Cable Connection

Section 3.10 Lifter Motor Installation

INSTALLATION PROCEDURES 3-2 Manual 0-2556

The Standoff Control Assembly and external cable instal-

lation is the same for all systems.

3.05 Mounting Bracket Assembly

Installation

The Mounting Bracket Assembly is used to mount the

Standoff Control Assembly and must be installed in a suit-

able location where it is easily accessable to the system

operator. The unit can be mounted on top of or under-

neath a mounting surface.

Install the Mounting Bracket Assembly per the following

procedure:

1. Select the mounting surface for the Mounting Bracket.

2. Mount the bracket to the surface either on top of or

underneath the surface using four 1/4" bolts (not sup-

plied). It is recommended to use at least four bolts to

mount the bracket but a minimum of two are required.

NOTE

There are seven holes provided in the Mounting

Bracket. Use any four holes that are convenient

for the application.

1/4" Mounting Bolts

(Not Supplied)

Mounting Holes

(Seven Places)

A-00671

Figure 3-1 Bracket Mounting On Top Of Surface

A-00672

1/4" Mounting Bolts

(Not Supplied)

Mounting Holes

(Seven Places)

Figure 3-2 Bracket Mounting Underneath Surface

3.06 Standoff Control Assembly

Installation

Mount the Standoff Control Assembly per the following

procedure:

1. Install the Mounting Bracket per Section 3.05.

2. Insert two of the #10-32 x 3/8" hex head bolts into the

slots on each side of the Standoff Control unit. The

slot prevents the bolts from turning when the knobs

are installed.

Slot

Hex Head Bolt

#10-32 x 3/8"

Knob

A-00688

TORCH

Figure 3-3 Bolt Installation

3. Set the Standoff Control unit into the Mounting

Bracket being sure the four bolts are in the mounting

slots.

Manual 0-2556 3-3 INSTALLATION PROCEDURES

A-01428

Customer's

Power Source

(120/240 VAC)

External Power

Supply

Standoff Control

SC11

Supplied Input Power Cable

With 120 VAC Plug

Supplied Output Power Cable

Attached to External

Power Supply

Figure 3-5 External Power Supply

3. Connect the end of the output power cable from the

external power supply, to the rear panel of the Stand-

off Control (SC11). Make the connection to the EX-

TERNAL POWER connector (J41).

4. Plug the input power cable into a mating connector

from the customer's power source. If a different type

plug is required do the following:

a. Cut off the 120 VAC plug.

b. Install the correct type plug (customer supplied)

onto the end of the input power cable.

This completes the installation of the external power sup-

ply for the Automated System.

3.08 Internal Selections

A. Switch (SW1) Selection

The Standoff Control Assembly has one internal switch

(SW1) that is used for some plasma cutting systems with-

out an arc transfer or motion signal. Turning ON SW1-1

and SW1-2 will generate the signal as soon as the pilot

arc voltage drops from open circuit to under 195v. This

occurs as soon as pilot is initiated so the PIERCE DELAY

should be used to delay the motion signal. This will al-

low time for arc transfer and piercing.

NOTE

Switch SW1 is not needed for Automated Systems

(Merlin 1000, PakMaster XL Plus or Pak Master

150XL) and both positions should be in the OFF

position.

To check or change the switch selection use the following

procedure:

1. Remove the two cover mounting screws on the top of

the Standoff Accessory.

Knob

Hex Head

Bolts

Knob

Mounting Bracket

A-00674

Figure 3-4 Knob Installation

4. Place one knob on each of the bolts protruding from

the bracket slots.

5. The Standoff Control unit can be adjusted for the best

viewing angle. Adjust the viewing angle per the fol-

lowing:

a. Loosen the four knobs sercuring the Standoff Con-

trol to the Mounting Bracket.

b. Adjust the Standoff Control for the desired angle.

c. Tighten all four knobs.

d. If the angle is not correct, loosen knobs, adjust the

unit until the proper viewing angle is found, and

retighten all knobs.

3.07 Installation With Automated

Systems

This Section describes the installation of an external power

supply components to allow use of the Standoff Control

with an Automated Cutting System.

WARNING

Disconnect primary power at the source before as-

sembling or disassembling power supply, torch

parts, or torch and leads assemblies.

1. Locate the external power supply assembly and cables

shipped with the Standoff control.

2. Connect the supplied input power cable , with 120

VAC plug, to the input of the external power supply.

INSTALLATION PROCEDURES 3-4 Manual 0-2556

PIE

(in

che

0.1

T (%

)

TORCH

MODE

LIFTER

SPEED

PIE

ec)

0.75

.25

0.1

A-00689

Screw

Cover

Figure 3-6 Cover Removal

2. Remove the enclosure cover by lifting straight up at

the rear of the cover and pulling it towards the rear of

the unit. The front edge of the cover fits under a lip

on the front panel assembly.

3. Identify internal switch SW1 and confirm that the

switch is set for the desired system as follows:

System

SW1-

Without Motion Signal (OK-To-Move) ON ON

With Motion Signal (OK-To-Move) OFF* OFF*

* = Factory Setting

NOTE

Refer to Section 4.04-E for operation when start-

ing the the cutting operation off the plate (work-

piece).

Standoff Control

PC Board Assembly

A-00861

SW1

Type System

Selection

Figure 3-7 Switch SW1 Location

B. CNC Interface

Isolated START, standoff inhibit (CSD) and motion

(OK-To-Move) signals are available at the Rear Panel

CNC (J40) connector or an internal terminal strip (J11).

The motion signal (OK-To-Move) may be selected to

be either a contact closure or 24 VAC switched

through the contact. The Standoff Control is factory-

set for 24 VAC operation. The purpose of selecting

24 VAC is to drive a relay coil whose current must

not exceed 150 ma.

NOTE

The 24 VAC may be required by some cutting ma-

chine controllers.

Manual 0-2556 3-5 INSTALLATION PROCEDURES

Standoff Control

PC Board Assembly

A-01424

J11

Pin 6

Pin 7

Figure 3-8 Motion (OK-To-Move) Jumper Location

A jumper wire is connected between the terminal block

J11 pin 7 and the lug connection E1 on the PC board. Se-

lect the proper operation by moving the end of the wire

connected to the terminal block per the following chart:

Motion (OK-To-Move) Selection J11

Contacts or External 115V 6

24 VAC 7*

* = Factory Setting

3.09 External Cable Connections

There are four standard output connectors and one strain

relief at the rear panel of the unit. Connect the required

control cables per the following:

A-00693

MOTOR

J43

Lifter Motor

Control Cable

PLASMA

J42

EXTERNAL

POWER

J41

CNC

J40

CNC

Strain Relief

CNC Control

Cable

External Input

Power Cable

Plasma Power

Supply Control

Cable

Figure 3-9 Cable Connections

1. Lifter Motor Cable

Connect the Lifter Motor Control Cable to the rear

panel of the Standoff Control to the receptacle marked

J43 (MOTOR). The other end of the cable is connected

to the lifter motor equipment.

2. Power Supply Control Cable

Connect the Power Supply Control Cable to the rear

panel of the Standoff Control to the receptacle marked

J42 (PLASMA). Connect the other end of the cable to

the Power Supply receptacle marked TO REMOTE

CONTROL. Power Supply connector is J22 on Mer-

lin 1000 Systems.

NOTE

Some systems may supply the +48 volts external

power from the Plasma Power Supply via the Con-

trol Cable. These Remote Cables have two connec-

tors for PLASMA (J42) and EXTERNAL POWER

(J41).

3. External +48 Volt Power Source

Connect the External Power Source Cable to the rear

panel of the Standoff Control to the receptacle marked

J41 (EXTERNAL POWER). The other end of the cable

is connected to the external +48 volt power source.

The factory supplied external power source can be

connected to 115 or 220 VAC, 50/60Hz.

NOTE

Plasma Power Supplies that do not have a +48 volt

output require a seperate external power source.

INSTALLATION PROCEDURES 3-6 Manual 0-2556

4. CNC Control Cable Using AMP Connector

Connect the CNC Control Cable to the rear panel of

the Standoff Control to the AMP receptacle marked

J40 (CNC). Connect the other end of the cable to the

CNC Control Assembly. Terminate the shield(s) of

the cable to earth or chassis ground at the cutting

machine.

5. CNC Control Cable - Hard Wired

If the CNC cable from the CNC equipment cannot be

supplied with a mating AMP connector to J40 (CNC)

the cable can be hard wired to the Standoff Control

Accessory. To wire the cable to the unit use the fol-

lowing procedure:

a. Remove the cover of the Standoff Control to gain

access to the internal connection on the PC board.

b. Feed the control cable through the strain relief at

the rear panel of the Standoff Control.

c. Locate the terminal block J11 on the PC board.

Standoff Control

PC Board Assembly

A-01425

J11

Figure 3-10 Terminal Block J11 Location

d. Connect the ends of the CNC control cable to J11

on the PC Board per the following chart:

Pin # Description

1 Standoff Inhibit/Corner Slowdown (CSD)

2 Standoff Inhibit/Corner Slowdown (CSD) Return

3 START/STOP

4 START/STOP Return

5 Motion (OK-To-Move)

8 Motion (OK-To-Move)

e. Tighten the strain relief to secure the control cable.

f. Reinstall the cover to the Standoff Control Acces-

sory.

g. Connect the other end of the cable to the CNC

Control Assembly.

3.10 Lifter Motor Installation

A. Mounting Holes

NOTE

Refer to the exploded view of the Lifter Motor As-

sembly for parts location and assembly.

The Lifter Motor Assembly must be mounted to the Cut-

ting Table. Mount the assembly per the following proce-

dure:

1. Lossen the four screws securing the Front Cover to

the assembly.

2. Remove the Torch Holder and Front Cover from the

assembly.

3. Use the template at the end of this Manual to locate

the four mounting holes noting the following:

• The bottom edge of the Lifter Motor Assembly

must be able to clear any obstructions in the cut-

ting path.

• The assembly must be mounted low enough to

allow proper operation of the Torch Assembly.

4. Drill and tap four holes for 1/4-20 bolts.

5. Mount the Lifter Motor Assembly to the four tapped

holes using the four bolts and washers supplied.

6. Install the Hose Holder (Torch Leads Support Bracket)

to the Gear Rack using the two bolts provided.

7. Reinstall the Front Cover and Torch Holder.

8. Tighten the four cover screws.

Manual 0-2556 3-7 INSTALLATION PROCEDURES

B. Torch Assembly Installation

1. Place the end of the mounting pin on the Torch Mount-

ing Tube Assembly into the Torch Holder Pivot.

2. Tighten the wing nut and washer to secure the Torch

Mounting Tube Assembly to the Lifter Motor Assem-

bly.

3. Route the Torch Leads up and over the Hose Holder

(Torch Leads Support Bracket). Leave some slack in

the Torch Leads between the Mounting Tube and the

Hose Holder.

Standoff Distance

Straight Arc

Trailing Arc

Leading Arc

Direction of Torch Travel

Shown with

Rack and Pinion

Mounting Assembly

A-01556

Figure 3-11 Lifter Motor and Torch Mounting

4. Connect the end of the Torch Leads per the appropri-

ate Torch Manual.

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Manual 0-2556 4-1 OPERATION

SECTION 4:

OPERATION

4.01 Introduction

This Section provides a description of the Standoff Con-

trol Accessory followed by operating procedures.

4.02 Functional Overview

The Standoff Control Accessory extends the necessary sys-

tem controls away from the power supply and is an ac-

cessory with standard machine torch systems.

There is are various connections available at the Rear

Panel of the Standoff Control Accessory. These connec-

tions provide inputs and outputs to allow various parts

of the system to be operated from one station.

4.03 Operating Controls

A. Front Panel

A-00691

PLASMA ON

ARC VOLTS

REMOTE STANDOFF CONTROL

T.H.C. ACTIVE

PIERCE

HT (inches)

0.1

0.3

0.4

0.5

0.2

END OF CUT

RETRACT (%)

25 75

100

TORCH

MODE

LIFTER

SPEED

PIERCE

DELAY (sec)

0.5

0.75

0.25

0.1

AUTO

FIND

Figure 4-1 Front Panel Operating Controls

1. MODE Pushbutton and Indicators

The momentary MODE pushbutton switch selects

one of four modes of operation.

• Fully automatic - AUTO HT and FIND HT in-

dicators ON

• Automatic height - AUTO HT indicator ON

and FIND HT indicator OFF

• Find height - AUTO HT indicator OFF and

FIND HT indicators ON

• Fully Manual - AUTO HT and FIND HT indi-

cators OFF

When power is supplied the Standoff Control enters

the fully automatic mode. The AUTO HT and FIND

HT indicators will be ON. Pressing MODE once turns

FIND HT indicator OFF. Pressing MODE again turns

AUTO HT indicator OFF and FIND HT indicator ON.

Pressing MODE a third time turns both indicators

OFF for fully manual mode. Pressing MODE the

forth time returns to fully automatic operation.

2. LIFTER SPEED Pushbutton and Indicators

The momentary LIFTER SPEED pushbutton switch

selects one of two torch lifter speeds.

• High speed - HI indicator ON and LO indicator OFF

• Low speed - LO indicator ON and HI indicator OFF

Pressing the LIFTER SPEED switch toggles between

HI and LO.

When power is supplied the Standoff Control auto-

matically selects the HI Lifter Speed mode. The HI

indicator will be ON. Pressing LIFTER SPEED once

turns HI indicator OFF and LO indicator ON. Press-

ing LIFTER SPEED the thrid time returns to the HI

Lifter Speed mode.

At lower cutting speeds the HI mode may cause os-

cillation or diving toward the work during the cut. If

this happens it is recommended that the operator se-

lect the LO lifter speed.

3. PLASMA ON Indicator

When the Standoff Control sends a start signal to the

Plasma Power Supply the PLASMA ON indicator

turns ON. The start signal is sent automatically after

finding height.

4. ARC VOLTS Control and Display

The ARC VOLTS control allows the operator to se-

lect the desired arc voltage from 65 to 195, as indi-

cated at the ARC VOLTS Display. Volts above 199

will cause the display to indicate over range (left dis-

play digit is "1"). The standoff, distance from torch

to work, may be changed during cutting by chang-

ing the ARC VOLTS setting.

Prior to enabling the PLASMA ON indicator a deci-

mal point will be displayed on the right hand side of

the ARC VOLTS Display indicating preview mode.

After the PLASMA ON indicator is turned ON the

ARC VOLTS Display indicates the actual arc volts

from 0 to 199.

Three decimal points displayed in the ARC VOLTS

Display indicate the Standoff Control is receiving a

standoff inhibit (corner slowdown - CSD) signal.

5. PIERCE HT (inches) Control

The PIERCE HT (height) controls the starting distance

from torch to workpiece from nearly zero to 1/2

inches.

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ESAB Standoff Control Model SC11 User manual

Brand: ESAB

Model: Standoff Control Model SC11

Category: Welding System

Type: User manual

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ESAB Standoff Control Model SC11 User manual

ESAB Standoff Control Model SC11 User manual

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