precision plasmarc system
F-15-480-E
July, 2007
Installation, Operation and Maintenance Manual for the
PRECISION PLASMARC SYSTEM
with Electronic Flow Control
CUTTING SYSTEMS
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 be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total
customer satisfaction. We constantly look for
ways to improve our products, service and
documentation.
As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15480
March-01 date reflects added cable part nos. in
Sect 2. Corrected Pressure in Section 6.
Dec.-01 Replacement parts section updated
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
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 ..............................................................
3.9 Replacement of EPROM in the Plasmarc Power Source Programmable
Logic Controller (PLC) ...........................................................................................
11
i
12
Precision Plasma Electronic Flow Control
Table of Contents
Section 4 Operation
4.1 Power Supply Controls
4.1.1 Main Power Switch .................................................................................. 1
4.1.2 Pilot Arc Switch........................................................................................ 1
4.1.3 Fault Indicator Lights ............................................................................... 2
4.1.4 Meters...................................................................................................... 2
4.1.5 Current Control Switch............................................................................. 2
4.2 Cut Quality .......................................................................................................
4.2.1 Introduction .............................................................................................. 3
4.2.2 Cut Angle ................................................................................................. 3
4.2.3 Cut Flatness............................................................................................. 4
4.2.4 Surface Finish.......................................................................................... 5
4.2.5 Dross ....................................................................................................... 6
4.2.6 Dimensional Accuracy ............................................................................. 8
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction .............................................................................................. 9
4.3.2 Aluminum................................................................................................. 9
4.3.3 Carbon Steel............................................................................................ 10
4.3.4 Stainless Steel ......................................................................................... 11
4.4 Process Data
4.4.1 Introduction .............................................................................................. 13
4.4.2 Process Data Settings ............................................................................. 14
Plasma Marking Data ...................................................................... 54
4.4.3 Relationship of Kerf Width to Amperes and Material Thickness.............. 76
4.4.3.1 Aluminum Kerf Values ..................................................................... 76
4.4.3.2 Carbon Steel Kerf Values ................................................................ 78
4.4.3.3 Stainless Steel Kerf Values O2/N2/O2 ............................................. 81
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4 .......................................... 82
4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4 ........................................... 83
4.4.3.6 Stainless Steel Kerf Values N2/N2 ................................................... 84
4.4.3.7 Stainless Steel Kerf Values Air/Air.................................................. 86
ii
Precision Plasma Electronic Flow Control
Table of Contents
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
iii
Precision Plasma Electronic Flow Control
Table of Contents
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 and 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-O2, SG-O2 ................................................................. 28
Carbon Steel PG-O2, SG-N2/O2 ............................................................ 30
Carbon Steel PG-O2, Sg-O2 .................................................................. 32
Stainless Steel PG-N2, SG-N2 ............................................................. 34
Stainless Steel PG-N2, SG-N2/CH4 ....................................................... 36
Stainless Steel PG-Air, SG-Air ............................................................. 38
Stainless Steel PG-Air, SG-Air/CH4 ...................................................... 40
Aluminum PG-N2, SG- N2 ..................................................................... 42
Aluminum PG-N2, SG-N2/CH4 ............................................................... 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
7.12 Interface Cables and Hoses .......................................................................... 44
Customer/Technical Information Resource
Back Manual Cover
iv
SECTION 1
SAFETY
1.1 Introduction
The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. However, as with
any machine tool, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of usefulness.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious personnel injury or
severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the field of
cutting and welding apparatus, obtain and read the
publications listed in the Recommended References.
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.
! DANGER
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
! WARNING
Used to call attention to potential hazards
that could result in personal injury or loss of
life.
! CAUTION
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
CAUTION
Used to call attention to minor hazards to
equipment.
NOTICE
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
1-1
SECTION 1
SAFETY
1.3 General Safety Information
! WARNING
! WARNING
Machine starts automatically.
This equipment moves in various directions and
speeds.
•
Moving machinery can crush.
•
Only qualified personnel should operate or
service equipment.
•
Keep all personnel, materials, and equipment
not involved in production process clear of
entire system area.
•
Keep gear racks and rails clear of debris or
obstructions, such as tools or clothing.
•
Fence off entire work cell to prevent
personnel from passing through area or
standing in the working envelope of the
equipment.
•
Post appropriate WARNING signs at every
work cell entrance.
•
Follow lockout procedure before servicing.
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual
before using machine.
•
Read entire procedure before operating or
performing any system maintenance.
•
Special attention must be given to all
hazard warnings that provide essential
information regarding personnel safety
and/or possible equipment damage.
•
All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
•
Read all safety publications made available
by your company.
1-2
SECTION 1
! WARNING
SAFETY
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety warning labels
on machine.
Refer to operator’s manual for additional
safety information.
1.4 Installation Precautions
! WARNING
Improperly installed equipment can cause
injury or death.
Follow these guidelines while installing machine:
Do not connect a cylinder directly to machine
inlet. An appropriate cylinder regulator must be
installed on a fuel gas cylinder to reduce
pressure to a reasonable inlet supply pressure.
Machine regulator is then used to obtain
pressure required by torches.
Contact your ESAB representative before
installation. He can suggest certain precautions
regarding piping installation and machine lifting,
etc. to ensure maximum security.
Never attempt any machine modifications or
apparatus additions without first consulting a
qualified ESAB representative.
Observe machine clearance requirements for
proper operation and personnel safety.
1-3
SECTION 1
SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to this manual’s
Installation section for detailed grounding
instructions.
! WARNING
Electric shock hazard.
Improper grounding can cause severe injury or
death.
Machine must be properly grounded before put
into service.
! WARNING
Improper grounding can damage machine
and electrical components.
•
Machine must be properly grounded before
put into service.
•
Cutting table must be properly grounded to a
good Earth ground rod.
1.6 Operating A Plasma Cutting Machine
! WARNING
! WARNING
Flying debris and loud noise hazards.
•
Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying
debris generated during operation.
•
Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.
•
From plasma arc can damage hearing. Wear
correct ear protection when cutting above
water.
Burn hazard.
Hot metal can burn.
•
Do not touch metal plate or parts immediately
after cutting. Allow metal time to cool, or
douse with water.
•
Do not touch plasma torch immediately after
1-4
SECTION 1
SAFETY
cutting. Allow torch time to cool.
1-5
SECTION 1
! WARNING
! WARNING
SAFETY
Hazardous voltages. Electric shock
can kill.
•
Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
•
Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
•
Always turn power off to plasma power
supplies before opening or servicing plasma
plumbing or flow control box.
•
Do not touch live electrical parts.
•
Keep all panels and covers in place when
machine is connected to power source.
•
Insulate yourself from workpiece and
electrical ground: wear insulating gloves,
shoes and clothing.
•
Keep gloves, shoes, clothing, work area, and
equipment dry.
Pinch hazard.
Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during
operation.
! WARNING
Fume hazard.
Fumes and gases generated by the plasma
cutting process can be hazardous to your health.
•
Do NOT breathe fumes.
•
Do not operate plasma torch without fume
removal system operating properly.
•
Use additional ventilation to remove fumes if
necessary.
•
Use approved respirator if ventilation is not
1-6
SECTION 1
SAFETY
adequate.
1-7
SECTION 1
! WARNING
SAFETY
Radiation hazard.
Arc rays can injure eyes and burn skin.
•
Wear correct eye and body protection.
•
Wear dark safety glasses or goggles with side
shields. Refer to following chart for
recommended lens shades for plasma
cutting:
Arc Current
Up to 100 Amps
100-200 Amps
200-400 Amps
Over 400 Amps
! WARNING
Lens Shade
Shade No. 8
Shade No. 10
Shade No. 12
Shade No. 14
•
Replace glasses/goggles when lenses are
pitted or broken
•
Warn others in area not to look directly at the
arc unless wearing appropriate safety
glasses.
•
Prepare cutting area to reduce reflection and
transmission of ultraviolet light.
•
Paint walls and other surfaces with dark
colors to reduce reflections.
•
Install protective screens or curtains to
reduce ultraviolet transmission.
Ruptured Gas Cylinders Can Kill
Mishandling gas cylinders can rupture and
violently release gas.
•
Avoid rough handling of cylinders.
•
Keep cylinder valves closed when not in use.
•
Maintain hoses and fittings in good condition.
•
Always secure cylinders in an upright
position by chain or strap to a suitable stable
object not part of an electrical circuit.
•
Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
•
Refer to CGA Standard P-1, “Precautions for
Safe Handling of Compressed Gases in
Cylinders”, available from Compressed Gas
Association.
1-8
SECTION 1
! WARNING
SAFETY
Spark hazard.
Heat, spatter, and sparks cause fire and burns.
CAUTION
•
Do not cut near combustible material.
•
Do not cut containers that have held
combustibles.
•
Do not have on your person any combustibles
(e.g. butane lighter).
•
Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when
activating plasma process.
•
Wear correct eye and body protection.
•
Wear gauntlet gloves, safety shoes and hat.
•
Wear flame-retardant clothing that covers all
exposed areas.
•
Wear cuffless trousers to prevent entry of
sparks 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:
•
reduced consumable life
•
degradation of cut quality
Cutting above water may result in poor cutting
performance. Water vapor created when hot
material or sparks contact liquid may cause
arcing inside torch.
When cutting on a water table, reduce the water
level to provide maximum clearance between
water and material.
1-9
SECTION 1
! WARNING
SAFETY
Explosion hazard.
Certain molten aluminum-lithium (Al-Li) alloys
can cause explosions when plasma cut OVER
water.
Do not plasma cut the following Al-Li alloys
with water:
Alithlite (Alcoa)
Alithally (Alcoa)
2090 Alloy (Alcoa)
X8090A (Alcoa)
X8092 (Alcoa)
X8192 (Alcoa)
Navalite (US Navy)
Lockalite (Lockheed)
Kalite (Kaiser)
8091 (Alcan)
•
These alloys should only be dry cut on a dry
table.
•
DO NOT dry cut over water.
•
Contact your aluminum supplier for additional
safety information regarding hazards
associated with these alloys.
1.7 Service Precautions
CAUTION
Establish and adhere to preventive maintenance.
A composite program can be established from
recommended schedules in the instruction
literature.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical
damage could occur to equipment or machine.
! CAUTION
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter.
Integrated circuits are susceptible to over voltage
damage. Power off before using test probes to
prevent accidental shorting of components.
All circuit boards securely seated in sockets, all
cables properly connected, all cabinets closed
and locked, all guards and covers replaced
before power is turned on.
Never plug or unplug a printed circuit board
while machine power is on. Instantaneous
surges of voltage and current can damage
electronic components.
1-10
SECTION 1
SAFETY
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.
1-11
SECTION 1
SAFETY
This page intentionally left blank.
1-12
SECTION 2
DESCRIPTION
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)
P/N 37357
Electronic Flow Control Box (required)
P/N 22406
Junction Box (required)
P/N 22407
PT-24 Torch Electronic Flow Series A/M (one required)
Power Bundle (one required)
Gas Line Bundle (one required)
Standard Cable
Control Lead – Flow Console to Junction Box
(one required)
Flex cable (recommended
for power track applications)
2-1
4.5 ft. (1.4 m)
P/N 0558001463
12 ft. (4.4 m)
P/N 0558001877
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
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
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
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
100 ft. (30 m)
P/N 56997115
SECTION 2
DESCRIPTION
Control Lead – Power Source to Cutting Machine I/O
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
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
High Frequency Power Cable – Power Supply to Junction 100 ft. (30.5 m) P/N 57000422
Box –or- Power Supply to Cutting Machine I/O, depending
125 ft. (38.1 m) P/N 57000423
on configuration
150 ft. (45.7 m) P/N 57000424
175 ft. (53.3 m) P/N 57000425
200 ft. (61 m)
Torch Coolant (one gallon (3.8 l) containers.
four gallons (15 l) required)
P/N 57000426
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
2-2
SECTION 2
DESCRIPTION
JUNCTION BOX
POWER SUPPLY
6.75" (171mm)
PILOT
ARC
CONTROL
POWER
10.62" (270mm)
19.75" (502mm)
CURRENT
RECISION
PLASMARC
WEIGHT = 26.5 lbs.(12 kg)
44" (1118mm)
ELECTRONIC FLOW CONTROL BOX
42" (1067mm)
22" (559mm)
14.5" (1118mm)
WEIGHT = 560 lbs. (254 kg)
O2
N2
O2
AIR
N2
AIR
PLASMA GAS
NO.1
PLASMA GAS
NO.2
SHIELD GAS
NO.1
METH
H-35
N2
SHIELD GAS
NO.2
NITROG EN
NITROG EN
OXYGEN
METHANE
NITROG EN
OXYGEN
EN
HYDROG
AIR
12.25" (311mm)
AIR
ARGON
12" (305mm)
WEIGHT = 51 lbs. (23 kg)
2-3
SECTION 2
DESCRIPTION
2.4.2 Plasma Gas Technical Specifications
Type
O2, N2, Air
Pressure
125 psig (8.6 bars)
100 cfh (47 l/min) max. (varies with
application)
O2-99.995%
N2-99.995%
Air-clean, dry and oil free
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
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)
Flow
Purity Required*
Recommended Liquid Cylinder
Service Regulators
Recommended Cylinder 2-Stage
Regulators
Recommended Heavy –Duty Hi-flow
Station or Pipeline Regulators
Recommended High-capacity Station
or Pipeline Regulators
Gas Filter Required
Oxygen: R-76-150-024 (P/N 19151)
R-6703 (P/N 22236)
25 micron w/bowl guard (P/N 56998133)
2.4.3 Start Gas Technical Specifications
Type
N2, Air
Pressure
125 psig (8.6 bar)
60 cfh (28 l/min) max (varies
with application)
99.995%
Flow
Minimum Purity Required
2.4.4 Secondary Gas Technical Specifications
Type
Pressure
Flow
Minimum Purity Required
N2, O2, H-35, Methane, Air
100 psig (6.6 bar) H-35,
Methane; 125 psig (8.6 bar) N2,
O2, Air
60 cfh (28 l/min) max (varies
with application)
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)
2-4
SECTION 3
INSTALLATION
3.1 General
NOTICE
3.2 Equipment Required
Proper installation can contribute materially to the
satisfactory and trouble-free operation of the
Precision Plasmarc System. It is suggested that
each step in this section be studied and carefully
followed.
•
•
•
•
3.3 Location
•
•
•
! CAUTION
Gas Supply and Hoses. Gas supply may be from
a bulk source or from a bank of manifold
cylinders and regulated to supply 125 psig (8.6
bar) to the Flow Control (gas flowing).
Work Lead. No. 4 AWG cable is recommended
for connecting workpiece to power source.
Primary Input Cable.
25 micron gas filters (or better) are required on
the supply side for the EFC to function properly.
Ventilation is necessary to provide proper cooling
of the power supply.
Minimize dirt, dust and exposure to external heat
sources.
Allow a minimum of two feet clearance around
the power supply for free air movement.
Do Not Restrict Air Flow
Restricting intake air with any type of filter on or
around the power supply may void the warranty.
3-1
SECTION 3
INSTALLATION
3.4 Primary Electrical Input Connections
! DANGER
Electric Shock Can Kill!
Provide maximum protection against electrical
shock.
Before any connections are made inside the
machine, open the line (wall) disconnect switch
and unplug the power cord.
! WARNING
Input Power Configuration
Machine must be properly configured for your
input power.
The machine is shipped from the factory
configured for 575 V, 60 Hz input.
Do NOT connect a power source of any other
voltage unless machine is reconfigured. Damage
to the machine will occur.
Input Power Connection At Wall
A line (wall) disconnect switch with fuses or circuit
breakers should be provided at the main power
panel.
Connect the input power cable of the power source
directly to the disconnect switch or a proper plug and
receptacle may be purchased from a local electrical
supplier. (See table on the next page for
recommended input conductors and fuses )
Recommended Sizes For Input Conductors And Line Fuses
Input requirements
Volts
Phase
Amps
208
230
380
415
460
575
3
3
3
3
3
3
70
60
50
40
30
25
3-2
Input & ground
conductor,
cu/awg/mm2
No. 4
25
No. 6
16
No. 8
10
No. 10
6
No. 10
6
No. 10
6
Fuse ratings /
phase, amps
100
80
80
60
50
40
SECTION 3
INSTALLATION
The following procedure explains the proper
installation steps for connecting primary electrical
power to the power source.
1. Remove right side panel.
2. Ensure input power cable is disconnected from
all electrical sources.
3. Route input power cable through the strain relief
located at the rear panel.
Ground Connection
Input Power Cable
(Customer supplied) 4. Pull input power cable through the strain relief to
allow cable wires sufficient length to connect to
the main contactor. Tighten strain relief to
ensure input power cable is secured.
TB2
5. Connect input power cable ground wire to the
ground lug provided on the base of the power
source.
K1
200
230
380
415
460
575
Main
Contactor
7 Position
Terminal Block
Auto
Transformer
PHASE 2
PHASE 3
200
230
380
415
460
575
PHASE 1
200
230
380
415
460
575
TB1
200
230
380
415
460
575
6. Connect three power leads of the input power
cable to the terminals located atop the main
contactor. Secure the leads by tightening each
screw.
7. Connect jumper power cables from the bottom of
the main contactor to the proper input voltage
marked on the auto transformer. The unit is
factory set for 575 V as shown to the left.
Factory Wired
for 575 volts
! CAUTION
Input Power Jumper Connection
Ensure each input power jumper cable is
connected to the correct input voltage on auto
transformer.
Factory wired for 575 V.
8. Connect jumper wire to the proper input voltage
connector located on the 7-position terminal block.
TB2
3-3
SECTION 3
INSTALLATION
3.5 Interconnecting Lines
Black
Red/Orange
Yellow
Blue
1. All interconnecting service lines supplied are
numbered or color coded on each end with
corresponding numbers/colors marked on the
cabinets.
Mounting Plate
Gas Line Bundle
Gas Bundle
Installation
2. Connect all four lines in Gas Line Bundle to
Flow Control Box and Junction Box. Lines and
connections are color coded. In addition,
mounting plate hole spacing is asymmetrical to
prevent improper connection. Order of colors
should be: blue, yellow, red/orange, black
3-4
SECTION 3
INSTALLATION
Power supply and EFC Connections to J-Box
Power Supply Bundle
Power Supply Negative
Connection
#7 Hose
Connection
(from power
source)
Pilot Arc
Connection
#6 Hose Connection
(to power source)
3. Connect power and coolant lines in Power
Supply Bundle from power source to junction
box. Power bundle consists of #6 and # 7
coolant lines (with 5/8-18 L.H. fittings), power
cable (#3 AWG) and yellow pilot arc cable
(#16 AWG). Both coolant lines are stamped
with a 6 or 7 on the fitting to assist in
identification.
Gas Bundle
Connections
Control Lead Connection
from EFC
3-5
SECTION 3
INSTALLATION
Junction Box to Torch
Torch Hose/Power
Cable Connection
Torch
Solenoid
Electrical
Connection
Torch Bundle
Torch Pilot Arc
Connection
4. Connect Torch Bundle Leads/Hoses to
Junction box. (see Interconnecting Block
Diagram)
3-6
SECTION 3
INSTALLATION
Precision Plasmarc Component Interconnecting Diagram
25 micron Filters
EFC
Control Lead
EFC/Junction
Box
ASIOB
High
Frequency
120VAC
CNC
N2
O2
CH4
Air
High Frequency 120VAC
Gas Line Bundle
Junction
Box
Power Bundle
Torch
Cutting Table
Ground Rod
Work Lead
Control Lead
Power Supply to CNC
3-7
Primary Power Cable
Ar
SECTION 3
INSTALLATION
Gas Line Contamination Will Damage
Proportional Valves
! CAUTION
Purge Gas Lines
Before connecting gas delivery lines to the
Electronic Flow Control, purge all lines
thoroughly. Residue from the hose
manufacturing process may clog/damage the
proportional valves in your EFC.
5. Purge gas lines between supply and the EFC
before connecting. Proportional valves in the
EFC are very sensitive to dust and other
foreign particles.
1/4 NPT
6. Connect Gas Delivery lines to Electronic Flow
Control. Install 25 micron Gas filters in all
delivery lines between gas source and EFC.
25 micron Gas Filter
25μ Filters
N2
O2
CH4
Air
Ar
3-8
SECTION 3
INSTALLATION
Remove Access Cover
Pilot Arc
Work
Torch
Pilot Arc
7. Remove panel from rear of console and attach
the pilot-arc, torch and work lead.
Work
Torch
Power Source
CNC Control Lead
Flow Control
Lead
600 amp
Bus Fuse
Rating
Label
Serial
Tag
8. Connect control lead between the console and
the Electronic Flow Control. Connect coolant
lines of the Power Bundle.
Coolant In from Torch
# 6 Connection
Coolant Out to Torch
# 7 Connection
CONTROL LEAD
3-9
SECTION 3
INSTALLATION
3.6 Torch Mounting
CAUTION
Do Not Cover Vent Hole.
When mounting, do not to cover the small vent
hole in the side of the sleeve. This hole allows
coolant to drain from inside the sleeve should a
leak occur in a service line.
Torch Mounting Options.
1.812" (46mm)
Diameter Collar
2.0" (51mm)
Diameter Sleeve
Vent Hole
•
The torch is normally mounted by the 2.0 inch
diameter (51mm) sleeve. Do not cover vent hole.
•
For custom alternative mounting, the torch can
be mounted by the 1.812" (46 mm) dia collar
shown. This insulated collar and its shoulder are
machined relative to the nozzle retainer thread on
the torch body.
•
Use only specified mounting surfaces
3-10
SECTION 3
INSTALLATION
3.7 Torch Coolant
PILOT
ARC
L
CONTRO
POWER
T
CURREN
RECISION
PLASMARC
Coolant
Fill Cap
! CAUTION
•
Remove coolant fill cap at front of console and fill
coolant tank with 4 gallons (15 liters) of plasma
coolant, P/N 156F05 (one gallon).
•
Do not fill above maximum level
•
Reinstall Cap.
Commercial Antifreeze Will Cause Torch To
Malfunction
Use Special Torch Coolant! P/N156F05
Due to high electrical conductivity, DO NOT use
tap water or commercial antifreeze for torch
cooling. A specially formulated torch coolant is
REQUIRED. This coolant also protects for
freezing to –34° C.
Operating the unit without coolant will cause
permanent damage to the coolant pump.
3.8 Inspection of Gas and Coolant Lines
To complete installation, it is necessary to inspect field
assembled connections for leaks.
•
Gas lines, use a standard soap solution.
Pressurize the system from the control (SDP file)
•
Coolant- check connections for signs of moisture at
connections
3-11
SECTION 3
INSTALLATION
3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic
Controller (PLC)
The Precision Plasmarc System may be shipped
configured for a manual flow control (Series “A”).
If so, the EPROM in the Programmable Logic
Controller must be replaced with an EFC EPROM.
This EFC EPROM is shipped with the power
source.
! CAUTION
Using the Wrong EPROM Could Result In
Damaged System Components
The Series “A” and the EFC EPROMs are
programmed with different software. The EFC
EPROM ignores the process gas pressure
switch inputs and does not include the
process gas purge required for the Series “A”.
! CAUTION
Mishandling Can Damage Electronic
Components.
Handle electronic components with care.
• Do not drop
• Do not bend pins
• Do not touch circuit components- handle
along edges when possible
! CAUTION
Electronic Components Are Subject To
Electro-Static-Discharge (ESD) Damage
Integrated Circuit parts are sensitive to over
voltages. The damage may not be seen
immediately but show up as a premature
failure.
The EFC EPROM is shipped in an anti-static
bag. Store EPROM in this bag.
Wear a protective ground strap when handling
sensitive electronic components.
! WARNING
Electric shock Can Kill!
Unplug power cable from wall to power source
before any connections or adjustments are
made inside power source.
3-12
SECTION 3
INSTALLATION
PILOT
ARC
CONTROL
POWER
CURRENT
PLASMARC
RECISION
Left Side Panel
1. Ensure the Plasmarc Power Source is
disconnected from electricity source.
2. Expose the PLC by removing the left side
panel of the Plasmarc Power Source.
3. Pop the EPROM cover on the PLC to expose
the EPROM.
PLC
EFC EPROM
Package Location
3-13
SECTION 3
INSTALLATION
CAUTION
Using An EPROM Puller Tool May Damage
Socket
Forcibly removing a clamped EPROM in the
PLC may cause the socket/EPROM to break.
Special Zero Force EPROM Socket is used to
eliminate the need for special tools.
EPROM Locked In Place
4. Remove the EPROM from the socket. THIS
DOES NOT REQUIRE A PULLER. Release
the clamp locking the EPROM in place, lift the
Series “A” EPROM from the socket.
5. Remove the EFC EPROM from the packaging.
6. Carefully align the EFC EPROM pins with the
socket holes and insert.
7. Lock the EPROM by moving the lever back
while holding the EPROM in place.
8. Replace the EPROM cover and the Power
Source left side panel.
EPPESA= Series “A” EPROM, manual flow
control
P/N 99513607
EPPSEFC= EFC EPROM, electronic flow control
P/N 99513608
EPROM Lock Released
3-14
SECTION 4
OPERATION
4.1 Power Supply Controls
4.1.1 Main Power Switch
LO
W
D
ON
O
TSW
ITC
H
W
H
ILEC
U
TTIN
G
EMERGENCY
STOP
Pilot Arc Switch
Used to select HIGH or LOW Start Pilot Arc
depending on cutting conditions. See Process Data
for more information on which conditions High and
Low Start are used.
4.1.2 Pilot Arc Switch
EMERGENCY
STOP
Main Power Switch
Controls the input power to the fan, water cooler and
the PC Board. Amber indicator light to the left of the
switch.
POWER
ON
WARNING
Adjusting Pilot Arc While in Operation Could
Damage Torch.
Do not adjust pilot arc switch while in operation.
Adjust before torch starts.
Precision Plasma with Electronic Flow Control -
4-1
SECTION 4
OPERATION
4.1.3 Fault Indicator Lights
Fault Indicator Lights
•
•
•
•
•
•
•
4.1.4 Meters
4-2
Coolant flow will show low coolant flow. When
unit is turned on, the light will briefly show a fault
and then go out.
Plasma Gas Pressure fault indicator -- low
Plasma Gas Pressure. Torch will not fire when
indicated. Not used for the EFC.
Start Gas Pressure fault indicator -- low start
gas pressure. Torch will not fire when indicated.
Not used for the EFC.
P/S Temp fault indicator -- over temperature in
the inverter power source. Power source will
shut down.
P/S Fault Indicator – fault in plasma control PCB
in the inverter power source. Power source will
shut down.
Over-Under Voltage fault Indicator -- indicate
input voltage is above or below the tolerances of
the PCU console. Will latch until power is
recycled by main power switch.
Emergency Stop fault indicator -- shows CNC
Interlock condition. Power Source will not work.
•
Cutting Current Meter (A) -- Displays actual
cutting current in amperes.
•
Cutting Voltage Meter (V) -- Displays actual
cutting voltage.
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
4.1.5 Current Control Switch
Control Remote/Panel Switch
•
•
•
Panel Position – Output current is set by the
output current dial
Output Current Dial – sets the cutting current
when current setting is made from the console
front panel. Dial reads 0 to 99.9 amps. 70.0
amps shown.
Remote Position – output current is set by the
CNC (or remote pot) with an analog dc signal
0-10 Vdc = 0-100 Adc
Precision Plasma with Electronic Flow Control -
4-3
SECTION 4
OPERATION
4.2 Cut Quality
4.2.1 Introduction
Causes affecting cut quality are interdependent.
Changing one variable affects all others. Determining
a solution may be difficult. The following guide offers
possible solutions to different undesirable cutting
results. To begin select the most prominent condition:
ƒ
4.2.2 Cut Angle, negative or positive
ƒ
4.2.3 Cut not flat, rounded or undercut
ƒ
4.2.4 Surface roughness
ƒ
4.2.5 Dross
Usually the recommended cutting parameters will give
optimal cut quality, occasionally conditions may vary
enough that slight adjustments will be required. If so:
•
•
•
NOTICE
4-4
Make small incremental adjustments when
making corrections.
Adjust Arc Voltage in 5 volt increments, up or
down as required.
Adjust cutting speed 5% or less as required
until conditions improve.
Before attempting ANY corrections, check cutting
variables with the factory recommended
settings/consumable part numbers listed in
Process Data.
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
4.2.2 Cut Angle
Part
Drop
Negative Cut Angle
Top dimension is greater than the bottom.
•
Misaligned torch
•
Bent or warped material
•
Worn or damaged consumables
•
Standoff low (arc voltage)
•
Cutting speed slow (machine travel rate)
Part
Part
Positive Cut Angle
Top dimension is less than the bottom dimension.
•
Misaligned torch
•
Bent or warped material
•
Worn or damaged consumables
•
High standoff High (arc voltage)
•
Cutting speed fast
•
Drop
Part
Current high or low. (See Process Data for
recommended current level for specific nozzles).
Precision Plasma with Electronic Flow Control -
4-5
SECTION 4
OPERATION
4.2.3 Cut Flatness
Top And Bottom Rounded
Condition usually occurs when material is .25” thick
(6,4mm) or less.
•
Drop
High current for given material thickness (See
Process Data for proper settings).
Part
Top Edge Undercut
•
Drop
4-6
Standoff low (Arc Voltage)
Part
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
4.2.4 Surface Finish
Process Induced Roughness
Cut face is consistently rough. May or may not be
confined to one axis.
Top View
•
Incorrect Shield Gas mixture (See Process Data)
•
Worn or damaged consumables
Machine Induced Roughness
Can be difficult to distinguish from Process Induced
Roughness. Often confined to only one axis.
Roughness is inconsistent.
•
or
Process Induced
Roughness
Machine Induced
Roughness
•
Dirty rails, wheels and/or drive rack/pinion.
(Refer to Maintenance Section in machine
owners manual).
Carriage wheel adjustment
Precision Plasma with Electronic Flow Control -
4-7
SECTION 4
OPERATION
4.2.5 Dross
Dross is a by-product of the cutting process. It is the
undesirable material that remains attached to the
part. In most cases, dross can be reduced or
eliminated with proper torch and cutting parameter
setup. Refer to Process Data.
Lag Lines
Cut Face
Roll over
High Speed Dross
Material weld or rollover on bottom surface along
kerf. Difficult to remove. May require grinding or
chipping. “S” shaped lag lines.
•
Standoff high (arc voltage)
•
Cutting speed fast
Side view
Lag Lines
Cut Face
Slow Speed Dross
Forms as globules on bottom along kerf. Removes
easily.
Globules
•
Cutting speed slow
Side View
4-8
Precision Plasma with Electronic Flow Control -
SECTION 4
Side View
OPERATION
Splatter
Top Dross
Appears as splatter on top of material. Usually
removes easily.
•
Cutting speed fast
•
Standoff high (arc voltage).
Cut Face
Intermittent Dross
Appears on top or bottom along kerf.
Non-continuous. Can appear as any kind of dross
•
Possible worn consumables
Other Factors Affecting Dross;
•
•
•
Material temperature
Heavy mill scale or rust
High carbon alloys
Precision Plasma with Electronic Flow Control -
4-9
SECTION 4
OPERATION
4.2.6 Dimensional Accuracy
Generally using the slowest possible speed (within
approved levels) will optimize part accuracy. Select
consumables to allow a lower arc voltage and slower
cutting speed.
NOTICE
Recommended cutting speed and arc voltage will
give optimal cutting performance in most cases.
Small incremental adjustments may be needed
due to material quality, material temperature and
specific alloy. The operator should remember
that all cutting variables are interdependent.
Changing one setting affects all others and cut
quality could deteriorate. Always start at the
recommended settings.
NOTICE
4-10
Before attempting ANY corrections, check
cutting variables with the factory recommended
settings/consumable part numbers listed in the
Process Data.
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction
All gases are not suitable for all situations. Certain
gases assist in cutting specific materials and
thickness. The following explains why certain gases
are selected and their influence on the finished part.
Other influences such as arc voltage and gas
flow/pressure are covered in the Process Data.
Refer to Cutting Process Data in this section for
recommended flow/pressure settings.
NOTICE
4.3.2 Aluminum
Material
All thickness’ between .062" to .625" (1,6 mm to 15,9 mm)
Thickness:
Cut Qualities:
•
•
Smooth cut face
Virtually no dross
Plasma Gas: Nitrogen
Shield Gas: Nitrogen/Methane
Discussion:
Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1
part methane ratio is desired. Incorrect ratio results in heavy dross.
Precision Plasma with Electronic Flow Control -
4-11
SECTION 4
OPERATION
Refer to Cutting Process Data in the PT24
Manual for recommended flow/pressure
settings.
NOTICE
4.3.3 Carbon Steel
Material Thickness: 26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm)
• Smooth cut face
Cut Qualities:
• Virtually no dross
Plasma Gas: Oxygen
Shield Gas: Oxygen/Nitrogen
Shield gas is normally nitrogen. A small amount of oxygen combined
with nitrogen can effectively improve dross formation on thin material
Discussion:
of 26 GA to 10 GA carbon steel. Also, an oxygen only shield may
provide acceptable results on thinner materials.
Material Thickness: .125" to .75" (3,2 mm to 19,1 mm)
Cut Qualities:
•
•
Smooth cut face
Virtually no dross
Plasma Gas: Oxygen
Shield Gas: Nitrogen
Cutting carbon steel with oxygen results in an exothermic reaction.
This chemical reaction causes the carbon in the material to burn
Discussion:
similar to when oxy-fuel cutting. This plus the electrical energy uses
lower amperage levels without sacrificing cut speed.
4-12
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
Refer to Cutting Process Data in the PT24
Manual for recommended flow/pressure
settings.
NOTICE
4.3.4 Stainless Steel
Material Thickness: 22 GA (.028") to 16 GA (.062") (0,7 mm to 1,6 mm)
•
•
•
Cut Qualities:
Positive cut angle
Excellent dross performance
Shiny cut surface.
Plasma Gas: Nitrogen
Shield Gas: Nitrogen/Methane
Discussion:
Because of high cut speeds, a positive cut face angle is expected.
Use a 70-amp nozzle at 50 amps to allow more gas to exit the nozzle.
Material Thickness: 26 GA (.018") to 16 GA (.062") (0,5 mm to 1,6 mm)
Cut Qualities:
•
•
•
Dark cut face
Virtually dross free
Improved cut squareness
Plasma Gas: Oxygen
Shield Gas: Oxygen/Nitrogen
Low amperage cutting/slower speeds produce squarer cuts in thin
Discussion: materials. The oxygen allows for a lower arc voltage, improving cut
squareness. The “B” nozzle is used at 30 amps
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Cut Qualities:
•
•
•
Cut edge dark
good dross performance
Good cut angle
Plasma Gas: Air
Shield Gas: Air
When they are the same, the shield and plasma gases combine. This
Discussion: combination has the effect of increasing the cut gas flow/pressure.
This increased flow/pressure directly influences cut squareness.
Precision Plasma with Electronic Flow Control -
4-13
SECTION 4
OPERATION
Refer to Cutting Process Data for recommended
flow/pressure settings.
NOTICE
Stainless Steel
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Cut Qualities:
•
•
•
•
Matted cut edge appearance
Light gray color
Much smoother finish
Possible slight increase in cut angle
Plasma Gas: Air
Shield Gas: Air/Methane
Too much methane in the shield gas mixture can result in more dross
formation. 4:1 ratio air to methane is recommended. Because
Discussion:
methane is a fuel gas, possible slight increase in cut angles could be
experienced.
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Cut Qualities:
•
•
•
Dark cut face similar to air
Excellent dross performance
Good cut angle
Plasma Gas: Nitrogen
Shield Gas: Nitrogen
Shield and plasma gases combine, the volume/pressure of shield gas
Discussion: can negatively affect cut squareness. Higher shield volume produces
a negative cut angle. A lower volume, produces a positive angle.
Material Thickness: .187" to .625" (4,7 mm to 15,9 mm)
Cut Qualities:
•
•
•
Shiny cut face
Lip formation at the bottom
Dross formation can be extensive and difficult to remove
Plasma Gas: Nitrogen
Shield Gas: Nitrogen/Methane
Because methane is a fuel gas, flow/pressure rates can affect the cut
angle. High flow/pressure results in a negative cut angle, low
flow/pressure results in a positive cut angle. Nitrogen to methane ratio
Discussion:
is 10 to 14 parts N2/ 1 part CH4. The lip formed on the cut face bottom
is severe, making Nitrogen/Methane shield gas combination unsuitable
for some finished part applications.
4-14
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
4.4 Process Data
4.4.1 Introduction
The following information is a result of many hours of
testing and is a general guide for setting up and
cutting with a PT-24 Precision Plasmarc System. In
most cases these settings will provide a quality cut.
The data contains values for:
•
cutting aluminum, carbon and stainless steel
•
arc voltage (standoff)
•
cutting speed
•
current (amperes)
•
gas flow rates for all plasma/shield gas
combinations
This same data is contained in SDP files. (See your
control manual for more information on SDP files.)
Also included is information on consumable part
numbers for current being used.
Precision Plasma with Electronic Flow Control -
4-15
SECTION 4
OPERATION
4.4.2 Process Data
Material:
Amperes:
RECISION
LASMARC
Aluminum
30
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21536 (3 holes)
! Nozzle
P/N 21541, "B"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-16
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
30 Amperes
Aluminum
Process Data
PG
SG1
SG2
N2
N2
CH4
0.062
0.075
0.090
0.125
0.187
0.250
1,6
1,9
2,3
3,2
4,7
6,4
0
0
0
0
0
0
40
40
40
40
40
40
55
55
55
55
55
55
SG1-Start
45
45
45
45
45
45
SG1- Cut
20
20
20
20
20
20
SG2- Cut Flow
10
10
10
10
10
10
150
152
153
158
170
189
IPM
150
135
105
78
30
25
MM/MIN
3810
3429
2667
1981
762
635
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-17
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Aluminum
55
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21542, "C"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-18
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
55 Amperes
Aluminum
Process Data
Aluminum
PG
SG1
SG2
N2
N2
CH4
0.062
0.125
0.187
0.250
1,6
3,2
4,7
6,4
0
0
0
0
45
45
45
45
75
75
75
85
SG1-Start
55
55
55
55
SG1- Cut
20
20
20
20
SG2- Cut Flow
10
10
10
10
136
139
152
168
IPM
170
130
78
46
MM/MIN
4318
3302
1981
1168
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-19
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Aluminum
70
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21543, "D"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-20
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
70 Amperes
Aluminum
Process Data
PG
SG1
SG2
N2
N2
CH4
0.187
0.250
0.375
0.500
4,7
6,4
9,5
12,7
0
0
0.1
0.2
65
65
65
65
100
100
100
100
SG1-Start
45
45
45
45
SG1- Cut
20
20
20
20
SG2- Cut Flow
10
10
10
10
150
157
168
178
80
65
55
30
2032
1651
1397
762
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-21
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Aluminum
100
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-22
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
100 Amperes
Aluminum
Process Data
PG
SG1
SG2
N2
N2
CH4
0.250
0.375
0.500
0.625
6,4
9,5
12,7
15,9
0
0
0.1
0.1
80
80
80
80
100
100
100
100
SG1-Start
60
60
60
60
SG1- Cut
31
31
31
31
SG2- Cut Flow
10
10
10
10
155
160
166
174
95
80
65
50
2413
2032
1778
1270
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-23
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Carbon Steel
16
Plasma Gas: Oxygen (O2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Oxygen (O2) @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21852 (2 holes)
! Nozzle
P/N 21540, "A"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-24
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
16 Amperes
Carbon Steel
Process Data
PG
SG1
SG2
O2
N2
O2
20GA
18GA
16GA
14GA
12GA
10GA
0,9
1,2
1,6
2,0
2,7
3,4
0
0
0
0.1
0.5
0.5
20
20
20
20
20
20
11
11
11
11
11
11
SG1-Start
20
20
20
20
20
20
SG1- Cut
0
0
0
0
0
0
SG2- Cut Flow
6
6
6
6
6
7
103
105
115
118
116
117
IPM
100
85
80
60
50
36
MM/MIN
2540
2159
2032
1524
1270
914
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-25
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Carbon Steel
35
Plasma Gas: Oxygen (O2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Oxygen (O2) @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21536 (3 holes)
! Nozzle
P/N 21541, "B"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-26
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
35 Amperes
Carbon Steel
Process Data
PG
SG1
SG2
O2
N2
O2
14GA
0.125
0.135
0.187
0.250
1,9
3,2
3,4
4,7
6,4
0
0
0
0
0
38
38
38
38
38
15
15
15
15
15
SG1-Start
50
50
50
50
50
SG1- Cut
0
0
0
0
0
SG2- Cut Flow
6
6
6
6
6
113
119
120
122
124
80
55
52
40
30
3032
1397
1320
1016
762
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-27
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Carbon Steel
45
Plasma Gas: Oxygen (O2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Oxygen (O2) @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21542, "C"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-28
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
45 Amperes
Carbon Steel
Process Data
PG
SG1
SG2
O2
N2
O2
0.125
0.135
0.187
0.250
0.375
MM
3,2
3,4
4,7
6,4
9,5
Pierce Delay (SEC.)
0.3
0.3
0.3
0.3
0.4
50
50
50
50
50
20
20
20
20
20
SG1-Start
50
50
50
50
50
SG1- Cut
18
18
18
18
10
SG2- Cut Flow
0
0
0
0
0
108
111
114
121
124
60
50
45
35
20
1524
1270
1143
889
508
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-29
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Carbon Steel
70
Plasma Gas: Oxygen (O2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Oxygen (O2) @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21543, "D"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-30
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
70 Amperes
Carbon Steel
Process Data
PG
SG1
SG2
O2
N2
O2
0.187
0.250
0.312
0.375
0.500
0.625
MM
4,7
6,4
7,9
9,5
12,7
12,9
Pierce Delay (SEC.)
0.3
0.3
0.3
0.4
0.5
0.5
60
60
60
60
60
60
25
25
25
25
25
25
SG1-Start
60
60
60
60
60
60
SG1- Cut
33
33
33
33
20
20
SG2- Cut Flow
0
0
0
0
0
0
108
110
114
113
135
140
IPM
110
95
70
60
30
25
MM/MIN
2794
2413
1778
1524
762
635
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-31
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Carbon Steel
100
Plasma Gas: Oxygen (O2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Oxygen (O2) @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-32
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
100 Amperes
Carbon Steel
Process Data
PG
SG1
SG2
O2
N2
O2
0.312
0.375
0.500
0.625
0.750
MM
7,9
9,5
12,9
15,9
19,1
Pierce Delay (SEC.)
0.3
0.3
0.4
0.5
0.5
80
80
80
80
80
30
30
30
30
30
SG1-Start
60
60
60
60
60
SG1- Cut
30
30
30
30
30
SG2- Cut Flow
0
0
0
0
0
115
120
132
137
143
90
80
50
30
25
2290
2030
1270
760
630
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-33
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
30
Plasma Gas: Oxygen (O2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Oxygen (O2) @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21536 (3 holes)
! Nozzle
P/N 21541, "B"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-34
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
30 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
O2
N2
O2
26GA
24GA
22GA
18GA
16GA
0,4
0,6
0,7
1,2
1,6
0
0
0
0
0
45
45
45
45
45
18
18
18
18
18
SG1-Start
40
40
40
40
40
SG1- Cut
20
20
20
20
20
SG2- Cut Flow
5
5
5
5
5
105
105
107
109
111
IPM
250
200
190
140
100
MM/MIN
6350
5080
4826
3556
2540
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-35
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
50
Plasma Gas: Air @ 125 psi (8.6 bar)
Shield Gas: Air @ 125 psi (8.6 bar)
Shield Mix Gas: Air @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21542, "C"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-36
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
50 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
Air
Air
Air
0.125
0.187
0.250
0.375
3,2
4,7
6,4
9,5
0
0
0.1
0.2
60
60
60
60
95
95
95
95
SG1-Start
45
45
45
45
SG1- Cut
35
35
35
35
SG2- Cut Flow
0
0
0
0
134
140
145
157
90
60
40
22
2286
1524
1016
559
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-37
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
70
Plasma Gas: Air @ 125 psi (8.6 bar)
Shield Gas: Air @ 125 psi (8.6 bar)
Shield Mix Gas: Air @ 125 psi (8.6 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21543, "D"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-38
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
70 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
Air
Air
Air
0.187
0.250
0.375
0.500
MM
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
70
70
70
70
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
40
40
40
40
SG2- Cut Flow
0
0
0
0
131
152
158
162
IPM
100
50
28
24
MM/MIN
2540
1270
711
609
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-39
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
100
Plasma Gas: Air @ 125 psi (8.6 bar)
Shield Gas: Air @ 125 psi (8.6 bar)
Shield Mix Gas: Air @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-40
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
100 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
Air
Air
Air
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
15,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
65
65
65
70
SG1-Start
60
60
60
60
SG1- Cut
35
35
35
40
SG2- Cut Flow
0
0
0
0
129
135
142
150
80
60
35
25
2030
1520
889
635
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-41
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
70
Plasma Gas: Air @ 125 psi (8.6 bar)
Shield Gas: Air @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21543, "D"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-42
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
70 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
Air
Air
CH4
0.125
0.187
0.250
0.387
0.500
MM
3,2
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.2
0.3
0.4
0.5
0.6
70
70
70
70
70
100
100
100
100
100
SG1-Start
60
60
60
60
60
SG1- Cut
40
40
40
40
40
SG2- Cut Flow
10
10
10
10
10
131
146
154
166
175
IPM
120
80
50
30
24
MM/MIN
3048
2032
1270
762
609
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-43
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
100
Plasma Gas: Air @ 125 psi (8.6 bar)
Shield Gas: Air @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-44
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
100 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
Air
Air
CH4
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
15,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
100
100
100
100
SG1-Start
60
60
60
60
SG1- Cut
40
40
40
40
SG2- Cut Flow
10
10
10
10
140
150
159
170
80
60
35
25
2030
1524
889
635
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-45
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
50
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21542, "C"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-46
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
50 Amperes
Stainless Steel
Process Data
PG
SG1
N2
N2
0.125
0.187
0.250
0.375
3,2
4,7
6,4
9,5
0
0
0.1
0.2
60
60
60
60
85
85
85
85
SG1-Start
45
45
45
45
SG1- Cut
35
35
35
35
SG2- Cut Flow
0
0
0
0
128
133
144
155
90
60
40
22
2286
1524
1016
558
Material Thickness
IN
MM
Pierce Delay (SEC.)
SG2
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-47
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
70
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21543, "D"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-48
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
70 Amperes
Stainless Steel
Process Data
PG
SG1
N2
N2
0.187
0.250
0.375
0.500
MM
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
70
70
70
70
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
40
40
40
40
SG2- Cut Flow
0
0
0
0
132
150
154
159
75
50
28
24
1905
1270
711
609
Material Thickness
IN
SG2
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-49
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
100
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-50
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
100 Amperes
Stainless Steel
Process Data
PG
SG1
N2
N2
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
15,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
50
35
35
35
SG2- Cut Flow
0
0
0
0
135
145
153
157
80
60
35
25
2032
1520
889
635
Material Thickness
IN
SG2
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-51
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
70
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
! Swirl Baffle
P/N 21692 (4 holes)
! Nozzle
P/N 21543, "D"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-52
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
70 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
N2
N2
CH4
0.187
0.250
0.375
0.500
MM
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
75
75
75
75
85
85
85
85
SG1-Start
60
60
60
60
SG1- Cut
43
43
43
43
SG2- Cut Flow
5
5
5
5
136
150
159
162
70
50
28
24
1778
1270
711
609
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-53
SECTION 4
OPERATION
Material:
Amperes:
RECISION
LASMARC
Stainless Steel
100
Plasma Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Gas: Nitrogen (N2) @ 125 psi (8.6 bar)
Shield Mix Gas: Methane (CH4) @ 100 psi (6.9 bar)
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-54
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
100 Amperes
Stainless Steel
Process Data
PG
SG1
SG2
N2
N2
CH4
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
5,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
45
45
45
45
SG2- Cut Flow
5
5
5
7
138
150
162
170
80
60
35
25
2032
1524
889
635
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-55
SECTION 4
OPERATION
Plasma Marking “B” Nozzle
Amperes: 10
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21536 (3 Holes)
!Nozzle
P/N 21541 “B”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-56
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“B” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
35
35
SG1-Start
35
SG1- Cut
35
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
200
MM/MIN
5080
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-57
SECTION 4
OPERATION
Plasma Marking “B” Nozzle
Amperes: 15
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21536 3 holes
!Nozzle
P/N 21541 “B”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-58
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“B” Nozzle
Plasma Marking
15 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
35
35
SG1-Start
35
SG1- Cut
35
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
300
MM/MIN
7620
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-59
SECTION 4
OPERATION
Plasma Marking “C” Nozzle
Amperes: 10
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21542 “C”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-60
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“C” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
62
62
SG1-Start
37
SG1- Cut
37
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
100
MM/MIN
2540
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-61
SECTION 4
OPERATION
Plasma Marking “C” Nozzle
Amperes: 15
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21542 “C”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-62
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“C” Nozzle
Plasma Marking
15 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
62
62
SG1-Start
35
SG1- Cut
35
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
200
MM/MIN
5080
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-63
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
Amperes: 10
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21543 “D”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-64
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
77
77
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
100
MM/MIN
2540
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-65
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
Amperes: 15
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-66
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
15 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
62
62
SG1-Start
37
SG1- Cut
37
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
300
MM/MIN
7620
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-67
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
Amperes: 20
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21543 “D”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-68
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
20 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
77
77
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
200
MM/MIN
5080
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-69
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
Amperes: 30
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21543 “D”
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-70
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
30 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
77
77
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
MM/MIN
500
12700
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-71
SECTION 4
OPERATION
Plasma Marking “E” Nozzle
Amperes: 10
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-72
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“E” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
85
85
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
100
MM/MIN
2540
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-73
SECTION 4
OPERATION
Plasma Marking “E” Nozzle
Amperes: 20
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-74
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“E” Nozzle
Plasma Marking
20 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
85
85
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
300
MM/MIN
7620
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-75
SECTION 4
OPERATION
Plasma Marking “E” Nozzle
Amperes: 30
RECISION
LASMARC
Plasma Gas: Argon @ 125 PSI / 8.6 Bar
Shield Gas: Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
!Swirl Baffle
P/N 21692 (4 holes)
!Nozzle
P/N 21923, "E"
Nozzle
Retainer/Diffuser
Shield Cup Insulator
P/N 22010
Insulator Shield
Retainer w/O-Ring
O-Ring - Shield Retainer
. (Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage
4-76
Precision Plasma with Electronic Flow Control -
SECTION 4
OPERATION
“E” Nozzle
Plasma Marking
30 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
85
85
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
MM/MIN
500
12700
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
Precision Plasma with Electronic Flow Control -
4-77
SECTION 4
OPERATION
4.4.3.1 Aluminum Kerf Values N2/N2/CH4
Aluminum N2/N2/CH4 30 Amperes
Material Thickness (mm)
1.575
1.905
2.286
3.175
4.750
6.350
0.140
3.556
0.120
3.048
0.100
2.540
0.080
0.087
1.524
0.060
1.270
1.270
2.032
1.651
1.524
0.065
1.270
0.060
0.040
0.050
0.050
0.050
Kerf (mm)
Kerf (inches)
2.210
1.016
0.020
0.508
0.000
0.000
0.062
0.075
0.090
0.125
0.187
0.250
Material Thickness (inches)
Aluminum N2/N2/CH4 50 Amperes
Material Thickness (mm)
3.175
4.775
0.140
3.556
0.120
3.048
2.362
0.100
Kerf (inches)
6.350
2.032
0.080
1.651
0.093
2.032
0.080
1.524
0.060
1.524
0.065
0.060
0.040
1.016
0.020
0.508
0.000
0.000
0.062
0.125
0.188
Material Thickness (inches)
4-78
2.540
Precision Plasma with Electronic Flow Control -
0.250
Kerf (mm)
1.575
SECTION 4
OPERATION
Aluminum N2/N2/CH4 70 Amperes
Material Thickness (mm)
6.350
9.525
12.700
0.190
4.826
0.170
4.318
0.150
3.810
0.130
3.048
3.302
2.845
0.110
0.090
2.540
0.112
2.540
0.100
0.120
0.100
2.794
Kerf (mm)
Kerf (inches)
4.750
2.286
0.070
1.778
0.050
1.270
0.187
0.250
0.375
0.500
Material Thickness (inches)
Aluminum N2/N2/CH4 100 Amperes
Material Thickness (mm)
9.525
12.700
15.875
0.190
4.826
0.170
4.318
0.150
3.810
3.302
0.130
3.302
2.921
0.110
0.090
2.667
2.540
0.100
0.130
2.794
0.115
Kerf (mm)
Kerf (inches)
6.350
0.105
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
0.625
Material Thickness (inches)
Precision Plasma with Electronic Flow Control -
4-79
SECTION 4
OPERATION
4.4.3.2 Carbon Steel Kerf Values O2/N2/O2
Carbon Steel O2/N2/O2 16 Amperes
Material Thickness (mm)
3.404
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.473
0.060
1.524
1.118
0.040
0.058
Kerf (mm)
Kerf (inches)
1.219
1.016
0.044
0.020
0.508
0.000
0.000
0.048
0.134
Material Thickness (inches)
Carbon Steel O2/N2/O2 35 Amperes
Material Thickness (mm)
3.175
6.350
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.499
0.060
1.524
1.321
1.168
0.059
0.052
0.040
1.016
0.046
0.020
0.508
0.000
0.000
0.060
0.125
Material Thickness (inches)
4-80
Precision Plasma with Electronic Flow Control -
0.250
Kerf (mm)
Kerf (inches)
1.524
SECTION 4
OPERATION
Carbon Steel O2/N2/O2 45 Amperes
Material Thickness (mm)
3.175
6.350
9.525
0.140
3.556
0.120
3.048
2.413
2.540
0.095
1.930
0.080
1.626
0.060
2.032
0.076
1.524
0.064
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
0.100
0.000
0.125
0.250
0.375
Material Thickness (inches)
Carbon Steel O2/N2/O2 70 Amperes
Material Thickness (mm)
3.429
6.350
9.525
12.700
0.140
3.556
0.120
3.048
2.540
2.540
2.032
0.080
1.778
1.575
0.100
2.032
0.080
0.070
0.060
1.524
0.062
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
0.100
0.000
0.135
0.250
0.375
0.500
Material Thickness (inches)
Precision Plasma with Electronic Flow Control -
4-81
SECTION 4
OPERATION
Carbon Steel O2/N2/O2 100 Amperes
Material Thickness (mm)
9.525
12.700
19.050
0.140
3.556
3.048
0.120
3.048
0.120
2.540
0.100
2.540
2.337
0.080
0.092
2.032
0.060
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.375
0.500
Material Thickness (inches)
4-82
Precision Plasma with Electronic Flow Control -
0.750
Kerf (mm)
Kerf (inches)
0.100
SECTION 4
OPERATION
4.4.3.3 Stainless Steel Kerf Values O2/N2/O2
Stainless Steel O2/N2/O2 30 Amperes
Material Thickness (mm)
0.584
0.726
1.207
1.588
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
0.060
1.524
1.143
0.040
0.889
0.035
0.889
0.035
0.889
0.035
0.889
0.045
Kerf (mm)
Kerf (inches)
0.457
1.016
0.035
0.020
0.508
0.000
0.000
26GA
24GA
22GA
18GA
16GA
Material Thickness (inches)
Precision Plasma with Electronic Flow Control -
4-83
SECTION 4
OPERATION
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4
Stainless Steel Air/Air/CH4 70 Amperes
Material Thickness (mm)
3.175
4.775
6.350
9.525
12.700
0.140
3.556
2.921
0.120
0.115
2.540
0.100
3.048
2.540
2.286
2.032
0.080
0.090
1.778
2.032
0.080
0.060
0.070
1.524
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
0.100
0.000
0.125
0.188
0.250
0.375
0.500
Material Thickness (inches)
Stainless Steel Air/Air/CH4 100 Amperes
Material Thickness (mm)
9.525
12.700
0.190
4.826
0.170
4.318
0.150
Kerf (inches)
15.875
3.556
0.130
3.048
0.140
0.120
0.110
3.810
3.302
2.794
2.540
2.286
0.100
0.090
2.286
0.090
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
4-84
Precision Plasma with Electronic Flow Control -
0.625
Kerf (mm)
6.350
SECTION 4
OPERATION
4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4
Stainless Steel N2/N2/CH4 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
2.921
0.120
3.048
2.667
2.032
2.540
0.105
0.095
0.080
2.032
0.080
0.060
1.524
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
0.115
2.413
0.100
0.000
0.187
0.250
0.375
0.500
Material Thickness (inches)
Stainless Steel N2/N2/CH4 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
0.190
4.826
0.170
4.318
3.810
3.810
3.302
0.150
0.130
3.302
0.130
2.794
0.110
2.794
2.540
0.110
0.090
0.100
Kerf (mm)
Kerf (inches)
0.150
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
0.625
Material Thickness (inches)
Precision Plasma with Electronic Flow Control -
4-85
SECTION 4
OPERATION
4.4.3.6 Stainless Steel Kerf Values N2/N2
Stainless Steel N2/N2 50 Amperes
Material Thickness (mm)
4.750
6.350
9.525
0.140
3.556
0.120
3.048
0.100
2.540
2.032
0.080
2.032
1.778
1.524
0.060
0.080
1.651
0.070
0.065
1.524
0.060
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
3.175
0.000
0.125
0.187
0.250
0.375
Material Thickness (inches)
Stainless Steel N2/N2 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
0.120
3.048
2.540
0.100
2.286
2.540
2.286
0.080
0.060
1.778
0.090
2.032
0.070
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.187
0.250
0.375
Material Thickness (inches)
4-86
Precision Plasma with Electronic Flow Control -
0.500
Kerf (mm)
Kerf (inches)
0.100
0.090
SECTION 4
OPERATION
Stainless Steel N2/N2 100 Amperes
Material Thickness (mm)
9.525
12.700
0.190
4.826
0.170
4.318
0.150
Kerf (inches)
15.875
3.556
0.130
3.048
2.794
0.110
0.140
0.120
3.810
3.302
2.794
2.540
0.110
0.090
0.100
Kerf (mm)
6.350
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
0.625
Material Thickness (inches)
Precision Plasma with Electronic Flow Control -
4-87
SECTION 4
OPERATION
4.4.3.7 Stainless Steel Kerf Values Air/Air
Stainless Steel Air/Air 50 Amperes
Material Thickness (mm)
4.750
6.350
0.140
3.556
0.120
3.048
2.413
0.100
Kerf (inches)
9.525
2.032
2.540
0.095
0.080
2.032
1.524
0.060
0.080
1.651
1.524
0.065
0.060
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
3.175
0.000
0.125
0.187
0.250
0.375
Material Thickness (inches)
Stainless Steel Air/Air 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
2.921
0.110
0.100
Kerf (inches)
2.921
2.794
0.115
0.115
2.540
1.905
0.080
2.032
0.075
0.060
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.187
0.250
0.375
Material Thickness (inches)
4-88
3.048
Precision Plasma with Electronic Flow Control -
0.500
Kerf (mm)
0.120
SECTION 4
OPERATION
Stainless Steel Air/Air 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
0.190
4.826
4.064
Kerf (inches)
0.150
3.556
3.302
0.130
2.921
0.110
0.160
0.140
4.318
3.810
3.302
0.130
2.794
0.115
0.090
2.286
0.070
1.778
0.050
Kerf (mm)
0.170
1.270
0.250
0.375
0.500
0.625
Material Thickness (inches)
Precision Plasma with Electronic Flow Control -
4-89
SECTION 4
OPERATION
Page intentionally left blank.
4-90
Precision Plasma with Electronic Flow Control -
SECTION 5
Maintenance
5.1 General
If this equipment does not operate properly, stop
work immediately and investigate the cause.
Qualified personnel must perform maintenance work.
Do NOT permit untrained persons to inspect, clean
or repair equipment. Use only recommended
replacement parts.
Electric Shock Can Kill!
WARNING
Before attempting any inspection or repair inside
any of the components of the Precision Plasma,
open wall disconnect or wall circuit breaker.
5.2 Inspection And Cleaning
Frequent inspection and cleaning of the Precision
Plasmarc System is recommended for safety and
proper operation. Consider the following during
inspection and cleaning:
Location of pump
filter
CAUTION
•
Check work cable to workpiece connection.
•
Check safety earth ground at workpiece and at
power source chassis.
•
Check heat shield on torch. Replace if damaged.
•
Check torch electrode and cutting nozzle for wear
daily.
•
Ensure cable and hoses are not damaged or
kinked.
•
Ensure all plugs, fittings, and ground connections
are tight.
•
Check screen filter in coolant pump located
inside Power Source periodically and flush as
required.
Flying Debris Hazard.
Flying Debris Can Seriously Injure Eyes
Wear protective eyewear whenever cleaning with
compressed air.
PT-24 Precision Plasmarc with EFC
5-1
SECTION 5
Maintenance
Avoid Potential Equipment Damage
CAUTION
Water and/or oil can accumulate in compressed
air lines. Be sure to direct the first air blast away
from equipment to avoid damaging the junction
box or flow control box.
•
With all input power disconnected and with
proper eye and face protection, blow out the
inside of the power source, flow control, and
junction box using low-pressure, clean/dry
compressed air.
•
Occasionally, bleed all water from the filter below
the air filter-regulator.
•
Mounting. The torch can be mounted by the 2"
(51 mm) dia. sleeve or by the 1.812" (46 mm) dia
machined surface shown. This insulated surface
and its shoulder are machined relative to the
nozzle retainer thread on the torch body. They
are held concentric to the cutting nozzle within a
total indicator reading of 0.010" (0.25 mm) or the
nozzle bore is within 0.005" (0.127 mm) of any
point on the 1.812" (46 mm) dia.
When
mounting, do not to cover the small vent hole in
the side of the sleeve. This hole prevents coolant
from building inside the sleeve if a leak occurs.
•
Service Lines. 4.5 ft. (1.4m), 12 ft. (3.7m), 17ft.
(5.2m) and 20 ft. (6.1m) lines are shielded and
connect to the junction box by a friction fit
grounded connection.
5.3 PT-24 Torch Description
1.812" (46 mm)
Diameter Collar
2.0" (51 mm)
Diameter Sleeve
Vent Hole
5-2
PT-24 Precision Plasmarc with EFC
SECTION 5
Maintenance
Argon
O2
125 psi
Process
Air
•
N2
125 psi
H35
100 psi
CH4
100 psi
Gas In from supply
Plasma Cut and Start Gas. These gases enter
the torch through connections that house check
valves within the torch body. The valves acting in
conjunction with solenoid valves control the back
and forth switching of start and cut gases.
Ar
AIR-1
O2-1
N2-1
PS1
AIR-2
N2-2
METH
Process Air
Pressure Switch
O2-2
GAS FLOW SCHEMATIC
N2-3
METH
Air
O2
N2
Ar
Solenoid Valve
Pressure Switch
PS5
PS4
PS2
PS3
Sentronic Valve
Flow Meter
Check Valve
Interface
Board
VALVE 4
6-BAR
SENTRONIC
VALVE 3
6-BAR
SENTRONIC
VALVE 2
9-BAR
SENTRONIC
VALVE 1
9-BAR
SENTRONIC
Check Valve
2 Way Solenoid Valve
SG2
BLK
SG1
ORG
PG2
YEL
PG1
BLU
Gas Quick Coupling
EFC J-Box
SG2
SG1
PG2
PG1
Electronic
Manifold
Assembly
Note: Shop air should not be
used for process air.
PT-24 Torch
PT-24 Precision Plasmarc with EFC
5-3
SECTION 5
Maintenance
•
Shield Gas. Shield preflow, cut shield and
postflow enter the torch through one connection.
These gases pass through:
ƒ
the torch body,
ƒ
the shield gas diffuser,
ƒ
•
out the orifice in the shield cap surrounding
the plasma jet.
Power and Pilot Arc Lines. Coolant IN to the
torch is through the power cable (-). Coolant
OUT from the torch is through the pilot arc (+)
line.
Water Cooling.
1. Coolant enters the torch through the power cable
(-),
Coolant In via
Power Cable
Coolant Out via
Pilot Arc Cable
Crossover
Tube
2. circulates through the torch body and the
electrode,
3. crosses over to the nozzle (+) section of the torch
body through nonconductive crossover tubes,
4. travels back through the body and circulates
between the nozzle retainer and the nozzle,
5. back through the torch body to the junction box
via the pilot arc cable.
Electrode Body
Pilot Arc Body
Swirl Baffle
Water Baffle
Electrode
Nozzle
Nozzle Retainer
5-4
PT-24 Precision Plasmarc with EFC
SECTION 5
Maintenance
5.4 Torch Maintenance
WARNING
Electric Shock Can Kill
Before performing torch maintenance:
•
Turn power switch on the console to the OFF
position.
•
Disconnect primary input power.
Torch Body O-Rings
O-ring
P/N 950714
•
Each day before starting operation, check Orings on the torch body . Replace if damaged or
worn.
•
Apply a thin coat of silicone grease to O-rings
before assembling to torch. Do not use Krytox.
•
The O-ring, P/N 638797, inside the torch body
that seals the nozzle is especially critical.
O-ring
P/N 86W62
O-ring
P/N 638797
ƒ
Damage or wear is not readily apparent
because of its location,
ƒ
We recommend replacing this O-ring on a daily
basis.
ƒ
Be careful not to scratch or damage the torch
surface.
ƒ
A wooden toothpick works well for removing Orings.
ƒ
The O-ring can be replaced without removing
the water baffle P/N 21725; however if the baffle
is removed, always use a 3/16" (5 mm) hex
wrench or nut driver.
Torch Sleeve Vent
•
Water leaks, moisture or coolant dripping from
the sleeve vent hole indicates service line
damage.
•
If service lines must be replaced, always use two
wrenches to avoid twisting the metal tubes.
Vent Hole
PT-24 Precision Plasmarc with EFC
5-5
SECTION 5
Maintenance
Sleeve P/N 22568
Torch Sleeve
Check Valve Body
P/N 21739
Ball P/N 21740
Spring P/N 21741
5-6
The torch sleeve P/N 22568 is threaded onto the
torch body.
•
If the sleeve is too tight for hand removal, use a
large adjustable wrench on the body flats or
lightly tighten these flats in a vise. With the body
secured, using two hands on the sleeve may
break it free. If not, use a strap wrench.
•
Before replacing sleeve, always check service
line connections for leaks.
Damaged Or Incorrect Torch Check Valve
Parts Will Affect Cutting Performance.
CAUTION
CAUTION
•
•
Do not damaged the check valve seat, ball
and spring when handling.
•
Do not substitute any other spring or ball. If
they are lost, dropped, or damaged, they must
be replaced with factory replacement parts.
•
Using non-authorized or damaged torch
check valve parts will affect set pressures
and cause poor starting and piercing.
Improperly Seated Fittings Will Cause Leaks
And Poor Performance.
•
Keep threads and seat surfaces clean when
re-assembling check valves.
•
If dirt or foreign matter contaminates check
valves, disassemble, clean or replace.
PT-24 Precision Plasmarc with EFC
SECTION 5
Maintenance
5.5 PT-24 Consumable Disassembly And Inspection
Electric Shock Can Kill!
WARNING
•
Turn power switch on the console OFF.
•
Disconnect primary input power.
If the nozzle retainer/diffuser is difficult to
remove, the console may be on because of
pressure inside the torch.
PT-24 Front End
NOTE:
If the console is on, the pump will be running and
coolant pressure behind the retainer will prevent it
from turning freely. Check the console before
attempting to remove the nut. Notice that a small
amount of coolant is lost each time consumables are
removed. This is normal and the coolant will
eventually have to be replaced. Check coolant
before each operation.
1. Unscrew the cup shield/retainer. Inspect around
orifice for damage. Replace orifice edge if nicked
or damaged. A distorted orifice will not
produce straight cuts.
Shield Cup
Insulator
2. Unscrew and remove insulator shield
Insulator Shield
Retainer
Cup Shield
w/Retainer
3. The shield cup insulator is sandwiched between
the cup and the nozzle retainer/diffuser. It may
remain attached to nozzle retainer because of the
very close fit between these members.
PT-24 Precision Plasmarc with EFC
5-7
SECTION 5
Maintenance
4. Unscrew the nozzle retainer/diffuser. Inspect for
damage, especially where the retainer contacts
the nozzle. The surface between the retainer
and the nozzle creates a metal to metal seal for
the coolant. Any damage to this sealing surface
will cause a leak resulting in poor cutting.
Replace as necessary, but do not attempt to
repair. Check small gas passages for blockages.
Clear blockages with an air stream.
Nozzle
Nozzle
Retainer
No damage to the
contact area.
Nozzle
5. Use the tool provided to remove the nozzle.
Place the slot around the nozzle groove and pull
it free.
Electrode and Nozzle Tool P/N 21765
Electrode
6. Remove the swirl baffle from the nozzle. If the
baffle remains in the torch, it will come free when
removing the electrode. Check the small gas
passages of the swirl baffle for blockage and
clear blockages with an air stream. If blockages
cannot be cleared, replace baffle. Do NOT insert
anything in these holes when trying to clear them.
Distorting these holes will impair cutting
performance.
Swirl Baffle
Nozzle
5-8
PT-24 Precision Plasmarc with EFC
SECTION 5
Maintenance
7. Use the electrode and nozzle tool provided to
unscrew the electrode. (P/N 21765).
5.6 PT-24 Torch Tip Re-assembly
1. Electrode
Apply a thin film of silicone grease to the O-ring, just
enough to produce a shiny surface. Thread
electrode in place and tighten snugly with tool
provided. DO NOT OVER TIGHTEN.
Nozzle Retainer
2. Nozzle & Swirl Baffle
Nozzle
Small Amount
of Krytox
Place swirl baffle into nozzle with the grooved end of
the baffle going inside nozzle.
When properly assembled, the small spherical tip of
nozzle makes a metal to metal coolant seal with the
nozzle retainer. Apply a small amount of Krytox
(anti-seizing compound) on the small diameter of the
nozzle retainer as shown. This grease prevents
possible galling/seizing between the nozzle and
retainer. It also facilitates a watertight seal. Do not
put Krytox on nozzle.
3. Nozzle Retainer/Diffuser
Thread the nozzle retainer onto torch and hand
tighten.
Water Seal
PT-24 Precision Plasmarc with EFC
5-9
SECTION 5
Maintenance
4. Shield Cup Insulator
Shield Cup
Insulator
Push the shield cup insulator on the nozzle retainer.
This component is a press fit and may remain
assembled when the assembly was taken apart.
Nozzle Retainer
5. Insulator Shield Retainer
Apply a thin coat of silicone grease to the O-ring and
thread insulator shield retainer on to Shield Cup.
Hand tighten.
NOTICE
Do not attach insulator to the torch
body first.
Threading insulator on to torch body first will not
allow shield gases to flow properly. Thread
insulator onto the shield cup first and then attach
both pieces onto the torch body.
6. Shield Cup And Retainer
Screw this assembly (Insulator/Shield Cup and
Retainer) onto the torch and hand tighten.
CAUTION
5-10
O-Ring Inspection & Lubrication
•
Inspect O-rings often for nicks and wear.
Worn or damaged O-rings will affect starting
and cut quality.
•
Applying a thin coat of silicone grease to the
torch tip O-rings during service assembly will
facilitate future disassembly.
•
Do not use Krytox on O-rings. Krytox is an
anti-seize lubricant and will dissipate over
time. Disassembly will be difficult.
PT-24 Precision Plasmarc with EFC
SECTION 6
TROUBLESHOOTING
6.1 General Safety
WARNING
WARNING
Electric Shock Can Kill!
Externally disconnect all primary power to
the machine before servicing.
Open the line (wall) disconnect switch or
circuit breaker before attempting
inspection or work inside the power
source.
High Voltages Can Be Stored In
Capacitors.
Even when power is disconnected or unit
is de-energized, capacitors can store high
voltages. Assure power supply capacitors
are grounded prior to performing
maintenance.
6.2 Programmable Logic Controller (PLC)
NOTICE
All PT-24 Precision power consoles do not
utilize a PLC. PLC functions were
transferred to the Vision CNC and ceased
to be necessary. Disregard information
under this header (6.2) if not present in
your console.
•
Located in the Precision Plasma Power
Source.
•
Capable of providing predefined outputs
depending on state of the inputs. The precise
conditions are programmed and permanently
stored in the PLC.
•
Visible through the plexiglas window on the left
side panel of the power source.
•
Provides predefined outputs in response to
input signals from external devices.
•
The signal exchange between the PLC and
external devices are both time dependent and
condition dependent. If a required signal is not
received in the proper sequence, the PLC will
discontinue the process and generate a fault
signal to the CNC.
6-1
SECTION 6
TROUBLESHOOTING
6.2.1 PLC LEDs (Light Emmiting Diode)
OUTPUT
Highly reliable indicators. It is not likely that one
will "burn out". However, if the technician is not
confident that the LEDs are working, the presence
of a signal can be confirmed by using a meter and
taking a measurement on the appropriate pin.
Refer to the schematic and wiring diagrams.
1 CH
0 1 2 3 4 5 6 7
8 9 10 11
•
This exchange of signals can be confirmed by
observing the LEDs on the top of the PLC
while troubleshooting. These indications are
useful in isolating a system failure to the most
likely device.
•
The LEDs are divided into two groups;
POWER
RUN
ALARM
ERROR
INPUT
ƒ
Input (0-15) light when the corresponding
signal is detected by the PLC.
ƒ
Output (0-11) light when the PLC issues a
signal to an external device.
0 CH
0 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
6.2.2 PLC LED Functions
INPUT
OUTPUT
LED
Function
LED
Function
0
Start/Stop
0
Not Used
1
Not Used
1
Hi-Frequency
2
Arc-On
2
Pilot Arc Relay
3
Not Used
3
Power Source
4
Not Used
4
Not Used
5
Fault
5
Fault Output
6
Not Used
6
Not Used
7
Not Used
7
Not Used
8
Not Used
8
Not Used
9
Not Used
9
Not Used
10
Not Used
10
Not Used
11
Not Used
11
Not Used
12
Not Used
13
Not Used
14
Not Used
15
Not Used
6-2
SECTION 6
TROUBLESHOOTING
6.3 Troubleshooting Guide
6.3.1 Reduced Consumable Life
Cutting Up Skeletons Cutting skeletons (discarded material left after all
pieces have been removed from a plate) to
facilitate their removal from the table can
adversely affect electrode life by:
•
Causing the torch to run off the work.
•
Continuous Pilot Arc edge starts
•
Greatly increasing the frequency of starts.
This is mainly a problem for O2 cutting and can
be alleviated by choosing a path with a
minimum number of starts.
•
Increase likelihood that the plate will spring up
against the nozzle causing a double arc. This
can be mitigated by careful operator attention
and by increasing standoff and reducing
cutting speeds.
If possible, use a gas torch for skeleton cutting.
Height Control Problems
•
Torch diving is usually caused by a change in
arc voltage when an automatic height control
is in use. Usually the voltage change is the
result of plate falling away from the arc. These
problems can effectively be eliminated by
disabling the height control and extinguishing
the arc earlier when finishing the cut on a
falling plate.
•
Diving can also be caused by a faulty height
control.
Piercing Standoff Too Low Increase pierce standoff
Starting on edges with Position torch more carefully or start on adjacent
continuous pilot arc scrap material.
Work Flipping The nozzle may be damaged if the torch hits a
flipped up part.
Catching on Pierce Spatter Increase standoff or start with longer lead-in
Pierce not complete before starting Increase initial delay time.
6-3
SECTION 6
TROUBLESHOOTING
See Cut Quality In Section 4
6.3.2 Poor Cut Quality
6.3.3 No Pilot Arc
Contaminated Electrode Clean or replace electrode
Insufficient spark gap setting Set spark gap to 0.040” (1.016 mm)
in plumbing box.
Pilot Arc Contactor (PAC) Replace contactor
malfunctioning
6.3.4 No Arc Transfer
Cutting current Raise cutting current (see Process Data)
setting too low.
Torch too high Lower torch standoff (see Process Data)
above workpiece
Work lead not Ensure work lead is firmly connected to workpiece
connect to cutting table or cutting table
N2 or O2 check valve in torch
body may be stuck open
See maintenance section for check valve repair.
6.3.5 No Preflow
No start signal Check input 0 LED on PLC. Should be lit. This
verifies a start command has been given
Emergency stop signal open Check for continuity between TB3-18 and TB3-19
Shorted, closed or jumpered out Check cooling water LED on front panel. Should
Cooling Water Flow Switch be lit.
No Cooling Water Check reservoir. Add coolant until full.
6.3.6 Torch Fails To Fire
Start Gas Lower start gas flow
Cooling water Flow Pump pressure too low. Should be 115psi.
(7.9 bar)
Faulty cooling water flow switch Replace CWFS switch
(CWFS)
Obstruction in torch Coolant flow through torch should be greater than
limiting cooling water flow 0.5 gal/min (1.5 l/min)
6-4
SECTION 6
TROUBLESHOOTING
6.3.7 Nozzle Life Extremely Short
Pilot Arc H/L switch Refer to Process Data
in wrong position
Nozzle arcing inside bore Nitrogen quality too low. Requires 99.995 %
purity
Start gas flow too low Check Process Data cutting parameters
6.3.8 Short Electrode Life
Insufficient cooling Check pump for 115 psi (7.9 bar) output pressure
Start gas quality Gas quality needs to be 99.995 % purity minimum
Cut gas quality Oxygen gas needs to be 99.8 % purity
6.3.9 Short Electrode And Nozzle Life
Water leak on torch front-end Follow torch leak procedure
6-5
SECTION 6
TROUBLESHOOTING
1
2
2
PLASMA GAS 2
SHIELD GAS 1
3
3
SHIELD GAS 1
4
SHIELD GAS 2
COMMON
P4
SHIELD GAS 2
5
PLASMA GAS 1
PLASMA GAS 2
4
PLASMA GAS 1
1
6.4 Flow Control Schematic
5
6
7
A. C. COMMON
8
CHASSIS
P5
COMMON
120 vac (11 ne)
6
4
7
1
2
3
9
9
10
10
1
CHASSIS GROUND
2
24 vdc GROUND
3
VALVE 1 SET PT.
4
VALVE 1 + 24 VDC
5
VALVE 2 SET PT.
6
VALVE 1 GND (GN)
8
4 amp
7
8
5
6
VALVE 1 SHIELD (SH)
FUSED 24vac TO CNC
24vac COMMON
VALVE 2 +24 VDC
VALVE 1 SET PT. (SP)
VALVE 1 +24 VALVE (PR)
}
PLASMA GAS 1
VALVE 2 SHIELD (SH)
VALVE 2 GND (GN)
VALVE 2 SET PT. (SP)
VALVE 2 +24V (PR)
}
PLASMA GAS 2
}
SHIELD GAS 1
}
SHIELD GAS 2
VALVE 3 SHIELD (SH)
P1
VALVE 3 GND
VALVE 3 SET PT.
8
VALVE 3 +24 VDC
9
VALVE 4 SET PT.
10
VALVE 4 +24 VDC
1
PRES. SW. 15 V. SOURCE (SR1)
2
PRES. SW 24 V. SOURCE (SR2)
3
VALVE 3 +24 V (PR)
7
VALVE 3 SET PT. (SP)
PS5 (SHIELD GAS 2)
VALVE 4 SHIELD (SH)
VALVE 4 GND (GN)
VALVE 4 SET PT. (SP)
VALVE 4 +24V (PR)
{
{
{
{
{
PS5
JP1
(SHIELD GAS 2)
PS5
PS4
JP2
(SHIELD GAS 1)
4
PS4
P2
PS1
PS1 (PROCESS AIR)
SELECTOR VALVE COMMON
1
METHANE
2
H-35 NOT USED
3
N2-3
4
N2-2
5
N2-1
RC1
8
1
METH
2
H-35
3
SOLENOID
METH
7
(PROCESS AIR)
PS2 (PLASMA GAS 1)
JP5
PS1
H.F 120 V FROM POWER SUPPLY
H.F. 120 V TO J-BOX
6
PS2
10
JP4
PS2
(PLASMA GAS 1)
PS3 (PLASMA GAS 2)
5
PS3
PS4 (SHIELD GAS 1)
H.F. 120 V FROM POWER SUPPLY
H.F. 120 V TO J-BOX
JP3
(PLASMA GAS 2)
9
PS3
1 amp
N-3
RC2
4
5
SOLENOID
H-35
1 amp
RC3
6
N-2
7
SOLENOID
N-3
1 amp
RC4
8
N-1
9
N-1
10
O-2
11
O-2
12
O-1
13
SOLENOID
N-2
1 amp
RC5
SOLENOID
1 amp
P3
RC6
6
7
O2-1
8
AIR-2
9
AIR-1
10
SOLENOID
O2-2
ARGON
1 amp
15
AIR-2
16
AIR-1
17
AIR-1
18
AR
19
RC7
14
SOLENOID
O-1
AIR-2
1 amp
RC8
SOLENOID
1 amp
RC9
SOLENOID
1 amp
RC10
20
SOLENOID
1 amp
TB1
6-6
SECTION 6
TROUBLESHOOTING
Process Air
125 psi
Argon
125 psi
O2
125 psi
N2
125 psi
H35
100 psi
CH4
100 psi
6.5 Gas Flow Schematic
Ar
AIR-1
O2-1
N2-1
PS1
AIR-2
N2-2
METH
O2-2
N2-3
METH
N2
O2
Air
Solenoid Valve
Ar
Pressure Switch
PS5
PS4
PS2
PS3
Sentronic Valve
Flow Meter
Check Valve
Interface
Board
VALVE 4
6-BAR
SENTRONIC
VALVE 3
6-BAR
SENTRONIC
VALVE 2
9-BAR
SENTRONIC
VALVE 1
9-BAR
SENTRONIC
Check Valve
2 Way Solenoid
Valve
SG2
BLK
SG1
ORG
PG2
YEL
PG1
BLU
Gas Quick Coupling
EFC Junction
Box
Electronic
Manifold
Assembly
PT-24 Torch
6-7
SECTION 6
6.6 Junction Box Wiring Diagram
TROUBLESHOOTING
Drawing 37516
6-8
SECTION 6
TROUBLESHOOTING
TO FLOW
CONTROL J2
6.7 Junction Box Schematic
CABLE
CONNECTIONS
TO CONSOLE
MANIFOLD
EFC A/M
TORCH CONNECTIONS
SCHEMATIC DIAGRAM
6-9
TROUBLESHOOTING
6.8 Power Module Wiring Diagram
PCB2 P1
PCB3 P1
PCB1 P3
PCB1 P4
NEXT PAGE
P3
4 1
P3
C17
C16
P4
1
SECTION 6
4
P4
P5
1
P1
1
PCB1
*
1
J1
1 TS2-2(SPLICE)(VIO)
2 TS1-1(VIO)
3 PCB1 P5-1(ORN)
4 PCB1 P5-2(WHT)
5 PCB1 P5-5(BLK)
6 PCB1 P5-6(RED)
7 PCB1 P6-12(BLU)
8 PCB1 P6-14(BRN)
9 PCB1 P6-13(ORN)
10PCB1 P2-12(YEL)
11PCB1 P2-12(YEL)
12PCB1 P2-13(GRY)
13PCB1 P2-13(GRY)
14PCB1 P6-10(BLK)
15PCB1 P6-11(RED)
16
J1
R2
+
C3
C5
J1-2(VIO)
TS2-1(VIO)
16
L1
SEE NOTE 3
H1
C4(-)
*
*
BR1-F
C9(+) BUSS (BLK)
GND1
C6
R4
1
R5
C7
D2
C9
J2
T3-X2
**
*
1
X1
X2
1
TS2
**
H1
MOV3
1
10
MOV1
2
*
BR1
*
*
* L2-X1
G
TB2-1(RED)
C8
PCB1 P1-8(ORN)
PCB1 P1-7(ORN)
PCB1 P2-6(BRN)
R9
C15
R7
C13
R3
R5-2(BLK)
T3-H1
T3-H2
J2
* T3-X1
J4
MOV2
+
X1
T2
10
SCR1
X2
TB2-2(GRY)
R8
C14
R6
C12
-
BUSS TO
SH1
C1
D1
J3
1
H3
H1
8
L2
T3
X2
X1
T1
BOTTOM
H2
*
Q1-C2E1
C9(+) BUSS
D1-3
D2-3
**
**
PCB1 P1-4(BRN)
PCB1 P2-11(VIO)
PCB1 P2-14(VIO)
PCB1 P1-3(BRN)
PCB1 P2-4(ORN)
PCB1 P2-1(ORN)
7
8
9
11
10
12
7
T1
TOP
1
6
J3
1 J4-1(BLK)
2 J4-2(WHT)
3 J4-3(RED)
4 J4-4(ORN)
5 J4-5(BLU)
6 J4-6(YEL)
7 J4-7(BRN)
8 J4-8(GRY)
9 J4-9(VIO)
10J4-10(BLK)
D1/D2-2 BUSS
TB3
12
* PCB1 P6-11(RED)
* PCB1 P6-10(BLK)
SEE NOTE 3
BLK R1-1 (YEL)
R1-2 (YEL)
TS1-2(VIO)
J1-1(SPLICE)(VIO)
PCB1 P2-5(YEL)
L1-H1
SH1
+
Q1
C4(+)(WHT)
Q2
1
1
C11
2
TS1
1
2
3
4
5
6
7
8
H2
PCB2
2
PCB3
2
C2
C4
-
-
R1
1
2
+
1
SCR1(+) (YEL)
SCR1(-) (YEL)
2
PCB3 P1
L1-H2
R2-1(BLK)
SCR1(+)(WHT)
R2-2(RED)
C4(+)(RED)
PCB1
C4(-)(BLK)
PCB2 P1
P4
*
*
14
P1
P2
P6
14
12J1-10(YEL)
J1-11(YEL)
13J1-12(GRY)
J1-13(GRY)
14T1-X12(VIO)
PCB1 P6-7(VIO)
P1
1
P6
5 SCR1-G (YEL)
6 SCR1(+) (BRN)
7
8
9
10
11T1-X11(VIO)
P5
1
2 J1-16(WHT)
3
4
5
6
7 PCB1 P2-14 (VIO)
8
9
10 J1-14(BLK)
SH1 (-) (BLK)
11 J1-15(RED)
SH1(+) (RED)
12 J1-7 (BLU)
13 J1-9(ORN)
14 J1-8(BRN)
12
**
1 J1-3(ORN)
2 J1-4(WHT)
3 T1-X1(YEL)
4 T1-X2(YEL)
5 J1-5(BLK)
6 J1-6(RED)
7
8
9
10
11
12
1 T1-X7(ORN)
2
3
4 T1-X8(ORN)
P6
1
PCB1 P1-2(BLK)
PCB1 P1-1(BLK)
T1-X9(BRN)
T1-X10(BRN)
T1-X5(BLU)
T1-X6(BLU)
T2-X2(ORN)
T2-X1(ORN)
T1-X3(WHT)
T1-X4(WHT)
PCB1 P1-12(BLK)
PCB1 P1-11(BLK)
GND1
P5
P2
1
2
3
4
5
6
7
8
9
10
11
12
P2
12
P1
6
PCB1 P1-6(BLU)
PCB1 P1-5(BLU)
PCB1 P1-10(WHT)
6-10
5
4
3
2
1
PCB1 P5-3(YEL)
PCB1 P5-4(YEL)
PCB1 P1-9(WHT)
SECTION 6
TROUBLESHOOTING
Power Module Wiring Diagram Part 2
Previous Page
2
+
C2
C4
-
*
T1-H1(RED)
2
PCB2
T1-H3(GRY)
*
C11
C6
1
1
2
Q1
M1
TB2
* BLK
* BLK
1
2
J4
J4
1
+
G
T2
10
1 J3-1(BLK)
2 J3-2(WHT)
3 J3-3(RED)
4 J3-4(ORN)
5 J3-5(BLU)
6 J3-6(YEL)
7 J3-7(BRN)
8 J3-8(GRY)
9 J3-9(VIO)
10J3-10(BLK)
H1
T3
H2
NOTES:
1DENOTES SELF LEADS.
2DENOTES SPLICE
3- TP DENOTES TWISTED PAIR
4. SOLDERING AND CRIMPING WIRES AND TERMINALS ARE
VERY IMPORTANT TO THE OPERATION AND RELIABILITY
OF THIS POWER MODULE. ADDITIONAL INSPECTION
MUST BE DONE.
*
6-11
J4
1
6
SECTION 6
TROUBLESHOOTING
C1
E1
G1
Q(x) C2E1
G2
E2
E2
C(x)
6.9 Precision Plasma Power Module Schematic
DETAIL
4
6-12
SECTION 6
TROUBLESHOOTING
6.10 Power Module Schematic – CE Version
6-13
SECTION 6
TROUBLESHOOTING
6.11 Power Module Wiring Diagram – CE Version
Page 1
6-14
SECTION 6
TROUBLESHOOTING
Power Module Wiring Diagram
Page 2
6-15
SECTION 6
TROUBLESHOOTING
6.12 Precision Plasma Power Source Wiring Diagram
Part 1 drawing 37349
PCB1
P1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P2
P4-14(BRN)
P4-13(RED)
PCB1 P1-6(BLK)
PCB1 P1-5(BLK)
PLC1 P2-11(WHT)
PLC1 P2-12(ORN)
PLC1 P2-13(GRY)
PLC1 P2-14(YEL)
PCB1 P1-12(BLK)
PCB1 P1-11(BLK)
MOD1 P1-5 (BLK)
MOD1 P1-6 (RED)
MOD1 P1-2 (BLU)
MOD1 P1-1 (VIO)
PCB1 P1-18(BLK)
PCB1 P1-17(BLK)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
P3
P4-10(VIO)
P4-9(VIO)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P4-8(ORN)
P4-7(ORN)
P3-3(GRY)
P3-4(RED)
P3-5(GRY)
P4-4(BRN)
P4-3(BRN)
P4-2(BLU)
P4-1(BLU)
P3-1(YEL)
P3-2(YEL)
P4-11(GRY)
P4-12(BLU)
MOD1 P1-3(ORN)
MOD1 P1-4(WHT)
PCB-TB P1-6(YEL)
MOD1 P1-7(BLU)
11
12
13
14
15
16
17
18
PLC1 P1-1(BRN)
PLC1 P1-2(GRY)
MOD1 P3-1(RED)
MOD1 P3-2(YEL)
PLC1
PLC1
PLC1
PLC1
P7
P5
P4
1
2
3
4
5
6
7
8
9
10
1
2
PLC1 P1-5 (BLK)
PLC1 P1-6 (VIO)
1 PLC1 P2-5(BLK)
2
3 TB6-5(RED)
P9
P10
1
2
3
4
5
1 MOD1 P1-14(RED)
2
3 MOD1 P1-15(BLK)
S3-5(VIO)
S3-2(RED)
P3-7(BLK)
P3-6(WHT)
P3-8(WHT)
P1-3(YEL)
P1-8(ORN)
P1-3(YEL)
P1-4(WHT)
MOD1
MOD1
MOD1
MOD1
MOD1
MOD1
P3-7(RED)
P3-8(BLK)
P3-9(VIO)
P3-10(YEL)
P3-3(BLU)
P3-4(ORN)
J1
A
B
2
1 3
MOD1 P1-9 (ORN)
S3-1 (BRN)
S3-4 (BLU)
VIEW OF R2
1
P1
PLC1 J2-4 (ORN)
PLC-COMM6 (BLU)
F
PLC-0109 (GRY)
G
K5-A (BLK)
H
SEE
VIEW
OF R2
R2-3(BLU) 4 5 6
1,3
S3
R2-2(BRN) 1 2 3
2
PCB1 P10-2(RED) R2
TB6-7(ORN)
PLC-0108 (YEL)
C
D
E
PCB1 P10-1(VIO)
TB6-8(GRY)
MOD1 P1-7(BLU)
GND2 (GRN)
18
J
PLC-0110 (WHT)
K
K6-A (YEL)
L
PLC-0111 (BRN)
M
PLC-0101 (VIO)
N
PLC1 J2-9 (GRY)
P
16
4
P9
1
4
P5
1
R
L1
P2
1
PCB4
H2
H1
S2-5 (BLK)
S
K2-L3(BLU)
T
U
18
3
P7
1
V
P3
J2
1
18
1
J1-A (GRN)
K1-L2 (BLU)
F4-1 (YEL)
12
S1 3 4
56
K1-L1 (BRN)
14
25
36
S2
P4
*
M1-GND (GRN)
GND2
MOD1 TB2-1 (RED)
T3-H1 (RED)
P10
1
5
L1-H2 (BLK)
BLK
S2
A
TB3-20 (BLU)
B
TB3-21 (GRY)
C
TB3-13 (ORN)
D
TB3-23 (BLK)
E
TB3-18 (VIO)
F
TB3-19 (YEL)
G
TB3-4 (WHT)
H
TB3-14 (BRN)
I
TB3-3 (ORN)
J
TB3-12 (VIO)
K
TB3-22 (WHT)
L
TB3-11 (RED)
M
TB3-2 (GRY)
N
TB3-1 (BRN)
K2-L3 (BLU)
J2
CB1-1 (BLK)
TB2-3 (RED)
M2-4 SPLICE (WHT)
CB2-1 (BLK)
M1-2 (WHT)
MOD1 TB2-2(GRY)
3
J1
*
TB2-1(BLU)
6
2
R1-2 (BLK)
S1-2(YEL)
4
5
1
R7-2 (ORN)
12
F4
12
CB2
*
GND GND2 (GRN)
M1
2
*
NC RED*
FS1C BLK
*
NO ORN
J4-14(BRN)
J4-13(RED)
6-16
MOD1 TB2-1(BLK)*
1
12
CB1
*
CB1-1 (WHT)
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
X5
X6
J3-2(YEL)
X7 J4-2(BLU)
X8 J4-1(BLU)
J4-3(BRN)
J3-1(YEL)
X4
X1 J4-10(VIO)
J4-9(VIO)
J4-4(BRN)
X2
X3
J3-4(BLK)
J3-5(GRY)
X16
T2-AH2
MOVB
T2-BH2
MOVC
MOV
T2-CH2
TB2
SEE
DETAIL
L2
L1
ZD1
A
T1
(BLK)
H1
T1
T2
L3
B
J4-12(BLU)
T3
K1
SEE
DETAIL
TB1
MOV1
MOD1 BR1-A
T3-H1(GRY)
H3
H2
H5
H4
(YEL)
T3-H3(GRY)
H7
H6
TOP
(VIO)
F4-2(BLU)
T3-H2(BLK)
T3-H3(GRY)
CB2-1(RED)
T3-H4(YEL)
T3-H5(BRN)
T3-H6(ORN)
T3-H7(VIO)
J4-11(GRY)
T1
(ORN)
(BRN)
X15
J3-8(WHT)
J3-3(GRY)
X14
X12
X13
J4-8(ORN)
X9
X10
X11
J4-7(ORN)
J3-6(WHT)
J3-7(RED)
MOD1
A
S1-1 (BLU)
BR1
S1-5 (BRN)
Part 2
AH2
SEE T3
DETAIL
T3
BH2
M2
MOD1 BR1-B
SEE DETAIL
MOD1 BR1-C
CH2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
MOV2
MOV3
BLK
BLK
BLK
T2
SPLICE
M2
1
3
2
GRN
6
MOD1 TB2-1(RED)
WHT (INTERNAL)
RED (INTERNAL)
TB2-4 (YEL)
4
CB2-2 (WHT)
BRN (INTERNAL)
H4
H1
S1-6 (RED)
T1-H1 (RED)
TB2-5 (BRN)
H5
T3
TB2-6 (ORN)
SPLICE
TB2-7 (VIO)
H6
H2
H7
H3
TB2-2 (BLK)
TB2-3 (GRY)
T1-H3 (GRY)
6-17
TB2
1
2
3
4
5
6
7
BLK
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
Part 3
MOD1
TB2
CB1-2(GRY)
M1-1(BLK)
2
1
S1-6(RED)
M2-1 SPLICE (RED)
MOD1
MOD1
P4
1
TB3-7(RED)
2
TB3-8(YEL)
3
TB3-9(BLU)
4
TB3-10(ORN)
5
TB3-11(RED)
6
TB3-12(VIO)
7
F3-1(RED)
8
TB3-16(BLK)
9
MOD1 P4-7 (RED)
1
2 TB3-15 (RED)
F3
TB4
SEE DETAIL
TB2
TB3
TB3
1
PA
P4
1
3
WORK
TB3-18(VIO)
2
10
4
TORCH
6
J3
7
1
T1-X5(YEL)
8
2
T1-X6(YEL)
9
3
T1-X14(GRY)
10
4
T1-X15(BLK)
5
T1-X16(GRY)
6
T1-X11(WHT)
1
13
7
T1-X12(RED)
J4
14
8
T1-X13(WHT)
J3
11
1
12
15
16
T1-X8(BLU)
2
T1-X7(BLU)
3
T1-X4(BRN)
4
T1-X3(BRN)
18
19
20
21
22
5
23
6
7
T1-X10(ORN)
8
T1-X9(ORN)
9
T1-X2(VIO)
10
T1-X1VIO)
11
K1-A(GRY)
12
K1-B(BLU)
13
FS1-NO(RED)
14
FS1-C(BRN)
24
15
16
16
17
J4
1
REAR VIEW
WITH REAR PANEL
REMOVED
6-18
PLC1 J1-5 (BLK)
PLC1 J1-6 (VIO)
5
10 TB3-19(YEL)
8
PLC-0000 (BRN)
J2-N (BRN)
PLC(-24VDC) (GRY)
J2-M (GRY)
J2-I(ORN)
PLC-COMM 2 (ORN)
J2-G(WHT)
PLC-0100 (WHT)
MOD1 P4-1(RED)
MOD1 P4-2(YEL)
MOD1 P4-3(BLU)
MOD1 P4-4(ORN)
MOD1 P4-5(RED)
J2-L(RED)
MOD1 P4-6(VIO)
J2-J(VIO)
PCB2 P1-2(ORN)
J2-C(ORN)
PCB2 P1-3(BRN)
J2-H(BRN)
F3-2 (RED)
MOD1 P4-8(BLK)
MOD1 P4-9(VIO)
J2-E(VIO)
MOD1 P4-10(YEL)
J2-F (YEL)
K8-9 (BLU)
J2-A (BLU)
K8-6 (GRY)
J2-B(GRY)
K7-B (WHT)
J2-K(WHT)
K7-A (BLK)
J2-D(BLK)
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
Part 4
PLC1 MODULE
PLC
TB4-1(VIO)
L2
PLC1 J2-1(BLK)
PLC-COMM1(BLK)
TB3-4 (WHT)
TB3-3 (ORN)
J1-M (VIO)
PLC1 J2-7 (BLU)
PLC-COMM4 (BLU)
PLC1 J2-10(RED)
PLC-COMM3 (BLU)
PLC1 J1-1(BRN)
PLC1 J1-2(GRY)
K3-A (VIO)
K4-A (WHT)
K8-A (ORN)
0100
COMM 2
0101
COMM 3
0102
COMM 4
0103
COMM 5
0104
0105
0106
0107
COMM 6
TB5
PCB2-PA(YEL)
PCB2
K2-T1 (YEL)
PA
MOD1 SH1-2(BLK)
PLC1 J2-5(RED)
PCB2 P1-1 (RED)
0108
0109
0110
0111
COMM 7
WORK
PCB2 P1-6 (BLK)
MOD1 TB3-1(BLK)
TORCH
VIEW F-F
J1
L1
J2
1
PLC-0103(BRN)
1
PLC-L2(BLK)
2
PLC-COMM5(GRY)
2
TB4-1 (VIO)
3
TB4-1(VIO)
3
PLC-COMM7(BLU)
4
PLC-0002(WHT)
4
J1-C(ORN)
5
TB3-5 (BLK)
5
TB5-WORK(RED)
6
TB3-6 (VIO)
6
7
8
9
7
PLC-COMM3 (BLU)
8
PLC-0006(ORN)
9
J1-N(GRY)
10 PLC-0102(RED)
10
11 K3-6(WHT)
12 K3-9(ORN)
13 K4-9(GRY)
14 K4-6(YEL)
PLC-COMM 7 (BLU)
J1-D(BLU)
J1-B (YEL)
J1-F (GRY)
J1-J (WHT)
J1-L (BRN)
PLC1 J2-3(BLU)
PLC-COMM 6 (BLU)
15 TB4-2(BRN)
16
TB5-PA(YEL)
0000
0001
HS COMM
0002
0003
0004
0006
COMM 1
+24VDC
-24VDC
PCB2 - P1
P1-1
P1-2
TB5-WORK(RED)
TB3-13(ORN)
P1-3
TB3-14(BRN)
P1-6
TB5-TORCH(BLK)
VIEW E-E
TB3-1 (BRN)
K7-4 (BLU)
PLC-(+24VDC) (VIO)
PLC1 J1-4(WHT)
K5-9 (YEL)
K6-9 (RED)
PLC1 J1-8(ORN)
PLC-L2(BLK)
PLC-HS COMM (VIO)
TB3-2 (GRY)
K7-6 (GRY)
E
J1
L1
L2
0100
COMM 2
0101
COMM 3
0102
COMM 4
0103
COMM 5
0104
0105
0106
0107
COMM 6
0108
0109
0110
0111
COMM 7
PCB2
2
2
BLU
BLU
1
BLU
1
R9
R8
K8
1
1 3
46
79
AB
R7
R10
+24VDC
-24VDC
J2
F
1
1
COMM 1
TB5
2
2
0006
0007
BLU
2
0000
0001
HS COMM
0002
0003
0004
BLU
PLC
S2-3 (BLK)
S2-6 (ORN)
F
K6
K7
1 3
4 6
79
AB
K5
1 3
4 6
79
AB
K4
1 3
4 6
79
AB
1 3
4 6
79
AB
K3
1 3
4 6
79
AB
TB4
PLC1 J2-2(VIO)
R1
PLC1 J2-15(BRN)
K3-B(BRN)
PLC-L1(VIO)
K5-6(VIO)
K4-B(BRN)
1
K6-6(VIO)
2
TB4
K5-B(BRN)
K6-B(BRN)
PLC1 J1-3(VIO)
K8-B (BRN)
T2
K6
K5
K4
K3
1
4
7
A
1
4
7
A
1
4
7
A
1
4
7
A
6-19
3
6
9
B
PLC1 J2-11(WHT)
3
6
9
B
TB4-2(BRN)
3
6
9
B
PLC1 J2-12(ORN)
3
6
9
B
TB4-2(BRN)
PLC1 J2-13(GRY)
PLC1 J2-14(YEL)
PLC-0104 (VIO)
J1-K (YEL)
ZD3
TB3-22 (WHT)
TB3-23 (BLK)
PLC-0001 (BLU)
3
6
9
B
TB4-2(BRN)
PLC-0003 (YEL)
TB4-1(VIO)
PLC-0105 (WHT)
K7
1
4
7
A
3
6
9
B
TB4-2(BRN)
TB3-20 (BLU)
TB3-21 (GRY)
PLC-0106 (ORN)
1
4
7
A
TB4-2(BRN)
PLC-0004 (RED)
TB4-1(VIO)
J1-G (BLK)
K8
PLC-(-24VDC) (GRY)
MOD1 SH1-1 (GRY)
E
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
Part 5
MOD1
P3
P1
P2
PCB1 P4-3(RED)
1
1
PCB1 P1-16(VIO)
1
R10-1 (GRY)
2
PCB1 P4-4(YEL)
2
2
PCB1 P1-15(BLU)
2
TB5-WORK(BLK)
3
PCB1 P4-15(BLU)
3
3
PCB1 P3-12(ORN)
4
PCB1 P4-16(ORN)
4
4
PCB1 P3-13(WHT)
5
TB6-6(BRN)
5
5
PCB1 P1-13(BLK)
6
TB6-8(GRY)
6
6
PCB1 P1-14(RED)
7
PCB1 P4-11(RED)
7
7
PCB1 P3-18(BLU)
8
PCB1 P4-12(BLK)
8
9
PCB1 P4-13(VIO)
8
PCB-TB P1-1(YEL)
10 PCB1 P4-14(YEL)
9
R2-1(ORN)
NOT USED
S3-4(BLU)
10
11
12
13
14 PCB1 P9-1(RED)
15 PCB1 P9-3(BLK)
16
R3
PCB1 P7-3(RED)
MOD1-TB3-1 (RED)
R4
1 2 3 4 5 6 7 8
MOD1 P3-6(GRY)
S3-6(GRY)
S3-3(ORN)
R5
R6
MOD1 P3-5(BRN)
C2-2 (WHT)
TB5-PA (YEL)
C2-1 (YEL)
TB6
MOD1
WHT
T1
T2
T3
P1
8
P1
1
K2
ZD2
A
L1
L2
L3
B
1
P3
1
K2-L3 (BLU)
16
L1-H1 (BLU)
PLC1 P2-10 (RED)
SEE DETAIL
S2-2 (BLU)
1 2 3 4 5 6 7 8
C1-1 (BLU)
PLC1 P2-9 (VIO)
WHT
TB6
P3
1
PCB1 P2-15(YEL)
2
PCB1 P2-16(YEL)
3
PCB1 P2-8(GRY)
4
PCB1 P2-9(RED)
5
PCB1 P2-10(GRY)
6
PCB1 P10-4(WHT)
7
PCB1 P10-3(BLK)
8
PCB1 P10-5(WHT)
P4
1
PCB1 P2-14(BLU)
16
2
PCB1 P2-13(BLU)
3
PCB1 P2-12(BRN)
4
PCB1 P2-11(BRN)
P2
P1
1
2
3
PCB1 P4-1(BRN)
1
P4-10(VIO)
PLC1 P2-7 (VIO)
PCB1 P4-2(GRY)
PCB1 P4-7(YEL)
2
P4-9(VIO)
4
PCB1 P4-10(WHT)
3
P4-2(BLU)
5
PCB1 P5-1 (BLK)
4
P4-1(BLU)
8
PLC1 P2-15(BLU)
PCB1 P5-2(VIO)
5
7
PCB1 P4-8(ORN)
1
PCB1 P7-1(BLK)
2
R11
1
2
SH1
K2-T1(YEL)
K2-T3(WHT)
R14-1 (GRY)
TB6-2(RED)
TB5-TORCH(BLK)
1
D1
8
R15-2 (RED)
1
PLC MOD
P3
PLC1 P2-9 (VIO)
PCB1 P4-9(YEL)
6
R13
PLC1 MODULE
1
C1
16
R12
C2
10
P2
1
P2
TB3
8
1
P4
PLC1 P2-4(BLU)
6
9
7
10
8
9
PLC1 P2-1 (VIO)
SH1
1
MOD1 TB3-1 (RED)
2
2 R15
1
PLC1 P2-2 (VIO)
PLC1 P2-3(BLU)
D1(-) GRY
R14 1
5
K2-A (VIO)
6
10 K2-B(RED)
11 PCB1 P1-7(WHT)
12 PCB1 P1-8(ORN)
13 PCB1 P1-9(GRY)
7
PCB1 P2-5(ORN)
8
PCB1 P2-4(ORN)
9
PCB1 P2-2(VIO)
10
PCB1 P2-1(VIO)
PLC1 P2-2(VIO)
14 PCB1 P1-10(YEL)
15 PLC1 P2-4(BLU)
PLC1 P2-1(VIO)
16
FRONT VIEW
WITH FRONT
PANEL REMOVED
6-20
11
PCB1 P3-1(GRY)
12
PCB1 P3-2(BLU)
13
PCB1 P1-3(RED)
14
PCB1 P1-2(BRN)
15
16
SECTION 6
TROUBLESHOOTING
This page intentionally left blank.
6-21
SECTION 6
TROUBLESHOOTING
6.11 Schematic- Precision Plasma Power Source
Part 1 Drawing 37346 rev C
PLC1
PLC MODULE #1
1
P2 J2
2
1
2
H3
H2
H2
H1
H1
230V
2
200V
1
F4 2
15A
120VAC
11
P3-1
12
P3-2
13
P1-3
14
15
16
J4 P4
P1-2
TB2
1
12VAC
NC
2
3
LED5
LED8
5
2
1
M1
PLASMA GAS
P1-10
LED9
575V
460V
415V
380V
MOV2
230V
200V
18
17
16
15
14
13
MOV3
CB1
3A
L2 T2
460V
415V
380V
230V
200V
12
11
10
9
8
7
P4-1
P4-2
P4-7
P4-8
P4-9
T2
610V
575V
460V
415V
6
380V
230V
200V
6
5
4
3
2
1
K5
B
6
CH5
CH4
P1-12
K6
B
15
16
17
18
19
20
9
6
A
P4-10
P5-1
4
P5-2
6
K8
CH3
21
B
22
5
23
P1-11
24
25
P1-18
CH2
P1-17
26
CH1
BH6
BH5
BH4
BH3
27
28
29
30
P4-14
P4-13
P4-12
P4-11
P10-1
P10-2
P4-16
P4-15
P4-4
P4-3
PCB TRIM
POT
838193
31
32
33
34
P3-18(-)
P3-17(+)
1
BH2
6
P9-3
P9-1
P1-14
P1-13
P3-13
P3-12
P1-15
P1-16
BH1
AH8
T1
6
A
CH6
AH7
L1
B
7
9
10
1
2
3
8
2
MOV1
ØA
B
6
K4
9
P1 J1
BH8
575V
K3
9
13
A
BH7
610V
ØB
6
A
V1
VOLTMETER
AUTO XFMR
5
9
12
9
CH8
610V
11
A
B
L3 T3
11
14
P1-9
CH7
4
ØC
6
P1-8
START GAS
120VAC
A
5
P7-3
12
1
K1
P7-1
P1-7
AM1
AMMETER
ZD1,180V
10
14
LED6
LED3
S1
1
8
C
6
FNT PNL
ON/OFF
7
8
13
+
NO FS1
9
10
P1-6
3
LED2
P1-5
H3
380V
24VAC
LED7
P6
H4
LED4
-
H4
24VAC
7
+
4
1
2
3
4
5
6
X10
7
X9
8
X2
9
X1
10
LED1
-
H5
415V
24VAC
4
5
TB4-2
6
9
+
H5
460V
18VAC
18VAC
P8
H6
18VAC
18VAC
PCB1
ISOLATION AMPLIFIER AND
FAULT SIGNAL PCB
38103
P10-5
P10-3
P10-4
P2-10
P2-9
P2-8
P2-16
P2-15
P2-14
P2-13
P2-12
P2-11
P2-7
P2-6
P2-5
P2-4
P2-2
P2-1
+
7A
H7
H6
8
7
6
5
4
3
2
1
-
6
5
2
H7
575V
J3 P3
X13
X12
X11
X16
X15
X14
X6
X5
X8
X7
X4
X3
-
7
1
T3
1
CB2
2
T1
3
TB4-1
3
4
15
PUMP
MOTOR
M2
1
4
35
AH6
36
AH5
AH4
J2
37
NOT USED ON
PRECISION PLASMA CONSOLE
1
2
3
4
5
6
7
8
38
P1
1
2
3
4
AH3
AH2
AH1
TB2-2
TB2-1
BR1-A
BR1-B
BR1-C
TB1
6-22
MOD1
POWER MODULE #1
5
6
7
8
9 10 11 12 13 14 15 16
SECTION 6
TROUBLESHOOTING
Schematic- Precision Plasma Power Source
Part 2
1
2
3
4
5
J1
6
A
7
B
C
8
D
9
10
TO FLOW
CONTROL BOX
J1
E
11
12
13
14
ZD3
180 VAC
A
K7
B
4
6
L1
1
0000 1
L2
2
0001 2
3
HS COMM 3
4
0002 4
5
0003 5
6
0004 6
7
7 0100
8 Comm 2
0006 8
9 0101
0007 9
10 Comm 3
10
11 PLC 11 0102
12 Comm 4
12
13 0103
13
14 Comm 5
14
START GAS
15 0104
15
PLASMA GAS
16 0105
16
17 0106
17
COMM 1 18
18 0107
19
19 Comm 6
START GAS ON, NITROGEN
20 0108
20
CUT GAS ON, OXYGEN
21
21 0109
FULL SHIELD
22
22 0110
REGULATED SHIELD
+24VDC 23
23 0111
COMMON
-24VDC 24
24 Comm 7
F
G
H
J
K
L
M
N
P
R
S
T
U
V
J2
TB3
120VAC RELAY
15
16
1
N
2
M
3
I
4
G
5
ARC ON SIGNAL
FROM P.S. TO CNC,
TRANSISTOR
6
17
7
18
9
20
10
21
START SIGNAL FROM
CNC TO P.S., 24VAC
11
PLC1
PLC MODULE #1
22
23
1
F3 2
L
12
J
+10VDC REMOTE CURRENT
SETTING FROM CNC TO P.S.
13
C
VOLTAGE DIVIDER, (+)
14
H
VOLTAGE DIVIDER, (-)
18
E
19
F
EMERGENCY STOP FROM CNC TO P.S.
RELAY/CONTACTOR NORMALLY CLOSED
OPEN IN CASE OF EMERGENCY
20
A
21
B
22
K
23
D
15
1A
24
ARC ON SIGNAL FROM P.S.
TO CNC, RELAY CLOSING
START SIGNAL FROM
CNC TO P.S., 120VAC
8
19
START SIGNAL FROM
CNC TO P.S., RELAY CLOSING
16
25
17
A
31
B
K2
L1
T1
L2
T2
L3
T3
TB6-5
R6
39K
2W
120VAC RELAY
R3
4.99K
36
R5
39K
2W
TB6-4
2
5
37
FRONT PNL
PILOT ARC
SELECTOR S2
6
5 HI
4
H2
L1
H1
FRONT PNL
CURRENT
SETTING
LOCAL/REMOTE
DPDT S3
3
2
C1
38
1 2 3 4 5 6 7 8 9 10
20uf
400V
P3
D1
P4
10
9
7
R7
10K
OHM
8W
6
R15
20 OHM
50W
5
MOD1
4
3
2
1
SH1-2
SH1-1
TB3-1
6-23
LO
R1
R7
20 OHM 300W
R8
20 OHM
300W
20 OHM 300W
R9
1
R7
10K
OHM
8W
R14
20 OHM
50W
8
POWER MODULE #1
120VAC PREFLOW SIGNAL
FROM CNC TO P.S.
24
TB6-2
4
6
1
10K
8W
CURRENT SETTING POT
R2
10K
MIN
MAX
1
3
2
R4
4.99K
35
3
R11
20uf
400V
TB6-8
TB6-6
TB6-7
32
33
34
C2
FAULT SIGNAL FROM P.S. TO CNC
RELAY CLOSING, DRY CONTACT
20 OHM 300W
P1-2
P1-3
R10
3.1 OHM
300W
WORK
P1-1
START UP
PCB2
838131
PA
PILOT ARC
TORCH
TO JUNCTION BOX J1
27
28
29
30
TO CUTTING MACHINE CNC
CONNECTOR CHASSIS GND SUPPLIED
BY CUTTING MACHINE GROUP
ZD2
180
VAC
P1-6
26
SECTION 6
TROUBLESHOOTING
6.12 Technical Guide To Using And
Understanding The Operation Of The
Electronic Flow Control
Introduction
The following information is a guide for
troubleshooting The Precision Plasma Electronic
Flow Control. Knowledge of machine and control
operation is required.
6-24
SECTION 6
TROUBLESHOOTING
6.12.1 Precision Process Timers
Timer
Plasma Preflow Time
Line Purge Time
Description
The minimum interval of time between the receipt of a
plasma process start signal and the issuance of the
signal to turn the plasma power supply on. Plasma
process start gas flows are in effect during this time.
The interval of time allowed to purge the plasma process
gas lines. Plasma process purge/fill gas flows are in
effect during this time.
Plasma Firing Time
The maximum interval of time allowed for receipt of an
arc-on signal from the issuance of the signal to turn the
plasma power supply on. Plasma process start gas
flows are in effect during this time.
Plasma Pierce Time
The interval of time allowed for piercing the work piece
after receipt of the arc-on signal. Plasma process cut
gas flows are in effect during this time. (Torch stationary,
AHC disabled, machine stationary).
Plasma AHC Delay
The interval of time allowed after expiration of the
PLASMA PIERCE TIME timer before enabling AHC.
Plasma process cut gas flows are in effect during this
time. (Torch stationary, AHC disabled, machine moving).
Plasma Arc Delay
The interval of time for filtering the arc-on signal to allow
the signal to assume a stable mode / condition. Plasma
process cut gas flows are in effect during this time.
Master Up
Analog Channel Disable
The interval of time allowed to raise the plasma torch
after receipt of a plasma process off signal. Plasma
process start gas flows are in effect during this time.
The interval of time allowed before enabling the plasma
process idle flow analog values. Plasma process start
gas flow analog values are in effect during this time.
Line Fill Time
The interval of time allowed to fill the plasma process gas
lines. Plasma process purge/fill gas flows are in effect
during this time.
Plasma Postflow
The interval of time allowed for plasma process gases to
flow after expiration of the MASTER UP timer. Plasma
process start gas flows are in effect during this time.
Line Vent Time
The interval of time allowed to vent the plasma process
gas lines. Plasma process idle gas flows are in effect
during this time.
Flow Control Vent Time
The interval of time allowed to vent the flow control gas
lines. Plasma process purge/fill gas flows are in effect
during this time.
6-25
SECTION 6
TROUBLESHOOTING
6.12.2 Process Timer Values For Vision Cutting Record File PARAM.CUT
Vision Interpretation Data File DEF.TEC
V
(Hidden Flag)
DEF .TEC
Qx
(Upper Editing
Limit)
Ux
(Lower Editing
Limit)
Wx
(Preset Value)
PARAM.CUT
V = Hidden Flag Enabled
TIMERS
Plasma Preflow Time
0.6
0.5
50.0
V
Line Purge Time
1.0
1.0
50.0
V
Plasma Firing Time
6.0
4.0
6.0
V
Plasma Pierce Time
0.0
0.0
50.0
Plasma Ahc Delay
0.0
0.0
50.0
Plasma Arc Delay
0.3
0.0
0.5
Master Up
2.0
0.0
50.0
600.0
600.0
600.0
V
Line Fill Time
5.0
5.0
50.0
V
Plasma Postflow
5.0
5.0
50.0
V
Line Vent Time / Flow Control Vent Time
2.0
2.0
50.0
V
Analog Channel Disable
6-26
V
SECTION 6
TROUBLESHOOTING
6.12.3 Process Window Key Functions
Key Function
Description
•
Plasma AHC Allow Icon
•
•
(F2 Push-Button)
•
•
Plasma AHC Icon
•
(F3 Push-Button)
Plasma Start Parameter Test Icon
•
Icon permits the machine operator to allow or
disallow plasma AHC.
Icon does not turn plasma AHC on.
Plasma AHC is allowed if the icon is highlighted
(darkened).
Plasma AHC is not allowed if the icon is not
highlighted.
Icon permits machine operator to manually turn
plasma AHC on or off.
Icon also permits the operator to perform a
plasma IHS cycle if the plasma process is not
active.
The plasma AHC allow icon must be
highlighted.
•
Icon permits the machine operator to manually
test/adjust the plasma process start parameters
with the exception of the plasma gas 2 start
flow.
•
Icon permits the machine operator to manually
test/adjust the plasma gas 2 start flow.
The plasma start parameter test icon must
be highlighted.
(F4 Push-Button)
Plasma Gas 2 Test Icon
•
(F5 Push-Button)
Plasma Cut Parameter Test Icon
•
•
(F6 Push-Button)
Plasma Start Icon
•
•
(F6 Push-Button)
6-27
Icon permits the machine operator to manually
test/adjust the plasma process cut parameters.
The plasma start parameter test icon must
be highlighted.
Icon permits the machine operator to manually
start or stop the plasma process.
The plasma start parameter test icon must not
be highlighted.
SECTION 6
TROUBLESHOOTING
6.12.4 Proportional Valve Analog Flow Values
For Param.Cut And Def.Tec
Jx
(Upper
Channel
Limit)
100.0
0.0
100.0
0.0
255.0
Plasma Gas 1 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 2 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 2 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 1 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 1 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 2 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 2 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 1 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Plasma Gas 1 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Plasma Gas 1 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Plasma Gas 2 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Plasma Gas 2 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Plasma Gas 2 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Shield Gas 1 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Shield Gas 1 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Shield Gas 1 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Shield Gas 2 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Shield Gas 2 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Shield Gas 2 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Analog Flow Values
V
(Hidden
Flag)
0.0
Qx
(Upper
Editing
Limit)
0.0
Ux
(Lower
Editing
Limit)
Plasma Gas 1 Start Flow Analog Out
Wx
(Preset
Value)
Ix
(Lower
Channel
Limit)
Yy
(Upper
Parameter
Limit)
DEF.TEC
Xx
(Lower
Parameter
Limit)
PARAM.CUT
V = Hidden Flag Enabled
6-28
SECTION 6
TROUBLESHOOTING
6.12.5 Process Gas Selection Requirements
•
Plasma process gas selection is accomplished
with activation of the appropriate SDP file.
•
The correct CUTTING RECORD FLAG must be
in each SDP file.
•
Selection is keyed to the value in the CUTTING
RECORD FLAG.
•
Please refer to the ATAS description of the
cutting package for a detailed explanation of
The cutting record flag.
Material Type
Plasma Gas
Shield Gas
Abbreviation
Cutting Record Flag
Carbon steel
O2
N2
CS1-O2-N2
M1000000000000000
Carbon steel
O2
N2 with O2 mix
CS2-O2-N2/O2
M0100000000000000
Carbon steel
O2
O2
CS3-O2-O2
M0000000000010000
Stainless steel
N2
N2
SS1-N2-N2
M0010000000000000
Stainless steel
N2
N2 with CH4 mix
SS2-N2-N2/CH4
M0001000000000000
Stainless steel
Air
Air
SS4-Air-Air
M0000010000000000
Stainless steel
Air
Air with CH4 mix
SS5-Air-Air/CH4
M0000001000000000
Aluminum
N2
N2
Al1-N2-N2
M0000000010000000
Aluminum
N2
N2 with CH4 mix
Al2-N2-N2/CH4
M0000000001000000
Plasma marking
Argon
Air
PM1-Argon-Air
M0000000000100000
6-29
SECTION 6
TROUBLESHOOTING
6.12.6 EFC Process Gas Flow Chart
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
Error
condition?
yes
no
no
Line fill
4
Station on?
no
no
yes
ready
5
Plasma stop
7
yes
Plasma
test?
10
yes
Error
condition?
yes
no
yes
yes
no
no
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-30
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
no
Station on?
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
no
yes
no
SECTION 6
TROUBLESHOOTING
Finish
16 Milliseconds
0.5 Seconds
1.0 Second
0.5 Seconds
1.5 Seconds
2.0 Seconds
Start
16 Milliseconds
6.12.7 Station On, Flush/Pressurize Cycle
PG-N2,O2 SG-N2
X = OPEN / ENABLED, BLANK = CLOSED / DISABLED,
ANALOG VALUE = 0 - 10 VDC
SOLENOID VALVES
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
Plasma Gas 2 Torch Solenoid Valve
Shield Gas 1 Torch Solenoid Valve
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
Shield Gas 1 Cut Flow Analog Out
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O
t
Plasma
Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O
t
Plasma
Gas 2 Idle Flow Analog Out
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-31
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
Off)
10
Idle (Station
On)
9
Test (Cut)
8
Test (Start)
(O2)
7
Test (Start)
6
Process
Cut
Process
Post
Flow
5
Process
Start
4
Ready
Flow Control
Vent
3
Line
Fill
2
Line
Purge
1
Line Vent
6.12.8 Solenoid And Proportional Valve Requirements
Carbon Steel PG-O2, SG-N2
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
SOLENOID VALVES
X
Plasma Gas 1 Supply Solenoid Valve N2-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
X
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
X
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
X
X
X
Plasma Gas 2 Cut Flow Analog Out
X
Shield Gas 1 Start Flow Analog Out
X
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
6-32
SECTION 6
TROUBLESHOOTING
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
X
X
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
Station on?
Error
condition?
yes
no
no
4
Station on?
no
no
yes
ready
5
Plasma stop
7
New SDP file
selected?
Plasma
test?
10
yes
Error
condition?
yes
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
Station on?
New
SDP file
selected?
no
Plasma test?
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
Plasma test
(start O2)?
no
no
Station on?
yes
yes
yes
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-33
Plasma
test cut?
no
Test (start O2)
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
no
yes
no
no
yes
New
SDP file
selected?
no
yes
yes
no
no
yes
yes
no
no
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
no
yes
no
12
13
Idle (Station
On)
Idle (Station
Off)
11
Test (Cut)
10
9
Test (Start)
(O2)
8
Test (Start)
7
Process
Post Flow
6
Process Cut
5
Process Start
Line Purge
4
Ready
3
Flow Control
Vent
2
Line Vent
1
Line Fill
6.12.9 Gas Error Monitoring
Carbon Steel PG-O2, SG-N2
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
Off)
10
Idle (Station
On)
9
Test (Cut)
8
Test (Start)
(O2)
7
Process
Cut
Process
Post
Flow
6
Process
Start
5
Ready
4
Line
Fill
3
Line
Purge
2
Flow Control
Vent
Line Vent
1
Test (Start)
6.12.10
Solenoid And Proportional Valve Requirements
Carbon Steel PG-O2, SG-N2/O2
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
SOLENOID VALVES
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Supply Solenoid Valve O2-2
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve O2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
X
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
X
X
X
Plasma Gas 2 Cut Flow Analog Out
X
Shield Gas 1 Start Flow Analog Out
Shield Gas 1 Cut Flow Analog Out
X
X
Shield Gas 2 Start Flow Analog Out
X
X
X
X
X
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
6-34
X
SECTION 6
TROUBLESHOOTING
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
X
X
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
Error
condition?
yes
no
no
4
no
yes
ready
5
no
Plasma stop
7
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-35
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
no
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
no
Station on?
Station on?
yes
yes
yes
Line fill
no
yes
no
Station on?
yes
no
12
13
Idle (Station
Off)
Test (Cut)
11
Idle (Station
On)
10
9
Test (Start)
(O2)
8
Test (Start)
7
6
Process
Post Flow
5
Process Cut
Line Purge
4
Process Start
3
Ready
2
Flow Control
Vent
Line Vent
1
Line Fill
6.12.11
Gas Error Monitoring
Carbon Steel PG-O2, SG-N2/O2
SECTION 6
TROUBLESHOOTING
9
10
11
12
13
Idle (Station
Off)
8
Idle (Station
On)
Line
Fill
7
Test (Cut)
Line
Purge
6
Test (Start)
(O2)
Flow Control
Vent
5
Test (Start)
4
Process
Cut
Process
Post
Flow
3
Process
Start
2
Ready
1
Line Vent
6.12.12
Solenoid And Proportional Valve Requirements
Carbon Steel PG-O2, SG-O2
X = Open / Enabled, Blank = Closed / Disabled,,
Analog Value = 0 - 10 Vdc
SOLENOID VALVES
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Supply Solenoid Valve O2-2
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve O2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
X
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
X
X
X
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
X
X
X
Plasma Gas 2 Cut Flow Analog Out
X
Shield Gas 1 Start Flow Analog Out
Shield Gas 1 Cut Flow Analog Out
X
X
Shield Gas 2 Start Flow Analog Out
X
X
X
X
X
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
6-36
X
SECTION 6
TROUBLESHOOTING
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
X
X
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
Error
condition?
no
4
Station on?
no
no
yes
ready
5
no
Plasma stop
yes
yes
no
yes
yes
Plasma test
(start O2)?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-37
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
7
Station on?
yes
Plasma test?
Plasma test
cut?
no
New SDP file
selected?
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
no
Station on?
yes
yes
yes
Line fill
no
yes
no
no
yes
no
12
13
Idle (Station
Off)
Test (Cut)
Test (Start)
(O2)
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Vision Shift/Start
11
Idle (Station
On)
10
9
Test (Start)
8
Process
Post Flow
7
6
Process Cut
5
Process Start
4
Ready
Flow Control
Vent
3
Line Fill
2
Line Purge
1
Line Vent
6.12.13
Gas Error Monitoring
Carbon Steel PG-O2, SG- O2
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
On)
Idle (Station
Off)
9
11
Test (Cut)
8
Test (Start)
7
Process Post
Flow
6
Process Cut
5
Process
Start
4
Ready
Flow Control
Vent
3
Line Fill
2
Line Purge
1
Line Vent
6.12.14
Solenoid And Proportional Valve Requirements
Stainless Steel PG-N2, SG-N2
X = OPEN / ENABLED, BLANK = CLOSED / DISABLED,
ANALOG VALUE = 0 - 10 VDC
Solenoid Valves
Plasma Gas 1 Supply Solenoid Valve N2-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve CH4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-38
SECTION 6
TROUBLESHOOTING
11
Plasma Gas 1 Pressure Switch
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
O
X
X
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
X
X
O
X
X
Process Gas Pressure Switches
Shield Gas 2 Pressure Switch
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
yes
yes
no
yes
yes
Plasma test
(start O2)?
no
New SDP file
selected?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-39
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
7
Station on?
yes
Plasma test?
Plasma test
cut?
Plasma stop
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
no
no
yes
no
12
13
Idle (Station
Off)
9
Idle (Station
On)
Process
Start
8
Test (Cut)
Ready
7
6
Test (Start)
5
Process Post
Flow
4
Process Cut
3
Line Fill
2
Flow Control
Vent
Line Vent
1
Line Purge
6.12.15
Gas Error Monitoring
Stainless Steel PG-N2, SG-N2
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
Off)
11
Idle (Station
On)
9
Test (Cut)
8
Test (Start)
7
Process Post
Flow
6
Process Cut
5
Process Start
4
Ready
Flow Control
Vent
SOLENOID VALVES
3
Line Fill
2
Line Purge
1
Line Vent
6.12.16
Solenoid And Proportional Valve Requirements
Stainless Steel PG-N2, SG-N2/CH4
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve CH4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
X
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-40
X
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station)
Off)
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
X
X
O
X
X
Shield Gas 2 Pressure Switch
9
Idle (Station
On)
8
Test (Cut)
Process
Start
7
Test (Start)
6
Process
Post
Flow
5
Process Cut
4
Ready
Flow
Control
Vent
3
Line Fill
2
Line Purge
1
Line Vent
6.12.17
Gas Error Monitoring
Stainless Steel PG-N2, SG-N2/CH4
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-41
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
no
yes
no
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
Off)
9
Idle (Station
On)
8
Test (Cut)
7
Test (Start)
6
Process Post
Flow
Line Purge
5
Process Cut
Flow Control
Vent
Solenoid Valves
4
Process Start
3
Ready
2
Line Fill
1
Line Vent
6.12.18
Solenoid And Proportional Valve Requirements
Stainless Steel PG-Air, SG-Air
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-42
SECTION 6
TROUBLESHOOTING
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
O
11
X
Test (Cut)
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
yes
Plasma test
(start O2)?
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-43
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
Station on?
no
yes
no
12
13
Idle (Station)
Off)
9
Idle (Station
On)
8
Test (Start)
Process
Start
7
Process
Post
Flow
6
Process Cut
5
Ready
Flow
Control
Vent
O
4
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
3
Line Fill
2
Line Purge
1
Line Vent
6.12.19
Gas Error Monitoring
Stainless Steel PG-Air, SG-Air
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
Off)
9
Idle (Station
On)
8
Test (Cut)
7
Test (Start)
6
Process Post
Flow
Line Purge
5
Process Cut
Flow Control
Vent
Solenoid Valves
4
Process Start
3
Ready
2
Line Fill
1
Line Vent
6.12.20
Solenoid And Proportional Valve Requirements
Stainless Steel PG-Air, SG-Air/CH4
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
X
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-44
X
SECTION 6
TROUBLESHOOTING
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
yes
yes
no
yes
yes
Plasma test
(start O2)?
no
New SDP file
selected?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-45
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
7
Station on?
yes
Plasma test?
Plasma test
cut?
Plasma stop
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
Station on?
no
yes
no
12
13
Idle (Station)
Off)
9
Idle (Station
On)
8
Test (Cut)
Process
Start
7
Test (Start)
6
Process
Post
Flow
5
Process Cut
4
Ready
Flow
Control
Vent
Process Gas Pressure Switches
3
Line Fill
2
Line Purge
1
Line Vent
6.12.21
Gas Error Monitoring
Stainless Steel PG-Air, SG-Air/CH4
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
Off)
11
Idle (Station
On)
9
Test (Cut)
8
Test (Start)
7
Process Post
Flow
6
Process Cut
5
Process Start
4
Ready
Flow Control
Vent
Solenoid Valves
3
Line Fill
2
Line Purge
1
Line Vent
6.12.22
Solenoid And Proportional Valve Requirements
Aluminum PG-N2, SG-N2
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-46
SECTION 6
TROUBLESHOOTING
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
X
X
O
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
Plasma stop
yes
yes
7
yes
yes
Plasma test
(start O2)?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-47
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
no
Station on?
yes
Plasma test?
Plasma test
cut?
no
New SDP file
selected?
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
no
yes
no
12
13
Idle (Station)
Off)
9
Idle (Station
On)
8
Test (Cut)
Process
Start
7
Test (Start)
6
Process
Post
Flow
5
Process Cut
4
Ready
Flow
Control
Vent
Process Gas Pressure Switches
3
Line Fill
2
Line Purge
1
Line Vent
6.12.23
Gas Error Monitoring
Aluminum PG-N2, SG-N2
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
Off)
11
Idle (Station
On)
9
Test (Cut)
8
Test (Start)
7
Process Post
Flow
6
Process Cut
5
Process Start
4
Ready
Flow Control
Vent
Solenoid Valves
3
Line Fill
2
Line Purge
1
Line Vent
6.12.24
Solenoid And Proportional Valve Requirements
Aluminum PG-N2, SG-N2/CH4
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
X
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-48
X
SECTION 6
TROUBLESHOOTING
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
yes
Plasma test
(start O2)?
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-49
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
Station on?
no
yes
no
12
13
Idle (Station)
Off)
9
Idle (Station
On)
8
Test (Cut)
Process
Start
7
Test (Start)
6
Process
Post
Flow
5
Process Cut
4
Ready
Flow
Control
Vent
Process Gas Pressure Switches
3
Line Fill
2
Line Purge
1
Line Vent
6.12.25
Gas Error Monitoring
Aluminum PG-N2, SG-N2/CH4
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
Off)
9
Idle (Station
On)
8
Test (Cut)
7
Test (Start)
6
Process Post
Flow
Line Purge
5
Process Cut
Flow Control
Vent
Solenoid Valves
4
Process Start
3
Ready
2
Line Fill
1
Line Vent
6.12.26
Solenoid And Proportional Valve Requirements
Marking PG-Argon, SG-Air
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 1 Idle Flow Analog Out
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog
O t
Plasma Gas 2 Idle Flow Analog Out
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog
O t
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog
O t
Shield Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
6-50
SECTION 6
TROUBLESHOOTING
Plasma Gas 1 Pressure Switch
O
Plasma Gas 2 Pressure Switch
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
O
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-51
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
no
yes
no
12
13
Idle (Station)
Off)
9
Idle (Station
On)
8
Test (Cut)
Process
Start
7
Test (Start)
6
Process
Post
Flow
5
Process Cut
4
Ready
Flow
Control
Vent
Process Gas Pressure Switches
3
Line Fill
2
Line Purge
1
Line Vent
Gas Error Monitoring --Marking PG-Argon, SG-Air
SECTION 6
TROUBLESHOOTING
This page intentionally left blank.
6-52
SECTION 7
REPLACEMENT PARTS
7.1 General
Always provide the serial number of the unit on
which the parts will be used. The serial number is
stamped on the unit nameplate.
7.2 Ordering
To ensure proper operation, it is recommended
that only genuine ESAB parts and products be
used with this equipment. The use of non-ESAB
parts may void your warranty.
Replacement parts may be ordered from your
ESAB Distributor or from:
ESAB Welding and Cutting Products
ATTN: Customer Service Department
PO Box 100545 Ebenezer Road
Florence, SC USA 29501-0545
Phone (843) 664-4405
(800) ESAB-123 (372-3123)
ESAB Cutting Systems - Canada
6010 Tomken Road
Mississauga, Ontario, Canada L5T 1X9
Phone (905) 670-0220
Fax
(905) 670-4879
ESAB Cutting Systems GMBH
Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Phone 011-49-6039-400
Fax 011-49-6039-403-02
http://www.esab.de
Be sure to indicate any special shipping
instructions when ordering replacement parts.
Refer to the Communications Guide located on
the last page of this manual for a list of customer
service phone numbers.
7-1
SECTION 7
REPLACEMENT PARTS
7.3 Plasmarc Power Source-Exterior Components
1
3
2
6
8
4
5
7
7-2
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2
995227
Label Warning-Exposed High Volt
3
2091514
Label Warning
4
34941
5
13734588
Logo ESAB Clear
6
35924YL
Panel Right Side
7
35923YL
Panel Left Side
8
61328087
Screw, HMH ¼-20 X .50 L
35925YL
Symbol
(Elec-Ay)
Description
Cover-Top
Lens Clear
7-3
SECTION 7
REPLACEMENT PARTS
6
5
4
3
2
1
7
8
9
11
10
See
"TEE"
Detail
Page 7-12
7-4
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
672508
Symbol
(Elec-Ay)
S1
Description
Switch Toggle 2PST 2 Pos 15A
2
634518
S2,3
Switch Toggle DPDT 2 Pos 15A
3
951061
AM1,VM1
Meter LED 5VDC
4
951061
AM1,VM1
Meter LED 5VDC
5
634518
S2,3
6
2234589
R2
7
954751
8
32286GY
9
598481
Gauge 200 PSI
10
952182
Spout Remote Filler w/Cap
11
36346GY
Switch Toggle DPDT 2 Pos 15A
POT 10K 10 Turn
Overlay Precision Plasma
Panel Front
BRKT, Remote Filler
7-5
SECTION 7
REPLACEMENT PARTS
1
11
2
10
13
9
3
12
4
8
5
6
7
7-6
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
952209
J1
Conn Box Recpt 19 FS SH
3
952210
J2
Conn Box Recpt 14 FS SH
4
97W6
5
23610197
6
952571
7
32202GY
8
58V75
Adaptor B/A-W F ¼ NPTM BKHD
9
954599
Label Rating Precision Plasma
10
950829
11
950937
Strain Relief
12
13730763
Plate, Serial
13
950874
Door Access Rear
35928GY
3 Strain Relief
Plug Hole .875 Dia. .125 CT Nyl BK
F4
Fuse 7A 600 VAC Fast Acting
Panel Rear
CB1
CB2
Circuit Breaker 3 AMP
Circuit Breaker 7 AMP
7-7
SECTION 7
REPLACEMENT PARTS
7.4 Plasmarc Power Source-Internal Components
18
17
Reference: PCB1
Isolation Amp
Reference:
Meter LED
AM1,VM1
4
3
5
3
6
7
8
15
2
16
10
1
12
11
7-8
13
14
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
2
950487
TB4
3
838103
950096
952053
952034
952030
952032
952205
PCB1
PCB1 P9,7
Description
Base, Precision Plasma
35920GY
PCB1 P10
PCB1 P1,3,4
PCB1 P2
PCB1 P5
Term Block 2 pos
PCB Isolation AMP
Housing Contact, Crimp 3 pin
Standoff #6-32 X .88 L
Plug 5 Pos
Plug 18 Pos
Plug 16 Pos
Receptacle P/C 4 Pos
Box PLC
4
37345GY
5
951209
PLC
6
38131
PCB2
Board, PC Startup
7
950760
K3-6,8
Relay Enclosed DPDT 24VAC
8
17300020
R1,7,8,9
10
13735308
K7
11
952012
12
35682
13
952179
Tank, Water
14
952013
Caster Swivel
15
639533
Bushing, Snap .88 I.D. X 1.09 MH X .45 L
16
17300931
17
952095
18
71200732
PLC Controller
Resistor 300W 20ohm 10%
Relay Enclose DPDT 120VAC 20A
Caster Fixed
T2
XFMR Auto
Resistor, 300W 3.1ohm 10%
Spacer, LED
Adhesive, SIRBR Clr
7-9
SECTION 7
REPLACEMENT PARTS
4
3
2
1
14
11
5
12
6
7
13
10
7
9
8
7-10
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
952026
Symbol
(Elec-Ay)
TB2
Description
2
673502
K1
3
672002GY
4
2062334
5
36417GY
6
951215
7
951347
Pump, Carb w/Strainer
8
950179
Tee, Pipe Branch ¼ Brs
9
10Z30
Adaptor, B/A-W M ¼ NPTM
10
182W82
11
37348
Kit, Wire Primary
12
33551
BRKT, Water Tank
13
37805
14
32203GY
Terminal Block
Contactor 3 Pole 75A
Shroud, Fan
M1
Motor, Fan
Shroud, Fan
M2
Motor, Carb 1/3 Hp
Elbow 90 DEG. ¼ NPT
T3
Auto XFMR
BRKT, Auto XFMR
7-11
SECTION 7
REPLACEMENT PARTS
5
8
6
9
4
1
7
9
8
2
2
3
7
9
3
12
13
11
“TEE” Detail
10 X5
7-12
7
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
950001
3
21124
Valve, Check Assy
4
36539
Hose, Assy Flowswitch To Core
5
90858009
TBG, Nylobrade 3/8 I.D X .625 O.D.
6
36418
Hose Assy Tank Bottom- Pump Inlet
7
58V75
Adaptor, B/A-W F ¼ NPTM BKHD
8
182W82
9
10Z30
Adaptor, B/A-W M ¼ NPTM
10
994471
Clamp, Hose W/D .50 Dia X 1.06 SS
11
952179
Tank, Water
12
952182
Spout, Remote Filler w/Cap
13
952181
Tee, Plastic Pipe
Hose, Assy Pump Outlet- Torch out
36538
FS1
Switch, Flow .25 GPM SPSTB
Elbow 90 Deg. ¼ NPT
7-13
SECTION 7
REPLACEMENT PARTS
10
6
5
4
3
7
2
9
7
1
8
7-14
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
950823
Bushing, Snap
3
950167
Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W
4
995103
TB3
Terminal Block 24 POS 15A
5
36919
TB5
Board, Terminal Output
6
96W10
Holder, Fuse
7
92W57
Grommet, Rub .63 I.D. X .88 O.D. X .06 W
8
639533
Bushing, Snap .88 I.D. X 1.09 MH X .45 L
9
35930GY
BRKT, Heat Exchanger
10
2234891
Plug, 10 Pos
Heat Exchanger
13735961
7-15
SECTION 7
REPLACEMENT PARTS
6
13
5
7
8
4
9
3
10
2
11
1
12
7-16
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
17750020
3
36527GY
4
951161
C1,2
Cap, Metpoly 20uf 400VDC
5
673458
K2
Contactor, Pilot Arc 3P 40A
6
2234521
P4,MOD1
P1,PLC1 P2
Plug, 16 Pos
7
2234891
MOD1 P3, 4,
PLC1 P1
Plug, 10 Pos
8
2234518
J3
9
2234521
P1,PLC1 P2
Plug, 16 Pos
10
2234519
J4, PLC1 J2
Receptacle, 16 Pos
11
635686
TB6
12
647065L1
13
38193
Bushing, Snap
950823
R11,12
Res 20 ohm 50W
Cover, Terminal Board
Receptacle, 8 Pos
Terminal Strip, 8 Pos
Choke Signal #Ch12
PCB-TB
Printed Circuit Board Trim Pot
7-17
SECTION 7
REPLACEMENT PARTS
7.5 Power Source Power Module
4
3
2
5
6
1
7
7-18
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
37102
Bracket, PCB KYDEX
3
35799
Wire Kit, Power Module
4
951339
951340
5
37101GY
6
951981
7
35700
Base Power Module
35914GY
PCB1 P1, 5
PCB1 P2, 6
Plug, Female 12 Position
Plug, Female 14 Position
Deck, Power Module
Heat Sink
L1
Inductor, Power Factor
7-19
SECTION 7
REPLACEMENT PARTS
A
2
3
4
1
5
A
6
8
7
Section A-A
7-20
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2234877
Symbol
(Elec-Ay)
J3,4
Description
2
951182
M1
Fan, Axial
3
950487
TB2
Terminal Strip 2 Position
4
950823
5
35700
L1
Inductor, Power Factor
6
17280215
R2
Resistor 1.5K OHM 100W
7
35680
L2
Inductor Assembly Output
8
35681
T3
Transformer Assembly, Main
Block Terminal 10 Position
Bushing, Snap
7-21
SECTION 7
REPLACEMENT PARTS
3
4
5
2
1
6
7
7-22
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2234518
Symbol
(Elec-Ay)
J2
Description
2
38047
SH1
3
2234519
J1
4
35917GY
5
951981
6
2234877
J3, 4
Block Terminal, 10 Position
7
674156
TB3
Adaptor
Block Terminal, 8 Position
Shunt, Feedback
Block Terminal, 16 Position
Baffle Heatsink
Heatsink
7-23
SECTION 7
REPLACEMENT PARTS
14
12
13
10
11
8
9
10
7
6
15
5
16
4
17
3
18
19
2
20
1
19
21
22
7-24
21
23
24
21
25
26
27
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2
951978
951192
3
35794
4
951979
951196
SCR1
SCR 90A
Pad Thermal SCR Module
5
951980
Q1,2
IGBT 300A 600V
6
17750020
951194
R4,5
Resistor 20OHM 50W NI
Pad Thermal Power Resistor 50W
7
647345
8
17250005
9
951940
C6,7
Capacitor 1uf 600VDC
10
951983
C4,5
Capacitor 3300 uf
11
35793
Busbar IGBT (-)/Capacitor
12
950823
Bushing Snap .687
13
35792
Busbar IGBT (+)/Capacitor
14
5844
Nomex Insulator
15
951191
Pad Thermal IGBT 1200V
16
35799
Wire Kit Module
17
35918
Busbar Shunt
18
639533
Bushing Snap .875 I.D. X 1.093 MH
19
17721020
R6,7,8,9
Resistor 20 OHM 25W NI
20
951185
D1,2
Module Diode 100A 600V
21
647345
Bushing Snap 1.31 I.D. X 1.5 MH .44 L
22
36873
Busbar Capacitor/IGBT
23
952255
24
36872
25
32958
T2
26
950711
TS1,2
27
35790
35940
Symbol
(Elec-Ay)
T1
BR1
Description
Transformer Control
Bridge Diode 3PH 130A
Pad Thermal Bridge
Busbar Input Bridge
Bushing Snap 1.31 I.D. X 1.5 MH .44 L
Resistor 5OHM 50W
C8,9
Capacitor Film 40uf 400VDC
Busbar Capacitor
Transformer, Current
Switch Thermal 194 Deg. F.
Busbar Jumper
7-25
SECTION 7
REPLACEMENT PARTS
7.6 Precision Plasma Junction Box Replacement Parts
2
A
1
2 REF
8
7
3
6
5
4
A
7-26
Section A-A
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
674969
PCB1
PCB Assembly Filter
3
37250
T2,3
XFMR H.F. Auto
4
2062119
J2
Conn ( Pos
5
37391
BKHD A/A-W*F B/A-W*F
6
37392
BKHD A/A-W*F B/A-W*F
7
950256
C1
Cap Mica .002uf 10 KwV
8
677905
SG1
Spark Gap Assy
Wire Kit, Junction Box Precision Plasma
37515
7-27
SECTION 7
REPLACEMENT PARTS
4
B
2
1
C
C
B
5
3
Section B-B
7-28
6
7
8
Section C-C
SECTION 7
Item
Number
REPLACEMENT PARTS
Part Number
Symbol
(Elec-Ay)
J1
Description
Conn Box Recpt 14 MP Shell 20
1
6271128
2
37522
Base Kydex J Box
3
37523
Cover Kydex J Box
4
Ref
5
Ref
Torch Cable Conn Reference
6
Ref
Torch Conn NEG Reference
7
Ref
Pilot Arc Torch Reference
8
Ref
PCB1
J2
7-29
SECTION 7
REPLACEMENT PARTS
1
2
4
5
7-30
3
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
954075
Name Plate
2
37361
Torch Conn Shield
951188
Locknut, Conduit 2NPT
3
954509
Label Warning High Volt Symbol
4
952928
Coupling, Quick Disconn F 14 Hose
5
950518
Grommet RBR 2.12 I.D. X 2.50 O.D. X .06W
7-31
SECTION 7
REPLACEMENT PARTS
7.7 Electronic Flow Control Box
1
ℵ P/N 952920
3
2
TB1
N-1
O-2
AIR1
AR
Air
Air
N2
Air-2
Air-1
Argon
Nitrogen
Argon
Argon
O2
Air
O2
N2
O2-2
N2-3
N2-2
O2-1
N2-1
Oxygen
Nitrogen
H-35
Methane
Meth
H-35
N2
H-35
H-35
∅ P/N 953914
7-32
PS1
SP
V1
ℑ P/N 952868
Process
Air
Oxygen
PR
5
⊕ P/N 952922
Argon
SH
GN
ASSY. 000-005-0007
RC8
RC7
SH
GN
PR
PS2
PS3
V2 SP
SR2
SR1
SR2
RC10
SR2
SR1
SR2
SR1
SR2
SR1
P1
1
PS4
PS5
PR
GN
SP
SH
SP
V3
SH
JP1
GN
PR
JP2
V4
JP3
6
JP4
4
7
JP5
SR1
RC9
1
P2
AIR2
O-1
RC4
RC5
RC6
1
P3
N-2
1
N-3
P4
H35
METH
RC1
RC2
1
RC3
P5
ℜ P/N 952921
Methane
℘ P/N 952913
Methane
⊗ P/N 952915
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
952920
Switch, Pressure 50 PSI Non-Adj
2
952686
PCB Prec Flow Control Interface Board
3
952921
Valve Sol 2-Way 02
4
952913
Manifold Assembly Complete Prec Flow
5
952915
XMFR Control 115/230V 50/60 HZ
6
952922
Lamp Pilot 28V Green
7
952914
Manifold Assembly w/Check Valves ONLY
7-33
SECTION 7
REPLACEMENT PARTS
Plasma Gas 1
Plasma Gas 2
Shield Gas 1
6
7
Shield Gas 2
Vent 1
Vent 2
Vent 3
Valve 1
Valve 2
Valve 3
Vent 4
Valve 4
1
5
4
2
3
6
7
ℑℜ℘⊗ P/Ns 952919,952918, 952916, 952917
7-34
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
Purchase Locally
2
952916
Valve, Analog 0-6 Bar 0-10 VDC Valve 4 SG2
3
952917
Valve, Analog 0-6 Bar 0-10 VDC Valve 3 SG1
4
952918
Valve, Analog 0-9 Bar 0-10 VDC Valve 2 PG2
5
952919
Valve, Analog 0-9 Bar 0-10 VDC Valve 1 PG1
6
639571
Flow Meter Tube ONLY
SG1, SG2
¼-33-G-5 PG2,
7
0558002392
Flow Meter Tube ONLY
¼ -15-G-5 PG1
Fuse, Glass Body, Slow Acting 3AG 4A
7-35
SECTION 7
REPLACEMENT PARTS
7.8 PT-24 Torch Assembly EFC Series A/M P/N 0558001462
Notes:
1* = Plasma 2 in Yellow
2* = Plasma 2 Out Yellow
3* = Plasma 1 in Blue
4* = Plasma 1 Out Blue
5* = Shield 2 In Black
6* = Shield 2 Out Black
7* = Shield 1 In Orange/Red
8* = Shield 1 Out Orange/Red
20
18
7*
6*
13
5*
4*
3*
16
2*
1*
10
14
19
6
9
8
11
2
7
12
4
3
5
1
5/8 - 18
L.H. (Ref)
21
3/8 - 24
L.H. (Ref)
22
23
24
25
7-36
Not Shown
SECTION 7
Item
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
REPLACEMENT PARTS
Part Number
Description
21758
22568
22381
22380
22382
See Process
Data
See Process
Data
22007
22010
21712
21539
22531
0558001336
22375
21765
0558001447
77500101
2234133
996565
0558001470
0558001875
0558001471
21739
21740
21741
37609
Body & Tube Assembly PT-24 Torch
Sleeve, Torch PT-24
Gas Line Start Blue
Gas Line Cut Yellow
Gas Line Shield Orange/Red
Swirl Baffle (See Process Data)
Nozzle (see Process Data)
Retainer/Diffuser
Insulator Shield Cup
Insulator Shield Retainer
Electrode
Cup Shield w/Retainer
T Gas Shutoff VLV Assembly EFC
Protector Gortiflex Sensor 7LG
Tool Electrode & Nozzle (NOT Shown)
Quick Disconnect 90 Deg. Elbow 1.18 L
LUB Grease DOW DC-111 (NOT Shown)
Clamp, Worm Drive
Clamp, Hose
PT-24 Cable Bundle Assembly 4.5 Ft.
PT-24 Cable Bundle Assembly 12 Ft.
PT-24 Cable Bundle Assembly 17 Ft.
Check Valve Body
Ball
Spring
PT-24 Start-up Kit (Quantity of each)
Nozzle “A”(2); Nozzle “B”(2); Nozzle “C”(2); Nozzle “D”(2); Nozzle
“E”(2); Swirl Baffle 15A(1); Swirl Baffle 30A(1); Swirl Baffle
50/70A(1); Lubricant(1); Electrode and Nozzle Tool(1); Shield
Insulator Cup(1); O-ring 1.239 x 0.07(1); O-ring 0.614 X 0.07(1), O-ring
1.498 X 0.07(1); Electrode(5)
25
Torch Spare Parts Kit (Quantity of each)
56996213
21536, 21539
21541, 21542
21543, 21692
21693, 21725
21765, 21923
22007, 22101
22531, 86W62
638797, 950714
Swirl Baffle(2), Oxy Electrode(5)
Nozzle “B”(5), Nozzle “C”(5)
Nozzle “D”(5), Swirl Baffle 50/70A(2)
Retainer Shield Cup(1), Water Baffle(1)
Electrode and Nozzle Tool(1), Nozzle “E”(3)
Retainer diffuser Nozzle(1), Shield Insulator Cup(3)
Shield(6), O-ring 1.239 x 0.07(3)
O-ring 0.614 X 0.07(3), O-ring 1.498 X 0.07(3)
7-37
SECTION 7
REPLACEMENT PARTS
7.9 T Gas Shut-off Valve Assembly EFC Series A/M
3
2
1
2
3
4
5
6
1
7-38
Plasma 1 & 2 Common
Shield 1 & 2 Common
Shield 1
Shield 2
Plasma 2
Plasma 1
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
0558001502
Flange
2
952921
2 Way Solenoid Valves
3
593985
O-Ring
7-39
SECTION 7
REPLACEMENT PARTS
7.10 PT-24 Torch EFC Version 1
16
18
14
10
13
19
6
9
8
11
7
12
Detail Torch Front End
2
15
17
4
3
5
21
20
22
1
23
24
7-40
Not Shown
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
21758
Body & Tube Assembly PT-24 Torch
2
22568
Sleeve, Torch PT-24
3
22381
Gas Line Start Blue
4
22380
Gas Line Cut Yellow
5
22382
Gas Line Shield Orange/Red
6
See Process
7
Data
8
See Process
9
Data
10
22007
Insulator Shield Retainer
11
22010
Electrode
12
21712
Cup Shield w/Retainer
13
21539
Solenoid Assembly Electronic Flow Control V1
14
22531
Protector Gortiflex Sensor 7LG
15
22422
Tool Electrode & Nozzle (NOT Shown)
16
22375
Clamp, Band-it
17
21765
LUB Grease DOW DC-111 (NOT Shown)
18
951168
Clamp, Worm Drive
19
77500101
Clamp, Hose
20
2234133
PT-24 Cable Bundle Assembly 4.5 Ft.
996565
“
“
“
“
12 Ft.
0558001470
“
“
“
“
17 Ft.
0558001875
Cable, Solenoid 4 ft.
0558001471
Cable, Solenoid 12 ft.
22378
Cable, Solenoid 17 ft.
22
22427
Check Valve Body
23
22389
Ball
24
21739
Spring
21
Symbol
(Elec-Ay)
Description
Swirl Baffle (See Process Data)
Nozzle (see Process Data)
Retainer/Diffuser
Insulator Shield Cup
21740
21741
7-41
SECTION 7
REPLACEMENT PARTS
7.11 Solenoid Assembly Torch, Electronic Flow Control Version 1
4
1
11
11
8
2
6
6
7
7
8
10
5
9
9
5
11
7-42
C OM/C OM
C OM/C OM
S hield 2
S hield 1
P las ma 2
P las ma 1
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
22422
Solenoid Assembly Electronic Flow Version 1
2
596985
O-Ring, 1.42 X .103 NEOP 70A
3
952931
Plug Block 6 Pos
4
22421
Bracket, Solenoid EFC
5
952703
Solenoid, 2 Way
6
22367
Quick Disconnect Connector, Yellow
7
952697
Solenoid, 3 Way
8
22366
Quick Disconnect Connector, Blue
9
22365
Quick Disconnect Connector, Orange/Red
10
22364
Quick Disconnect Connector, Silver
11
0558006291
ELBOW STREET 90 DEG 1/8 BRS
7-43
SECTION 7
REPLACEMENT PARTS
7.12 Interface Cables/Hoses
1
ASIOB
2
3
N2
4
O2
5
CNC
6
7
Cutting Table
8
7-44
10
9
CH4
Air
Ar
SECTION 7
REPLACEMENT PARTS
Item
Number
Part Number
Description
1
Reference
CNC Interface Cables, 12/c and 18/c flex, see machine schematic
2
21917
21918
21919
21920
21921
56997111
56997112
56997113
0560986745
59667114
56997115
3
Reference
High Freq, Console to EFC
37533
37534
37535
37536
37537
57000419
57000420
57000421
57000422
57000423
57000424
57000425
57000426
22428
21905
22504
21906
22505
21907
10 ft. (3 m), Gas Line Bundle
20 ft. (6 m), Gas Line Bundle
30 ft. (9 m), Gas Line Bundle
60 ft. (18 m), Gas Line Bundle
100 ft. (30 m), Gas Line Bundle
3ft (.9 m), High Freq Cable, EFC/Junction Box
50 ft. (15.2 m), High Freq Cable, EFC/Junction Box
75 ft. (23 m), High Freq Cable, EFC/Junction Box
100 ft. (30 m), High Freq Cable, EFC/Junction Box
125 ft. (38 m), High Freq Cable, EFC/Junction Box
150 ft. (46 m), High Freq Cable, EFC/Junction Box
175 ft. (53 m), High Freq Cable, EFC/Junction Box
200 ft. (61 m), High Freq Cable, EFC/Junction Box
12 ft. (3.6 m), Power Bundle
25 ft. (7.6 m), Power Bundle
40 ft. (12 m), Power Bundle
60 ft. (18 m), Power Bundle
80 ft. (24 m), Power Bundle
100 ft. (30 m), Power Bundle
7
Reference
Work Lead (positive)
8
Reference
Earth Ground Cable
9
57002248
57002249
57002250
57002251
57002252
30 ft. (9 m), Control Lead, Console / Machine I/O
50 ft. (15 m), Control Lead, Console / Machine I/O
75 ft. (23 m), Control Lead, Console / Machine I/O
100 ft. (30.5 m), Control Lead, Console / Machine I/O
160 ft. (49 m), Control Lead, Console / Machine I/O
10
Reference
Primary Power from Wall Disconnect
4
5
6
10 ft. (3 m), Control Lead EFC/Junction Box, Standard Cable
20 ft. (6 m), Control Lead EFC/Junction Box, Standard Cable
30 ft. (9 m), Control Lead EFC/Junction Box, Standard Cable
60 ft. (18 m), Control Lead EFC/Junction Box, Standard Cable
100 ft. (30 m), Control Lead EFC/Junction Box, Standard Cable
10 ft. (3 m), Control Lead EFC/Junction Box, Flex Cable
20 ft. (6 m), Control Lead EFC/Junction Box, Flex Cable
30 ft. (9 m), Control Lead EFC/Junction Box, Flex Cable
40 ft. (12 m), Control Lead EFC/Junction Box, Flex Cable
60 ft. (18 m), Control Lead EFC/Junction Box, Flex Cable
100 ft. (30 m), Control Lead EFC/Junction Box, Flex Cable
7-45
SECTION 7
Notes:
7-46
REPLACEMENT PARTS
revision history
1. Revision "E" of 07/2007 - Updated replacement parts per CN #073135.
Customer // Technical Support
(843) 664-4405
(800) ESAB-123 (372-2123)
ESAB Welding and Cutting Products
PO BOX 100545 Ebenezer Road
Florence, SC 29501-0545
http://www.esab.com
ESAB Cutting Systems – Canada
6010 Tomken Road
Mississauga, Ontario Canada L5T 1X9
Phone: (905) 670-0220
Fax: (905) 670-4879
ESAB-Hancock GmbH
Cutting Technologies
P.O Box 1128
D-61174 Karben
Robert-Bosch-Strasse 20
D-61184 Karben
Phone + 49 60 39 40-0
Fax
+ 49 60 39 40 301_302
http://www.esab.com
[email protected]
F15-480-E
07/2007
Printed in U.S.A
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement