ESAB Precision PLASMARC® Cutting and High Speed Marking System Installation guide

F-15-652

November, 2003

Installation, Operation and Maintenance Manual for the

Precision PLASMARC Cutting

and High Speed Marking SYSTEM

with Integrated Flow Control

411 s. Ebenezer Road

Florence, SC 29501-0545

The equipment described in this manual is

potentially hazardous. Use caution when installing,

operating and maintaining this equipment.

Purchaser is solely responsible for the safe

operation and use of all products purchased,

including compliance with OSHA and other

government standards. ESAB Cutting

Systems has no liability for personal injury or

other damage arising out of the use of any

product manufactured or sold by ESAB. See

standard ESAB terms and conditions of sale

for a specific statement of ESAB’s

responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total customer

satisfaction. We constantly look for ways to

improve our products, service and documentation.

As a result, we make enhancements and/or design

changes as required. ESAB makes every possible

effort to ensure our documentation is current. We

cannot guarantee that each piece of documentation

received by our customers reflects the latest design

enhancements. Therefore, the information

contained in this document is subject to change

without notice.

This manual is ESAB Part Number F15-652

Rev A indicates new IFC Schematic, installation

instructions (p13-14) and fluid schematic mod.

December: Updated Torch solenoid wiring, updated

parts section

This manual is for the convenience and use of the

cutting machine purchaser. It is not a contract or

other obligation on the part of ESAB Cutting

Systems.

Printed in U.S.A.

Precision Plasma Integrated Flow Control - CE Table of Contents

i

Page

Section 1 Safety

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

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

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

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

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

1.6 Operating A Plasma Cutting Machine .................................................. 4-9

1.7 Service Precautions............................................................................. 9

1.8 Safety References ............................................................................... 10

Section 2 Description

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

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

2.3 Package Options Available .................................................................. 1

2.4 Technical Specifications

2.4.1 Precision Plasma System ........................................................... 2

2.4.2 Plasma Gas ............................................................................... 3

2.4.3 Start Gas ................................................................................... 3

2.4.4 Secondary Gas .......................................................................... 3

2.4.5 Cut Gas ..................................................................................... 3

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

Section 3 Installation

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

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

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

3.4 Primary Electrical Input Connections.................................................... 2-3

3.5 Alternate Connection Locations for IFC................................................ 4

3.6 IFC Basic Component Identification ..................................................... 4

3.7 Interconnecting Lines .......................................................................... 5-10

3.8 Precision Plasmarc Component Interconnecting Diagram .................... 7

3.9 Torch Mounting................................................................................... 11

3.10 Torch Coolant .................................................................................... 12

3.11 Inspection Of Gas And Coolant Lines.................................................. 12

3.12 Using the 5 Solenoid Torch Manifold.................................................. 13

3.13 Adapting to use a 4 Solenoid Torch Manifold ..................................... 14

Precision Plasma Integrated Flow Control - CE Table of Contents

ii

Page

Section 4 Operation

4.1 Power Supply Controls

4.1.1 Main Power Switch ..................................................................... 1

4.1.2 Pilot Arc Switch .......................................................................... 1

4.1.3 Fault Indicator Lights................................................................... 2

4.1.4 Meters........................................................................................ 2

4.1.5 Current Control Switch................................................................ 2

4.2 Cut Quality .........................................................................................

4.2.1 Introduction ................................................................................ 3

4.2.2 Cut Angle ................................................................................... 3

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

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

4.2.5 Dross ......................................................................................... 6-7

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

4.3 Influence of Gas Options on Cut Quality

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

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

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

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

4.4 Process Data

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

4.4.2 Process Data Settings................................................................. 14-55

Aluminum ............................................................................ 14-21

Carbon Steel........................................................................ 22-31

Stainless Steel ..................................................................... 32-55

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness..... 56

4.4.3.1 Aluminum Kerf Values ......................................................... 56

4.4.3.2 Carbon Steel Kerf Values..................................................... 58

4.4.3.3 Stainless Steel Kerf Values O

2

/N

2

/O

2

................................... 61

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4

................................ 62

4.4.3.5 Stainless Steel Kerf Values N

2

/N

2

/CH

4

................................. 63

4.4.3.6 Stainless Steel Kerf Values N

2

/N

2

........................................ 64

4.4.3.7 Stainless Steel Kerf Values Air/Air ....................................... 66

Plasma Marking Data .......................................................... 68

Precision Plasma Integrated Flow Control - CE Table of Contents

iii

Page

Section 5 Maintenance

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

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

5.3 PT-24 Torch Description ..................................................................... 2-4

5.4 IFC Fluid Schematic ............................................................................ 3

5.4 Torch Maintenance ............................................................................. 5-6

5.5 PT-24 Consumable Disassembly and Inspection.................................. 7-10

5.6 PT-24 Torch Re-Assembly .................................................................. 10-11

5.7 Flow Control ....................................................................................... 12

5.8 Proportional Valve Removal................................................................. 13

Section 6 Troubleshooting

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

6.2 Troubleshooting Guide ........................................................................ 1

6.2.1 Reduced Consumable Life........................................................... 2

6.2.2 Poor Cut Quality.......................................................................... 2

6.2.3 No Pilot Arc................................................................................. 3

6.2.4 No Arc Transfer........................................................................... 3

6.2.5 No Preflow.................................................................................. 3

6.2.6 Torch Fails to Fire........................................................................ 3

6.2.7 Nozzle Life Extremely Short ......................................................... 4

6.2.8 Short Electrode Life..................................................................... 4

6.2.9 Short Electrode AND Nozzle Life.................................................. 4

6.3 IFC Fluid Schematic ............................................................................ 5

IFC Manifold Valve Identification................................................... 5

6.4 IFC Electrical Schematic...................................................................... 6-7

6.5 Precision Plasma Power Source Electrical Schematic........................... 8-9

6.6 Precision Plasma Power Source Wiring Diagram (includes CE Version) 10-14

6.7 Power Module Schematic – CE Version............................................... 15

6.8 Precision Plasma Power Module Wiring Diagram – CE Version............. 16-17

6.9 Torch Manifold.................................................................................... 18

Precision Plasma Integrated Flow Control - CE Table of Contents

iv

Page

Section 7 Replacement Parts

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

7.2 Ordering............................................................................................. 1

7.3 Plasmarc Power Source – Exterior Components.................................. 2-7

7.4 Plasmarc Power Source – Internal Components .................................. 8-17

7.5 Power Source Module ........................................................................ 18-25

7.6 IFC..................................................................................................... 26-27

7.7 IFC Manifold ....................................................................................... 28-29

7.8 PT-24 Torch Assembly IFC Series with Marking..................................

30-31

7.9 Torch Manifold with marking ...............................................................

32-33

7.10 Interface Cables and Hoses ..............................................................

34-35

Customer/Technical Information Back Manual Cover

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-1

1.1 Introduction

The process of cutting metals with plasma equipment

provides industry with a valuable and versatile tool.

ESAB cutting machines are designed to provide both

operation safety and efficiency. However, as with any

machine tool, sensible attention to operating

procedures, precautions, and safe practices is

necessary to achieve a full measure of usefulness.

Whether an individual is involved with operation,

servicing, or as an observer, compliance with

established precautions and safe practices must be

accomplished. Failure to observe certain precautions

could result in serious personnel injury or severe

equipment damage. The following precautions are

general guidelines applicable when working with

cutting machines. More explicit precautions pertaining

to the basic machine and accessories are found in the

instruction literature. For a wide scope of safety

information on the field of cutting and welding

apparatus, obtain and read the publications listed in

the Recommended References.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-2

DANGER

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

1.2 Safety Notations And Symbols

The following words and symbols are used throughout

this manual. They indicate different levels of required

safety involvement.

!

ALERT or ATTENTION. Your safety is involved

or potential equipment failure exists. Used with

other symbols and information.

Used to call attention to immediate hazards

which, if not avoided, will result in serious

personal injury or loss of life.

Used to call attention to potential hazards that

could result in personal injury or loss of life.

Used to call attention to hazards that could result

in minor personal injury or equipment damage.

Used to call attention to minor hazards to

equipment.

Used to call attention to important installation,

operation or maintenance information not

directly related to safety hazards.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-3

1.3 General Safety Information

WARNING

!

Machine starts automatically.

This equipment moves in various directions and

speeds.

· Moving machinery can crush.

· Only qualified personnel should operate or service

equipment.

· Keep all personnel, materials, and equipment not

involved in production process clear of entire

system area.

· Keep gear racks and rails clear of debris or

obstructions, such as tools or clothing.

· Fence off entire work cell to prevent personnel

from passing through area or standing in the

working envelope of the equipment.

· Post appropriate WARNING signs at every work

cell entrance.

· Follow lockout procedure before servicing.

WARNING

!

Failure to follow operating instructions

could result in death or serious injury.

Read and understand this operator’s manual before

using machine.

· Read entire procedure before operating or

performing any system maintenance.

· Special attention must be given to all hazard

warnings that provide essential information

regarding personnel safety and/or possible

equipment damage.

· All safety precautions relevant to electrical

equipment and process operations must be

strictly observed by all having system

responsibility or access.

· Read all safety publications made available by

your company.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-4

WARNING

!

Failure to follow safety warning label

instructions could result in death or

serious injury.

Read and understand all safety warning labels on

machine.

Refer to operator’s manual for additional safety

information.

1.4 Installation Precautions

WARNING

!

Improperly Installed Equipment Can Cause

Injury Or Death.

Follow these guidelines while installing machine:

· Do not connect a cylinder directly to machine inlet.

An appropriate cylinder regulator must be installed

on a fuel gas cylinder to reduce pressure to a

reasonable inlet supply pressure. Machine

regulator is then used to obtain pressure required

by torches.

· Contact your ESAB representative before

installation. He can suggest certain precautions

regarding piping installation and machine lifting,

etc. to ensure maximum security.

· Never attempt any machine modifications or

apparatus additions without first consulting a

qualified ESAB representative.

· Observe machine clearance requirements for

proper operation and personnel safety.

· Always have qualified personnel perform

installation, troubleshooting and maintenance of

this equipment.

· Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-5

1.5 Electrical Grounding

Electrical grounding is imperative for proper machine

operation and SAFETY. Refer to this manual’s

Installation section for detailed grounding instructions.

WARNING

!

Electric shock hazard.

Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into

service.

WARNING

!

Improper Grounding Can Damage

Machine And Electrical Components.

· Machine must be properly grounded before put

into service.

· Cutting table must be properly grounded to a good

Earth ground rod.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-6

1.6 Operating A Plasma Cutting Machine

WARNING

!

Flying debris and loud noise hazards.

· Hot spatter can burn and injure eyes. Wear

goggles to protect eyes from burns and flying

debris generated during operation.

· Chipped slag may be hot and fly far. Bystanders

should also wear goggles and safety glasses.

· Noise from plasma arc can damage hearing. Wear

correct ear protection when cutting above water.

WARNING

!

Burn hazard.

Hot metal can burn.

· Do not touch metal plate or parts immediately after

cutting. Allow metal time to cool, or douse with

water.

· Do not touch plasma torch immediately after

cutting. Allow torch time to cool.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-7

WARNING

!

Hazardous voltages. Electric shock

can kill.

· Do NOT touch plasma torch, cutting table or cable

connections during plasma cutting process.

· Always turn power off to plasma power supplies

before touching or servicing plasma torch.

· Always turn power off to plasma power supplies

before servicing any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when machine

is connected to power source.

· Wear insulating gloves, shoes and clothing to

insulate yourself from workpiece and electrical

ground.

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

equipment dry.

· Replace worn or damaged cables.

WARNING

!

Fume hazard.

Fumes and gases generated by the plasma cutting

process can be hazardous to your health.

· Do NOT breathe fumes.

· Do not operate plasma torch without fume removal

system operating properly.

· Use additional ventilation to remove fumes if

necessary.

· Use approved respirator if ventilation is not

adequate.

·

Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper,

zinc, beryllium, or cadmium. Do not breathe these

fumes.

·

Do not operate near degreasing and spraying

operations. Heat or arc rays can react with

chlorinated hydrocarbon vapors to form phosgene,

a highly toxic gas and other irritant gases.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-8

WARNING

!

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn skin.

· Wear correct eye and body protection.

· Wear dark safety glasses or goggles with side

shields. Refer to following chart for recommended

lens shades for plasma cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

· Replace glasses/goggles when lenses are pitted or

broken

· Warn others in area not to look directly at the arc

unless wearing appropriate safety glasses.

· Prepare cutting area to reduce reflection and

transmission of ultraviolet light.

§ Paint walls and other surfaces with dark

colors to reduce reflections.

§ Install protective screens or curtains to

reduce ultraviolet transmission.

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and violently

release gas.

· Avoid rough handling of cylinders.

· Keep cylinder valves closed when not in use.

· Maintain hoses and fittings in good condition.

· Always secure cylinders in an upright position by

chain or strap to a suitable stable object not part of

an electrical circuit.

· Locate cylinders away from heat, sparks and

flames. Never strike an arc on a cylinder.

· Use approved pressure reducing regulator for the

specific gas.

· Refer to CGA Standard P-1, “Precautions for Safe

Handling of Compressed Gases in Cylinders”,

available from Compressed Gas Association.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-9

CAUTION

WARNING

!

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

· Do not cut near combustible material.

· Do not have on your person any combustibles (e.g.

butane lighter).

· Pilot arc can cause burns. Keep torch nozzle

away from yourself and others when activating

plasma process.

· Wear correct eye and body protection.

· Wear gauntlet gloves, safety shoes and hat.

· Wear flame-retardant clothing covering all exposed

areas.

· Wear cuff-less trousers to prevent entry of sparks

and slag.

· Have fire extinguishing equipment available for use.

Poor Performance Will Result When

Cutting Above Water.

The PT-24 is designed to be a dry cutting

process.

Cutting above water may result in:

· reduced consumable life

· degradation of cut quality

Cutting above water may result in poor cutting

performance. Water vapor created when hot material

or sparks contact liquid may cause arcing inside torch.

When cutting on a water table, reduce the water level

to provide maximum clearance between water and

material.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-10

WARNING

!

Explosion hazard.

· Certain molten aluminum-lithium (Al-Li) alloys can

cause explosions when plasma cut OVER water.

§ These alloys should only be dry cut on a dry

table.

§ DO NOT dry cut over water.

§ Contact your aluminum supplier for

additional safety information regarding

hazards associated with these alloys

.

· Do not cut in atmospheres containing explosive

dust or vapors.

·

Do not carry any combustibles on your person

(e.g. butane lighter)

· Do not cut containers that have held combustibles.

WARNING

!

Pinch hazard.

Moving vertical slides can crush or pinch.

Keep hands clear of torch and slide during operation.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-11

1.7 Service Precautions

WARNING

!

Hazardous voltages. Electric shock

can kill.

· Do NOT touch plasma torch, cutting table or cable

connections during plasma cutting process.

· Always turn power off to plasma power supplies

before touching or servicing plasma torch.

· Always turn power off to plasma power supplies

before removing covers or panels to service any

system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when machine

is connected to power source.

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

equipment dry.

· Inspect power and ground leads cables for wear or

cracking. Replace worn or damaged cables. Do

not use if damaged.

· Never bypass safety interlocks.

· Follow lock-out procedures.

CAUTION

Establish and adhere to preventive maintenance. A

composite program can be established from

recommended schedules.

Avoid leaving test equipment or hand tools on

machine. Severe electrical or mechanical damage

could occur to equipment or machine.

CAUTION

!

Extreme caution should be used when probing

circuitry with an oscilloscope or voltmeter. Integrated

circuits are susceptible to over voltage damage.

Power off before using test probes to prevent

accidental shorting of components.

All circuit boards securely seated in sockets, all cables

properly connected, all cabinets closed and locked, all

guards and covers replaced before power is turned

on.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-12

1.8 Safety References

The following nationally recognized publications on

safety in welding and cutting operations are

recommended. These publications have been

prepared to protect persons from injury or illness and

to protect property from damage, which could result

from unsafe practices. Although some of these

publications are not related specifically to this type of

industrial cutting apparatus, the principles of safety

apply equally.

Domestic

· “Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting

Systems.

· “Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529. ESAB Cutting Systems.

· “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

· “Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

· “Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

· “Recommended Practices for Arc Cutting” - AWS C5.2, American

Welding Society.

· “Safe Practices” - AWS SP, American Welding Society.

· “Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B, National Fire Protection Association, 60

Batterymarch Street, Boston, Massachusetts, 02110.

· “Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51, National Fire

Protection Association.

· “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting

Systems. Obtainable through your ESAB representative or local

distributor.

· "Design and Installation of Oxygen Piping Systems," Form 5110.

ESAB Cutting Systems.

· “Precautions for Safe Handling of Compressed Gases in

Cylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with

gaseous materials is also available from the Compressed Gas

Association, Inc., 500 Fifth Ave., New York, NY 10036.

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-13

International

Accident Prevention

VBG 1 General Provisions

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working

methods

VBG 48 Shot Blasting Works

VBG 61 Gases

VBG 62 Oxygen

VBG 87 Operating liquid jet cutting machines

VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE Regulations

VDE 0100 Erection of power installations with normal

voltages up to 1000 volts

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users

guide (DIN EN 60825)

VDE 0837-

50

Specification for laser guards

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-204 Acetylene lines

TRAC-206 Acetylene cylinder battery systems

TRAC-207 Safety devices

TRG Technical Rules for Pressure gases

TRG 100 General regulations for pressure gases

TRG 101 Pressure gases

TRG 102 Technical gas mixtures

TRG 104 Pressure gases; alterative use of

compressed gas tanks

SECTION 1 SAFETY

Precision Plasma with Integrated Flow Control -

1-14

DIN Standards

DIN 2310

Part 1

Thermal cutting; terminology and

nomenclature

DIN 2310

Part 2

Thermal cutting; determination of quality of cut

faces

DIN 2310

Part 4

Thermal cutting; arc plasma cutting; process

principles, quality, dimensional tolerances

DIN 2310

Part 5

Thermal cutting; laser beam cutting of metallic

materials; process principles

DIN 4844

Part 1

Safety markings (DIN EN 7287)

DIN EN ISO Harmonized Standards

DIN EN

292/1 and 2

Safety of machinery

DIN EN 559 Hoses for welding, cutting and allied

processes

DIN EN 560 Hose connections and hose couplings for

equipment for welding, cutting and allied

processes

DIN EN 561 Gas welding equipment hose couplings

DIN EN

626-1

Safety of machines, reduction of risks to

health

DIN EN

848-1

Single spindle vertical milling machines

DIN EN

1829

High pressure water jet machines

DIN EN

9013

Thermal cutting, oxygen cutting, process

principles, dimensional tolerances

DIN EN

12584

Imperfections in oxy/fuel flame cuts, laser

beam cuts and plasma

DIN EN

12626

Laser processing machines

DIN EN

28206

Acceptance testing for oxygen cutting

machines

DIN EN

31252

Laser Equipment

DIN EN

31553

Laser and laser related equipment

DIN EN

60204-1

Electrical equipment of machines

DIN EN

60825

Radiation safety of laser products

DIN EN 999 Arrangement of protection devices

VDI Guidelines

VDI 2906 Quality of cut faces on metallic workpieces;

abrasive water jet cutting and arc plasma

cutting

VDI 2084 Room air; Technical systems for welding

workshops

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