ESAB Precision Plasmarc System with Electronic Flow Control Installation guide

Category
Welding System
Type
Installation guide

This manual is also suitable for

CUTTING SYSTEMS
F-15-679
March, 2002
Installation, Operation and Maintenance Manual for the
PRECISION PLASMARC SYSTEM
with Electronic Flow Control
411 s. Ebenezer Road
Florence, SC 29501-0545
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold 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
ESAB Cutting Systems first priority is total customer ESAB Cutting Systems first priority is total customer
ESAB Cutting Systems first priority is total customer
satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to
improve our products, service and documentation.
improve our products, service and documentation. improve our products, service and documentation.
improve our products, service and documentation.
As a result, we make e
As a result, we make eAs a result, we make e
As a result, we make en
nn
nhancements and/or de
hancements and/or dehancements and/or de
hancements and/or design
sign sign
sign
changes as r
changes as rchanges as r
changes as re
ee
equired. ESAB makes every possible
quired. ESAB makes every possible quired. ESAB makes every possible
quired. ESAB makes every possible
effort to ensure our documentation is current. We
effort to ensure our documentation is current. We effort to ensure our documentation is current. We
effort to ensure our documentation is current. We
cannot guarantee that each piece of docume
cannot guarantee that each piece of documecannot guarantee that each piece of docume
cannot guarantee that each piece of documen
nn
ntation
tation tation
tation
received by our customers reflects the latest design
received by our customers reflects the latest design received by our customers reflects the latest design
received by our customers reflects the latest design
enhancements. Therefore, the information
enhancements. Therefore, the information enhancements. Therefore, the information
enhancements. Therefore, the information
contain
containcontain
contained in this document is subject to change
ed in this document is subject to change ed in this document is subject to change
ed in this document is subject to change
without n
without nwithout n
without no
oo
otice.
tice.tice.
tice.
This manual is ESAB Part Number F15679
This manual is ESAB Part Number F15679This manual is ESAB Part Number F15679
This manual is ESAB Part Number F15679
New Date (April,01) given to reflect added cable
part Nos. section 2.
(June01) reflects document formatting changes
(Dec01) Corrected/clarified p7-35 part nos.
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.
©
©©
© ESAB Cutting Systems, 2001
Printed in U.S.A.
Precision Plasma Electronic Flow Control Table of Contents
i
Page
Section 1 Safety
1.1 Introduction......................................................................................... 1
1.2 Safety Notations And Symbols............................................................. 1
1.3 General Safety Information................................................................... 2
1.4 Installation Precautions........................................................................ 3
1.5 Electrical Grounding ............................................................................ 4
1.6 Operating A Plasma Cutting Machine................................................... 4
1.7 Service Precautions............................................................................. 8
1.8 Safety References ............................................................................... 9
Section 2 Description
2.1 General............................................................................................... 1
2.2 Scope................................................................................................. 1
2.3 Package Options Available .................................................................. 1-2
2.4 Technical Specifications
2.4.1 Precision Plasma System ............................................................ 2-3
2.4.2 Plasma Gas................................................................................. 4
2.4.3 Start Gas..................................................................................... 4
2.4.4 Secondary Gas............................................................................ 4
2.4.5 PT-24 Torch................................................................................ 4
Section 3 Installation
3.1 General............................................................................................... 1
3.2 Equipment Required............................................................................ 1
3.3 Location.............................................................................................. 1
3.4 Primary Electrical Input Connections.................................................... 2
3.5 Interconnecting Lines .......................................................................... 4
Precision Plasmarc Component Interconnecting Diagram..................... 8
3.6 Torch Mounting................................................................................... 10
3.7 Torch Coolant ..................................................................................... 11
3.8 Inspection of Gas and Coolant Lines.................................................... 11
3.9 Replacement of EPROM in the Plasmarc Power Source
Programmable Logic Controller (PLC) .................................................. 12
Precision Plasma Electronic Flow Control Table of Contents
ii
Section 4 Operation
4.1 Power Supply Controls
4.1.1 Main Power Switch ..................................................................... 1
4.1.2 Pilot Arc Switch........................................................................... 1
4.1.3 Fault Indicator Lights................................................................... 2
4.1.4 Meters ........................................................................................ 2
4.1.5 Current Control Switch................................................................ 3
4.2 Cut Quality
4.2.1 Introduction ................................................................................ 4
4.2.2 Cut Angle.................................................................................... 5
4.2.3 Cut Flatness................................................................................ 6
4.2.4 Surface Finish ............................................................................. 7
4.2.5 Dross.......................................................................................... 8
4.2.6 Dimensional Accuracy................................................................. 10
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction ................................................................................ 11
4.3.2 Aluminum.................................................................................... 11
4.3.3 Carbon Steel............................................................................... 12
4.3.4 Stainless Steel............................................................................. 13
4.4 Process Data
4.4.1 Introduction ................................................................................ 15
4.4.2 Process Data Settings................................................................. 16
Plasma Marking Data .......................................................... 56
4.4.3 Relationship of Kerf Width to Amperes and Material Thickness..... 78
4.4.3.1 Aluminum Kerf Values.......................................................... 78
4.4.3.2 Carbon Steel Kerf Values..................................................... 80
4.4.3.3 Stainless Steel Kerf Values O
2
/N
2
/O
2
.................................... 83
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH
4
................................ 84
4.4.3.5 Stainless Steel Kerf Values N
2
/N
2
/CH
4
................................. 85
4.4.3.6 Stainless Steel Kerf Values N
2
/N
2
......................................... 86
4.4.3.7 Stainless Steel Kerf Values Air/Air ....................................... 88
Precision Plasma Electronic Flow Control Table of Contents
iii
Section 5 Maintenance
5.1 General............................................................................................... 1
5.2 Inspection and Cleaning ...................................................................... 1
5.3 PT-24 Torch Description...................................................................... 2
5.4 Torch Maintenance.............................................................................. 5
5.5 PT-24 Consumable Disassembly and Inspection.................................. 7
5.6 PT-24 Torch Re-Assembly................................................................... 9
Section 6 Troubleshooting
6.1 General Safety..................................................................................... 1
6.2 Programmable Logic Controller (PLC) ................................................. 1
6.2.1 PLC LED Introduction................................................................. 2
6.2.2 PLC LED Functions .................................................................... 2
6.3 Troubleshooting Guide
6.3.1 Reduced Consumable Life........................................................... 3
6.3.2 Poor Cut Quality .......................................................................... 4
6.3.3 No Pilot Arc................................................................................. 4
6.3.4 No Arc Transfer ........................................................................... 4
6.3.5 No Preflow .................................................................................. 4
6.3.6 Torch Fails to Fire ........................................................................ 4
6.3.7 Nozzle Life Extremely Short.......................................................... 5
6.3.8 Short Electrode Life ..................................................................... 5
6.3.9 Short Electrode AND Nozzle Life.................................................. 5
6.4 Flow Control Schematic....................................................................... 6
6.5 Gas Flow Schematic............................................................................ 7
6.6 Junction Box Wiring Diagram............................................................... 8
6.7 Junction Box Schematic....................................................................... 9
6.8 Precision Plasma Power Module Wiring Diagram.................................. 10-11
6.9 Power Module Schematic.................................................................... 12
6.10 Power Source Wiring Diagrams ......................................................... 13-17
6-11 Power Source Schematic.................................................................. 18-19
Precision Plasma Electronic Flow Control Table of Contents
iv
6.12 Technical Guide to Using/Understanding the Operation of the EFC 20
6.12.1 Precision Process Timers .......................................................... 21
6.12.2 Process Timer Values................................................................ 22
6.12.3 Process Window Key Functions ................................................ 23
6.12.4 Proportional Valve Analog Values for PARAM.CUT
PARAM.CUTPARAM.CUT
PARAM.CUT and DEF.TEC
DEF.TECDEF.TEC
DEF.TEC 24
6.12.5 Process Gas Selection Requirements ........................................ 25
6.12.6 EFC Process Gas Flow Chart .................................................... 26
6.12.7 Station On, Flush/Pressurize Cycle Timers................................. 27
6.12.8 Solenoid/Proportional Valve Requirements and
Gas Error Monitoring
Carbon Steel PG-O
2
, SG-O
2
..................................................... 28
Carbon Steel PG-O
2
, SG-N
2
/O
2
................................................. 30
Carbon Steel PG-O
2
, Sg-O
2
...................................................... 32
Stainless Steel PG-N
2
, SG-N
2
.................................................. 34
Stainless Steel PG-N
2
, SG-N
2
/CH
4
............................................ 36
Stainless Steel PG-Air, SG-Air .................................................. 38
Stainless Steel PG-Air, SG-Air/CH
4
........................................... 40
Aluminum PG-N
2
, SG- N
2
......................................................... 42
Aluminum PG-N
2
, SG-N
2
/CH
4
................................................... 44
Marking PG-Argon, SG-Air ....................................................... 46
Section 7 Replacement Parts
7.1 General............................................................................................... 1
7.2 Ordering ............................................................................................. 2
7.3 Plasmarc Power Source – Exterior Components.................................. 3
7.4 Plasmarc Power Source – Internal Components .................................. 8
7.5 Power Source Module......................................................................... 18
7.6 EFC Junction Box............................................................................... 26
7.7 Electronic Flow Control Box ................................................................ 32
7.8 PT-24 Torch Assembly EFC Series A/M.............................................. 36
7.9 T Gas Shut-off Valve Assembly - Series A/M Torch.............................. 38
7.10 PT-24 Torch Assembly – Version 1.................................................... 40
7.11 Solenoid Assembly - EFC Torch – Version 1 ...................................... 42
Customer/Technical Information Back Manual Cover
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control – 1-1
DANGER
!
WARNING
!
CAUTION
!
CAUTION
NOTICE
1.1 Introduction
The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. With any machine
tool, sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or as an
observer, compliance with established precautions
and safe practices must be accomplished. Failure to
observe certain precautions could result in serious
personnel injury or severe equipment damage. The
following precautions are general guidelines applicable
when working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature. For
a wide scope of safety information on the field of
cutting and welding apparatus, obtain and read the
publications listed in the Recommended References.
1.2 Safety Notations And Symbols
The following words and symbols are used throughout
this manual. They indicate different levels of required
safety involvement.
!
ALERT or ATTENTION. Your safety is involved
or potential equipment failure exists. Used in
concurrence with other symbols and information.
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
Used to call attention to potential hazards
that could result in personal injury or loss of
life.
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
Used to call attention to minor hazards to
equipment.
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control – 1-2
1.3 General Safety Information
WARNING
!
Machine starts automatically.
This equipment moves in various directions and
This equipment moves in various directions and This equipment moves in various directions and
This equipment moves in various directions and
speeds.
speeds.speeds.
speeds.
Moving machinery can crush.
Moving machinery can crush.Moving machinery can crush.
Moving machinery can crush.
Only qualified personnel should operate or service
Only qualified personnel should operate or service Only qualified personnel should operate or service
Only qualified personnel should operate or service
equipment.
equipment.equipment.
equipment.
Keep all personnel, materials, and equipment not
Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not
Keep all personnel, materials, and equipment not
involved in production process
involved in production process involved in production process
involved in production process clear of entire
clear of entire clear of entire
clear of entire
system area.
system area.system area.
system area.
Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or
obstructions, such as tools or clothing.
obstructions, such as tools or clothing.obstructions, such as tools or clothing.
obstructions, such as tools or clothing.
Fence off entire work cell to prevent personnel
Fence off entire work cell to prevent personnel Fence off entire work cell to prevent personnel
Fence off entire work cell to prevent personnel
from passing through area or standing in the
from passing through area or standing in the from passing through area or standing in the
from passing through area or standing in the
working envelope of the equipment.
working envelope of the equipment. working envelope of the equipment.
working envelope of the equipment.
Post approp
Post appropPost approp
Post appropriate WARNING signs at every work
riate WARNING signs at every work riate WARNING signs at every work
riate WARNING signs at every work
cell entrance.
cell entrance. cell entrance.
cell entrance.
Follow lockout procedure before servicing.
Follow lockout procedure before servicing.Follow lockout procedure before servicing.
Follow lockout procedure before servicing.
WARNING
!
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’
Read and understand this operator’Read and understand this operator’
Read and understand this operator’s manual before
s manual before s manual before
s manual before
using machine.
using machine.using machine.
using machine.
Read entire procedure before operating or
Read entire procedure before operating or Read entire procedure before operating or
Read entire procedure before operating or
performing any system maintenance.
performing any system maintenance. performing any system maintenance.
performing any system maintenance.
Special attention must be given to all hazard
Special attention must be given to all hazard Special attention must be given to all hazard
Special attention must be given to all hazard
warnings that provide essential information
warnings that provide essential information warnings that provide essential information
warnings that provide essential information
regarding personnel safety and/or possible
regarding personnel safety and/or possible regarding personnel safety and/or possible
regarding personnel safety and/or possible
equipment dama
equipment damaequipment dama
equipment damage.
ge.ge.
ge.
All safety precautions relevant to electrical
All safety precautions relevant to electrical All safety precautions relevant to electrical
All safety precautions relevant to electrical
equipment and process operations must be
equipment and process operations must be equipment and process operations must be
equipment and process operations must be
strictly observed by all having system
strictly observed by all having system strictly observed by all having system
strictly observed by all having system
responsibility or access.
responsibility or access. responsibility or access.
responsibility or access.
Read all safety publications made available by
Read all safety publications made available by Read all safety publications made available by
Read all safety publications made available by
your company.
your company.your company.
your company.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control – 1-3
WARNING
!
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety warning labels on
Read and understand all safety warning labels on Read and understand all safety warning labels on
Read and understand all safety warning labels on
machine.
machine.machine.
machine.
Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety
information.
information.information.
information.
1.4 Installation Precautions
WARNING
!
Improperly installed equipment can cause
injury or death.
Follow these guidelines while installing
Follow these guidelines while installingFollow these guidelines while installing
Follow these guidelines while installing machine:
machine: machine:
machine:
Do not connect a cylinder directly to machine inlet. An
Do not connect a cylinder directly to machine inlet. An Do not connect a cylinder directly to machine inlet. An
Do not connect a cylinder directly to machine inlet. An
appropriate cylinder regulator must be installed on a
appropriate cylinder regulator must be installed on a appropriate cylinder regulator must be installed on a
appropriate cylinder regulator must be installed on a
fuel gas cylinder to reduce pressure to a reasonable
fuel gas cylinder to reduce pressure to a reasonable fuel gas cylinder to reduce pressure to a reasonable
fuel gas cylinder to reduce pressure to a reasonable
inlet supply pressure. Machine regulator is then used
inlet supply pressure. Machine regulator is then used inlet supply pressure. Machine regulator is then used
inlet supply pressure. Machine regulator is then used
to obtain pressure required
to obtain pressure requiredto obtain pressure required
to obtain pressure required by torches.
by torches. by torches.
by torches.
Contact your ESAB representative before installation.
Contact your ESAB representative before installation. Contact your ESAB representative before installation.
Contact your ESAB representative before installation.
He can suggest certain precautions regarding piping
He can suggest certain precautions regarding piping He can suggest certain precautions regarding piping
He can suggest certain precautions regarding piping
installation and machine lifting, etc. to ensure
installation and machine lifting, etc. to ensure installation and machine lifting, etc. to ensure
installation and machine lifting, etc. to ensure
maximum security.
maximum security.maximum security.
maximum security.
Never attempt any machine modifications or apparatus
Never attempt any machine modifications or apparatus Never attempt any machine modifications or apparatus
Never attempt any machine modifications or apparatus
additions withou
additions withouadditions withou
additions without first consulting a qualified ESAB
t first consulting a qualified ESAB t first consulting a qualified ESAB
t first consulting a qualified ESAB
representative.
representative.representative.
representative.
Observe machine clearance requirements for proper
Observe machine clearance requirements for proper Observe machine clearance requirements for proper
Observe machine clearance requirements for proper
operation and personnel safety.
operation and personnel safety. operation and personnel safety.
operation and personnel safety.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-4
1.5 Electrical Grounding
Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to this manuals
Installation section for detailed grounding instructions.
WARNING
!
Electric shock hazard.
Impr
ImprImpr
Improper grounding can cause severe injury or death.
oper grounding can cause severe injury or death.oper grounding can cause severe injury or death.
oper grounding can cause severe injury or death.
Machine must be properly grounded before put into
Machine must be properly grounded before put into Machine must be properly grounded before put into
Machine must be properly grounded before put into
service.
service.service.
service.
WARNING
!
Improper grounding can damage machine
and electrical components.
Machine must be properly grounded before put
Machine must be properly grounded before put Machine must be properly grounded before put
Machine must be properly grounded before put
into service.
into service. into service.
into service.
Cutting table must be properly grounded to
Cutting table must be properly grounded toCutting table must be properly grounded to
Cutting table must be properly grounded to a good
a good a good
a good
Earth ground rod.
Earth ground rod.Earth ground rod.
Earth ground rod.
1.6 Operating A Plasma Cutting Machine
WARNING
!
Flying debris and loud noise hazards.
Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear
goggles to protect eyes
goggles to protect eyesgoggles to protect eyes
goggles to protect eyes from burns and flying
from burns and flying from burns and flying
from burns and flying
debris generated during operation.
debris generated during operation.debris generated during operation.
debris generated during operation.
Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.
should also wear goggles and safety glasses.should also wear goggles and safety glasses.
should also wear goggles and safety glasses.
From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear
correct ear protection when cutting above water.
correct ear protection when cutting above water. correct ear protection when cutting above water.
correct ear protection when cutting above water.
WARNING
!
Burn hazard.
Hot metal can burn.
Hot metal can burn.Hot metal can burn.
Hot metal can burn.
Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after
cutting. Allow metal time
cutting. Allow metal timecutting. Allow metal time
cutting. Allow metal time to cool, or douse with
to cool, or douse with to cool, or douse with
to cool, or douse with
water.
water.water.
water.
Do not touch plasma torch immediately after
Do not touch plasma torch immediately after Do not touch plasma torch immediately after
Do not touch plasma torch immediately after
cutting. Allow torch time to cool.
cutting. Allow torch time to cool.cutting. Allow torch time to cool.
cutting. Allow torch time to cool.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-5
WARNING
!
Hazardous voltages. Electric shock
can kill.
Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.
connections during plasma cutting process.connections during plasma cutting process.
connections during plasma cutting process.
Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before touching or servicing plasma torch.
before touching or servicing plasma torch. before touching or servicing plasma torch.
before touching or servicing plasma torch.
Always turn po
Always turn poAlways turn po
Always turn power off to plasma power supplies
wer off to plasma power supplies wer off to plasma power supplies
wer off to plasma power supplies
before opening or servicing plasma plumbing or
before opening or servicing plasma plumbing or before opening or servicing plasma plumbing or
before opening or servicing plasma plumbing or
flow control box.
flow control box.flow control box.
flow control box.
Do not touch live electrical parts.
Do not touch live electrical parts.Do not touch live electrical parts.
Do not touch live electrical parts.
Keep all panels and covers in place when machine
Keep all panels and covers in place when machine Keep all panels and covers in place when machine
Keep all panels and covers in place when machine
is connected to power source.
is connected to power source.is connected to power source.
is connected to power source.
Insulate yourself from workpiece and electr
Insulate yourself from workpiece and electrInsulate yourself from workpiece and electr
Insulate yourself from workpiece and electrical
ical ical
ical
ground: wear insulating gloves, shoes and
ground: wear insulating gloves, shoes and ground: wear insulating gloves, shoes and
ground: wear insulating gloves, shoes and
clothing.
clothing.clothing.
clothing.
Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and
equipment dry.
equipment dry.equipment dry.
equipment dry.
WARNING
!
Pinch hazard.
Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.
WARNING
!
Fume hazard.
Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
process can be hazardous to your health.process can be hazardous to your health.
process can be hazardous to your health.
Do NOT breathe fumes.
Do NOT breathe fumes.Do NOT breathe fumes.
Do NOT breathe fumes.
Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal
system operating properly.
system operating properly. system operating properly.
system operating properly.
Use additional ventilat
Use additional ventilatUse additional ventilat
Use additional ventilation to remove fumes if
ion to remove fumes if ion to remove fumes if
ion to remove fumes if
necessary.
necessary.necessary.
necessary.
Use approved respirator if ventilation is not
Use approved respirator if ventilation is not Use approved respirator if ventilation is not
Use approved respirator if ventilation is not
adequate.
adequate.adequate.
adequate.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-6
WARNING
!
WARNING
!
Radiation hazard.
Arc rays can injure eyes and burn skin.
Arc rays can injure eyes and burn skin.Arc rays can injure eyes and burn skin.
Arc rays can injure eyes and burn skin.
Wear correct eye and body protection.
Wear correct eye and body protection.Wear correct eye and body protection.
Wear correct eye and body protection.
Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with side
shields. Refer to following chart for recommended
shields. Refer to following chart for recommended shields. Refer to following chart for recommended
shields. Refer to following chart for recommended
lens shades for plasma cutting:
lens shades for plasma cutting:lens shades for plasma cutting:
lens shades for plasma cutting:
Arc Current
Arc CurrentArc Current
Arc Current
Lens Shade
Lens Shade Lens Shade
Lens Shade
Up
Up Up
Up to 100 Amps
to 100 Ampsto 100 Amps
to 100 Amps
Shade No. 8
Shade No. 8Shade No. 8
Shade No. 8
100
100100
100-
--
-200 Amps
200 Amps200 Amps
200 Amps
Shade No. 10
Shade No. 10Shade No. 10
Shade No. 10
200
200200
200-
--
-400 Amps
400 Amps400 Amps
400 Amps
Shade No. 12
Shade No. 12Shade No. 12
Shade No. 12
Over 400 Amps
Over 400 AmpsOver 400 Amps
Over 400 Amps
Shade No. 14
Shade No. 14Shade No. 14
Shade No. 14
Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or
broken
brokenbroken
broken
Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses
unless wearing appropriate safety glassesunless wearing appropriate safety glasses
unless wearing appropriate safety glasses.
..
.
Prepare cutting area to reduce reflection and
Prepare cutting area to reduce reflection and Prepare cutting area to reduce reflection and
Prepare cutting area to reduce reflection and
transmission of ultraviolet light.
transmission of ultraviolet light.transmission of ultraviolet light.
transmission of ultraviolet light.
Paint walls and other surfaces with dark colors to
Paint walls and other surfaces with dark colors to Paint walls and other surfaces with dark colors to
Paint walls and other surfaces with dark colors to
reduce reflections.
reduce reflections.reduce reflections.
reduce reflections.
Install protective screens or curtains to reduce
Install protective screens or curtains to reduce Install protective screens or curtains to reduce
Install protective screens or curtains to reduce
ultraviolet transmission.
ultraviolet transmission.ultraviolet transmission.
ultraviolet transmission.
Ruptured Gas Cylinders Can Kill
Mishandling gas cylinders can rupture and violently
Mishandling gas cylinders can rupture and violently Mishandling gas cylinders can rupture and violently
Mishandling gas cylinders can rupture and violently
release gas.
release gas. release gas.
release gas.
Avoid rough handling of cylinders.
Avoid rough handling of cylinders.Avoid rough handling of cylinders.
Avoid rough handling of cylinders.
Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.
Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.
Always secure cylinders in an upright position by
Always secure cylinders in an upright position by Always secure cylinders in an upright position by
Always secure cylinders in an upright position by
chain or strap to a suitable stable object not part of
chain or strap to a suitable stable object not part of chain or strap to a suitable stable object not part of
chain or strap to a suitable stable object not part of
an electrical circuit.
an electrical circuit.an electrical circuit.
an electrical circuit.
Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.
Refer to CGA Standard P
Refer to CGA Standard PRefer to CGA Standard P
Refer to CGA Standard P-
--
-1, Precautions for Safe
1, Precautions for Safe 1, Precautions for Safe
1, Precautions for Safe
Handling of Compressed Gases in Cylinders
Handling of Compressed Gases in CylindersHandling of Compressed Gases in Cylinders
Handling of Compressed Gases in Cylinders,
, ,
,
available from Compressed Gas Association.
available from Compressed Gas Association.available from Compressed Gas Association.
available from Compressed Gas Association.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-7
CAUTION
WARNING
!
Spark hazard.
Heat, spatter, and sparks cause fire a
Heat, spatter, and sparks cause fire aHeat, spatter, and sparks cause fire a
Heat, spatter, and sparks cause fire and burns.
nd burns. nd burns.
nd burns.
Do not cut near combustible material.
Do not cut near combustible material.Do not cut near combustible material.
Do not cut near combustible material.
Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.
Do not have on your person any combustibles (e.g.
Do not have on your person any combustibles (e.g. Do not have on your person any combustibles (e.g.
Do not have on your person any combustibles (e.g.
butane lighter).
butane lighter).butane lighter).
butane lighter).
Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activati
away from yourself and others when activatiaway from yourself and others when activati
away from yourself and others when activating
ng ng
ng
plasma process.
plasma process.plasma process.
plasma process.
Wear correct eye and body protection.
Wear correct eye and body protection.Wear correct eye and body protection.
Wear correct eye and body protection.
Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.
Wear flame
Wear flameWear flame
Wear flame-
--
-retardant clothing that covers all
retardant clothing that covers all retardant clothing that covers all
retardant clothing that covers all
exposed areas.
exposed areas.exposed areas.
exposed areas.
Wear cuffless trousers to prevent entry of sparks
Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks
Wear cuffless trousers to prevent entry of sparks
and slag.
and slag.and slag.
and slag.
POOR PERFORMANCE WILL RESULT
WHEN CUTTING ABOVE WATER.
The PT-24 is designed to be a dry cutting
process.
Cutting above water may result in:
Cutting above water may result in: Cutting above water may result in:
Cutting above water may result in:
reduced consumable life
reduced consumable lifereduced consumable life
reduced consumable life
degradation of cut quality
degradation of cut qualitydegradation of cut quality
degradation of cut quality
Cutting above water may result in poor cutting
Cutting above water may result in poor cutting Cutting above water may result in poor cutting
Cutting above water may result in poor cutting
performance. Water vapor created when hot
performance. Water vapor created when hot performance. Water vapor created when hot
performance. Water vapor created when hot material
material material
material
or sparks contact liquid may cause arcing inside torch.
or sparks contact liquid may cause arcing inside torch.or sparks contact liquid may cause arcing inside torch.
or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level
When cutting on a water table, reduce the water level When cutting on a water table, reduce the water level
When cutting on a water table, reduce the water level
to provide maximum clearance between water and
to provide maximum clearance between water and to provide maximum clearance between water and
to provide maximum clearance between water and
material.
material. material.
material.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-8
WARNING
!
Explosion hazard.
Certain molten aluminum
Certain molten aluminumCertain molten aluminum
Certain molten aluminum-
--
-lithium (Al
lithium (Allithium (Al
lithium (Al-
--
-Li) alloys can
Li) alloys can Li) alloys can
Li) alloys can
cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water.
Do not plasma cut the following Al
Do not plasma cut the following AlDo not plasma cut the following Al
Do not plasma cut the following Al-
--
-Li alloys with
Li alloys with Li alloys with
Li alloys with
water:
water:water:
water:
Al
AlAl
Alithlite (Alcoa)
ithlite (Alcoa)ithlite (Alcoa)
ithlite (Alcoa)
X8192 (Alcoa)
X8192 (Alcoa)X8192 (Alcoa)
X8192 (Alcoa)
Alithally (Alcoa)
Alithally (Alcoa)Alithally (Alcoa)
Alithally (Alcoa)
Navalite (US Navy)
Navalite (US Navy)Navalite (US Navy)
Navalite (US Navy)
2090 Alloy (Alcoa)
2090 Alloy (Alcoa)2090 Alloy (Alcoa)
2090 Alloy (Alcoa)
Lockalite (Lockheed)
Lockalite (Lockheed)Lockalite (Lockheed)
Lockalite (Lockheed)
X8090A (Alcoa)
X8090A (Alcoa)X8090A (Alcoa)
X8090A (Alcoa)
Kalite (Kaiser)
Kalite (Kaiser)Kalite (Kaiser)
Kalite (Kaiser)
X8092 (Alcoa)
X8092 (Alcoa)X8092 (Alcoa)
X8092 (Alcoa)
8091 (Alcan)
8091 (Alcan)8091 (Alcan)
8091 (Alcan)
These alloys should only be dry cut on a dry table.
These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.
These alloys should only be dry cut on a dry table.
DO NOT dry cut over water.
DO NOT dry cut over water.DO NOT dry cut over water.
DO NOT dry cut over water.
Contact your
Contact yourContact your
Contact your aluminum supplier for additional
aluminum supplier for additional aluminum supplier for additional
aluminum supplier for additional
safety information regarding hazards associated
safety information regarding hazards associated safety information regarding hazards associated
safety information regarding hazards associated
with these alloys
with these alloyswith these alloys
with these alloys
.
1.7 Service Precautions
CAUTION
Establish and adhere to preventive maintenance. A
Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A
Establish and adhere to preventive maintenance. A
composite program can be established from
composite program can be established from composite program can be established from
composite program can be established from
recommended schedules in the
recommended schedules in the recommended schedules in the
recommended schedules in the instruction literature.
instruction literature.instruction literature.
instruction literature.
Avoid leaving test equipment or hand tools on
Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage
could occur to equipment or machine.
could occur to equipment or machine.could occur to equipment or machine.
could occur to equipment or machine.
CAUTION
!
Extreme caution should be used when probing
Extreme caution should be used when probing Extreme caution should be used when probing
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter. Int
circuitry with an oscilloscope or voltmeter. Intcircuitry with an oscilloscope or voltmeter. Int
circuitry with an oscilloscope or voltmeter. Integrated
egrated egrated
egrated
circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage. circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
Power off before using test probes to prevent Power off before using test probes to prevent
Power off before using test probes to prevent
accidental shorting of components.
accidental shorting of components.accidental shorting of components.
accidental shorting of components.
All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all
gua
guagua
guards and covers replaced before power is turned
rds and covers replaced before power is turned rds and covers replaced before power is turned
rds and covers replaced before power is turned
on.
on.on.
on.
Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while
machine power is on. Instantaneous surges of voltage
machine power is on. Instantaneous surges of voltage machine power is on. Instantaneous surges of voltage
machine power is on. Instantaneous surges of voltage
and current can damage electronic components.
and current can damage electronic components.and current can damage electronic components.
and current can damage electronic components.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-9
1.8 Safety References
The following nationally recognized publications on safety in welding
and cutting operations are recommended. These publications have
been prepared to protect persons from injury or illness and to protect
property from damage, which could result from unsafe practices.
Although some of these publications are not related specifically to this
type of industrial cutting apparatus, the principles of safety apply
equally.
“Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
“Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
“Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
“Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
“Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
“Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
“Safe Practices” - AWS SP, American Welding Society.
“Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
“Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
“Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
"Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
Precautions for Safe Handling of Compressed Gases in
Cylinders, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.
SECTION 1 SAFETY
Precision Plasma with Electronic Flow Control 1-10
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SECTION 2 DESCRIPTION
Precision Plasma with Electronic Flow Control –
2-1
2.1 General
The Precision Plasmarc System consists of four
separate components. The power source, the
junction box, the flow control box, and the PT-24
torch. The power source provides power and coolant
to the PT-24 torch via the junction box.
2.2 Scope
The purpose of this manual is to provide the operator
with all the information required to install and operate
the Precision Plasmarc System. Technical reference
material is also provided to assist in troubleshooting
the cutting package.
2.3 Package Options Available
Precision Plasmarc package options available through your ESAB dealer
Precision Plasmarc Power Source (
200/230/380/415/460/575) 3-phase 50/60 Hz
(required) - CE Version
P/N 37358
Electronic Flow Control Box (required) P/N 22406
Junction Box (required) P/N 22407
4.5 ft. (1.4 m) P/N 0558001463
12 ft. (4.4 m) P/N 0558001877
PT-24 Torch Electronic Flow Series A/M (one required)
17 ft. (5.2 m) P/N 0558001464
12 ft. (3.6 m) P/N 22428
25 ft. (7.6 m) P/N 21905
40 ft. (12.2 m) P/N 22504
60 ft. (18 m) P/N 21906
80 ft. (24.4 m) P/N 22505
Power Bundle (one required)
100 ft. (30 m) P/N 21907
10 ft. (3 m) P/N 37533
20 ft. (6 m) P/N 37534
30 ft. (9 m) P/N 37535
60 ft. (18 m) P/N 37536
Gas Line Bundle (one required)
100 ft. (30 m) P/N 37537
10 ft. (3 m) P/N 21917
20 ft. (6 m) P/N 21918
30 ft. (9 m) P/N 21919
60 ft. (18 m) P/N 21920
Standard Cable
100 ft. (30 m) P/N 21921
10 ft. (3 m) P/N 56997111
20 ft. (6 m) P/N 56997112
30 ft. (9 m) P/N 56997113
40 ft. (12 m) P/N 0560986745
60 ft. (18 m) P/N 56997114
Flex cable (recommended for
power track applications)
100 ft. (30 m) P/N 56997115
Control Lead – Flow Console to Junction Bo
x
(one required)
SECTION 2 DESCRIPTION
Precision Plasma with Electronic Flow Control
2-2
30 ft. (9.1 m ) P/N 57002248
50 ft. (15.2 m) P/N 57002249
75 ft. (22.8 m ) P/N 57002250
100 ft. (30.5 m) P/N 57002251
Control Lead Power Source to Cutting Machine I/O
160 ft. (48.8 m) P/N 57002252
3 ft. (.9 m) P/N 57000419
50 ft. (15.2 m) P/N 57000420
75 ft. (22.8 m) P/N 57000421
100 ft. (30.5 m) P/N 57000422
125 ft. (38.1 m) P/N 57000423
150 ft. (45.7 m) P/N 57000424
175 ft. (53.3 m) P/N 57000425
High Frequency Power Cable Power Supply to Junction
Box or- Power Supply to Cutting Machine I/O, depending
on configuration
200 ft. (61 m) P/N 57000426
Torch Coolant (one gallon (3.8 l) containers. four gallons (15 l) required) P/N 156F05
NOTES:
Control lead from the power source to customer CNC is supplied based on customer order.
Gas supply, hoses, work lead and input primary cable are all supplied by the customer.
See Process Data Sheets for a list of torch consumable parts.
2.4 Precision Plasma Technical Specifications
2.4.1 System
Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz
Input Current 65/60/50/40/30/25 amps per phase
Power Factor 0.95
Output Current Range 15-100 amps dc
Output Load Voltage 120 V dc
Duty Cycle 100%
Open Circuit Voltage 315 V dc
SECTION 2 DESCRIPTION
Precision Plasma with Electronic Flow Control
2-3
Power Supply
Junction Box
44"
(1118 mm)
6.75"
(171mm)
19.75" (502mm)
10.62" (270mm)
42" (1067mm) Weight = 26.5 lbs (12 kg)
22" (559mm)
Weight = 560 lbs. (254 kg)
Electronic Flow Control Box
14.5"
(1118mm)
12.25" (311mm)
12" (305mm)
Weight = 51 lbs. (23 kg)
RECISION PLASMARC
PILOT
A
RC
POWER
CONTROL
CURRENT
NITROGEN
O2
AIR
METH
H-35
O2
N2
A
IR
N2
N2
PLASMA GA
S
NO.1
PLASMA GA
S
NO.2
SHIELD GA
S
NO.1
SHIELD GA
S
NO.2
ARGON
AIR
OXYGEN
NITROGEN
AIR
OXYGEN
NITROGEN
HYDROGEN
METHAN E
SECTION 2 DESCRIPTION
Precision Plasma with Electronic Flow Control
2-4
2.4.2 Plasma Gas Technical Specifications
Type O
2
, N
2
, Air
Pressure 125 psig (8.6 bars)
Flow 100 cfh (47 l/min) max. (varies with application)
Purity Required*
O
2
-99.995%
N
2
-99.995%
Air-clean, dry and oil free
Recommended Liquid Cylinder Service
Regulators
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
Recommended Cylinder 2-Stage Regulators
Oxygen: R-77-150-540 (P/N 998337
Hydrogen/Methane:R-77-150-350 (P/N 998342)
Nitrogen: R-77-150-580 (P/N 998344)
Industrial Air: R-77150=590 (P/N 998348)
Recommended Heavy Duty Hi-flow Station or
Pipeline Regulators
Oxygen: R-76-150-024 (P/N 19151)
Recommended High-capacity Station or
Pipeline Regulators
R-6703 (P/N 22236)
Gas Filter Required 25 micron w/bowl guard (P/N 56998133)
2.4.3 Start Gas Technical Specifications
Type N
2
, Air
Pressure 125 psig (8.6 bar)
Flow 60 cfh (28 l/min) max (varies with application)
Minimum Purity Required 99.995%
2.4.4 Secondary Gas Technical Specifications
Type N
2
, O
2
, H-35, Methane, Air
Pressure
100 psig (6.6 bar) H-35, Methane; 125 psig (8.6
bar) N
2
, O
2
, Air
Flow 60 cfh (28 l/min) max (varies with application)
Minimum Purity Required 99.995%
2.4.5 Pt-24 Torch Technical Specifications
Type Water-Cooled, Dual Gas
Rating 100 amps @ 100 % duty cycle
Dimensions See Package Options (2.3)
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ESAB Precision Plasmarc System with Electronic Flow Control Installation guide

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Welding System
Type
Installation guide
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