ESAB m2™ Plasma Smart Plasmarc™ 200 Cutting System Instruction manual

Instruction Manual

0558012312 04/2015

Smart Plasmarc 200

TM

Be sure this information reaches the operator.

You can get extra copies through Your supplier.

caution

these instructions are for experienced operators. if you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “precautions and safe practices for arc Welding, cutting, and gouging,” form 52-529. Do not permit untrained persons to install, operate, or maintain this equipment. Do not attempt to install or operate this equipment until you have read and fully understand these instructions. if you do not fully understand these instructions, contact your supplier for further information. Be sure to read the safety precautions before installing or operating this equipment.

user responsiBilitY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

reaD anD unDerstanD the instruction manual Before installing or operating.

protect Yourself anD others!

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Smart Plasmarc 200

TM table of contents

safetY

safety - english . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Description

general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

m2 smart plasmarc 200 system interconnect Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Package Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

hoses and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

plasma console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Interface Control (IC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

combined gas control (cgc-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

remote arc starter-2 (ras) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Mounting Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

pt-36 mechanized plasmarc cutting torch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Package Options Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Recommended Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

installation

installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Check upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Elements of a Ground System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Earth Ground Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Machine Grounding Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

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placement of plasma console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Input Conductors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Coolant Connection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Individual Component Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

placement of combined gas control (cgc-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Connections from CGC-2 to RAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

placement of ras Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Connections on the RAS Box - Remote mounting on the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Connections on the RAS Box - Local mounting on the Plasma Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

torch connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Connection of Torch to Plasma System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Mounting Torch to Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Preparing to Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

operation

operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

interface control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Display Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Operation Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Digital I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Interface Wiring Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

cut Data

cut Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Carbon Steel Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113

Aluminum Production. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Stainless Steel Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

maintenance / trouBleshooting

maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Fault Isolation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

ic maintenance/troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Error Messages on the IC Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Module Errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Process Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

CAN PS Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

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torch maintenance/troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Torch Front End Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Torch Front End Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Torch Front End Assembly using the Speedloader (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Torch Body Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Torch Body Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Reduced Consumable Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Checking for Coolant Leaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

replacement parts

replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Ordering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

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SAFETY

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safety - english

Warning: these safety precautions are for your protection. they summarize precautionary information from the references listed in additional safety information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. failure to observe safety precautions can result in injury or death.

protect Yourself anD others -- some welding, cutting, and gouging processes are noisy and require ear protection. the arc, like the sun, emits ultraviolet (uV) and other radiation and can injure skin and eyes. hot metal can cause burns. training in the proper use of the processes and equipment is essential to prevent accidents. therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy longsleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal.

A flameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

SAFETY fires anD explosions -- heat from flames and arcs can start fires. hot slag or sparks can also cause fires and explosions. therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protection

Association, Battery march Park, Quincy, MA 02269.

11

SAFETY electrical shocK -- contact with live electrical parts and ground can cause severe injury or death. Do not use ac welding current in damp areas, if movement is confined, or if there is danger of falling.

1. Be sure the Plasma Console frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and Plasma

Console.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.

electric anD magnetic fielDs — may be dangerous. electric current flowing through any conductor causes localized electric and magnetic fields (emf).

Welding and cutting current creates emf around welding cables and welding machines. therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work cables. Route cables on the same side of your body.

D. Connect the work cable to the work piece as close as possible to the area being welded.

E. Keep welding Plasma Console and cables as far away from your body as possible.

fumes anD gases -- fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. shielding gases can cause asphyxiation. therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

12

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California

Health & Safety Code §25249.5 et seq.)

cYlinDer hanDling -- cylinders, if mishandled, can rupture and violently release gas. sudden rupture of cylinder, valve, or relief device can injure or kill. therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed

Gas Association, 1235 Jefferson Davis Highway,

Arlington, VA 22202.

eQuipment maintenance -- faulty or improperly maintained equipment can cause injury or death. therefore:

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are qualified to perform such work.

SAFETY

2. Before performing any maintenance work inside a Plasma Console, disconnect the Plasma Console from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and Plasma Console in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

aDDitional safetY information -- for more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "precautions and safe practices for arc Welding, cutting and gouging", form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc

Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc

Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

13

SAFETY meaning of sYmBols - as used throughout this manual: means attention! Be alert! Your safety is involved.

Danger caution

Warning means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

means potential hazards which could result in personal injury or loss of life.

means hazards which could result in minor personal injury.

enclosure class

The ip code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked ip21s may be stored, but is not intended to be used outside during precipitation unless sheltered.

caution this product is solely intended for plasma cutting. any other use may result in personal injury and / or equipment damage.

if equipment is placed on a surface that slopes more than 15°, toppling over may occur. personal injury and

/ or significant damage to equipment is possible.

to avoid personal injury and/or equipment damage, lift using method and attachment points shown here.

maximum allowable tilt

15°

14

safety - spanish

aDVertencia: estas precauciones de seguridad son para su protección. ellas hacen resumen de información proveniente de las referencias listadas en la sección

"información adicional sobre la seguridad". antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. el no observar las precauciones de seguridad puede resultar en daño a la persona o muerte.

proteJase usteD Y a los Demas-- algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. el arco, como el sol , emite rayos ultravioleta (uV) y otras radiaciones que pueden dañar la piel y los ojos. el metal caliente causa quemaduras. el entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. por lo tanto:

1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.

SAFETY la escoria puede estar caliente y desprenderse con velocidad. personas cercanas deberán usar gafas de seguridad y careta protectora.

fuego Y explosiones -- el calor de las flamas y el arco pueden ocacionar fuegos. escoria caliente y las chispas pueden causar fuegos y explosiones. por lo tanto:

1

. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of

Cutting and Welding Processes", disponible a través de la

National Fire Protection Association, Batterymarch Park,

Quincy, MA 02269.

choQue electrico -- el contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. no use soldadura de corriente alterna (ac) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo.

15

SAFETY

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.

Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC

Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

campos electricos Y magneticos - son peligrosos. la corriente eléctrica fluye através de cualquier conductor causando a nivel local campos eléctricos y magnéticos

(emf). las corrientes en el área de corte y soldadura, crean emf alrrededor de los cables de soldar y las maquinas. por lo tanto:

1. Soldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.

por lo tanto: humo Y gases -- el humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. no inhale el humo o gases. el gas de protección puede causar falta de oxígeno.

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada.

Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo.

No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.

16

SAFETY

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California

Health & Safety Code §25249.5 et seq.)

maneJo De cilinDros-- los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

mantenimiento Del eQuipo -- equipo defectuoso o mal mantenido puede causar daño o muerte. por lo tanto:

1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera.

informacion aDicional De seguriDaD -- para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "precautions and safe practices for arc Welding, cutting and gouging-form

52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc

Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc

Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

17

SAFETY significaDo De los simBolos -- según usted avanza en la lectura de este folleto: los símbolos significan ¡atención! ¡esté alerta! se trata de su seguridad.

peligro significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

aDVertencia cuiDaDo

significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

significa el posible riesgo que puede resultar en menores daños a la persona.

clase de envolvente

El código ip indica la clase de envolvente, es decir, el grado de protección contra la penetración de objetos sólidos o agua. Se provee protección contra el toque con un dedo, penetración de objetos sólidos de un tamaño superior a 12 mm y contra rocío de agua de hasta 60 grados de la vertical. El equipo marcado ip21s se puede almacenar, pero no se debe usar en el exterior durante periodos de precipitaciones a menos que esté protegido.

aDVertencia

este producto sólo se debe usar para corte por plasma cualquier otro uso puede causar lesiones físicas y/o daños en los equipos.

aDVertencia

si el equipo se coloca sobre una superficie con una inclinación superior a 15°, se puede producir un volcamiento. es posible que se produzcan lesiones físicas y/o daños importantes en los equipos.

aDVertencia

para evitar lesiones físicas y/o daños en los equipos, levante mediante el método y los puntos de sujeción que se indican en esta ilustración.

Inclinación máxima permitida

15°

18

safety - french

aVertissement : ces règles de sécurité ont pour but d'assurer votre protection. ils récapitulent les informations de précaution provenant des références dans la section des informations de sécurité supplémentaires. avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les fiches d'information sur la sécurité du matériel et sur les étiquettes, etc. tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles. protÉgeZ-Vous -- les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. l'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures

à la peau et les yeux. le métal incandescent peut causer des brûlures. une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. par conséquent:

1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les

écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

SAFETY incenDies et explosions -- la chaleur provenant des flammes ou de l'arc peut provoquer un incendie. le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. par conséquent :

1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif.

Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire

Protection Association, Batterymarch Park, Quincy, MA

02269.

choc ÉlectriQue -- le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. ne pas utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

19

SAFETY

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de terre

électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porte-

électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

champs ÉlectriQues et magnÉtiQues — comportent un risque de danger. le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magnétiques localisés. le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps.

les Vapeurs et les gaZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. ne respirez pas les vapeurs et les gaz. le gaz de protection risque de causer l'asphyxie. par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.

N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'effectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation.

Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.

20

SAFETY

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme

étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health

& Safety Code §25249.5 et seq.)

manipulation Des cYlinDres -- la manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz. une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur.

Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez CGA

Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis

Highway, Arlington, VA 22202.

entretien De l'ÉQuipement -- un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. par conséquent :

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualifié.

N'effectuez aucune réparation électrique à moins d'être qualifié à cet effet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation

électrique.

3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des flaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'effectuez aucune modification.

informations supplÉmentaires relatiVes À la sÉcuritÉ -- pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "precautions and safe practices for arc Welding, cutting and gouging", form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc

Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc

Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon

Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal

Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

21

SAFETY signification Des sYmBoles ce symbole, utilisé partout dans ce manuel, signifie "attention" ! soyez vigilant ! Votre sécurité est en jeu.

Danger

aVertissement

signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles. signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

attention

signifie un danger qui peut entraîner des blessures corporelles mineures.

classe de protection de l’enveloppe

L’indice de protection (codification ip) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale. Les équipements portant la marque ip21s peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

aVertissement

ce produit a été conçu pour la découpe au plasma seulement. toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.

aVertissement

l’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante.

aVertissement

soulevez à l’aide de la méthode et des points d’attache illustrés afin d’éviter de vous blesser ou d’endommager l’équipement.

Angle d’inclinaison maximal

15°

22

Description

This page intentionally left blank.

description

24

description

Warning

use of torches not DesigneD for use With this console coulD create an electric shocK haZarD.

general

The m2 Smart Plasmarc

TM

200 Cutting System can be assembled as shown on the interconnect diagram and is ready to cut after being connected to input power and a source of compressed air. The system uses the heavy duty PT-36 torch to deliver cutting power for severing materials up to 2.00” (50 mm) thick. Refer to the following pages for descriptions of the packages available as well as performance specifications. The interconnect diagram shows configurations available on the m2 Smart Plasmarc

TM

200 Cutting System. A variety of configurations are available to meet customer’s requirements.

The purpose of this manual is to provide the operator with all the information required to install and operate the cutting package. Technical reference material is also provided to assist in troubleshooting the cutting package.

start-up Kit m2 200a pt-36 .....................................................................................p/n 0558012329

Qty

5

5

5

5

5

5

1

1

5

5

10

part no

0558002533

0558001625

0558012000

0558012318

0558011619

0558010722

0004470031

0558009551

0004485648

0004470034

0558010084

Description

BAFFLE 4 HOLE x .032" PT-36

BAFFLE 8 HOLE x .047" PT-36

ELECTRODE AIR TL, Standard PT-36

ELECTRODE O2 TL, Standard PT-36

NOZZLE XR 1.9mm (.073") PT-36

NOZZLE XR 2.2mm (.085") PT-36

DIFFUSER 24-SLOT

SHIELD XR 5.1mm (.200") PT-36

O-RING 1.614 ID x .070 NBR

O-RING 1.114 ID x .070 CR

O-RING 0.864 ID x .070 FKM

25

To Auto Height Control

Combined Gas Control

Place Ferrite Core (supplied w/ Plasma Console) on CAN cable at Plasma Console end

Plasma Console w/ IC Interface Control

THREE PHASE INPUT POWER

Interface

Analog

Work

To CNC /

External Control

To Work Table

description hoses and cables cable

Description

Remote Arc Starter-2 (RAS) Control

(14PX-14S)

cable

Description

Combined Gas Control (CGC-2) Power & CAN

M12 (8P-8P)

cable

Description

CNC I/O

DB37 (37P-Free)

available lengths m ( ft. )

8m (26')

9m (30')

10m (33')

11m (36')

12m (39')

13m (43')

14m (46')

15m (50')

20m (66')

25m (82')

30m (100')

36m (118')

40m (131')

45m (150')

available lengths m ( ft. )

15m (50')

available lengths m ( ft. )

2.9m (9.5')

7.6m (25')

10m (33')

15m (50')

20m (66')

23m (75')

25m (82')

30m (100')

esaB part number

0558011840

0558011631

0558011632

0558011633

0558011634

0558011635

0558011636

0558011637

esaB part number

0558008471

0558008472

0558008473

0558008474

0558008475

0558008476

0558008477

0558008478

0558008479

0558008809

0558008481

0558008480

0558008482

0558008483

esaB part number

0558012480

28

description cable

Description

Console Enable

(2P-Free)

cable

Description

Voltage Divider (VDR)

M8 (3P-Free)

cable

Description

Power Output

(1/0 Welding Cable)

Pilot Arc

(#8 Welding Cable)

Ground

(8 Awg Green/Yellow)

hose

Description

Coolant Supply / Return

5/8” Black EPDM

Male LH 5/8-18 & Female RH 5/8-18

(*3/8” Black EPDM)

esaB part number

0558008329

0558008330

0558008331

0558008807

0558008808

0558009763

esaB part number

0560946753

0560946754

0560946755

0560946756

0560946757

esaB part number

73010004

0558101089

0560945427

esaB part number

0558012507

0558005246

0558005563

0558005564

0558005565

0558006629

0558005247

available lengths m ( ft. )

5m (16')

10m (33')

15m (50')

20m (66')

25m (82')

30m (100')

available lengths m ( ft. )

1.5m (5’)

3m (10’)

5m (16’)

10m (33’)

20m (66’)

available lengths m ( ft. )

Per Foot

Per Foot

Per Foot

available lengths m ( ft. )

*2.6m (8.5')

5m (16')

10m (33')

15m (50')

20m (66')

25m (82')

30m (100')

29

description plasma console

The m2 Plasma Console is designed for mechanized plasma cutting applications. It is used with other ESAB products such as the

PT-36 torch, RAS-2 and CGC-2 to provide a complete cutting package.

features

• Controls RAS-2 and CGC-2

• Easy-to-use LCD operator interface

• 25 to 200 amperes cutting current range

• Forced air-cooled

• Liquid-Cooled IGBTs

• Internal Coolant Circulator

• Solid-state DC power

• Thermally protected

• 100% duty cycle

specifications

output

(100 % duty cycle) part number

Voltage

Current range DC (cutting)

Power

Open Circuit Voltage (OCV)

Voltage (3-phase)

Current (3- phase)

Frequency m2 plasma console, 200a,

230/460V,

60hz,

0558012390

360 VDC

200/230/460 V

115/96/50 A RMS 60/57 A RMS

60 Hz 50 Hz

input

KVA

Power

39.5 KVA

35.5 KW

Power Factor

90%

Input Fuse (recommended)

150/125/70 A

Weight - lbs (kg)

941 (427)

m2 plasma console, 200a,

380 ccc,

50hz,

0558012391

160 VDC

m2 plasma console, 200a,

400V ce,

50hz,

0558012392

342/360 VDC

380/400 V

39.5 KVA

35.5 KW

90%

30A to 200A

80/75 A

939 (426)

32KW

360 VDC

400 V

57 A RMS

50 Hz

39.5 KVA

35.5 KW

90%

75 A

957 (434)

m2 plasma console, 200a,

575V,

60hz,

0558012393

366 VDC

575 V

43 A RMS

60 Hz

39.5 KVA

35.5 KW

90%

60 A

1085 (492)

30

Dimensions

description

23.75”

(603.25 mm)

47.25”

(1200 mm)

40.75”

(1035 mm)

interface control (ic)

The Interface Control (IC) provides the plasma process control including current and gas control. It also serves as the interface between the customer CNC and the Plasma

Console. At the same time, it functions as a hub for CAN communication.

31

cnc Direct Board

p/n 0558038419

The CNC Direct board is the control and interface board inside the IC. It provides the process control, interface to customer CNC, system setup, panel interface, etc. This illustration is a skeleton of this CNC board. It shows the major components and the major connectors on the board. The table below gives the functions of these connections.

description port

X1

X2

X3

X4

X6

X7

X8

X9

function

CNC Control, DB37

RS232

CAN1 and 24VDC input

CAN2

Spare I/O

Reserved

Aux Control, DB25

ASIOB1 Communication

port function

XP1

XP2

Programming port 1

Programming port 2

S2, S3 ID switches, by default S2=1, S3=4

V12 IC, Main processor

V13

V41

J1

EEPROM, Save data for system configuration, error history, etc.

IC for ASIOB1

32

description combined gas control (cgc-2)

p/n 0558012394

The Combined Gas Control regulates the output of the plasma gas (PG) and controls the flow of shield gas (SG). It is powered by 24 Volts DC from the

Plasma Console and receives commands via the CAN-bus directly from the

IC. It has 2 gas inputs (1 plasma gas, 1 shield gas) and 2 gas outputs (SG, PG).

Either of two adaptor fitting kits are available to adapt standard metric or

CGA hose connections. The gas output of the CGC-2 is monitored and fed back through the CAN-bus to the IC for self-diagnosis. The gas fittings and adaptors are listed in the following tables.

connections

There is one cable connected to the CGC-2 for power and CAN communication. There are 2 gas inputs: PG (N2/

Air/O2) and SG (N2/Air). The gas fittings are listed below.

note:

Chassis must be connected to the machine ground.

note:

The PT-36 Torch is shipped with hose lengths that will not allow the CGC-2 to be mounted more than 2 meters (6.6 ft) away from the torch. Please make sure the routing of the standard hoses will allow them to bend and connect properly before permanently mounting the CGC-2.

gas metric input adaptors plasma

N2/Air/O2

shield

N2/Air

cga input adaptors plasma shield outputs

Air

N2

O2

Air

N2

SG

PG

fitting

G-1/4” right hand male x G-1/4” right hand male

G-1/4” right hand male x G-1/4” right hand male

G-1/4” right hand male x “B” Air/Water right hand male

G-1/4” right hand male x “B” Inert Gas right hand female

G-1/4” right hand male x “B” Oxygen right hand male

G-1/4” right hand male x “B” Air/Water right hand male

G-1/4” right hand male x “B” Inert Gas right hand female

1/4” NPT x 5/8"-18 LH male

1/4” NPT x “A” Oxygen right hand male

esaB p/n

0558010163

0558010163

0558010165

0558010166

0558010167

0558010165

0558010166

10Z30

0558012518

33

specifications

Weight: 6.00 lbs. (2.7 kg)

power input: 24 VAC/DC

Dimensions

description a note:

CAN cable must be routed separate from torch leads.

5.00”

(127.0 mm)

c f

5.625”

(142.8 mm)

6.00”

(152.4 mm)

h g J

5.00”

(127.0 mm)

5.625”

(142.8 mm)

34

description

To

CNC /

External

Control

Remote Arc

Starter-2

(RAS)

Plasma

Console

Customer

Supplied

Gases

GND

CAN 1/CAN

Plasma Gas

Shield Gas

a

J c f combined gas control cgc-2 g h

Plasma Gas

Shield Gas

PT-36

Torch

Component Locator Designation

(See component illustrations)

combined gas control component locator Designations

note: Refer to Hoses and Cables section for available lengths and p/n’s.

To

Auto

Height

Control

(If Equipped)

35

cgc-2 flow Diagram

description

Each gas has a requirement for maximum flow and pressure as shown in chart below:

plasma shield air curtain gas

N2/Air/O2

N2/Air

Air

pressure

125 psi (8.6 bar), 255 SCFH (7.2 SCMH)

125 psi (8.6 bar), 250 SCFH (7.1 SCMH)

80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)

gas & pressure

Air (85psi / 5.9bar)

Process

Nitrogen

(125psi / 8.6bar)

Oxygen

(125psi / 8.6bar)

maximum gas flow rates - cfh (cmh)

With pt-36 torch

269

(7.6)

385

(10.9)

66

(1.9)

gas purity

Clean, Dry, Oil Free

Filtered to 25 microns

99.99%, Filtered to 25 microns

99.5%, Filtered to 25 microns

36

cgc-2 electrical schematic

description

37

description remote arc starter-2 (ras)

p/n 0558011591

The Remote Arc Starter-2 is commonly referred to as the RAS Box. The

RAS box serves as an interface between the plasma torch and the Plasma Console, helping to deliver a stable plasma arc. The RAS box also provides a voltage feedback to the plasma torch lift. This voltage is used to regulate the torch height while cutting, maintaining the proper height of the torch above the work piece.

Within the RAS box there is a High Frequency/Voltage Divider circuit board which provides pilot arc ionization and voltage divider functions to regulate torch height.

Coolant connections and torch power connections are made within the RAS box and provide an interface between the Plasma Console, coolant circulator and the torch.

specifications

Dimensions: 8.75” (222.3 mm) high x 7.50” (190.5 mm) wide x 17.00” (431.8 mm) deep

Weight: 28.5 lbs. (12.9 kg)

Dimensions

8.75”

(222.3 mm)

17.00”

(431.8 mm)

7.50”

(190.5 mm)

38

g, h

connections

f e a

D c description note:

Chassis must be connected to the machine ground.

letter

A

C

D

E

F

G, H

I

J

Description

3 Pin Voltage Divider Connection to the Lift

14 Pin Amphenol Plasma Console Connection

Plasma Console Enable

Coolant Inlet - Flowing to the Torch

Coolant Return - Flowing back to the Coolant Circulator from the Torch

Strain Relief Fittings

Torch Shroud Connection

Machine Ground Connection

J i

39

40 description

To

CNC /

External

Control

Plasma

Console

Component Locator Designation

(See component illustrations)

PS Enable

RAS Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Coolant Return Hose

D h e f c g a

Voltage Divider Cable

arc starter-2

(ras)

J i

Power/Coolant ,

Pilot Arc (Nozzle) ,

Ground

GND

Customer

Supplied

Gases

Combined

Gas Control

CGC-2

PT-36

Torch

To

Auto

Height

Control

(If Equipped)

remote arc starter-2 Box component locator Designations

note: Refer to Hoses and Cables section for available lengths and p/n’s.

description

mounting Dimensions

The box has four M6 x 1 threaded mounting holes shown in pattern below.

caution if fasteners are threaded into the box from below, the length of the fasteners must not allow them to extend more than 0.25” beyond the edge of the internal female threads. if fasteners are too long they can interfere with the components inside the box.

5.00”

(127.00 mm)

1.00”

(2.54 mm)

2.75”

(69.85 mm)

13.75”

(349.25 mm)

ras Box mounting plate Dimensions

p/n 0558008461

18.50"

(469.9 mm)

17.50"

(444.5 mm)

8.75"

(222.3 mm)

3.25"

(82.6 mm)

7.50"

(190.5 mm)

6.50"

(165.1 mm)

41

description pt-36 mechanized plasmarc cutting torch

The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the field. Only the torch front-end has replaceable parts.

The purpose of this section is to provide the operator with introductory information about the PT-36 Mechanized Plasmarc Cutting Torch. Technical reference material is also provided in the

Installation, Operation and Maintenance sections of this manual.

package options available

PT-36 package options available through your ESAB dealer. See Replacement Parts section for package and/or component part numbers.

specifications

type: Water cooled, Dual gas, mechanized plasmarc cutting torch

current rating: 1000 Amps @ 100% duty cycle

mounting Diameter: 2 “ (50.8 mm)

length of torch without leads: 16.7 “(42 cm)

iec 60974-7 Voltage rating: 500 volts peak

striking Voltage (maximum value of hi-freQuencY voltage): 8000 VAC

minimum coolant flowrate: 1.3 GPM (5.9 L/min)

minimum coolant pressure at inlet: 175 psig (12.1 bar)

maximum coolant pressure at inlet: 200 psig (13.8 bar)

minimum acceptable rating of coolant recirculator:

4,450 BTU/HR (1.3 kW) at High Coolant Temperature - Ambient = 45

°

F (25

°

C) and 1.6 USGPM (6 L/min)

maximum safe gas pressures at inlets to torch: 125 psig (8.6 bar)

safety interlocks: This torch is intended for use with ESAB plasmarc cutting systems and controls employing a water flow switch on the coolant return line from the torch. Removal of the nozzle retaining cup to service the torch breaks the coolant return path.

42

description

Dimensions

7.54"

(191.5 mm)

6.17"

(156.7 mm)

9.13"

(231.9 mm)

10.50" (266.7 mm)

Length of Sleeve

recommended regulators

LIquID CyLInDer SerVICe:

O

2

N

2

: R-76-150-540LC ...................................................................................................................................P/N 19777

: R-76-150-580LC ...................................................................................................................................P/N 19977

HIgH PreSSure CyLInDer SerVICe:

O

2

: R-77-150-540 ............................................................................................................................P/N 0558010676

AR & N

H

2

2

& CH

: R-77-150-580 ..................................................................................................................P/N 0558010682

4

: R-77-150-350 ..............................................................................................................P/N 0558010680

INDUSTRIAL AIR : R-77-150-590 ..............................................................................................P/N 0558010684

StAtIOn/PIPeLIne SerVICe:

O

2

: R-76-150-024 ............................................................................................................................P/N 0558010654

AR & N

AIR, H

2

2

: R-76-150-034 ..................................................................................................................P/N 0558010658

, & CH

4

: R-6703 ..............................................................................................................................P/N 22236

coolant

coolant plasma torch 25% pg ............................................................................p/n 0558004297

coolant plasma torch 50% eg ............................................................................ p/n 0560950312

2.00"

(50.8 mm)

43

description

pt-36 xr series speedloader Kit ........................................................................... p/n 0558006628

For usage instructions for the PT-36 XR Series Speedloader Kit see torch section.

2

3

4

5

6

item

1

9

10

11

12

7

8

5

6

2

3

4

Qty

1

1

10

10

2

3

1

1

1

1

1

1

part no

0558006164

0558006436

0558006435

61340094

64302996

995565

0558005916

0558005917

0558006624

0558006625

0558006626

0004485648

Description

SPEEDLOADER HANDHELD

(Includes Items 2 thru 8)

FIXTURE SPEEDLOADER

HANDLE SPEEDLOADER

SCREW SKT HEX 1/4-20 x 3.00

WASHER LOCK 1/4

PLUG HOLE .750 DIA

NOZZLE RETAINER SPEEDLOADER

TOOL PREASSEMBLY SPEEDLOADER

NOZZLE RETAINING CUP XR-SPEEDLOADER PT-36

SPACER XR-SPEEDLOADER PT-36

RETAINER XR-SPEEDLOADER PT-36

O-RING 1.614 ID x .070 NBR

Items 9-12 not shown. For items 7 and 8 see “Torch Front End Assembly using the Speedloader (optional)”.

44

installation

This page intentionally left blank.

installation

46

installation installation

general

Warning failure to folloW instructions coulD leaD to Death, inJurY or

DamageD propertY. folloW these instructions to preVent inJurY or propertY Damage. You must complY With local, state anD national electrical anD safetY coDes.

unpacking

• Inspect for transit damage immediately upon receipt.

• Remove all components from shipping container and check for loose parts in container.

• Inspect louvers for air obstructions.

check upon receipt

1.

Verify all the system components on your order have been received.

2.

Inspect the system components for any physical damage that may have occurred during shipping. If there is evidence of damage, please contact your supplier with the model number and serial number from the nameplate.

Before installation

Warning all installation anD serVice of the electrical anD plumBing sYstems must conform to national anD local electrical anD plumBing coDes. installation shoulD Be performeD onlY BY

QualifieD, licenseD personnel. consult Your local authorities for anY regulation issues.

Locate the major components to the right position prior to making electrical, gas, and interface connections.

Refer to the system interconnection diagrams for major components placement. Ground all major components to earth at one point. To prevent leaks, make sure to tighten all gas and water connections with specific torque.

47

48 installation grounding

introduction

Machine grounding is an important part of the installation process, which can be greatly simplified if prepared in advance. The most difficult part of the grounding process is designing and installing a low impedance Earth ground rod. However, the better the Earth ground rod, the less chance there is of having electromagnetic interference problems after the installation is complete.

Most national electric codes address grounding for the purpose of fire prevention and short circuit protection; they do not address equipment protection and electromagnetic interference noise reduction. Therefore, this manual presents more stringent requirements for machine grounding.

Warning

electric shocK haZarD.

improper grounDing can cause seVere inJurY or Death.

improper grounDing can Damage machine electrical components.

machine must Be properlY grounDeD

Before putting it into serVice.

the cutting taBle must Be connecteD to machine earth grounDing roD.

A common symbol used to identify a chassis ground on drawings.

A common symbol used to identify an earth ground on drawings.

installation

grounding overview

There are three parts to a ground system;

• Component or "chassis" ground

• Earth ground

• Protective Earth ground

Component grounding connects all pieces to a single component, like the machine chassis, which is then connected to a common point known as the star point. This provides a path for electromagnetic interference (EMI) from the enclosure to ground.

An earth ground provides a electromagnetic interference (EMI) to return to its source.

A protective earth (PE) ground provides a safe path for fault current. Without a properly grounded system, an unintended path through people or sensitive equipment may be found, resulting in serious injury, death, and/or premature equipment failure.

This section focuses on machines with a plasma cutting system. Machines with plasma cutting capability are particularly prone to electromagnetic interference problems and often utilize dangerous voltages and currents. All machines must have electrical components grounded and attached to an earth ground, regardless of process type (shape cutting, marking, or other material preparation).

A common symbol used to identify a protective earth (PE) ground.

49

installation

Basic layout

The electrical ground layout is similar for both large and small machines. The chassis ground , plasma

6

7

table. This common connection is referred to as a star point (see illustration below). One cable connects

5

1

9

8

3

output of the plasma Plasma Console . Specification of cable sizes is discussed later in this manual. Some country standards or directives require a separate ground rod for the plasma Plasma Console. Consult your machine schematics for more information.

50

8

note: the three phase electrical input to the plasma plasma console must include an electrical ground.

2

This illustration demonstrates multiple ground cables fastened with a single bolt to create a star

8

cutting table will vary.

installation

elements of a ground system

The ground system consists of five main components:

• plasma current return path

• plasma system safety ground

• utility power electrical ground

• cutting machine chassis ground

• rail system safety ground.

Ensure provisions are made during the installation for each of these elements for creating a complete ground system.

plasma current return path

The return path ground cable is the most important element of the ground system. It completes the path for the plasma current. Solid, low impedance, well maintained electrical connections are a necessity.

The plasma cutting current is generated by the plasma Plasma Console . A welding cable carries this current

5

4

2 3

torch. The current then arcs to the work piece on the cutting table. The current path must be closed so that the current can easily return to its source. This is done by connecting the cutting table to the positive (+) connection on the plasma Plasma Console. If the return path ground cable is not connected, the plasma system will not work. There will be no way for the arc to establish between the torch and the work piece. If the cable is connected, but the connections have a very high resistance, it will limit the current of the arc, and cause dangerous voltage levels between system components.

1

2

3

5

4

51

installation

The only way to ensure that all components are at the same voltage level (same potential), and thus eliminate the possibility of being shocked, is to ensure that all interconnections are making good electrical contact.

Good electrical contact requires that connections are made with bare metal to metal contact, the connections are very tight, and are protected from rust and corrosion. Use a grinder or wire wheel to clean all paint, rust, and dirt from the surface when connecting cable lugs to any metal surface. Use an electrical joint compound between cable lugs and metal surfaces to prevent future rust and corrosion. Use the largest size bolts, nuts, and washers possible, and tighten fully. Use lock washers to ensure that connections stay tight.

plasma system safety ground

The plasma system safety ground (or ground rod) serves several important purposes. It provides:

• Frame voltage for personnel safety by ensuring that there are no potential differences between system components and building components.

• A stable signal reference for all digital and analog electrical signals on the cutting machine.

• Helps control electromagnetic Interference (or EMI).

• Provides a discharge path for short circuits and high voltage spikes, such as those caused by lightening strikes.

52

installation

There are many misconceptions about the ground rod, and the role it plays in reducing electromagnetic interference. In theory, the ground rod is present to eliminate possible potential differences between equipment and building structures. However many people believe that the ground rod allows all radio

1

rod will eliminate radio frequency noise problems.

Misconception about Earth ground rods.

1

53

installation

In reality the ground rod is providing a low impedance path by which noise currents may return to their

2

1

Earth ground rod reality.

2

1

54

installation

rail system safety ground

The rail system safety ground makes sure that the entire rail is at ground potential, eliminating any possible shock hazard, and providing backup for the machine chassis ground in case of a plasma current short circuit. All four corners of the rail system should be connected to the cutting table.

55

installation

earth ground rod

The best way to make sure that your Earth ground connection is optimized is to enlist the services of a professional. There are a number of engineering firms which specializes in designing and installing Earth grounding systems. However, if this option cannot be used, then there are several things which can be done to ensure that your Earth ground connection is good:

ground rod

The ground rod itself can be optimized in two ways: length and diameter. The longer the grounding rod, the better the connection. The same is true for diameter: the larger the diameter, the better the connection.

However, if the soil resistance is very low, then a ground rod longer than 3m [10 feet] does not make a significant difference.

Since soil resistivity is rarely as good as it could be, a standard grounding rod should be

25mm [1 inch] in diameter and 6m [20 feet] long.

soil resistivity

Soil resistivity can be changed in two ways: by altering the mineral content, the moisture content, or both.

The ideal solution to poor soil resistivity is to excavate the immediate area and backfill with conditioned soil additives. In extremely dry areas, the moisture content can be improved by installing a drip system which continually moisturizes the soil surrounding the ground rod. A crude way of affecting soil moisture and content is to use salt water, or rock salt to condition the surrounding soil.

56

installation

utility power electrical ground

The utility power electrical ground must accompany all 3 phase and single phase power feeds. This electrical ground provides the proper reference for all incoming power. Failure to provide this ground is a violation of most electrical codes, and a serious safety hazard.

Depending on the 3 phase power arrangement (either a “Delta” or a “Y”), the line to ground voltage may be equal to, or less than the line to line voltage. A problem exists any time the line to ground voltage exceeds any individual line to line voltage (difference in potential). Contact your local utility company if you are not sure that your 3 phase power has a proper electrical ground. Make sure that your electrical contractor properly installs the electrical ground wire with all 3 phase and single phase power feeds.

The electrical ground must be connected to the appropriate terminal inside of the plasma Plasma Console. Size wire according to local electrical codes.

2

1

3

1

2

3

Utility Power Electrical Ground

3 Phase Electrical Supply

Plasma Plasma Console

57

installation

multiple ground rods

There are a number of reasons why multiple ground rods should not be used. While installing multiple rods may improve a safety ground or lightening ground, it offers no advantage for electromagnetic interference reduction, and can cause more problems than it is worth.

The problem with multiple ground rods is that each rod uses an “interfacing Electromagnetic Interference

1

2

Multiple ground points can also create undetectable

“sneak” pathways for radio frequency noise currents, actually causing more interference! Instead of considering multiple ground rods, take steps to make the single ground rod as good a ground connection as possible.

1.1

l l

1

2

2.5 l

Multiple ground rods should be avoided if possible.

However, if all other avenues have been explored to lessen your systems’ electronic interferences, multiple ground rods are an option.

Such a system should be installed by a professional and the distance between the rods should exceed

2.5 times the length of the rods.

58

installation

machine grounding schematic

1

2

3

10

5

6

7

8

9

3

4

1

2

10

Main Control Enclosure

Component Enclosures

Main Star Ground

Rails

Cutting Table

System Star Ground (on Table)

Earth Ground Rod

Plasma Plasma Console

Plasma Plasma Console Ground

(required by EU Standards)

Electrical System Ground

9

4

8

5

(+)

6

7

• all electrical enclosures bolted to the machine chassis.

• machine chassis grounded to star point on cutting table.

• rails grounded to cutting table.

• plasma ground connected to star point on cutting table.

• earth ground rod connected to star point on cutting table.

• a separate ground rod is required for the plasma plasma console by some regulations and directives. check with local regulations to determine if this additional ground rod is required.

59

installation placement of plasma console

• A minimum of 1 meter (3 ft.) clearance on front and back for cooling air flow.

• Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection.

• Locate the Plasma Console relatively close to a properly fused electrical panel.

• Keep area beneath Plasma Console clear for cooling air flow.

• Environment should be relatively free of dust, fumes and excessive heat. These factors will affect cooling efficiency.

Warning

conductive dust and dirt inside plasma console may cause arc flashover. equipment damage may occur. electrical shorting may occur if dust is allowed to build-up inside the unit. see maintenance section.

60

installation

input power connection

Warning

electric shocK can Kill!

proViDe maximum protection against electrical shocK.

Before anY connections are maDe insiDe the machine, open the line Wall Disconnect sWitch to turn poWer off.

primary power

Three-phase input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

Recommended input conductor and line fuse sizes:

input requirements at rated load

Volts input & ground copper conductors time

Delay line fuse amperes aWg / mm2 amperes

200

230

380 CCC

115

96

60

2/0 AWG

1 AWG

25mm2

150

125

80

400 CE

460

575

57

50

43

25mm2

4 AWG

4 AWG

75

70

60

Rated load is output of 200A at 160V

Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

To estimate the input current for a wide range of output conditions, use the formula below.

notice

Input current =

(V arc) x (I arc) x 0.73

(V line)

Dedicated power line may be necessary.

plasma unit is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.

61

installation

input conductors

• Customer supplied

• May consist either of heavy rubber covered copper conductors (three power and one ground) or run in solid or flexible conduit.

• Sized according to the chart.

Warning

improper grounDing can result in Death or inJurY.

chassis must Be connecteD to an approVeD electrical grounD. Be sure grounD leaD is not connecteD to anY primarY terminal. ensure the grounD leaD is sufficientlY long insiDe the machine. in an eVent Where the poWer corD is pulleD from the machine, the grounD leaD must not BreaK from the grounD connection Before the poWer leaDs haVe BroKen from their connection.

input connection procedure

1. Remove small rear panel of the plasma unit.

2. Thread cables through the access opening in the rear panel.

3. Secure cables with strain relief at the access opening.

4. Connect the ground lead to the stud on the chassis.

5. Connect the power leads to the primary terminals.

6. Connect the input conductors to the line (wall) disconnect.

7. Before applying power, replace the rear cover panel.

Primary Terminals

62

Power Input Cable Access

Opening (Rear Panel)

Chassis Ground

installation

input Voltage configuration and changeover

200/230/460 Vac models - As shipped from the factory, this model of EPP-202 is configured for the highest connectable voltage. If using other input voltages, the links on the terminal board (TB) inside the unit must be repositioned for the appropriate input voltage. See illustrations below for input voltage configurations. To gain access, remove the top panel or right side panel.

Jumper Wire

Jumper Wire

input terminal BoarD

230/460 Vac moDels

230 VAC CONFIGURATION

input terminal BoarD

230/460 Vac moDels

460 VAC CONFIGURATION

Unit is also configurable for 200/400 VAC input service, but the main transformer secondary connections must be re-located on all 3 transformer coils, and jumper wires on the TB2 must be re-positioned. A removable service panel is located above the transformer connections to improve access.

63

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

200/400 tap

230/460 tap

Jumper Wire

installation

1 2 3 4 5 6 7 8 9 10 11 12

tB2

JUMPER POSITIONS FOR 230/460 VAC

12

note:

TB2 wires connected on 230/460 must be reconnected to 200/400.

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

tB2

JUMPER POSITIONS FOR 200/400 VAC

note:

Wires connected on 230/460 main transformer tap must be re-connected to 200/400 main transformer tap on all

3 coils. Be sure to replace insulating vinyl covering over connections.

Jumper Wire

64 input terminal BoarD

230/460 Vac moDels

200 VAC CONFIGURATION

input terminal BoarD

230/460 Vac moDels

400 VAC CONFIGURATION

installation

380 Vac and 400 Vac models - As shipped from the factory, these models of EPP-202 are configured for the single input voltage listed on the rating plate. If using other input voltages, it is possible to configure these units for either 380 VAC or 400 VAC input.

There are 3 steps to follow when making this conversion:

1. Reconfigure the voltage tap on the control transformer (T2) for the proper input voltage:

Move this wire connection to:

400 VAC - H5

380 VAC - H4

460 VAC - (is shown)

65

1 2 3 4 5 6 7 8 9 10 11 12

installation

380 Vac and 400 Vac models (continued) -

2. Reconfigure TB2 terminal strip for proper voltage.

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

tB2

JUMPER POSITIONS FOR 400 VAC

1 2 3 4 5 6 7 8 9 10 11 12

tB2

JUMPER POSITIONS FOR 380 VAC

380 tap

1 2 3 4 5 6 7 8 9 10 11 12

1 2 3 4 5 6 7 8 9 10 11 12

400 tap

3. Reconfigure secondary taps on all three main transformer coils. A removable service panel is located above the transformer connections to improve access.

note:

Wires connected on main transformer tap must be re-connected to 400 or 380 main transformer taps on all 3 coils. Be sure to replace insulating vinyl covering over connections.

Access Panel

575 Vac models - this model is not configurable to any other input voltage.

66

installation

coolant connection procedure

caution

Do not allow pump to operate with coolant reservoir empty as permanent damage to the pump can result.

caution

Do not connect hoses to a solenoid valve that can be closed when the pump is operating as damage to pump can result.

1. Open access panel on the lower front of the Plasma Console by removing (4) M6 screws.

2. Remove packaged items from output compartments, which includes Remote Arc Starter (RAS) mounting brackets, ferrite core with cable tie, terminal lug and ferrules.

3. Thread coolant hoses through the openings at the bottom of the Plasma Console immediately behind the front panel.

4. Connect hoses to designated terminals mounted inside the Plasma Console.

5. Close front access panel.

Front Access

Panel Closed

Front Access

Panel Opened

Remove (4) M6 screws to open

Access Panel

Coolant

Connections

To ease connections, thread cables/ hoses through these 2 access holes

With the torch connected, fill the reservoir with the specially formulated torch coolant (approx 4 gallons). Do not use regular anti-freeze solutions, such as for an automobile, as the additives will harm the pump and torch. ESAB

P/N 0558004297 is recommended for service down to 12° F (-11° C). ESAB P/N 156F05 is recommended for service below 12° F (-11° C) to -34° F (-36° C).

After filling the reservoir, turn ON Plasma Console and allow the pump to run with reservoir cap removed in order to purge air from the radiator, hoses, and torch. Re-check coolant level to ensure reservoir is filled. Replace reservoir cap after purging and checking coolant level. Check for leaks.

67

installation

Delivery pressure adjustment

Delivery pressure is controlled by the relief valve mounted next to the pump in the tank compartment. Remove the top panel of the Plasma Console for access. Turning the pressure adjustment screw clockwise increases pressure on the spring and raises the delivery pressure. Turning it counterclockwise reduces pressure on the spring and reduces the delivery pressure. The pressure is adjusted at the factory to deliver approxomately 175 psig (12 bar) at 1.5 gallons per minute (5.7 l/min). This is an appropriate setting for the PT-36 on an m2 system. Ordinarily, this should not require further adjustment.

This relief valve sends bypassed coolant through the IGBT cold plate and back into the tank. Consequently, a closed discharge line should not damage the pump.

The pump also has a relief valve built in. This valve is set to be fully open at 225 psig (15.5 bar) by the pump manufacturer. Its sole purpose is to protect the pump should the external relief valve fail closed. This relief valve should not be adjusted in the field.

Pressure Adjustment Screw

Plasma Console unit viewed from above with top panel removed

68

installation

output connections

Warning

electric shocK can Kill! Dangerous Voltage anD current!

anY time WorKing arounD a plasma plasma console With coVers remoVeD:

• Disconnect plasma console at the line (Wall) Disconnect.

• haVe a QualifieD person checK the output Bus Bars (positiVe anD negatiVe) With a Voltmeter.

output cables

Choose plasma cutting output cables on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amps of output current.

note:

Do not use 100 volt insulated welding cable, it is not sufficient.

Warning

Do not operate the plasma unit With coVers remoVeD. high Voltage components are exposeD increasing shocK haZarD. internal components maY Be DamageD Because cooling fans Will lose efficiencY.

69

installation

output connection procedure

1. Open access panel on the lower front of the Plasma Console by removing (4) M6 screws.

2. Thread output cables through the openings at the bottom of the Plasma Console immediately behind the front panel.

3. Connect cables to designated terminals mounted inside the Plasma Console using UL listed pressure wire connectors.

4. Close front access panel.

Front Access

Panel Opened

Front Access

Panel Closed

Remove (4) M6 screws to open

Access Panel

To ease connections, thread cables/hoses through these

3 access holes

The plasma unit does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch.

70

installation

interface cable connectors

can cable connection

This is the CAN communication bus connector. The cable from this connector is tied to the CGC-2.

J1 (ras)

This is a connector for interfacing with Remote Arc Starter-2 (RAS) unit. The cable from this connector carries signals such as: Hi-Frequency ON.

analog interface (37 pin connector)

This is the connection used for interfacing with an external CNC.

Analog

Interface CAN

J1 (RAS)

Interface Cable Connectors Panel

(bottom side of front panel)

71

72 installation

individual component connections can cable

cable

Description

Combined Gas Control (CGC-2) Power

& CAN

M12 (8P-8P)

available lengths m ( ft. )

8m (26')

9m (30')

10m (33')

11m (36')

12m (39')

13m (43')

14m (46')

15m (50')

20m (66')

25m (82')

30m (100')

36m (118')

40m (131')

45m (150')

esaB part number

0558008471

0558008472

0558008473

0558008474

0558008475

0558008476

0558008477

0558008478

0558008479

0558008809

0558008481

0558008480

0558008482

0558008483

note:

CAN cable must be routed separate from torch leads.

Interface Cable Connectors Panel

(bottom side of front panel)

CGC front

installation

J1 (ras) interface cable

cable

Description

Remote Arc Starter-2 (RAS) Control

(14PX-14S)

available lengths m ( ft. )

2.9m (9.5')

7.6m (25')

10m (33')

15m (50')

20m (66')

23m (75')

25m (82')

30m (100')

esaB part number

0558011840

0558011631

0558011632

0558011633

0558011634

0558011635

0558011636

0558011637

Interface Cable Connectors Panel

(bottom side of front panel)

RAS front

73

installation

analog interface (37 pin connector)

cable

Description

CNC I/O

DB37 (37P-Free)

available lengths m ( ft. )

15m (50')

esaB part number

0558012480

Interface Cable Connectors Panel

(bottom side of front panel)

74

To

CNC /

External Control

installation

ferrite core (p/n 952157)

The Ferrite Core is used to suppress noise in the CAN communication cable. This item is packed in a cloth bag, inside the bottom front panel, along with a cable tie used for securing the ferrite in place.

CAN communication cable

The Ferrite Core is to be mounted as shown on the

CAN communication cable. Attach cable tie under ferrite to secure ferrite in place.

Ferrite Core cable tie

75

installation placement of combined gas control (cgc-2)

The CGC regulates the plasma gas and shield gas. For optimum performance, it must always be placed within 2 meters (6 ft.) of the torch body. According to the material being cut, the customer needs to select and connect the correct inlet gases. Inline filters are embedded into the inlet fittings. Please make sure all inlet gases meet the pressure and flow requirements.

note:

CAN cable must be routed separate from torch leads.

plasma shield air curtain gas

N2/Air/O2

N2/Air

Air

gas & pressure

Air (85psi / 5.9bar)

Process

Nitrogen

(125psi / 8.6bar)

Oxygen

(125psi / 8.6bar)

pressure

125 psi (8.6 bar), 255 SCFH (7.2 SCMH)

125 psi (8.6 bar), 250 SCFH (7.1 SCMH)

80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)

maximum gas flow rates - cfh (cmh)

With pt-36 torch

269

(7.6)

385

(10.9)

66

(1.9)

gas purity

Clean, Dry, Oil Free

Filtered to 25 microns

99.99%, Filtered to 25 microns

99.5%, Filtered to 25 microns

gas metric input adaptors plasma

N2/Air/O2

shield

N2/Air

cga input adaptors plasma shield outputs

N2

SG

PG

Air

N2

O2

Air

fitting

G-1/4” right hand male x G-1/4” right hand male

G-1/4” right hand male x G-1/4” right hand male

G-1/4” right hand male x “B” Air/Water right hand male

G-1/4” right hand male x “B” Inert Gas right hand female

G-1/4” right hand male x “B” Oxygen right hand male

G-1/4” right hand male x “B” Air/Water right hand male

G-1/4” right hand male x “B” Inert Gas right hand female

1/4” NPT x 5/8"-18 LH male

1/4” NPT x “A” Oxygen right hand male

esaB p/n

0558010163

0558010163

0558010165

0558010166

0558010167

0558010165

0558010166

10Z30

0558012518

76

installation

connections from cgc-2 to ras

The CGC-2 and RAS Box must be grounded together using the supplied ground connection wire.

77

installation placement of ras Box

The RAS Box can be mounted in 2 different configurations:

- Remote mounting on the machine

- Local mounting on the Plasma Console

connections on the ras Box - remote mounting on the machine

With this mounting configuration, the RAS box can mounted on the machine anywhere that allows connections to be run cleanly. Connections are as follows:

Warning

the cover is grounded to the remote arc starter-2 Box internally with a short ground wire. remove cover carefully to avoid damage to the wire or loosening of the ground wire.

1.

Remove or unlock the cover screws and lift the box cover off to expose internal components.

2.

Power cables pass through the strain relief fittings.

3.

Strip back the insulation of the 1/0 (53.5 mm

2

) cable, approximately 38 mm.

4.

Insert the 1/0 (53.5 mm

2

) cable in the Bus bar/block hole until copper extends to the edge of the Bus bar / block.

Pilot Arc Cable enters through strain relief fitting to Voltage Divider (VDR)

Coolant IN to Customer Interface for PS Enable Circuit to Plasma Console

Coolant OUT

Strain Relief Fittings

Power Source Cables enter through strain relief fittings

note:

Chassis must be connected to the machine ground.

78

Bus Bar / Block

installation

Nomex Insulation

VDR Connection

Locking Screw

Connection for Pilot Arc Cable

5.

Tighten the locking screw(s) down on the cable.

6.

On the (customer supplied) VDR cable, the end with the connector is to be connected to the RAS box to its corresponding socket which is labeled “Voltage Divider” .

cable

Description

Voltage Divider (VDR)

M8 (3P-Free)

available lengths m ( ft. )

1.5m (5’)

3m (10’)

5m (16’)

10m (33’)

20m (66’)

esaB part number

0560946753

0560946754

0560946755

0560946756

0560946757

VDr cable (with free end)

The free end of the VDR cable will be connected to the lifter. Although this is a three conductor cable, only two of the wires are used, BRN (VDR - ) and BLU (WORK). The black wire is a spare and is to be terminated and capped inside of the lifter. The corresponding pin at the RAS box comes terminated from the factory. The RAS box is not to be modified.

It is imperative that the BLUE wire be connected to ground. The BROWN wire is the VDR(-) output.

amperage

Up to 200 amps

required # of 1/0 cables

1

Customer

Supplied

Lifter

VDR (Voltage Divider Cable)

BRN (VDR-)

BLU (WORK)

BLK (SPARE)

ground in lifter is required for reference

79

installation

7. On the PS Enable Cable, the end with the connector is to be connected to the RAS box to its corresponding socket which is labeled “PS ENABLE”.

cable

Description

Console Enable

(2P-Free)

available lengths m ( ft. )

5m (16')

10m (33')

15m (50')

20m (66')

25m (82')

30m (100')

esaB part number

0558008329

0558008330

0558008331

0558008807

0558008808

0558009763

The free end of the PS Enable Cable needs to be connected to customer controller interface. This ENABLE signal must be closed in order to operate the power supply. Make the connections as shown below to the respective Enable signal on the customer side. If this connection is not made properly, the m2 Plasma Console will generate an error code (Error 23) implying the PS Enable signal is missing.

to RAS Box Plasma

Console Enable connection

80

installation

Warning

electric shocK can Kill! Dangerous Voltage anD current!

anY time WorKing arounD a plasma plasma console With coVers remoVeD:

• Disconnect plasma console at the line (Wall) Disconnect.

haVe a QualifieD person checK the output Bus Bars (positiVe anD negatiVe) With a Voltmeter.

connections on the ras Box - local mounting on the plasma console

With this mounting configuration, all connections are the same as with remote mounting on the machine.

The RAS box is capable of mounting on rear of the

Plasma Console as shown, with bracketry provided.

These brackets are packed in the output compartment at bottom front of unit.

When using the RAS box in this location, ensure the ground wire is installed before operation. It is recommended to attach ground wire inside output source prior to mounting the RAS.

Attach ground wire here, this ground must also be jumpered to the CGC-2

Route wire through bushing in Power

Source rear panel

Open cover

Attach ground wire here to lug provided

81

installation torch connections

connection of torch to plasma system

Danger

electric shock can Kill!

• Disconnect primary Plasma Console before making any adjustments.

• Disconnect primary source before doing maintenance on system components.

• Do not touch front-end torch parts (nozzle, retaining cup, etc.) without turning primary power off.

The PT-36 has two water-cooled power cables which must be connected to the RAS Box’s negative output from the Plasma Console. The right-handed 7/16-20 fitting is on the cable supplying coolant to the torch. The lefthanded 7/16-20 fitting is on the cable returning coolant from the torch. The pilot arc cable is also connected to the RAS Box. These cables have a green/yellow wire to be connected to the ground stud as shown. (All torch lengths except 50 ft (15 m) version).

Ground Stud

Pilot Arc Connection

Pilot Arc Cable

Chassis Ground green/yellow wire

(except 50 ft/15 m version)

Power Cable /

Coolant Connections

Power Cable / Coolant

SG Hose

PG Hose

82

installation

mounting torch to machine

Danger

clamping on torch BoDY maY cause Dangerous current to floW through machine chassis.

Mount torch on insulated sleeve here

• Do not mount on stainless steel torch body.

• Torch body is electrically insulated, however high frequency start current may arc through to find a ground.

• Clamping near torch body may result in arcing between body and machine.

• When this arcing occurs, torch body may require non-warranty replacement.

• Damage to machine components may result.

• Clamp only on insulated torch sleeve (directly above label) not less than 1.25"

(31.75mm) from the torch end of the sleeve.

DO NOT mount on steel torch body here

83

installation

preparing to cut

• Select an appropriate condition from the Cut Data (SDP File) and install recommended torch front-end parts (nozzle, electrode, etc.) See Cut Data to identify parts and settings.

• Position torch over material at desired start location.

• See Plasma Console section for proper settings.

• See Description and Installation sections for gas control and startup procedures.

mirror cutting

When mirror cutting, a reverse swirl gas baffle and reverse diffuser are required. These reverse parts will “spin” the gas in the opposite direction, reversing the “good” side of the cut.

reverse 4 x .032 Baffle reverse 8 x .047 Baffle reverse Diffuser p/n 0558002534 p/n 0558002530 p/n 0004470115

0558002530

cut Quality

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:

• Cut Angle, negative or positive

• Cut Flatness

• Surface Finish

• Dross

• Dimensional Accuracy

Usually the recommended cutting parameters will give optimal cut quality, occasionally conditions may vary enough that slight adjustments will be required. If so:

• 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.

84

installation caution

Before attempting anY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in cut Data.

cut angle

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

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

• Current high or low. (See Cut Data for

recommended current level for specific nozzles).

Drop

Part

Part

Drop

Part

85

installation

cut flatness

Top And Bottom Rounded. Condition usually occurs when material is .25" thick (6.4mm) or less.

• High current for given material thickness.

(See Cut Data for proper settings).

Drop Part

Top Edge Undercut

• Standoff low (Arc Voltage).

Drop

Part

86

installation

surface finish

process induced roughness

Cut face is consistently rough. May or may not be confined to one axis.

• Incorrect Shield Gas mixture (See Cut 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.

• Dirty rails, wheels and/or drive rack/pinion.

• Carriage wheel adjustment.

Top View

Cut Face

Process

Induced

Roughness or

Machine

Induced

Roughness

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 Cut Data.

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.

Lag Lines

Cut Face

Rollover

Side View

Lag Lines

Cut Face

slow speed Dross

Forms as globules on bottom along kerf. Removes easily.

• Cutting speed slow.

Globules

Side View

87

caution installation

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.

top Dross

Appears as splatter on top of material. Usually removes easily.

• Cutting speed fast

• Standoff high (arc voltage)

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

Side View

Splatter

Cut Face

caution

Before attempting anY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in the cut Data.

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.

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. Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in the Cut Data section and/or manual.

88

torch flow passages

installation

Water OUT & Power

Pilot Arc

Water IN (L.H.)

Plasma Gas IN

Shield Gas IN

89

90 installation

operation

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operation

92

operation operation

front panel

a - power light

This indicator illuminates when input power is applied to the Plasma Console.

B - fault light

Whenever there is a fault, this indicator illuminates. This may stay ON continuously or flash with 50% ON/OFF intervals depending on the type of fault. If the fault is a thermal failure, the indicator will stay ON continuously.

For other types of faults, the indicator will flash. The actual error/fault information is displayed on the front panel display.

c - interface control (ic) Display

This is the primary operator interface for setting up the plasma system.

D - interface control (ic) encoder Wheel

Used for navigating the Interface Control.

a

B c D

93

94 operation

m2 smart plasmarc J1 (ras) - interface Diagram

operation interface control

The Interface Control (IC) is used to interface the ESAB m2 Process Control with the customer CNC using digital

I/O.

The following pages describe how to operate the IC.

Interface Control (IC) display

Interface Control (IC) Encoder Wheel

95

operation

Display screens

On powerup the IC screen displays the following information for 3 seconds:

start-up screen top menu screen

Screen Number

Setup Screen

Main Screen

Error Log Screen

Diagnostics Screen

System Information Screen

96

Screen Number

Setup Screen

Main Screen

Error Log Screen

main screen

Back

If the circle is filled in, the parameters are not the default.

Screen Name

operation

Screen Number

Parameter selection. Comes from the database inside the

EEPROM, with a fixed width of 20 characters.

Select by scrolling.

Gas parameters. Can be modified, but when modified, causes the

"Custom Parameter" to fill in.

Restores the defaults for the parameters.

Status of the complete system:

• READY - ready to run

• PREFLOW - Preflowing the plasma and shield gas

• START - Starting the torch

• RUN - Cutting with the torch

• STOP - Stopping the cutting sequence

• FAULT - Fault on the system

• WARN - Coolant level is low

Module Status:

• Empty - Module missing from CAN bus

• Solid - Module on the CAN bus and ready

• Flashing - Module has an error

operation sequence

1. Turn the input gases ON for the CGC-2 unit.

2. Verify consumables in the PT-36 torch match your required cutting condition.

3. Turn the Plasma Console ON.

4. Go to the Main Screen (file select) and set the file to match your required cut data.

5. If there are no faults on the CNC, send a start signal to the m2 Smart Plasmarc system.

6. Wait for the ARC ON digital input from the system and set motion enable on the CNC to continue cutting with the machine.

7. For any faults on the display, refer to the troubleshooting section of this manual.

97

setup screen save screen

operation

Refer to Main Screen

Pre-flow time is the total time for pre-flowing before attempting to start the arc. It can not go lower than the minimum pre-flow time for the torch leads.

"Standard" displays the units in PSI/CFH. "Metric" displays the units in BAR/CMH.

Filters the parameter selection to the options selected.

Disable system errors

Saves the settings to EEPROM.

Reloads the settings from the EEPROM.

reload screen

Cancels save

Confirms saving of setup from EEPROM Cancels reload

Confirms reloading of setup from EEPROM

98

Cancels reload

setup-> error Disable screen

operation

Disables the plasma gas output pressure too high and too low errors.

Disables the shield gas output flow too high and too low errors.

Disables the current output too high and too low errors.

Disables the arc lost error.

editing a parameter on the Display

Only available when communication is set to none or Local/Remote switch is set to Local.

1.

Use the encoder wheel to scroll to the parameter.

2.

Push the wheel.

3.

Turn the wheel to edit the value.

4.

Push the wheel again to lock the value.

setup-> parameter filter screen

Material selection options available: MS, ALL

Plasma gas selection options: N2, O2, Air

99

accessing error log screen

operation

error log screen

Refer to Main Screen

Last error - refer to Maintenance/Troubleshooting

PrOC - see Process Errors section

IC - see IC Errors section

gC or PS - see Module Errors section

error screen

Clears the error log screen

Refer to Main Screen

Module Type

Number of starts since last reboot

Error code

Error details

100

accessing Diagnostics screen

operation

Diagnostics screen

Plasma Start from CNC

Hold signal from CNC

Gas Test from CNC

Arc On signal to CNC

Fault signal to CNC

Air Curtain output

Plasma Console diagnostics

Gas Control diagnostics

Diagnostics - > plasma console screen

Plasma start to control board

Arc On from control board

Coolant level from control board

Coolant flow

Output current

Pilot Arc current

Starting current

Cutting current

Stoping current

Current ramp up time

Current ramp down time

101

Diagnostics - > plasma console screen

operation

Refer to Main Screen

Commanded plasma gas pressure

Plasma gas output pressure

Commanded shield gas flow

Shield gas flow

Refer to Main Screen

accessing system information screen system information screen

Version of the firmware on the Interface Control.

Version of the firmware on the Plasma Console.

Version of the parameter data set.

Version of the firmware on the PCUP.

Version of the local PLC on the Gas Control.

102

operation

Digital i/o

Digital inputs

Digital inputs are to be only turned on with 24 VDC. Any other voltage may damage the board or cause unpredictable results. The best method is to send the 24 VDC from the DB37 connector back on the input, via a relay or opto-isolator chip.

signal name

Plasma Start

Gas Test

Hold

Description

Starts the plasma process

Starts the plasma process without igniting the torch

Prevents the system from starting the Plasma Console

Digital outputs

Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement.

signal name

Arc On

System Fault

Description

This signal is high when the arc is on

The IC has detected a problem which required the process to stop. Check the error log to get the exact set of errors.

103

operation

interface Wiring Descriptions interface Wiring

DB37 connector

This cable should be a twisted pair cable with an overall shield attached to the shell on both ends of the cable.

It has a DB37 male connector on one end and flush cut on the other end.

pin no.

Wire color

4 GRN

13

15

17

18

7

12

5

6

GRN/WHT

ORN/WHT

BLK/WHT

GRY/WHT

RED/WHT

GRY

RED

BLK

*23 ORN

Braided Shield

signal name

Digital Output 1 (-)

Digital Output 2 (-)

Digital Output 3 (-)

Digital Output 4 (-)

Digital Input 1

Digital Input 2

Digital Input 4

24VDC

GND

Digital Output 1 (+)

PE

* All digital output collectors are combined together.

Motion Enable Emitter

System Fault Emitter

Air Curtain Emitter

Spare Output Emitter

Hold Ignition

Gas Test

Cycle Start

24 VDC Power

Ground

Digital Output Collector

Potential Earthing

function recommended DB-37 i/o connections to customer controller

104

operation

Digital output Wiring examples

Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement. There are two good methods for doing this. There is a small voltage drop across the opto-isolator on the Interface Control Board, so it is recommended that a voltage of at least 12 VDC be used in order to protect against noise generated by the plasma system’s starting circuit.

24V

method 1: Using the 24 VDC to drive a digital input circuit on the

CNC’s input.

DO+ 1

R1 R2

DO- 1 5V

10K

R3

2.74K

1M

24V

24V

DO+ 1

tact on the coil however the CNC needs it.

DO- 1 5V

10K 1M

R3

2.74K

DO+ 1

DO- 1

A coil

B

External CNC

Serial

Digital I/O

DO+ 1

DO- 1

A coil

B

24V

External CNC

Serial

Digital I/O

External Power

230V/3A w/ Height Control

Water Injection

120V/3A w/o Height Control

Water Injection

Optional

Standard

ICH

(Interface

Control Hub)

CGC

RAS BOX or

External Power

230V/3A w/ Height Control

120V/3A w/o Height Control

B4 Lift

Optional

SGB

Standard

PGB

105

Water

Injection

ICH

(Interface

Control Hub)

CGC

RAS BOX or

CAN PS

B4 Lift

SGB

PGB

Water

Injection

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operation

106

cut Data

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cut data

108

cut data cut Data

Use the following pages for initial cutting parameters. Variations in material and conditions may require adjustments to be made to obtain desired results.

Danger

hydrogen explosion hazard! read the following before attempting to cut with a water table.

A hazard exists whenever a water table is used for plasma arc cutting. Severe explosions have resulted from the accumulation of hydrogen beneath the plate being cut. Thousands of dollars in property damage has been caused by these explosions. Personal injury or death could result from such an explosion. The best available information indicates that three possible sources of hydrogen exists in water tables:

1. molten metal reaction

Most of the hydrogen is liberated by a fast reaction of molten metal from the kerf in the water to form metallic oxides. This reaction explains why reactive metals with greater affinity for oxygen, such as aluminum and magnesium, release greater volumes of hydrogen during the cut than does iron or steel. Most of this hydrogen will come to the surface immediately, but some will cling to small metallic particles. These particles will settle to the bottom of the water table and the hydrogen will gradually bubble to the surface.

2. slow chemical reaction

Hydrogen may also result from the slower chemical reactions of cold metal particles with the water, dissimilar metals, or chemicals in the water. The hydrogen gradually bubbles to the surface.

3. plasma gas

Hydrogen may come from the plasma gas. At currents over 750 amps, H-35 is used as cut gas. This gas is 35% hydrogen by volume and a total of about 125 cfh of hydrogen will be released.

Regardless of the source, the hydrogen gas can collect in pockets formed by the plate being cut and slats on the table, or pockets from warped plate. There can also be accumulation of hydrogen under the slag tray or even in the air reservoir, if these are part of the table design. The hydrogen, in the presence of oxygen or air, can then be ignited by the plasma arc or a spark from any source.

4. follow these practices to reduce hydrogen generation and accumulation:

A. Clean the slag (especially fine particles) from the bottom of the table frequently. Refill the table with clean water.

B. Do not leave plates on the table overnight or a weekend.

C. If a water table has been unused for several hours, vibrate it in some way before the first plate is laid in position.

This will allow accumulated hydrogen in the refuse to break loose and dissipate before it is confined by a plate on the table. This might be accomplished by laying the first plate onto the table with a slight jolt, then raising the plate to permit hydrogen to escape before it is finally set down for cutting.

D. If cutting above water, install fans to circulate air between the plate and the water surface.

E. If cutting underwater, agitate the water under the plate to prevent accumulation of hydrogen. This can be done by aerating the water using compressed air.

F. If possible, change the level of the water between cuts to dissipate accumulated hydrogen.

G. Maintain pH level of the water near 7 (neutral). This reduces the rate of chemical reaction between water and metals.

109

cut data

Warning possible explosion hazard from plasma cutting aluminum-lithium alloys!

Aluminum-Lithium (Al-Li) alloys are used in the aerospace industry because of 10% weight savings over conventional aluminum alloys. It has been reported that molten Al-Li alloys can cause explosions when they come into contact with water. Therefore, plasma cutting of these alloys should not be attempted in the presence of water. These alloys should only be dry cut on a dry table. Alcoa has determined that "dry" cutting on a dry table is safe and gives good cutting results. DO NOT dry cut over water. DO NOT water injection cut.

The following are some of the Al-Li alloys currently available:

Alithlite (Alcoa)

Alithally (Alcoa)

2090 Alloy (Alcoa)

X8090A (Alcoa)

X8092 (Alcoa)

X8192 (Alcoa)

Navalite (U. S. Navy)

Lockalite (Lockheed)

Kalite (Kaiser)

8091 (Alcan)

For additional details and information on the safe use from the hazards associated with these alloys, contact your aluminum supplier.

Warning

oil and grease can Burn Violently!

• Never use oil or grease on this torch.

• Handle torch clean hands only on clean surface.

• Use silicone lubricant only where directed.

• Oil and grease are easily ignited and burn violently in the presence of oxygen under pressure.

Warning

hydrogen explosion hazard.

Do Not Cut Underwater With H-35! Dangerous buildup of hydrogen gas is possible in the water table. Hydrogen gas is extremely explosive. Reduce the water level to 4 inches minimum below the workpiece. Vibrate plate, stir air and water frequently to prevent hydrogen gas buildup.

Warning

spark hazard.

Heat, spatter, and sparks cause fire and burns.

• 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.

110

cut data

maximum gas flow rates With pt-36 torch gas & pressure

Air (85psi / 5.9bar)

Process

Nitrogen

(125psi / 8.6bar)

Oxygen

(125psi / 8.6bar)

maximum gas flow rates - cfh (cmh)

With pt-36 torch

269

(7.6)

385

(10.9)

66

(1.9)

gas purity

Filtered to 25 microns

DIN Quality ISO 8573-1

Oil Quality mg/m3 = 0.1 Class 2

Temperature +3°C Class 4

99.99%, Filtered to 25 microns

99.5%, Filtered to 25 microns

the cut data was gathered using the following materials:

Aluminum: 6061,Al-Mg1SiCu,AlMg1SiCu,3.3211

Carbon Steel: AISI 1008, ASTM A572 Gr.50, ASTM A36

Stainless Steel: 304, 1.4301 CrNi DIN 17440 X5CrNi18-10 DIN EN 10088

***materials with different compositions and properties may require adjustment of the published cutting parameters to achieve optimal results.***

111

pt-36 consumable and

Wears reference parts

cut data

Part No

0558003924

Part No

0558005457

0558002533

0558001625

electrode holders

Description

ELECTRODE HOLDER PT-36

Baffles

Description

BAFFLE 4 HOLE x .022" PT-36

BAFFLE 4 HOLE x .032" PT-36

BAFFLE 8 HOLE x .047" PT-36

Part No

0558005459

0558012318

0558012000

0558003928

Part No

0004470046

0558009548

Part No

0558003918

0558007105

0004470049

electrodes

Description

ELECTRODE O2/N2, Low Current PT-36

ELECTRODE O2/AIR T076 PT-36

ELECTRODE O2 TL, Standard PT-36

ELECTRODE N2/H35, Standard PT-36

Part No

0558006010

0558006014

0558006018

0558006023

Standard Shields

0558006130

0558006141

0558006166

standard nozzles

Description

NOZZLE 1.0mm (.040") PT-36

NOZZLE 1.4mm (.055") PT-36

NOZZLE 1.8mm (.070") PT-36

NOZZLE 2.3mm (.090") PT-36

XR Series Nozzles

0558011619

0558010722

Nozzle Retaining Cups

0004470045

0558009715

0558009550

0558006624

part no

NOZZLE RETAINING CUP PT-36

NOZZLE RETAINING CUP w/ BRASS CAP PT-36

NOZZLE RETAINING CUP XR PT-36

NOZZLE RETAINING CUP XR-SPEEDLOADER PT-36

Diffusers

part no

NOZZLE XR 1.9mm (.073") PT-36

NOZZLE XR 2.2mm (.085") PT-36

0004470030

0004470031

part no

DIFFUSER 16-HOLE

DIFFUSER 24-SLOT

part no

SHIELD 3.0mm (.120") PT-36

SHIELD 4.1mm (.160") PT-36

SHIELD 6.6mm (.259") PT-36

Part No

0558009551

xr series shields

Description

SHIELD XR 5.1mm (.200") PT-36

shield retainers

Description

SHIELD RETAINER PT-36

SHIELD RETAINER XR PT-36

tools

Description

TOOL ELECTRODE HOLDER PT-36

NUT DRIVER 7/16" (Electrode Tool)

WRENCH HEX KEY 0.109"

112

carbon steel production

Version 1.0 released on 28Oct14

rf in ss in

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114 Version 1.0 released on 28Oct14

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116 Version 1.0 released on 28Oct14

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120 Version 1.0 released on 28Oct14

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121

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122 Version 1.0 released on 28Oct14

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Version 1.0 released on 28Oct14

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124 Version 1.0 released on 28Oct14

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126 Version 1.0 released on 28Oct14

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131

aluminum production

132 Version 1.0 released on 28Oct14

aluminum production

Version 1.0 released on 28Oct14

rf in ss in

133

aluminum production

134 Version 1.0 released on 28Oct14

stainless steel production

Version 1.0 released on 28Oct14

rf in ss in

135

stainless steel production

136 Version 1.0 released on 28Oct14

stainless steel production

Version 1.0 released on 28Oct14

rf in ss in

137

stainless steel production

138 Version 1.0 released on 28Oct14

stainless steel production

Version 1.0 released on 28Oct14

rf in ss in

139

stainless steel production

140 Version 1.0 released on 28Oct14

stainless steel production

Version 1.0 released on 28Oct14

rf in ss in

141

stainless steel production

142 Version 1.0 released on 28Oct14

stainless steel production

Version 1.0 released on 28Oct14

rf in ss in

143

stainless steel production

144 Version 1.0 released on 28Oct14

stainless steel production

Version 1.0 released on 28Oct14

rf in ss in

145

stainless steel production

146 Version 1.0 released on 28Oct14

Maintenance/troubleshooting

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148

Maintenance/troubleshooting maintenance

general

Warning

electric shocK can Kill!

shut off poWer at the line (Wall) Disconnect Before attempting anY maintenance.

Warning

eYe haZarD When using compresseD air to clean.

• Wear approved eye protection with side shields when cleaning the Plasma

Console.

• Use only low pressure air.

caution

maintenance on this equipment should only Be performed By trained personnel.

cleaning

Regularly scheduled cleaning of the Plasma Console is required to help keep the unit running trouble free.

The frequency of cleaning depends on environment and use.

1. Turn power off at wall disconnect.

2. Remove side panels.

3. Use low pressure compressed dry air, remove dust from all air passages and components. Pay particular attention to heat sinks in the front of the unit. Dust insulates, reducing heat dissipation. Be sure to wear eye protection.

caution

air restrictions may cause plasma unit heat to over heat.

thermal switches may be activated causing interruption of function.

Do not use air filters on this unit.

Keep air passages clear of dust and other obstructions.

Warning

electric shocK haZarD!

Be sure to replace anY coVers remoVeD During cleaning

Before turning poWer BacK on.

149

150

Maintenance/troubleshooting

plasma console Block Diagram

Warning

Dangerous Voltages anD current! electric shocK can

Kill! Before operation, ensure installation anD grounDing proceDures haVe Been folloWeD. Do not operate this eQuipment With coVers remoVeD.

1 ~ T2

Control

Transformer

Fuse

F3

Pump

Main

Contactor

Main

Fan

Main

Transformer

3 ~

Rectifier

1 x 6000uf

450V

Capacitors

200/230/380/

400/460/575V

3 ~ Input

Input

Fuses

(F1, F2)

Soft

Start

Relay

3 x 2 Ohm

300 Watt

Resistors

IGBT Driver

Board

2 x 400 Amp

IGBT’s

Inductor

Output

Main Control

Board

CAN

IC

(Interface

Control)

Hall Sensors

Relay Block

Maintenance/troubleshooting

plasma console coolant flow Diagram

As soon as the Plasma Console is supplied with input power, the coolant pump motor turns ON. Coolant pumps out to the torch and returns back to the coolant tank through the radiators, filter, flow sensor, and IGBTs cold plate respectively. The pump has an internal adjustable bypass valve set to 225 psi (15.5 bar). There is also an external adjustable regulator, set to 175 psi (12 bar), to bypass the coolant flow if pressure exceeds 175 psi (12 bar).

The coolant flow diagram is as shown in the figure below.

GAUGE

IGBT COLD PLATE

FLOW SENSOR (FS1)

LEVEL SENSOR

(LS1)

151

Maintenance/troubleshooting

turbine flow sensor

features :

Small and compact dimension

Easy connection, 1/2” BSP thread

High reliability and durability

Installation flexibility : vertical or horizontal

Wide rated voltage : 2.4 to 26 VDC

Hall effect sensor, digital output

electrical :

Supply voltage : 2.4 – 26 V DC

Supply current : typical 3.0 mA, maximum 6.0 mA.

Output mode : open collector

Output rise time : typical 1.0μsecond. maximum 10μsecond.

Output falling time : typical 0. 3μsecond. maximum 1.5μsecond.

Wire connection : Termianl 1 (Red) : Vdd Terminal 2 (Brown) : Vout Terminal 3 (Black) : Gnd

application :

Mounting Method : Horizontal to Vertical

Range of Flow Rate : 1.5 – 25 L/min.

Maximum working pressure : 1MPa

Fluid : Cold / Warm Water

Fluid temperature : 0 ~ 80 o

C

Environment temperature : -20 ~ 80 o

C

Body Materials : PPS with 40% glass fiber

Inside turbine holder : Acetal copolymer (POM)

Turbine : plastic magnet

Turbine stick : ceramic

152

PROPRIETARY AND CONFIDENTIAL

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY

OF ESAB WELDING & CUTTING. ANY REPRODUCTION IN PART OR AS A

WHOLE WITHOUT THE WRITTEN PERMISSION OF ESAB WELDING & CUTTING

IS PROHIBITED.

VENDOR: MADISON COMPANY

VENDOR P/N: M8790

(8)0558011991

411 S. Ebenezer Rd

Florence, SC 29501

DESCRIPTION:

PLASTIC SIDE-MOUNTED SWITCH

STEM: POLYPROPYLENE

FLOAT: POLYPROPYLENE

MAX TEMP: 105C

NOM CURRENT: 30VA SPST SWITCH

FLOAT SG: 0.60

MAX PRESSURE: 100PSIG

LEADS: 22GA, 24INCHES

Maintenance/troubleshooting

level switch

Level switch is used to tell if the level of coolant in the tank drops below certain level. When the level of the coolant drops below level switch position in the tank, control board reads the switch open signal, an error signal is

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY

OF ESAB WELDING & CUTTING. ANY REPRODUCTION IN PART OR AS A

WHOLE WITHOUT THE WRITTEN PERMISSION OF ESAB WELDING & CUTTING

IS PROHIBITED.

(8)0558011991

411 S. Ebenezer Rd

Florence, SC 29501



VENDOR:

VENDOR P/N:











MADISON COMPANY

M8790





DESCRIPTION:

PLASTIC SIDE-MOUNTED SWITCH

STEM: POLYPROPYLENE

FLOAT: POLYPROPYLENE

MAX TEMP: 105C

NOM CURRENT: 30VA SPST SWITCH

FLOAT SG: 0.60

MAX PRESSURE: 100PSIG



coolant filter

A filter is used to prevent the foreign particles entering the Plasma Console through coolant and damaging the equipment.

REVISIONS

DESCRIPTION

DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL .03

TWO PLACE DECIMAL .015

THREE PLACE DECIMAL .005

DRAWN



NAME

MEA

PMD

MEA







MATERIAL

COMMENTS:



DATE APPROVED

FINISH

DO NOT SCALE DRAWING



DATE

11/14/12

11/14/12

11/15/12

PA6900-11-16

SIZE

A

SCALE:1:5

10/20/11

(8)0558011991

WEIGHT: SHEET 1 OF 1







153

NAME

MEA

PMD

MEA

DATE

11/14/12

11/14/12

11/15/12

PA6900-11-16 10/20/11

FINISH

REVISIONS

DESCRIPTION



DATE APPROVED

 

  

 

 



















  





DIMENSIONS ARE IN INCHES

TOLERANCES:

FRACTIONAL .03

ANGULAR: MACH .1 BEND .5

TWO PLACE DECIMAL .015

THREE PLACE DECIMAL .005

DRAWN

CHECKED

ENG APPR.

MATERIAL

COMMENTS:

SIZE

A

DWG. NO.

(8)0558011991

WEIGHT: SHEET 1 OF 1





















 









 

  

 

 













  



































 





Maintenance/troubleshooting troubleshooting

Warning

electric shocK can Kill!

Do not permit untraineD persons to inspect or repair this eQuipment. electrical WorK must Be performeD BY an experienceD electrician.

caution

stop work immediately if plasma console does not work properly.

have only trained personnel investigate the cause.

use only recommended replacement parts.

Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple. If the cause cannot be quickly located, shut off the input power, open up the unit, and perform simple visual inspection of all the components and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.

The cause of control malfunctions can be found by referring to the sequence of operations, electrical schematics and checking the various components. A volt-ohmmeter will be necessary for some of these checks.

troubleshooting guide

When the input power is applied to m2 Smart Plasmarc system, pump motor should turn ON immediately, the power light on the front panel will be ON and fault light will be OFF (if there are no errors/faults) indicating normal operation.

Check the following:

1. If pump motor doesn’t turn ON, fuse(F3) might be bad or check for a bad connection to pump motor.

2. If POWER light doesn’t turn ON or main contactor and main fan doesn’t turn ON, then it could be caused by blown fuses F1 or F2.

3. If the FAULT light is ON, then check the CNC/Process Controller display screen for the type of error message from Plasma Console.

Fault Light, Main Contactor and Main Fan status for different errors/faults:

type of fault

Thermal or Ambient

Servo Fault

All other Faults

fault light status on toggle toggle fault light frequency

Continuous

50% duty cycle with a period of 1 second

50% duty cycle with a period of 2 seconds

K1 and main fan status on off off

When fault light is in either one of the above-mentioned states, check the Interface Control screen for the description of the error and further details in this section.

154

fault isolation

Maintenance/troubleshooting

fan not Working

problem

Fan does not turn ON

possible cause

This is normal when unit is in idle mode for more than 5 minutes.

Broken or disconnected wire in fan motor circuit.

Faulty fan(s)

Relay failed to close

action

None

Repair wire.

Replace fans

Check relay connection and/or replace relay.

torch Will not fire

problem

Main Arc Transfers to the work with a short “pop”, placing only a small dimple in the workpiece.

Arc does not start. There is no arc at the torch. Open circuit voltage is OK.

possible cause action

Communication between plasma unit and CNC or process controller is lost.

CNC or Process Controller removes the start signal when the main arc transfers to the work.

Remote current values are not present.

Current value is too low.

Check communication cable.

Make sure CNC or Process Controller is sending start signal correctly.

Check if correct current values are sent down the CAN Bus.

Increase current value.

Open connection between the Plasma

Console positive output and the work. Repair connection.

Pilot current and/or start current should be increased for better starts when using consumables for 100A or higher (Refer to process data included in torch manuals).

Increase pilot current. (Refer to process data included in torch manuals).

Fault light is ON.

Faulty PCB1 (control board).

Check Help Codes table.

Replace PCB1 (control board).

155

Maintenance/troubleshooting ic maintenance/troubleshooting

Digital input problems

problem

The wrong input on the screen is changing when the CNC turns on an input to the IC

No input on the screen is changing when the

CNC turns on an input to the IC

resolution

Make sure the inputs are wired to the proper input on the IC.

Make sure the CNC is only sending the 24 VDC from DB37 connector back to the IC as the input when turning the input on.

Digital output problems

problem

The IC shows the output turning on but there is no voltage on the output’s emitter side.

resolution

Check for voltage on the collector side. If there is a DC voltage there greater than 10 volts, then call service.

gas problems

problem

The CNC turns on a gas test and no gas comes out of the torch.

resolution

Make sure the plasma gas box and shield gas box have power (green

LED on the same side as the cable connections is lit).

156

Maintenance/troubleshooting

error messages on the ic Display error log screen

Last received error always shown at top.

Clear all errors on screen.

This screen displays a log of the last 13 errors received by the IC. By moving the cursor to the error and pressing the hand wheel, more details of the error are displayed.

error screen

Module Type

Number of starts since last reboot

Error code

Error details

157

error screen

Maintenance/troubleshooting

Type of Error

Number of starts since IC boot up

Plasma Console error code

Error details

error screen

Type of Error

Number of starts since IC boot up

Error ID

Command value for error

Actual value when error occurred

Error details

158

module errors

Maintenance/troubleshooting iD

9

B

61

62

63

1E

1F

23

53

60

64

65

problem

The checksum of the station constants do not match the station constants.

The watchdog telegram has not been received in 400 ms.

solution

This error will normally correct itself. If it continues, replace the module/board.

The CAN send buffer has overflowed.

The CAN receive buffer has overflowed.

The checksum of the calibration data is wrong.

The checksum of the local PLC on the gas control is wrong.

The output to the valve on channel 1 is drawing too much current.

The output to the valve on channel 2 is drawing too much current.

The output to the valve on channel 3 is drawing too much current.

The output to the valve on channel 4 is drawing too much current.

The module's telegram counters do not match the interface control's telegram counters.

Replace the gas control module.

Replace the gas control module.

1. Check for a short on the output of the channel.

2. Replace the valve.

1. Check for a short on the output of the channel.

2. Replace the valve.

1. Check for a short on the output of the channel.

2. Replace the valve.

1. Check for a short on the output of the channel.

2. Replace the valve.

1. Check for all the dip switches on the IC board are toward the display.

2. Check for SW1 on the control board in the Plasma Console is set to "Closed"

3. Check for the CAN cable is properly connected to the module.

4. Check for coiling of the CAN cable near power leads.

The module has reset itself.

1. Check for all the dip switches on the IC board are toward the display.

2. Check for SW1 on the control board in the Plasma Console is set to "Closed"

3. Check for the CAN cable is properly connected to the module.

4. Check for coiling of the CAN cable near power leads.

159

160

Maintenance/troubleshooting

process errors

iD problem solution

1

2

3

4

5

6

7

8

9

A

B

C

D

E

F

10

The shield gas output flow is higher than expected. 1. Check that the correct consumables are installed in the torch.

2. Check for a leak in the shield output gas line from the gas control.

3. Check the flow reading while the start signal is low. If there is more than XX CFH

(X.X CMH), replace the shield gas pressure sensor.

The shield gas output flow is lower than expected.

1. Check that the correct consumables are installed in the torch.

2. Check for a clog in the shield output gas line from the gas control.

3. Check that there is power to the pressure sensor.

4. Check for a loose or misplaced wire from the pressure sensor.

The gas control is not properly communicating on the CAN bus.

1. Check for all the switches on SW1 of the IC board are toward the display.

2. Check for SW1 on the control board in the Plasma Console is set to "Closed"

3. Check for the CAN cable is properly connected to the module.

4. Check for power to the module.

The plasma gas output pressure is higher than expected.

The plasma gas output pressure is lower than expected.

1. Check that the correct consumables are installed in the torch.

2. Check for a clog in the plasma output gas line from the gas control.

3. Check the pressure reading while the start signal is low. If there is more than X

PSI (X.X BAR), replace the plasma gas pressure sensor.

1. Check that the correct consumables are installed in the torch.

2. Check for a leak in the plasma output gas line from the gas control.

3. Check that there is power to the pressure sensor.

4. Check for a loose or misplaced wire from the pressure sensor.

The current output of the Plasma Console is higher than expected.

The current output of the Plasma Console is lower than expected.

The arc was lost before plasma start signal was removed.

Coolant flow is lower than 1.0 GPM.

1. Pierce height is too high during start.

2. No plate under torch during cutting.

3. Pierce time is too long.

1. Check the coolant level in the coolant tank.

2. Check for a clog in the filter.

3. Check for a clog in the flow sensor.

4. Check for a kink in the coolant lines.

5. Check for power to the flow sensor.

The Plasma Console has thrown an error.

The control board is not properly communicating on the CAN bus.

The system failed to start.

Coolant level is below the recommended level for operation.

The cycle start was present during boot up.

The plasma gas pressure sensor was reading a pressure when there was no command.

The shield gas pressure sensor was reading a flow when there was no command.

Check the CAN PS error code for more details.

1. Check for all the switches on SW1 of the IC board are toward the display.

2. Check for SW1 on the control board in the Plasma Console is set to "Closed"

3. Check for the CAN cable is properly connected to the control board.

4. Check for power to the control board.

1. Check that the torch is close enough to the work piece.

2. Check that the work piece and work leads from the Plasma Console are connected electrically (< 10 Ohms).

1. Refill the coolant tank with coolant.

2. Replace the coolant level sensor.

1. Check the start signal to the interface control while the Plasma Console is off. If there is voltage on the input, find and fix the wiring error.

2. Check the start signal to the interface control while the Plasma Console is on. If there is voltage on the input while the output of the CNC is off, check the interface control wiring for a short to the input.

3. Replace the interface control.

1. Check the input pressure to the plasma gas.

2. Check the wiring for the plasma gas pressure sensor.

3. Replace the plasma gas pressure sensor.

1. Check the input pressure to the shield gas.

2. Check the wiring for the shield gas pressure sensor.

3. Replace the shield gas pressure sensor.

Maintenance/troubleshooting

can ps errors

Error code

01

02

03

04

05

06

08

09

11

12

13

14

15

problem

Solution

Supply Line Voltage exceeded or dropped below + / - 15% of rated input when machine is in Idle mode

1. Check the input voltage to the machine with a voltage meter.

2. Check the input power cable for correct size and resistance.

3. Check the Main Transformer (T1) voltage tapping connections.

4. Check the input fuses in the PS.

5. Check the input line fuses in the disconnect box.

6. Check the multi-color ribbon cable between J12 on PCB1 and J2 and PCB2.

Supply Line Voltage exceeded or dropped below + or - 20% of rated input while cutting

Control Transformer not supplying proper voltage to control board or the

+24 and +/-15 volt bias supplies are not balanced

There is a thermal fault inside the

Plasma Console. Fix any coolant flow errors before investigating this error.

1. Check the input line voltages to the machine with a voltage meter.

2. Check the input power cable for correct size and resistance.

3. Check the Main Transformer (T1) voltage tapping connections.

4. Check the input fuses in the PS.

5. Check the input line fuses in the disconnect box.

6. Check the multi-color ribbon cable between J12 on PCB1 and J2 and PCB2.

7. Notify your power company of the line stiffness issues.

1. Check the input voltage taps on the control transformer.

2. Check the control transformer output voltages on TB3, if the voltages read within +/-15% of the specified value then replace the control board else replace control transformer.

1. Wait 10 minutes for the unit to cool. If the thermal fault clears on its own then check for the ambient temperature being above 40C or dirt in the radiators.

2. Check if main fan is functioning and it is pulling air through the Plasma Console.

3. Shut off the Plasma Console and allow the machine to cool.

4. Check the diode bridge for an open thermal switch. If the switch is still open after certain time then replace the switch.

5. Check the IGBT module for an open thermal switch. If the switch is still open after certain time then replace the switch.

CYCLE START signal is high while the power source is booting up.

Failed to fire/ ignition did not take place within 4 seconds after HF is turned ON.

1. Check the start signal to the Plasma Console while the Plasma Console is OFF. If there is voltage on the input, find and fix the wiring error.

2. Check the start signal to the Plasma Console while the Plasma Console is ON. If there is voltage on the input while CNC is OFF, check the Plasma Console control wiring for a short to the input.

1. Check the distance from the work piece matches the recommended ignition height.

2. Check the electrical connection from the work piece to the work connection on the Plasma Console.

3. Check the HF relay inside the Plasma Console.

4. Check the 115VAC voltage on the control transformer.

5. Check the consumables.

Torch error/Electrode current was present before the PWM was enabled.

Arc voltage is greater than 40V in Idle mode.

Output current is greater than the minimum idle current.

A phase of the input power is missing.

Open circuit voltage did not reach 280 volts within 200 msec.

Ambient temperature exceeded 75° C in control enclosure.

Bus voltage failed to reach 200 VDC with in 500 ms.

1. Check the jumper inside the RAS box between pins L and J on the 14-pin Amphenol connector.

2. Check for short between electrode and nozzle.

3. Check the IGBT gate pulse voltage connection on the driver board.

4. Check for shorted IGBT.

5. Check for shorted diode (D9).

1. Check for shorted IGBT.

2. Check for shorted diode (D9).

3. Check the arc voltage feedback connection on the driver board from the Electrode (-) terminal.

4. Check IGBT gate pulse voltage connection on the driver board.

1. Check for shorted IGBT.

2. Check for shorted diode (D9).

3. Check the IGBT gate pulse voltage connection on the driver board. If there is positive voltage then replace the driver board.

4. Check the hall sensors and their connections to the control board.

5. Replace the control board.

1. Check the fuses in the disconnect box for bad fuse.

2. Check the main contactor contacts for any damage.

3. Verify the input to the Plasma Console is providing all 3 phases.

1. Check for short between the electrode and nozzle.

2. Check for short between the electrode cable and a connection to the work output of the Plasma Console.

3. Check for an open IGBT.

4. Check the IGBT gate pulse voltage connection on the driver board.

5. Check the multi-color ribbon connection from J12 on PCB1 to J2 on PCB2.

1. Check the temperature inside the control panel, if it reads below 55C and still the error is present then replace the control board.

2. Cool the area around the Plasma Console to below 40C. This is the upper limit of the rated operating range for the Plasma Console.

1. Check for faulty input fuse.

2. Check for shorted bus filter capacitor.

3. Check the bus charger contactor (K2) contacts and coil for any damage.

4. Check the bus-charger contactor relay (RB1-1) for failure.

5. Check bus charger resistors connections.

6. Check the ribbon cable connection between J6 and Relay Module (RB1).

7. Check the multi-color ribbon cable connection between J12 on PCB1 to J2 on PCB2.

8. Check the 24VAC supply on the control transformer.

161

Maintenance/troubleshooting

162

18

20

21

22

23

24

25

27

28

30

31

32

33

34

35

39

Output voltage fell below 70 volts during cutting or below 40 volts during marking.

Output or Arc voltage detected before

START signal issued

Main contactor failed to engage or disengage.

Work current is greater than Electrode current plus threshold limit during cutting.

The Plasma Console enable signal is missing.

There was an SPI communication error between the main and servo micro on control board.

The EEPROM on the control has failed.

The servo and supervisor on the control board of the Plasma Console has firmware version mismatch.

Jumper in the RAS box is missing.

1. Check for short in the torch cable.

2. Check cutting or marking height is too low.

3. Check for short between electrode and nozzle.

4. Check for short between Work (+) and Electrode (-) terminals on the Plasma Console.

5. Check for coiled or looped up electrode or work cables.

1. Check for a shorted IGBT.

2. Check the gate pulse voltage to IGBT from driver board. If there is a positive voltage during idle, replace the driver board.

3. Check the IGBT gate pulse voltage connections and make sure they are as per schematics.

4. Check the arc voltage feedback connections on the driver board.

5. Check for shorted diode (D9).

6. Check the multi-color ribbon cable connection between J12 on PCB1 and J2 on PCB2.

1. Check the input fuses inside the disconnect box.

2. Check the main contactor (K1) contacts.

3. Check the main transformer auxiliary windings connection on TB2 for 115VAC.

4. Check the relay RB1-2 on the relay module RB1.

5. Check the ribbon cable connection between J6 and relay module RB1.

1. Check the feedback from the hall sensors.

2. Check the connection from hall sensors to the control board.

3. Replace the control board.

1. Check the Plasma Console enable signal is present. This should be a dry contact output from the CNC.

2. Check for the Plasma Console enable signal going to J1 connector on PCB1.

3. Check the enable signal contacts on K4 relay.

4. Check control transformer 24VAC voltage on TB3 powering K4 and K5.

5. Replace the control board.

1. Shut off the Plasma Console for at least 5 minutes. If the error clears, check the grounding of the machine and the Plasma Console.

2. Replace the control board.

1. Shut off the Plasma Console for at least 5 minutes. If the error clears, check the grounding of the machine and the Plasma Console.

2. Replace the control board.

Replace the control board.

The servo on the control board has fault.

Coolant flow is below 0.45GPM.

Coolant flow is above 2.4GPM.

There was a watchdog error on the

CAN bus.

Ignition/Arc lost in dwell state immediately after it attached to the plate.

1. Check the jumper inside the RAS box between pins L and J on the 14-pin Amphenol connector.

2. Check for damaged control cable.

3. Replace the control board.

1. Check for bad hall sensor.

2. Check for diode (D9) connection on the IGBT module bus bars.

3. Shut off the Plasma Console for at least 5 minutes. If the error clears, check the grounding of the machine and the Plasma Console.

4. Replace the control board.

1. Check the coolant level.

2. Check for a clogged filter.

3. Check for leaks in the coolant return line.

4. Check the bypass regulator for bypassing too much coolant.

5. Check input power to the pump.

6. Check for proper pump function by looking for flow into the tank. If there is no flow and the motor in running, replace the pump head.

7. Check the connection of the flow sensor to the control board.

8. Check for the SW6 position set properly according the flow sensor either turbine flow or rotor flow sensor.

9. Replace the control board.

1. Check the connection of the flow sensor to the control board.

2. Check for the SW6 position set properly according the flow sensor either turbine flow or rotor flow sensor.

3. Replace the control board.

1. Check the CAN connection between the interface control and the Plasma Console’s control board.

2. Check the input power to the interface control.

3. Check for all the dip switches on the IC board are toward the display.

4. Check for SW5 on the control board in the Plasma Console is set to “CLOSE”.

5. Check for coiling of the CAN cable near power leads.

1. Check that the piercing distance of the torch is at the recommended level.

2. Check that the ignition distance of the torch is at the recommended level.

3. Check the consumables.

This will normally correct itself, if not replace the control board.

The station constant’s CRC received from the controller did not match the calculated CRC.

Hall Sensor Connector is removed or jumper is missing.

1. Check the hall sensor feedback connector for proper wiring.

Maintenance/troubleshooting torch maintenance/troubleshooting

torch front end Disassembly

Wear on torch parts is a normal occurrence to plasma cutting. Starting a plasma arc is an erosive process to both the electrode and nozzle. Regularly scheduled inspection and replacement of PT-36 parts must take place to maintain cut quality and consistent part size.

Danger

hot torch Will Burn sKin! alloW torch to cool Before serVicing.

1. Remove the Shield Cup Retainer.

note:

If the shield cup retainer is difficult to remove, try to screw the nozzle retaining cup tighter to relieve pressure on the shield cup retainer.

2. Inspect mating metal surface of shield cup and shield cup retainer for nicks or dirt that might prevent these two parts from forming a metal to metal seal. Look for pitting or signs of arcing inside the shield cup. Look for melting of the shield tip. Replace if damaged.

3. Inspect diffuser for debris and clean as necessary. Wear on the top notches does occur, effecting gas volume.

Replace this part every other shield replacement. Heat from cutting many small parts in a concentrated area or when cutting material greater than 0.75" (19.1mm) may require more frequent replacement.

caution

incorrect assembly of the diffuser in the shield will prevent the torch from working properly. Diffuser notches must be mounted away from the shield as illustrated.

Shield Cup

Diffuser

Nozzle Retaining Cup

Shield Cup Retainer

Nozzle

Electrode

Torch Body

163

Maintenance/troubleshooting

4. Unscrew nozzle retainer and pull nozzle straight out of torch body. Inspect insulator portion of the nozzle retainer for cracks or chipping. Replace if damaged.

Inspect nozzle for:

• melting or excessive current transfer.

• gouges from internal arcing.

• nicks or deep scratches on the O-ring seating surfaces .

• O-ring cuts, nicks, or wear.

• Remove hafnium particles (from the nozzle) with steel wool.

Replace if any damage is found.

note:

Discoloration of internal surfaces and small black starting marks are normal and do not effect cutting performance.

If the holder was tightened sufficiently, the electrode may unscrew without being attached to the electrode holder. When installing the electrode, use only sufficient force to adequately secure the electrode.

5. Remove electrode using electrode removal tool.

6. Disassemble electrode from electrode holder. Insert flats on the holder into a 5/16" wrench. Using the electrode tool, rotate electrode counter-clockwise to remove. Replace electrode if center insert is pitted more than 3/32” (2.4mm).

Torch Body

Electrode Removal Tool

Electrode

Replace electrode if center insert is pitted more than 3/32” (2.4mm)

164

Maintenance/troubleshooting

7. Remove electrode holder from torch body. Hex on the end of the electrode holder removal tool will engage in a hex in the holder.

Removal

Tool

Gas Baffle

Electrode Holder Assembly

Electrode

note:

The electrode holder is manufactured in two pieces. Do not disassemble. If the holder is damaged, replace the electrode holder assembly.

8. Disassemble electrode holder and gas baffle. Carefully remove O-ring from electrode holder and slide baffle from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not attempt to clear holes. Replace baffle if damaged.

note:

Check all O-rings for nicks or other damage that might prevent O-ring from forming a gas/water tight seal.

Gas Baffle

O-ring

Electrode Holder Assembly

note:

Discoloration of these surfaces with use is normal. It is caused by galvanic corrosion.

165

166

Maintenance/troubleshooting

torch front end assembly

caution

over-tightened parts will be difficult to disassemble and may damage torch. Do not over tighten parts during reassembly. threaded parts are designed to work properly when hand-tightened, approximately 40 to 60 inch/pounds.

• Reverse order of disassembly.

• Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates easy future assembly and disassembly for service.

• Installing the electrode requires only moderate tightening. If the electrode holder is made tighter than the electrode, it is possible to change worn electrodes without removing the electrode holder.

• Turn on the coolant circulator and purge the gases through the torch.

note:

When assembling, place the nozzle inside the nozzle retaining cup and thread the nozzle retaining cup/nozzle combination on the torch body. This will help align the nozzle with the assembly.

The shield cup and shield cup retainer should be installed only after installing the nozzle retaining cup and nozzle. Otherwise the parts will not seat properly and leaks may occur.

Diffuser

Shield Cup Retainer

Shield

Cup

Nozzle

Nozzle Retaining

Cup

Electrode

Torch body

Maintenance/troubleshooting

torch front end assembly using the speedloader (optional)

Use of a speedloader, p/n 0558006164, will ease assembly of the torch front end parts. step 1. To use the speedloader, first insert the nozzle into the nozzle retaining cup.

Nozzle

Nozzle Retaining Cup step 2. Screw the speedloader into the nozzle retaining cup to secure the nozzle.

Preassembly tool step 3. Secure retaining nut on nozzle with preassembly tool, p/n 0558005917 included with the speedloader.

step 4. Remove the speedloader. It is very important to remove the speedloader to ensure proper seating of the remaining parts.

step 5. Insert the diffuser into the shield cup.

Retaining nut p/n 0558005916

Shield Cup

Diffuser

Shield cup retainer step 6. Insert the nozzle retaining cup assembly into the shield cup retainer.

Nozzle retaining cup assembly

Shield cup retainer assembly step 7. Screw shield cup retainer assembly onto nozzle retaining cup assembly.

167

Maintenance/troubleshooting

torch Body maintenance

• Inspect O-rings daily and replace if damaged or worn.

• Apply a thin coat of silicone grease to O-rings before assembling torch. This facilitates easy future assembly and disassembly for service.

• O-ring [1.61" (41mm) I.D. x .07" (1.8mm) BUNA-70A] p/n 996528.

Warning

electric shocK can Kill!

Before performing torch maintenance:

• Turn power switch of the Plasma Console console to the OFF position.

• Disconnect primary input power.

168

O-Ring locations

• Keep electrical contract ring contact points free of grease and dirt.

• Inspect ring when changing nozzle.

• Clean with cotton swab dipped in isopropyl alcohol.

Contact Ring Points

Contact Ring

Contact Ring Screw

Contact Ring Points

Maintenance/troubleshooting

torch Body removal and replacement

Warning

electric shocK can Kill!

Before performing torch maintenance:

• Turn power switch of the Plasma Console console to the OFF position .

• Disconnect primary input power.

1. Loosen the worm gear hose clamp so that the torch sleeving can be freed and pulled back up the cable bundle. Approximately 7” (177.8mm) should be far enough. Unscrew the torch sleeve and slide it back until the pilot arc connection is exposed.

Handle

Torch Body

2. Disconnect the power cables which are threaded onto the shorter stems at the back of the torch. Note that one of these connections is left-handed. Unscrew the gas hoses from the torch head assembly by using a

7/16" (11.1mm) and a 1/2" (12.7mm) wrench. Removal of the gas hoses is easier if the power cables are removed first.

1/2" HEX Power Cable & Water

Return Connections

1/2" HEX Shield Gas

Connection

7/16" HEX Plasma Gas

Connection

169

Maintenance/troubleshooting

3. Unwrap the electrical tape at the back of the gray plastic insulator over the pilot arc connection. Slide the insulator back and undo the knife connectors.

Electrical Tape

(shown removed)

Pilot Arc Cable

PA Insulator

Knife-splice connection

4. To install the new torch head assembly - Connect the pilot arc cable and the main power cable by reversing the steps taken to disconnect them. Be sure the gas and water fittings are tight enough to prevent leaks, but do not use any kind of sealant on them. If the knife connection seems loose, tighten the connection by pressing on the parts with needle-nosed pliers after they are assembled. Secure the gray pilot arc insulator with 10 turns of electrical tape.

New Torch Head Assembly

5. Slide the handle forward and thread it firmly onto the torch body.

170

Maintenance/troubleshooting

reduced consumable life

1. cutting up skeletons

Cutting skeletons (discarded material left after all pieces have been removed from a plate). Their removal from the table can adversely affect electrode life by:

• Causing the torch to run off the work.

• Greatly increasing the start frequency. This is mainly a problem for O

2

cutting and can be alleviated by choosing a path with a minimum number of starts.

• Increasing 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 an OXWELD torch for skeleton cutting or operate the PT-36 at a high standoff.

2. height control problems

• Torch crashing is usually caused by a change in arc voltage when an automatic height control is used.

The voltage change is usually the result of plate falling away from the arc. Disabling the height control and extinguishing the arc earlier when finishing the cut on a falling plate can effectively eliminate these problems.

• Torch crashing can also occur at the start if travel delay is excessive. This is more likely to occur with thin material. Reduce delay or disable the height control.

• Torch crashing can also be caused by a faulty height control.

3. piercing standoff too low

4. starting on edges with

continuous pilot arc

5. Work flipping

Increase pierce standoff

Position torch more carefully or start on adjacent scrap material.

The nozzle may be damaged if the torch hits a flipped up part.

6. catching on pierce spatter

7. pierce not complete before

starting

Increase standoff or start with longer lead-in.

Increase initial delay time.

8. coolant flow rate low,

plasma gas flow rate high,

current set too high

9. coolant leaks in torch

Correct settings

Repair leaks

171

Maintenance/troubleshooting

checking for coolant leaks

Coolant leaks can originate from seals on the electrode, electrode holder, nozzle, and torch body. Leaks could also originate from a crack in the insulating material of the torch or nozzle retaining cup or from a power cable.

To check for leaks from any source remove the shield cup, clean off the torch, purge it, and place it over a clean dry plate. With the gases off, run the water cooler for several minutes and watch for leaks. Turn on the plasma gas and watch for any mist from the nozzle exit. If there isn’t any, turn off the plasma gas, turn on the shield gas, and watch for any mist from the shield gas passages in the nozzle retaining cup.

If a leak appears to be coming from the nozzle orifice, remove and inspect the o-rings on the nozzle, electrode, and electrode holder. Check the sealing surfaces on the electrode holder and stainless steel torch liner.

If you suspect that a leak is coming from the electrode itself, you can install a 100 to 200 amp 2-piece nozzle base without a nozzle tip. After purging, run the water cooler with the gas off and observe the end of the electrode. If water is seen to collect there, make sure it is not running down the side of the electrode from a leak at an o-ring seal.

Warning

if it is necessary to supply power to the plasma console to run the water cooler, it is possible to have high voltages at the torch with no arc present. never touch the torch with the plasma console energized.

172

replacement parts

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Replacement paRts

174

Replacement paRts replacement parts

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.

m2 plasma console, 200a,

230/460V,

60hz,

0558012390 m2 smart plasmarc information m2 plasma console, 200a,

380 ccc,

50hz,

0558012391 m2 plasma console, 200a,

400V ce,

50hz,

0558012392 m2 plasma console, 200a,

575V,

60hz,

0558012393

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.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.

note:

Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm

(11” x 17”) paper are included inside the back cover of this manual.

Items listed in the assembly drawing Bill of Materials (included in the back of this publication) that do not have a part number shown are not available from ESAB as a replaceable item and cannot be ordered. Descriptions are shown for reference only. Please use local retail hardware outlets as a source for these items.

175

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Replacement paRts

176

reVision historY

1. Originally released - 08/2014

2. revision 01/2015 - added/revised Input Voltage Configuration Changeover per D. Wiersema.

3. revision 02/2015 - updated m2-200 Ref Parts Update per J. Magee.

4. revision 04/2015 - added/revised info per D. Wiersema.

C.

B.

D.

A.

E.

F.

G.

H.

esaB Welding & cutting products, florence, sc communication guiDe - customer serVices

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Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

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