ESAB Precision Plasmarc System Installation guide

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.

©

©©

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 manual’s

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

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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