precision plasmarc system
F-15-480-D
October, 2000
Installation, Operation and Maintenance Manual for the
PRECISION PLASMARC SYSTEM
with Electronic Flow Control
CUTTING SYSTEMS
411 s. Ebenezer Road
Florence, SC 29501-0545
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
Every effort was made to ensure the accuracy
and completeness of this manual. Information
in this document is subject to change without
notice.
This manual is ESAB Part Number F15480
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
©
ESAB Cutting Systems, 2000
Printed in U.S.A.
Precision Plasma Electronic Flow Control
Table of Contents
Page
Section 1 Safety
1.1 Introduction
1
1.2 Safety Notations And Symbols
1
1.3 General Safety Information
2
1.4 Installation Precautions
3
1.5 Electrical Grounding
4
1.6 Operating A Plasma Cutting Machine
4
1.7 Service Precautions
8
1.8 Safety References
9
Section 2 Description
2.1 General
1
2.2 Scope
1
2.3 Package Options Available
1
2.4 Technical Specifications
2.4.1 Precision Plasma System
2
2.4.2 Plasma Gas
3
2.4.3 Start Gas
3
2.4.4 Secondary Gas
3
2.4.5 PT-24 Torch
3
Section 3 Installation
3.1 General
1
3.2 Equipment Required
1
3.3 Location
1
3.4 Primary Electrical Input Connections
2
3.5 Interconnecting Lines
4
Precision Plasmarc Component Interconnecting Diagram
8
3.6 Torch Mounting
10
3.7 Torch Coolant
11
3.8 Inspection of Gas and Coolant Lines
11
3.9 Replacement of EPROM in the Plasmarc Power Source
Programmable Logic Controller (PLC)
12
i
Precision Plasma Electronic Flow Control
Table of Contents
Section 4 Operation
4.1 Power Supply Controls
4.1.1 Main Power Switch
1
4.1.2 Pilot Arc Switch
1
4.1.3 Fault Indicator Lights
2
4.1.4 Meters
2
4.1.5 Current Control Switch
2
4.2 Cut Quality
4.2.1 Introduction
3
4.2.2 Cut Angle
3
4.2.3 Cut Flatness
4
4.2.4 Surface Finish
5
4.2.5 Dross
6
4.2.6 Dimensional Accuracy
8
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction
9
4.3.2 Aluminum
9
4.3.3 Carbon Steel
10
4.3.4 Stainless Steel
11
4.4 Process Data
4.4.1 Introduction
13
4.4.2 Process Data Settings
14
Plasma Marking Data
54
4.4.3 Relationship of Kerf Width to Amperes and Material Thickness
76
4.4.3.1 Aluminum Kerf Values
76
4.4.3.2 Carbon Steel Kerf Values
78
4.4.3.3 Stainless Steel Kerf Values O2/N2/O2
81
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4
82
4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4
83
4.4.3.6 Stainless Steel Kerf Values N2/N2
84
4.4.3.7 Stainless Steel Kerf Values Air/Air
86
ii
Precision Plasma Electronic Flow Control
Table of Contents
Section 5 Maintenance
5.1 General
1
5.2 Inspection and Cleaning
1
5.3 PT-24 Torch Description
2
5.4 Torch Maintenance
5
5.5 PT-24 Consumable Disassembly and Inspection
7
5.6 PT-24 Torch Re-Assembly
9
Section 6 Troubleshooting
6.1 General Safety
1
6.2 Programmable Logic Controller (PLC)
1
6.2.1 PLC LED Introduction
2
6.2.2 PLC LED Functions
2
6.3 Troubleshooting Guide
6.3.1 Reduced Consumable Life
3
6.3.2 Poor Cut Quality
4
6.3.3 No Pilot Arc
4
6.3.4 No Arc Transfer
4
6.3.5 No Preflow
4
6.3.6 Torch Fails to Fire
4
6.3.7 Nozzle Life Extremely Short
5
6.3.8 Short Electrode Life
5
6.3.9 Short Electrode AND Nozzle Life
5
6.4 Flow Control Schematic
6
6.5 Gas Flow Schematic
7
6.6 Junction Box Wiring Diagram
8
6.7 Junction Box Schematic
9
6.8 Precision Plasma Power Module Wiring Diagram
10-11
6.9 Power Module Schematic
12
6.10 Power Source Wiring Diagrams
13-17
6-11 Power Source Schematic
18-19
iii
Precision Plasma Electronic Flow Control
6.12 Technical Guide to Using/Understanding the Operation of the EFC
Table of Contents
20
6.12.1 Precision Process Timers
21
6.12.2 Process Timer Values
22
6.12.3 Process Window Key Functions
23
6.12.4 Proportional Valve Analog Values for PARAM.CUT and DEF.TEC
24
6.12.5 Process Gas Selection Requirements
25
6.12.6 EFC Process Gas Flow Chart
26
6.12.7 Station On, Flush/Pressurize Cycle Timers
6.12.8 Solenoid/Proportional Valve Requirements and
Gas Error Monitoring
Carbon Steel PG-O2, SG-O2
27
28
Carbon Steel PG-O2, SG-N2/O2
30
Carbon Steel PG-O2, Sg-O2
32
Stainless Steel PG-N2, SG-N2
34
Stainless Steel PG-N2, SG-N2/CH4
36
Stainless Steel PG-Air, SG-Air
38
Stainless Steel PG-Air, SG-Air/CH4
40
Aluminum PG-N2, SG- N2
42
Aluminum PG-N2, SG-N2/CH4
44
Marking PG-Argon, SG-Air
46
Section 7 Replacement Parts
7.1 General
1
7.2 Ordering
2
7.3 Plasmarc Power Source – Exterior Components
3
7.4 Plasmarc Power Source – Internal Components
8
7.5 Power Source Module
18
7.6 EFC Junction Box
26
7.7 Electronic Flow Control Box
7.8 PT-24 Torch Assembly EFC Series A/M
32
36
7.9 T Gas Shut-off Valve Assembly - Series A/M Torch
38
7.10 PT-24 Torch Assembly – Version 1
40
7.11 Solenoid Assembly - EFC Torch – Version 1
42
Customer/Technical Information
Back Manual Cover
iv
SECTION 1
SAFETY
1.1 Introduction
The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. However, as with any
machine tool, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of usefulness.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain precautions
could result in serious personnel injury or severe
equipment damage. The following precautions are
general guidelines applicable when working with
cutting machines. More explicit precautions pertaining
to the basic machine and accessories are found in the
instruction literature. For a wide scope of safety
information on the field of cutting and welding
apparatus, obtain and read the publications listed in
the Recommended References.
1.2 Safety Notations And Symbols
!
The following words and symbols are used throughout
this manual. They indicate different levels of required
safety involvement.
ALERT or ATTENTION. Your safety is involved
or potential equipment failure exists. Used in
concurrence with other symbols and information.
! DANGER
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
! WARNING
Used to call attention to potential hazards
that could result in personal injury or loss of
life.
! CAUTION
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
CAUTION
Used to call attention to minor hazards to
equipment.
NOTICE
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
1-1
SECTION 1
SAFETY
1.3 General Safety Information
! WARNING
! WARNING
Machine starts automatically.
This equipment moves in various directions and
speeds.
•
Moving machinery can crush.
•
Only qualified personnel should operate or service
equipment.
•
Keep all personnel, materials, and equipment not
involved in production process clear of entire
system area.
•
Keep gear racks and rails clear of debris or
obstructions, such as tools or clothing.
•
Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.
•
Post appropriate WARNING signs at every work
cell entrance.
•
Follow lockout procedure before servicing.
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual before
using machine.
•
Read entire procedure before operating or
performing any system maintenance.
•
Special attention must be given to all hazard
warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
•
All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
•
Read all safety publications made available by
your company.
1-2
SECTION 1
! WARNING
SAFETY
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety warning labels on
machine.
Refer to operator’s manual for additional safety
information.
1.4 Installation Precautions
! WARNING
Improperly installed equipment can cause
injury or death.
Follow these guidelines while installing machine:
Do not connect a cylinder directly to machine inlet. An
appropriate cylinder regulator must be installed on a
fuel gas cylinder to reduce pressure to a reasonable
inlet supply pressure. Machine regulator is then used
to obtain pressure required by torches.
Contact your ESAB representative before installation.
He can suggest certain precautions regarding piping
installation and machine lifting, etc. to ensure
maximum security.
Never attempt any machine modifications or apparatus
additions without first consulting a qualified ESAB
representative.
Observe machine clearance requirements for proper
operation and personnel safety.
1-3
SECTION 1
SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to this manual’s
Installation section for detailed grounding instructions.
! WARNING
Electric shock hazard.
Improper grounding can cause severe injury or death.
Machine must be properly grounded before put into
service.
! WARNING
Improper grounding can damage machine
and electrical components.
•
Machine must be properly grounded before put
into service.
•
Cutting table must be properly grounded to a good
Earth ground rod.
1.6 Operating A Plasma Cutting Machine
! WARNING
! WARNING
Flying debris and loud noise hazards.
•
Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying
debris generated during operation.
•
Chipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.
•
From plasma arc can damage hearing. Wear
correct ear protection when cutting above water.
Burn hazard.
Hot metal can burn.
•
Do not touch metal plate or parts immediately after
cutting. Allow metal time to cool, or douse with
water.
•
Do not touch plasma torch immediately after
cutting. Allow torch time to cool.
1-4
SECTION 1
! WARNING
! WARNING
SAFETY
Hazardous voltages. Electric shock
can kill.
•
Do NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.
•
Always turn power off to plasma power supplies
before touching or servicing plasma torch.
•
Always turn power off to plasma power supplies
before opening or servicing plasma plumbing or
flow control box.
•
Do not touch live electrical parts.
•
Keep all panels and covers in place when machine
is connected to power source.
•
Insulate yourself from workpiece and electrical
ground: wear insulating gloves, shoes and
clothing.
•
Keep gloves, shoes, clothing, work area, and
equipment dry.
Pinch hazard.
Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during operation.
! WARNING
Fume hazard.
Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
•
Do NOT breathe fumes.
•
Do not operate plasma torch without fume removal
system operating properly.
•
Use additional ventilation to remove fumes if
necessary.
•
Use approved respirator if ventilation is not
adequate.
1-5
SECTION 1
! WARNING
SAFETY
Radiation hazard.
Arc rays can injure eyes and burn skin.
•
Wear correct eye and body protection.
•
Wear dark safety glasses or goggles with side
shields. Refer to following chart for recommended
lens shades for plasma cutting:
Arc Current
Lens
Lens Shade
Up to 100 Amps
Shade No. 8
100-200 Amps
AmpsShade
Shade No. 10
200-400 Amps
AmpsShade
Shade No. 12
Over 400 Amps
Shade No. 14
! WARNING
•
Replace glasses/goggles when lenses are pitted or
broken
•
Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses.
•
Prepare cutting area to reduce reflection and
transmission of ultraviolet light.
•
Paint walls and other surfaces with dark colors to
reduce reflections.
•
Install protective screens or curtains to reduce
ultraviolet transmission.
Ruptured Gas Cylinders Can Kill
Mishandling gas cylinders can rupture and violently
release gas.
•
Avoid rough handling of cylinders.
•
Keep cylinder valves closed when not in use.
•
Maintain hoses and fittings in good condition.
•
Always secure cylinders in an upright position by
chain or strap to a suitable stable object not part of
an electrical circuit.
•
Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
•
Refer to CGA Standard P-1, “Precautions for Safe
Handling of Compressed Gases in Cylinders”,
available from Compressed Gas Association.
1-6
SECTION 1
! WARNING
SAFETY
Spark hazard.
Heat, spatter, and sparks cause fire and burns.
CAUTION
•
Do not cut near combustible material.
•
Do not cut containers that have held combustibles.
•
Do not have on your person any combustibles (e.g.
butane lighter).
•
Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activating
plasma process.
•
Wear correct eye and body protection.
•
Wear gauntlet gloves, safety shoes and hat.
•
Wear flame-retardant clothing that covers all
exposed areas.
•
Wear cuffless trousers to prevent entry of sparks
and slag.
POOR PERFORMANCE WILL RESULT
WHEN CUTTING ABOVE WATER.
The PT-24 is designed to be a dry cutting
process.
Cutting above water may result in:
•
reduced consumable life
•
degradation of cut quality
Cutting above water may result in poor cutting
performance. Water vapor created when hot material
or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level
to provide maximum clearance between water and
material.
1-7
SECTION 1
! WARNING
SAFETY
Explosion hazard.
Certain molten aluminum-lithium (Al(Al-Li)
Li) alloys can
cause explosions when plasma cut OVER water.
Do not plasma cut the following AlAl-Li
Li alloys with
water:
Alithlite (Alcoa)
Alithally (Alcoa)
2090 Alloy (Alcoa)
X8090A (Alcoa)
X8092 (Alcoa)
X8192 (Alcoa)
Navalite (US Navy)
Lockalite (Lockheed)
Kalite (Kaiser)
8091 ((Alcan)
Alcan)
•
These alloys should only be dry cut on a dry table.
•
DO NOT dry cut over water.
•
Contact your aluminum supplier for additional
safety information regarding hazards associated
with these alloys.
1.7 Service Precautions
CAUTION
Establish and adhere to preventive maintenance. A
composite program can be established from
recommended schedules in the instruction literature.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
could occur to equipment or machine.
! CAUTION
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
accidental shorting of components.
All circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned
on.
Never plug or unplug a printed circuit board while
machine power is on. Instantaneous surges of voltage
and current can damage electronic components.
1-8
SECTION 1
SAFETY
1.8 Safety References
The following nationally recognized publications on safety in welding
and cutting operations are recommended. These publications have
been prepared to protect persons from injury or illness and to protect
property from damage, which could result from unsafe practices.
Although some of these publications are not related specifically to this
type of industrial cutting apparatus, the principles of safety apply
equally.
•
“Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
•
“Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
•
“Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
•
“Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
•
“Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
•
“Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
•
“Safe Practices” - AWS SP, American Welding Society.
•
“Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
•
“Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
•
“Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
•
"Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
•
“Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.
1-9
SECTION 1
SAFETY
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1-10
SECTION 2
DESCRIPTION
2.1 General
The Precision Plasmarc System consists of four
separate components. The power source, the
junction box, the flow control box, and the PT-24
torch. The power source provides power and
coolant to the PT-24 torch via the junction box.
2.2 Scope
The purpose of this manual is to provide the
operator with all the information required to install
and operate the Precision Plasmarc System.
Technical reference material is also provided to
assist in troubleshooting the cutting package.
2.3 Package Options Available
Precision Plasmarc package options available through your ESAB dealer
Precision Plasmarc Power Source (200/230/380/415/460/575) 3-phase 50/60
Hz (required)
P/N 37357
Electronic Flow Control Box (required)
P/N 22406
Junction Box (required)
P/N 22407
PT-24 Torch Electronic Flow Series A/M (one required)
Power Bundle (one required)
Gas Line Bundle (one required)
Control Lead Flow Console to Junction Box
(one required)
Torch Coolant (one gallon (3.8 l) containers.
4.5 ft. (1.4 m)
P/N 0558001463
12 ft. (4.4 m)
P/N 0558001877
17 ft. (5.2 m)
P/N 0558001464
12 ft. (3.6 m)
P/N 22428
25 ft. (7.6 m)
P/N 21905
40 ft. (12.2 m)
P/N 22504
60 ft. (18 m)
P/N 21906
80 ft. (24.4 m)
P/N 22505
100 ft. (30 m)
P/N 21907
10 ft. (3 m)
P/N 37533
20 ft. (6 m)
P/N 37534
30 ft. (9 m)
P/N 37535
60 ft. (18 m)
P/N 37536
100 ft. (30 m)
P/N 37537
10 ft. (3 m)
P/N 21917
20 ft. (6 m)
P/N 21918
30 ft. (9 m)
P/N 21919
60 ft. (18 m)
P/N 21920
100 ft. (30 m)
P/N 21921
four gallons (15 l) required)
P/N 156F05
NOTES:
• Control lead from the power source to customer CNC is supplied based on customer order.
• Gas supply, hoses, work lead and input primary cable are all supplied by the customer.
• See Process Data Sheets for a list of torch consumable parts.
2-1
SECTION 2
DESCRIPTION
2.4 Precision Plasma Technical Specifications
2.4.1 System
Input Voltage
200/230/380/415/460/575 V 3 phase 50/60 Hz
Input Current
65/60/50/40/30/25 amps per phase
Power Factor
0.95
Output Current Range
15-100 amps dc
Output Load Voltage
120 V dc
Duty Cycle
100%
Open Circuit Voltage
315 V dc
JUNCTION BOX
POWER SUPPLY
6.75" (171mm)
PILOT
ARC
CONTROL
POWER
10.62" (270mm)
19.75" (502mm)
CURRENT
N
RECISIO
PLASMARC
WEIGHT = 26.5 lbs.(12 kg)
44" (1118mm)
ELECTRONIC FLOW CONTROL BOX
42" (1067mm)
22" (559mm)
14.5" (1118mm)
WEIGHT = 560 lbs. (254 kg)
O2
N2
O2
AIR
N2
AIR
GAS
PLASMA
NO.1
GAS
PLASMA
NO.2
SHIELD GAS
NO.1
METH
H-35
N2
SHIE LD GAS
NO.2
NITROG EN
NITROG EN
OXYGEN
METHAN
NITROG EN
E
OXYGEN
EN
HYDROG
AIR
12.25" (311mm)
AIR
ARGON
12" (305mm)
WEIGHT = 51 lbs. (23 kg)
2-2
SECTION 2
DESCRIPTION
2.4.2 Plasma Gas Technical Specifications
Type
O2, N2, Air
Pressure
125 psig (8.6 bars)
100 cfh (47 l/min) max. (varies with
application)
O2-99.995%
N2-99.995%
Air-clean, dry and oil free
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
Oxygen: R-77-150-540 (P/N 998337
Hydrogen/Methane:R-77-150-350 (P/N
998342)
Nitrogen: R-77-150-580 (P/N 998344)
Industrial Air: R-77150=590 (P/N
998348)
Flow
Purity Required*
Recommended Liquid Cylinder Service
Regulators
Recommended Cylinder 2-Stage
Regulators
Recommended Heavy –Duty Hi-flow
Station or Pipeline Regulators
Recommended High-capacity Station
or Pipeline Regulators
Gas Filter Required
Oxygen: R-76-150-024 (P/N 19151)
R-6703 (P/N 22236)
25 micron w/bowl guard (P/N 56998133)
2.4.3 Start Gas Technical Specifications
Type
N2, Air
Pressure
125 psig (8.6 bar)
60 cfh (28 l/min) max (varies with
application)
99.995%
Flow
Minimum Purity Required
2.4.4 Secondary Gas Technical Specifications
Type
Pressure
Flow
Minimum Purity Required
N2, O2, H-35, Methane, Air
100 psig (6.6 bar) H-35,
Methane; 125 psig (8.6 bar) N2,
O2, Air
60 cfh (28 l/min) max (varies with
application)
99.995%
2.4.5 Pt-24 Torch Technical Specifications
Type
Water-Cooled, Dual Gas
Rating
100 amps @ 100 % duty cycle
Dimensions
See Package Options (2.3)
2-3
SECTION 2
DESCRIPTION
Page intentionally left blank.
2-4
SECTION 3
INSTALLATION
3.1 General
NOTICE
3.2 Equipment Required
Proper installation can contribute materially to the
satisfactory and trouble-free operation of the Precision
Plasmarc System. It is suggested that each step in
this section be studied and carefully followed.
•
•
•
•
3.3 Location
•
•
•
! CAUTION
Gas Supply and Hoses. Gas supply may be from
a bulk source or from a bank of manifold cylinders
and regulated to supply 125 psig (8.6 bar) to the
Flow Control (gas flowing).
Work Lead. No. 4 AWG cable is recommended for
connecting workpiece to power source.
Primary Input Cable.
25 micron gas filters (or better) are required on the
supply side for the EFC to function properly.
Ventilation is necessary to provide proper cooling
of the power supply.
Minimize dirt, dust and exposure to external heat
sources.
Allow a minimum of two feet clearance around the
power supply for free air movement.
Do Not Restrict Air Flow
Restricting intake air with any type of filter on or around
the power supply may void the warranty.
3-1
SECTION 3
INSTALLATION
3.4 Primary Electrical Input Connections
! DANGER
Electric Shock Can Kill!
Provide maximum protection against electrical
shock.
Before any connections are made inside the
machine, open the line (wall) disconnect switch
and unplug the power cord.
! WARNING
Input Power Configuration
Machine must be properly configured for your
input power.
The machine is shipped from the factory
configured for 575 V, 60 Hz input.
Do NOT connect a power source of any other
voltage unless machine is reconfigured. Damage
to the machine will occur.
Input Power Connection At Wall
A line (wall) disconnect switch with fuses or circuit
breakers should be provided at the main power panel.
Connect the input power cable of the power source
directly to the disconnect switch or a proper plug and
receptacle may be purchased from a local electrical
supplier. (See table on the next page for
recommended input conductors and fuses )
Recommended Sizes For Input Conductors And Line Fuses
Input requirements
Volts
Phase
Amps
208
230
380
415
460
575
3
3
3
3
3
3
70
60
50
40
30
25
3-2
Input & ground
conductor,
2
cu/awg/mm
No. 4
25
No. 6
16
No. 8
10
No. 10
6
No. 10
6
No. 10
6
Fuse ratings /
phase, amps
100
80
80
60
50
40
SECTION 3
INSTALLATION
The following procedure explains the proper installation
steps for connecting primary electrical power to the
power source.
1. Remove right side panel.
2. Ensure input power cable is disconnected from all
electrical sources.
3. Route input power cable through the strain relief
located at the rear panel.
Ground Connection
Input Power Cable
(Customer supplied) 4. Pull input power cable through the strain relief to
allow cable wires sufficient length to connect to the
main contactor. Tighten strain relief to ensure
input power cable is secured.
TB2
K1
200
230
380
415
460
575
Main
Contactor
PHASE 2
7 Position
Terminal Block
Auto
Transformer
6. Connect three power leads of the input power
cable to the terminals located atop the main
contactor. Secure the leads by tightening each
screw.
7. Connect jumper power cables from the bottom of
the main contactor to the proper input voltage
marked on the auto transformer. The unit is
factory set for 575 V as shown to the left.
PHASE 3
200
230
380
415
460
575
PHASE 1
200
230
380
415
460
575
TB1
200
230
380
415
460
575
5. Connect input power cable ground wire to the
ground lug provided on the base of the power
source.
Factory Wired
for 575 volts
! CAUTION
Input Power Jumper Connection
Ensure each input power jumper cable is connected to
the correct input voltage on auto transformer.
Factory wired for 575 V.
8. Connect jumper wire to the proper input voltage
connector located on the 7-position terminal block.
TB2
3-3
SECTION 3
INSTALLATION
3.5 Interconnecting Lines
Black
Red/Orange
Yellow
Blue
1. All interconnecting service lines supplied are
numbered or color coded on each end with
corresponding numbers/colors marked on the
cabinets.
Mounting Plate
Gas Line Bundle
Gas Bundle
Installation
2. Connect all four lines in Gas Line Bundle to Flow
Control Box and Junction Box. Lines and
connections are color coded. In addition,
mounting plate hole spacing is asymmetrical to
prevent improper connection. Order of colors
should be: blue, yellow, red/orange, black
3-4
SECTION 3
INSTALLATION
Power supply and EFC Connections to J-Box
Power Supply Bundle
Power Supply Negative
Connection
#7 Hose
Connection
(from power
source)
3. Connect power and coolant lines in Power
Supply Bundle from power source to junction
box. Power bundle consists of #6 and # 7
coolant lines (with 5/8-18 L.H. fittings), power
cable (#3 AWG) and yellow pilot arc cable (#16
AWG). Both coolant lines are stamped with a 6
or 7 on the fitting to assist in identification.
Pilot Arc
Connection
#6 Hose Connection
(to power source)
Gas Bundle
Connections
Control Lead Connection
from EFC
3-5
SECTION 3
INSTALLATION
Junction Box to Torch Connections
Torch Hose/Power
Cable Connection
Torch
Solenoid
Electrical
Connection
Torch Bundle
Torch Pilot Arc
Connection
4. Connect Torch Bundle Leads/Hoses to
Junction box. (see Interconnecting Block
Diagram)
3-6
SECTION 3
INSTALLATION
Precision Plasmarc Component Interconnecting Diagram
25 micron Filters
EFC
Control Lead
EFC/Junction
Box
ASIOB
High
Frequency
120VAC
CNC
N2
O2
CH4
Air
High Frequency 120VAC
Gas Line Bundle
Junction
Box
Power Bundle
Torch
Cutting Table
Ground Rod
Work Lead
Control Lead
Power Supply to CNC
3-7
Primary Power Cable
Ar
SECTION 3
INSTALLATION
Gas Line Contamination Will Damage
Proportional Valves
! CAUTION
Purge Gas Lines
Before connecting gas delivery lines to the
Electronic Flow Control, purge all lines thoroughly.
Residue from the hose manufacturing process may
clog/damage the proportional valves in your EFC.
5. Purge gas lines between supply and the EFC
before connecting. Proportional valves in the
EFC are very sensitive to dust and other foreign
particles.
1/4 NPT
6. Connect Gas Delivery lines to Electronic Flow
Control. Install 25 micron Gas filters in all
delivery lines between gas source and EFC.
25 micron Gas Filter
25 µ Filters
N2
O2
CH4
Air
Ar
3-8
SECTION 3
INSTALLATION
Remove Access Cover
Pilot Arc
Work
Torch
Pilot Arc
7. Remove panel from rear of console and attach the
pilot-arc, torch and work lead.
Work
Torch
Power Source
CNC Control Lead
Flow Control
Lead
600 amp
Bus Fuse
Rating
Label
Serial
Tag
8. Connect control lead between the console and the
Electronic Flow Control. Connect coolant lines of
the Power Bundle.
Coolant In from Torch
# 6 Connection
Coolant Out to Torch
# 7 Connection
CONTROL LEAD
3-9
SECTION 3
INSTALLATION
3.6 Torch Mounting
CAUTION
Do Not Cover Vent Hole.
When mounting, do not to cover the small vent hole in
the side of the sleeve. This hole allows coolant to
drain from inside the sleeve should a leak occur in a
service line.
Torch Mounting Options.
1.812" (46mm)
Diameter Collar
2.0" (51mm)
Diameter Sleeve
Vent Hole
•
The torch is normally mounted by the 2.0 inch
diameter (51mm) sleeve. Do not cover vent hole.
•
For custom alternative mounting, the torch can be
mounted by the 1.812" (46 mm) dia collar shown.
This insulated collar and its shoulder are machined
relative to the nozzle retainer thread on the torch
body.
•
Use only specified mounting surfaces
3-10
SECTION 3
INSTALLATION
3.7 Torch Coolant
PILOT
ARC
L
CONTRO
POWER
T
CURREN
RECISION
PLASMARC
Coolant
Fill Cap
! CAUTION
•
Remove coolant fill cap at front of console and fill
coolant tank with 4 gallons (15 liters) of plasma
coolant, P/N 156F05 (one gallon).
•
Do not fill above maximum level
•
Reinstall Cap.
Commercial Antifreeze Will Cause Torch To
Malfunction
Use Special Torch Coolant! P/N156F05
Due to high electrical conductivity, DO NOT use tap
water or commercial antifreeze for torch cooling. A
specially formulated torch coolant is REQUIRED. This
coolant also protects for freezing to –34° C.
Operating the unit without coolant will cause
permanent damage to the coolant pump.
3.8 Inspection of Gas and Coolant Lines
To complete installation, it is necessary to inspect
field assembled connections for leaks.
•
Gas lines, use a standard soap solution.
Pressurize the system from the control (SDP file)
•
Coolant- check connections for signs of
moisture at connections
3-11
SECTION 3
INSTALLATION
3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic
Controller (PLC)
The Precision Plasmarc System may be shipped
configured for a manual flow control (Series “A”). If
so, the EPROM in the Programmable Logic
Controller must be replaced with an EFC EPROM.
This EFC EPROM is shipped with the power source.
! CAUTION
Using the Wrong EPROM Could Result In
Damaged System Components
The Series “A” and the EFC EPROMs are
programmed with different software. The EFC
EPROM ignores the process gas pressure
switch inputs and does not include the
process gas purge required for the Series “A”.
! CAUTION
Mishandling Can Damage Electronic
Components.
Handle electronic components with care.
• Do not drop
• Do not bend pins
• Do not touch circuit components- handle
along edges when possible
! CAUTION
Electronic Components Are Subject To
Electro-Static-Discharge (ESD) Damage
Integrated Circuit parts are sensitive to over
voltages. The damage may not be seen
immediately but show up as a premature
failure.
The EFC EPROM is shipped in an anti-static
bag. Store EPROM in this bag.
Wear a protective ground strap when handling
sensitive electronic components.
! WARNING
Electric shock Can Kill!
Unplug power cable from wall to power source
before any connections or adjustments are
made inside power source.
3-12
SECTION 3
INSTALLATION
PILOT
ARC
CONTROL
POWER
CURRENT
PLASMARC
RECISION
Left Side Panel
1. Ensure the Plasmarc Power Source is
disconnected from electricity source.
2. Expose the PLC by removing the left side panel
of the Plasmarc Power Source.
3. Pop the EPROM cover on the PLC to expose
the EPROM.
PLC
EFC EPROM
Package Location
3-13
SECTION 3
INSTALLATION
CAUTION
Using An EPROM Puller Tool May Damage
Socket
Forcibly removing a clamped EPROM in the
PLC may cause the socket/EPROM to break.
Special Zero Force EPROM Socket is used to
eliminate the need for special tools.
EPROM Locked In Place
4. Remove the EPROM from the socket. THIS
DOES NOT REQUIRE A PULLER. Release the
clamp locking the EPROM in place, lift the
Series “A” EPROM from the socket.
5. Remove the EFC EPROM from the packaging.
6. Carefully align the EFC EPROM pins with the
socket holes and insert.
7. Lock the EPROM by moving the lever back
while holding the EPROM in place.
8. Replace the EPROM cover and the Power
Source left side panel.
EPPESA= Series “A” EPROM, manual flow control
P/N 99513607
EPPSEFC= EFC EPROM, electronic flow control
P/N 99513608
EPROM Lock Released
3-14
SECTION 4
OPERATION
4.1 Power Supply Controls
4.1.1 Main Power Switch
ARC
LOW
DO NOT SWITCH
W HILE CUTTING
Main Power Switch
Controls the input power to the fan, water cooler and
the PC Board. Amber indicator light to the left of the
switch.
EMERGENCY
STOP
Pilot Arc Switch
Used to select HIGH or LOW Start Pilot Arc depending
on cutting conditions. See Process Data for more
information on which conditions High and Low Start
are used.
4.1.2 Pilot Arc Switch
EMERGENCY
STOP
POWER
ON
OFF
CAUTION
Adjusting Pilot Arc While in Operation Could
Damage Torch.
Do not adjust pilot arc switch while in operation.
Adjust before torch starts.
4-1
SECTION 4
4.1.3 Fault Indicator Lights
OPERATION
Fault Indicator Lights
•
•
•
•
•
•
•
4.1.4 Meters
Coolant flow will show low coolant flow. When
unit is turned on, the light will briefly show a fault
and then go out.
Plasma Gas Pressure fault indicator -- low
Plasma Gas Pressure. Torch will not fire when
indicated. Not used for the EFC.
Start Gas Pressure fault indicator -- low start gas
pressure. Torch will not fire when indicated. Not
used for the EFC.
P/S Temp fault indicator -- over temperature in the
inverter power source. Power source will shut
down.
P/S Fault Indicator – fault in plasma control PCB
in the inverter power source. Power source will
shut down.
Over-Under Voltage fault Indicator -- indicate
input voltage is above or below the tolerances of
the PCU console. Will latch until power is recycled
by main power switch.
Emergency Stop fault indicator -- shows CNC
Interlock condition. Power Source will not work.
•
Cutting Current Meter (A) -- Displays actual
cutting current in amperes.
•
Cutting Voltage Meter (V) -- Displays actual
cutting voltage.
4.1.5 Current Control Switch
Control Remote/Panel Switch
•
•
•
Panel Position – Output current is set by the
output current dial
Output Current Dial – sets the cutting current
when current setting is made from the console
front panel. Dial reads 0 to 99.9 amps. 70.0 amps
shown.
Remote Position – output current is set by the
CNC (or remote pot) with an analog dc signal
0-10 Vdc = 0-100 Adc
4-2
SECTION 4
OPERATION
4.2 Cut Quality
4.2.1 Introduction
Causes affecting cut quality are interdependent.
Changing one variable affects all others. Determining a
solution may be difficult. The following guide offers
possible solutions to different undesirable cutting
results. To begin select the most prominent condition:
§
4.2.2 Cut Angle, negative or positive
§
4.2.3 Cut not flat, rounded or undercut
§
4.2.4 Surface roughness
§
4.2.5 Dross
Usually the recommended cutting parameters will give
optimal cut quality, occasionally conditions may vary
enough that slight adjustments will be required. If so:
•
•
•
Make small incremental adjustments when
making corrections.
Adjust Arc Voltage in 5 volt increments, up or
down as required.
Adjust cutting speed 5% or less as required
until conditions improve.
Before attempting ANY corrections, check cutting
variables with the factory recommended
settings/consumable part numbers listed in
Process Data.
NOTICE
4.2.2 Cut Angle
Negative Cut Angle
Top dimension is greater than the bottom.
Part
Drop
•
Misaligned torch
•
Bent or warped material
•
Worn or damaged consumables
•
Standoff low (arc voltage)
•
Cutting speed slow (machine travel rate)
Part
4-3
SECTION 4
OPERATION
Part
Positive Cut Angle
Top dimension is less than the bottom dimension.
•
Misaligned torch
•
Bent or warped material
•
Worn or damaged consumables
•
High standoff High (arc voltage)
•
Cutting speed fast
•
Drop
Part
Current high or low. (See Process Data for
recommended current level for specific nozzles).
4.2.3 Cut Flatness
Top And Bottom Rounded
Condition usually occurs when material is .25” thick
(6,4mm) or less.
•
Drop
High current for given material thickness (See
Process Data for proper settings).
Part
4-4
SECTION 4
OPERATION
Top Edge Undercut
•
Standoff low (Arc Voltage)
Part
Drop
4.2.4 Surface Finish
Process Induced Roughness
Cut face is consistently rough. May or may not be
confined to one axis.
Top View
•
Incorrect Shield Gas mixture (See Process Data)
•
Worn or damaged consumables
Cut Face
Machine Induced Roughness
Can be difficult to distinguish from Process Induced
Roughness. Often confined to only one axis.
Roughness is inconsistent.
•
or
Machine
Induced
Roughness
•
Process
Induced
Roughness
4-5
Dirty rails, wheels and/or drive rack/pinion. (Refer
to Maintenance Section in machine owners
manual).
Carriage wheel adjustment
SECTION 4
OPERATION
4.2.5 Dross
Dross is a by-product of the cutting process. It is the
undesirable material that remains attached to the part.
In most cases, dross can be reduced or eliminated
with proper torch and cutting parameter setup. Refer
to Process Data.
Lag
Lines
Cut
Face
Rollover
High Speed Dross
Material weld or rollover on bottom surface along kerf.
Difficult to remove. May require grinding or chipping.
“S” shaped lag lines.
•
Standoff high (arc voltage)
•
Cutting speed fast
Side View
Lag
Lines
Cut Face
Globules
Slow Speed Dross
Forms as globules on bottom along kerf. Removes
easily.
•
Side View
4-6
Cutting speed slow
SECTION 4
Side View
OPERATION
Splatter
Top Dross
Appears as splatter on top of material. Usually
removes easily.
Cut
Face
•
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;
•
•
•
4-7
Material temperature
Heavy mill scale or rust
High carbon alloys
SECTION 4
OPERATION
4.2.6 Dimensional Accuracy
Generally using the slowest possible speed (within
approved levels) will optimize part accuracy. Select
consumables to allow a lower arc voltage and slower
cutting speed.
NOTICE
Recommended cutting speed and arc voltage will
give optimal cutting performance in most cases.
Small incremental adjustments may be needed
due to material quality, material temperature and
specific alloy. The operator should remember
that all cutting variables are interdependent.
Changing one setting affects all others and cut
quality could deteriorate. Always start at the
recommended settings.
NOTICE
Before attempting ANY corrections, check
cutting variables with the factory recommended
settings/consumable part numbers listed in the
Process Data.
4-8
SECTION 4
OPERATION
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction
All gases are not suitable for all situations. Certain
gases assist in cutting specific materials and
thickness. The following explains why certain gases
are selected and their influence on the finished part.
Other influences such as arc voltage and gas
flow/pressure are covered in the Process Data.
Refer to Cutting Process Data in this section for
recommended flow/pressure settings.
NOTICE
4.3.2 Aluminum
Material Thickness: All thickness’ between .062" to .625" (1,6 mm to 15,9 mm)
Cut Qualities:
•
•
Smooth cut face
Virtually no dross
Plasma Gas: Nitrogen
Shield Gas: Nitrogen/Methane
Discussion:
Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1
part methane ratio is desired. Incorrect ratio results in heavy dross.
4-9
SECTION 4
OPERATION
Refer to Cutting Process Data in the PT24
Manual for recommended flow/pressure
settings.
NOTICE
4.3.3 Carbon Steel
Material Thickness: 26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm)
Cut Qualities:
•
•
Smooth cut face
Virtually no dross
Plasma Gas: Oxygen
Shield Gas: Oxygen/Nitrogen
Shield gas is normally nitrogen. A small amount of oxygen combined
with nitrogen can effectively improve dross formation on thin material of
Discussion:
26 GA to 10 GA carbon steel. Also, an oxygen only shield may provide
acceptable results on thinner materials.
Material Thickness: .125" to .75" (3,2 mm to 19,1 mm)
Cut Qualities:
•
•
Smooth cut face
Virtually no dross
Plasma Gas: Oxygen
Shield Gas: Nitrogen
Cutting carbon steel with oxygen results in an exothermic reaction. This
chemical reaction causes the carbon in the material to burn similar to
Discussion:
when oxy-fuel cutting. This plus the electrical energy uses lower
amperage levels without sacrificing cut speed.
4-10
SECTION 4
OPERATION
Refer to Cutting Process Data in the PT24
Manual for recommended flow/pressure
settings.
NOTICE
4.3.4 Stainless Steel
Material Thickness: 22 GA (.028") to 16 GA (.062") (0,7 mm to 1,6 mm)
Cut Qualities:
•
•
•
Positive cut angle
Excellent dross performance
Shiny cut surface.
Plasma Gas: Nitrogen
Shield Gas: Nitrogen/Methane
Discussion:
Because of high cut speeds, a positive cut face angle is expected. Use
a 70-amp nozzle at 50 amps to allow more gas to exit the nozzle.
Material Thickness: 26 GA (.018") to 16 GA (.062") (0,5 mm to 1,6 mm)
Cut Qualities:
•
•
•
Dark cut face
Virtually dross free
Improved cut squareness
Plasma Gas: Oxygen
Shield Gas: Oxygen/Nitrogen
Low amperage cutting/slower speeds produce squarer cuts in thin
Discussion: materials. The oxygen allows for a lower arc voltage, improving cut
squareness. The “B” nozzle is used at 30 amps
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Cut Qualities:
•
•
•
Cut edge dark
good dross performance
Good cut angle
Plasma Gas: Air
Shield Gas: Air
When they are the same, the shield and plasma gases combine. This
Discussion: combination has the effect of increasing the cut gas flow/pressure. This
increased flow/pressure directly influences cut squareness.
4-11
SECTION 4
OPERATION
Refer to Cutting Process Data for recommended
flow/pressure settings.
NOTICE
Stainless Steel
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Cut Qualities:
•
•
•
•
Matted cut edge appearance
Light gray color
Much smoother finish
Possible slight increase in cut angle
Plasma Gas: Air
Shield Gas: Air/Methane
Too much methane in the shield gas mixture can result in more dross
Discussion: formation. 4:1 ratio air to methane is recommended. Because methane
is a fuel gas, possible slight increase in cut angles could be experienced.
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Cut Qualities:
•
•
•
Dark cut face similar to air
Excellent dross performance
Good cut angle
Plasma Gas: Nitrogen
Shield Gas: Nitrogen
Shield and plasma gases combine, the volume/pressure of shield gas
Discussion: can negatively affect cut squareness. Higher shield volume produces a
negative cut angle. A lower volume, produces a positive angle.
Material Thickness: .187" to .625" (4,7 mm to 15,9 mm)
Cut Qualities:
•
•
•
Shiny cut face
Lip formation at the bottom
Dross formation can be extensive and difficult to remove
Plasma Gas: Nitrogen
Shield Gas: Nitrogen/Methane
Because methane is a fuel gas, flow/pressure rates can affect the cut
angle. High flow/pressure results in a negative cut angle, low
flow/pressure results in a positive cut angle. Nitrogen to methane ratio is
Discussion:
10 to 14 parts N2/ 1 part CH4. The lip formed on the cut face bottom is
severe, making Nitrogen/Methane shield gas combination unsuitable for
some finished part applications.
4-12
SECTION 4
OPERATION
4.4 Process Data
4.4.1 Introduction
The following information is a result of many hours of
testing and is a general guide for setting up and
cutting with a PT-24 Precision Plasmarc System. In
most cases these settings will provide a quality cut.
The data contains values for:
•
cutting aluminum, carbon and stainless steel
•
arc voltage (standoff)
•
cutting speed
•
current (amperes)
•
gas flow rates for all plasma/shield gas
combinations
This same data is contained in SDP files. (See your
control manual for more information on SDP files.)
Also included is information on consumable part
numbers for current being used.
4-13
SECTION 4
OPERATION
4.4.2 Process Data
Amperes:
Aluminum
30
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21536 (3 holes)
Nozzle
P/N 21541, "B"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-14
SECTION 4
OPERATION
30 Amperes
Process Data
Aluminum
PG
SG1
SG2
N2
N2
CH4
0.062
0.075
0.090
0.125
0.187
0.250
1,6
1,9
2,3
3,2
4,7
6,4
0
0
0
0
0
0
40
40
40
40
40
40
55
55
55
55
55
55
SG1-Start
45
45
45
45
45
45
SG1- Cut
20
20
20
20
20
20
SG2- Cut Flow
10
10
10
10
10
10
150
152
153
158
170
189
IPM
150
135
105
78
30
25
MM/MIN
3810
3429
2667
1981
762
635
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-15
SECTION 4
OPERATION
Amperes:
Aluminum
55
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21542, "C"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-16
SECTION 4
OPERATION
55 Amperes
Process Data
Aluminum
PG
SG1
SG2
N2
N2
CH4
0.062
0.125
0.187
0.250
1,6
3,2
4,7
6,4
0
0
0
0
45
45
45
45
75
75
75
85
SG1-Start
55
55
55
55
SG1- Cut
20
20
20
20
SG2- Cut Flow
10
10
10
10
136
139
152
168
IPM
170
130
78
46
MM/MIN
4318
3302
1981
1168
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-17
SECTION 4
OPERATION
Amperes:
Aluminum
70
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543, "D"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-18
SECTION 4
OPERATION
70 Amperes
Process Data
Aluminum
PG
SG1
SG2
N2
N2
CH4
0.187
0.250
0.375
0.500
4,7
6,4
9,5
12,7
0
0
0.1
0.2
65
65
65
65
50
50
100
100
SG1-Start
45
45
45
45
SG1- Cut
20
20
20
20
SG2- Cut Flow
10
10
10
10
150
157
168
182
80
65
55
30
2032
1651
1397
762
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-19
SECTION 4
OPERATION
Amperes:
Aluminum
100
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-20
SECTION 4
OPERATION
100 Amperes
Process Data
Aluminum
PG
SG1
SG2
N2
N2
N2
0.250
0.375
0.500
0.625
6,4
9,5
12,7
15,9
0
0
0.1
0.1
80
80
80
80
100
100
100
100
SG1-Start
60
60
60
60
SG1- Cut
31
31
31
31
SG2- Cut Flow
10
10
10
10
155
160
166
174
65
80
65
50
2413
2032
1778
1270
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-21
SECTION 4
OPERATION
Amperes:
Carbon Steel
16
Plasma Gas:
Oxygen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Oxygen @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21852 (2 holes)
Nozzle
P/N 21540, "A"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-22
SECTION 4
OPERATION
16 Amperes
Process Data
Carbon Steel
PG
SG1
SG2
O2
N2
O2
20GA
18GA
16GA
14GA
12GA
10GA
0,9
1,2
1,6
2,0
2,7
3,4
0
0
0
0.1
0.5
0.1
20
20
20
20
20
20
11
11
11
11
11
11
SG1-Start
20
20
20
20
20
20
SG1- Cut
0
0
0
0
0
0
SG2- Cut Flow
6
6
6
6
6
6
103
105
115
118
116
117
IPM
100
85
80
60
50
36
MM/MIN
2540
2159
2032
1524
1270
914
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-23
SECTION 4
OPERATION
Amperes:
Carbon Steel
35
Plasma Gas:
Oxygen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Oxygen @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21536 (3 holes)
Nozzle
P/N 21541, "B"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-24
SECTION 4
OPERATION
35 Amperes
Process Data
Carbon Steel
PG
SG1
SG2
O2
N2
O2
14GA
0.125
0.135
0.187
0.250
1,9
3,2
3,4
4,7
6,4
0
0
0
0
0
38
38
38
38
38
15
15
15
15
15
SG1-Start
50
50
50
50
50
SG1- Cut
0
0
0
0
0
SG2- Cut Flow
6
6
6
6
6
113
119
120
122
124
80
55
52
40
30
3032
1397
1320
1016
762
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-25
SECTION 4
OPERATION
Amperes:
Carbon Steel
45
Plasma Gas:
Oxygen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Oxygen @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21542, "C"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-26
SECTION 4
OPERATION
45 Amperes
Process Data
Carbon Steel
PG
SG1
SG2
O2
N2
O2
0.125
0.135
0.187
0.250
0.375
MM
3,2
3,4
4,7
6,4
9,5
Pierce Delay (SEC.)
0.3
0.3
0.3
0.3
0.4
50
50
50
50
50
20
20
20
20
20
SG1-Start
50
50
50
50
50
SG1- Cut
16
16
16
16
10
SG2- Cut Flow
0
0
0
0
0
108
111
114
121
124
60
50
45
35
20
1524
1270
1143
889
508
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-27
SECTION 4
OPERATION
Amperes:
Carbon Steel
70
Plasma Gas:
Oxygen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Oxygen @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543, "D"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-28
SECTION 4
OPERATION
70 Amperes
Process Data
Carbon Steel
PG
SG1
SG2
O2
N2
O2
0.187
0.250
0.312
0.375
0.500
0.625
4,7
6,4
7,9
9,5
12,7
12,9
0
0
0
0.1
0.2
0.5
60
60
60
60
60
25
25
25
25
25
25
SG1-Start
60
60
60
60
60
60
SG1- Cut
33
33
33
33
20
20
SG2- Cut Flow
0
0
0
0
0
0
108
110
114
113
135
140
IPM
110
100
70
60
30
25
MM/MIN
2794
2413
1778
1524
762
635
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-29
SECTION 4
OPERATION
Amperes:
Carbon Steel
100
Plasma Gas:
Oxygen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Oxygen @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-30
SECTION 4
OPERATION
100 Amperes
Process Data
Carbon Steel
PG
SG1
SG2
O2
N2
O2
0.312
0.375
0.500
0.625
0.750
7,9
9,5
12,9
15,9
19,1
0
0
0.1
0.1
0.1
80
80
80
80
80
30
30
30
30
30
SG1-Start
60
60
60
60
60
SG1- Cut
30
30
30
30
30
SG2- Cut Flow
0
0
0
0
0
115
120
132
137
143
90
80
50
30
25
2290
2030
1270
760
630
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-31
SECTION 4
OPERATION
Amperes:
Stainless Steel
30
Plasma Gas:
Oxygen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Oxygen @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21536 (3 holes)
Nozzle
P/N 21541, "B"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-32
SECTION 4
OPERATION
30 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
O2
N2
O2
26GA
24GA
22GA
18GA
16GA
0,4
0,6
0,7
1,2
1,6
0
0
0
0
0
45
45
45
45
45
18
18
18
18
18
SG1-Start
40
40
40
40
40
SG1- Cut
20
20
20
20
20
SG2- Cut Flow
5
5
5
5
5
105
105
107
109
111
IPM
250
200
190
140
100
MM/MIN
6350
5080
4826
3556
2540
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-33
SECTION 4
OPERATION
Amperes:
Stainless Steel
50
Plasma Gas:
Air @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Air @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21542, "C"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-34
SECTION 4
OPERATION
50 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
Air
Air
Air
0.125
0.187
0.250
0.375
3,2
4,7
6,4
9,5
0
0
01
0.2
60
60
60
60
95
95
95
95
SG1-Start
45
45
45
45
SG1- Cut
35
35
35
35
SG2- Cut Flow
0
0
0
0
134
140
145
155
90
60
40
18
2286
1524
1016
457
Material Thickness
IN
MM
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-35
SECTION 4
OPERATION
Amperes:
Stainless Steel
70
Plasma Gas:
Air @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Air @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543, "D"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-36
SECTION 4
OPERATION
70 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
Air
Air
Air
0.187
0.250
0.375
0.500
MM
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
70
70
70
70
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
40
40
40
40
SG2- Cut Flow
0
0
0
0
131
152
158
162
IPM
100
50
28
20
MM/MIN
2540
1270
711
609
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-37
SECTION 4
OPERATION
Amperes:
Stainless Steel
100
Plasma Gas:
Air @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Air @ 125 PSI / 8.6 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-38
SECTION 4
OPERATION
100 Amperes
Process Data
Stainless Steel
PG
Material Thickness
IN
SG1
SG2
Air Air
Air
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
15,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
65
65
65
70
SG1-Start
60
60
60
60
SG1- Cut
35
35
35
40
SG2- Cut Flow
0
0
0
0
129
135
142
150
80
60
35
25
2030
1520
889
635
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-39
SECTION 4
OPERATION
Amperes:
Stainless Steel
70
Plasma Gas:
Air @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543, "D"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-40
SECTION 4
OPERATION
70 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
Air
Air
CH4
0.125
0.187
0.250
0.387
0.500
MM
3,2
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.2
0.3
0.4
0.5
0.6
70
70
70
70
70
100
100
100
100
100
SG1-Start
60
60
60
60
60
SG1- Cut
40
40
40
40
40
SG2- Cut Flow
10
10
10
10
10
131
146
154
166
175
IPM
120
80
50
30
24
MM/MIN
3048
2032
1270
762
609
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-41
SECTION 4
OPERATION
Amperes:
Stainless Steel
100
Plasma Gas:
Air @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-42
SECTION 4
OPERATION
100 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
Air
Air
CH4
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
15,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
100
100
100
100
SG1-Start
60
60
60
60
SG1- Cut
40
40
40
40
SG2- Cut Flow
7
10
10
10
140
150
159
170
80
60
35
25
2030
1524
889
635
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-43
SECTION 4
OPERATION
Amperes:
Stainless Steel
50
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Material:
Shield Mix Gas:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21542, "C"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-44
SECTION 4
OPERATION
50 Amperes
Process Data
Stainless Steel
PG
SG1
N2
N2
0.125
0.187
0.250
0.375
3,2
4,7
6,4
9,5
0
0
0.1
0.2
60
60
60
60
85
85
85
85
SG1-Start
45
45
45
45
SG1- Cut
35
35
35
35
SG2- Cut Flow
0
0
0
0
128
133
144
155
90
60
40
22
2286
1524
1016
558
Material Thickness
IN
MM
Pierce Delay (SEC.)
SG2
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-45
SECTION 4
OPERATION
Amperes:
Stainless Steel
70
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Material:
Shield Mix Gas:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543, "D"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-46
SECTION 4
OPERATION
70 Amperes
Process Data
Stainless Steel
PG
SG1
N2
N2
0.187
0.250
0.375
0.500
MM
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
70
70
70
70
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
40
40
40
40
SG2- Cut Flow
0
0
0
0
132
150
154
159
75
50
28
24
1905
1270
711
609
Material Thickness
IN
SG2
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-47
SECTION 4
OPERATION
Amperes:
Stainless Steel
100
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Material:
Shield Mix Gas:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-48
SECTION 4
OPERATION
100 Amperes
Process Data
Stainless Steel
PG
SG1
N2
N2
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
15,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
95
95
95
95
SG1-Start
60
60
60
60
SG1- Cut
50
35
35
35
SG2- Cut Flow
0
0
0
0
135
145
153
157
80
60
35
25
2032
1520
889
635
Material Thickness
IN
SG2
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-49
SECTION 4
OPERATION
Amperes:
Stainless Steel
70
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543, "D"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-50
SECTION 4
OPERATION
70 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
N2
N2
CH4
0.187
0.250
0.375
0.500
MM
4,7
6,4
9,5
12,7
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
75
75
75
75
85
85
85
85
SG1-Start
60
60
60
60
SG1- Cut
43
43
43
43
SG2- Cut Flow
5
5
5
5
136
150
159
162
75
50
28
24
1905
1270
711
609
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-51
SECTION 4
OPERATION
Amperes:
Stainless Steel
100
Plasma Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Gas:
Nitrogen @ 125 PSI / 8.6 Bar
Shield Mix Gas:
Methane @ 100 PSI / 6.9 Bar
Material:
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-52
SECTION 4
OPERATION
100 Amperes
Process Data
Stainless Steel
PG
SG1
SG2
N2
N2
CH4
0.250
0.375
0.500
0.625
MM
6,4
9,5
12,7
5,9
Pierce Delay (SEC.)
0.3
0.4
0.5
0.6
80
80
80
80
95
95
95
95
SG1-Start
50
70
60
42
SG1- Cut
45
45
45
42
SG2- Cut Flow
5
5
5
7
138
150
162
170
80
60
35
25
2032
1524
889
635
Material Thickness
IN
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
Flow Reading
Arc Voltage (standoff)
Travel Speed
IPM
MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-53
SECTION 4
OPERATION
Plasma Marking “B” Nozzle
10
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21536 (3 Holes)
Nozzle
P/N 21541 “ B”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-54
SECTION 4
OPERATION
“B” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
35
35
SG1-Start
35
SG1- Cut
35
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
200
MM/MIN
5080
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-55
SECTION 4
OPERATION
Plasma Marking “B” Nozzle
15
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21536 3 holes
Nozzle
P/N 21541 “ B”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-56
SECTION 4
OPERATION
“B” Nozzle
Plasma Marking
15 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
35
35
SG1-Start
35
SG1- Cut
35
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
300
MM/MIN
7620
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-57
SECTION 4
OPERATION
Plasma Marking “C” Nozzle
10
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21542 “ C”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-58
SECTION 4
OPERATION
“C” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
62
62
SG1-Start
37
SG1- Cut
37
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
100
MM/MIN
2540
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-59
SECTION 4
OPERATION
Plasma Marking “C” Nozzle
15
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21542 “ C”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-60
SECTION 4
OPERATION
“C” Nozzle
Plasma Marking
15 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
62
62
SG1-Start
35
SG1- Cut
35
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
200
MM/MIN
5080
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-61
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
10
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543 “D”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-62
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
77
77
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
100
MM/MIN
2540
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-63
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
15
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-64
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
15 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
62
62
SG1-Start
37
SG1- Cut
37
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
300
MM/MIN
7620
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-65
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
20
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543 “D”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-66
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
20 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
77
77
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
200
MM/MIN
5080
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-67
SECTION 4
OPERATION
Plasma Marking “D” Nozzle
30
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21543 “D”
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-68
SECTION 4
OPERATION
“D” Nozzle
Plasma Marking
30 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
77
77
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
MM/MIN
500
12700
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-69
SECTION 4
OPERATION
Plasma Marking “E” Nozzle
10
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-70
SECTION 4
OPERATION
“E” Nozzle
Plasma Marking
10 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
85
85
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
100
MM/MIN
2540
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-71
SECTION 4
OPERATION
Plasma Marking “E” Nozzle
20
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-72
SECTION 4
OPERATION
“E” Nozzle
Plasma Marking
20 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
85
85
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
300
MM/MIN
7620
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-73
SECTION 4
OPERATION
Plasma Marking “E” Nozzle
30
Amperes:
Plasma Gas:
Argon @ 125 PSI / 8.6 Bar
Shield Gas:
Air @ 125 PSI/ 8.6 Bar
PT-24 Torch
Torch Body
P/N 21758
Water Baffle
P/N 21725
O-Ring
P/N 638797
O-Ring
P/N 86W62
O-Ring
P/N 950714
O-Ring
P/N 98W18
Electrode
P/N 21539
Swirl Baffle
P/N 21692 (4 holes)
Nozzle
P/N 21923, "E"
Nozzle Retainer/Diffuser
P/N 22007
Shield Cup Insulator
P/N 22010
Insulator Shield Retainer
w/O-Ring P/N 21712
O-Ring - Shield Retainer .
(Ref. P/N 996528)
Cup shield w/Retainer
P/N 22531
Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
4-74
SECTION 4
OPERATION
“E” Nozzle
Plasma Marking
30 Amperes
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1
Plasma Cut Gas 1
Shield Gas
(Flow Reading)
85
85
SG1-Start
100
SG1- Cut
100
SG2- Cut Flow
0
Flow Reading
Arc Voltage (standoff)
77
Travel Speed
IPM
MM/MIN
500
12700
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
4-75
SECTION 4
OPERATION
4.4.3.1 Aluminum Kerf Values N 2/N 2/CH4
Aluminum N 2/N2/CH4 30 Amperes
Material Thickness (mm)
1.575
1.905
2.286
3.175
4.750
6.350
0.140
3.556
0.120
3.048
0.100
2.540
0.080
0.087
1.524
0.060
1.270
1.270
2.032
1.651
1.524
0.065
1.270
0.060
0.040
0.050
0.050
0.050
Kerf (mm)
Kerf (inches)
2.210
1.016
0.020
0.508
0.000
0.000
0.062
0.075
0.090
0.125
0.187
0.250
Material Thickness (inches)
Aluminum N 2/N2/CH4 50 Amperes
Material Thickness (mm)
3.175
4.775
0.140
3.556
0.120
3.048
0.100
2.362
2.032
Kerf (inches)
6.350
0.080
0.093
2.540
2.032
0.080
1.651
1.524
0.060
1.524
0.065
0.060
0.040
1.016
0.020
0.508
0.000
0.000
0.062
0.125
0.188
Material Thickness (inches)
4-76
0.250
Kerf (mm)
1.575
SECTION 4
OPERATION
Aluminum N 2/N2/CH4 70 Amperes
Material Thickness (mm)
6.350
9.525
12.700
0.190
4.826
0.170
4.318
0.150
3.810
0.130
3.048
3.302
2.845
0.110
0.090
2.540
2.540
0.112
0.100
0.120
0.100
2.794
Kerf (mm)
Kerf (inches)
4.750
2.286
0.070
1.778
0.050
1.270
0.187
0.250
0.375
0.500
Material Thickness (inches)
Aluminum N 2/N2/CH4 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
0.190
4.826
0.170
4.318
0.150
3.810
3.302
2.921
0.110
0.090
2.667
2.794
0.115
2.540
0.100
0.130
0.105
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
4-77
0.625
Kerf (mm)
Kerf (inches)
3.302
0.130
SECTION 4
OPERATION
4.4.3.2 Carbon Steel Kerf Values O2 /N 2/O2
Carbon Steel O 2/N2/O2 16 Amperes
Material Thickness (mm)
3.404
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.473
0.060
1.524
1.118
0.040
0.058
Kerf (mm)
Kerf (inches)
1.219
1.016
0.044
0.020
0.508
0.000
0.000
0.048
0.134
Material Thickness (inches)
Carbon Steel O 2/N2/O2 35 Amperes
Material Thickness (mm)
3.175
6.350
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.499
0.060
1.524
1.321
1.168
0.059
0.052
0.040
1.016
0.046
0.020
0.508
0.000
0.000
0.060
0.125
Material Thickness (inches)
4-78
0.250
Kerf (mm)
Kerf (inches)
1.524
SECTION 4
OPERATION
Carbon Steel O 2/N2/O2 45 Amperes
Material Thickness (mm)
3.175
6.350
9.525
0.140
3.556
0.120
3.048
2.413
2.540
0.095
1.930
0.080
1.626
0.060
2.032
0.076
1.524
0.064
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
0.100
0.000
0.125
0.250
0.375
Material Thickness (inches)
Carbon Steel O 2/N2/O2 70 Amperes
Material Thickness (mm)
3.429
6.350
9.525
12.700
0.140
3.556
0.120
3.048
2.540
0.100
2.540
0.080
0.100
2.032
1.778
0.080
1.575
0.070
0.060
1.524
0.062
0.040
1.016
0.020
0.508
0.000
0.000
0.135
0.250
0.375
Material Thickness (inches)
4-79
0.500
Kerf (mm)
Kerf (inches)
2.032
SECTION 4
OPERATION
Carbon Steel O 2/N2/O2 100 Amperes
Material Thickness (mm)
9.525
12.700
19.050
0.140
3.556
3.048
0.120
3.048
0.120
2.540
0.100
2.337
2.540
0.092
0.080
2.032
0.060
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.375
0.500
Material Thickness (inches)
4-80
0.750
Kerf (mm)
Kerf (inches)
0.100
SECTION 4
OPERATION
4.4.3.3 Stainless Steel Kerf Values O 2/N 2/O2
Stainless Steel O 2/N2/O2 30 Amperes
Material Thickness (mm)
0.584
0.726
1.207
1.588
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
0.060
1.524
1.143
0.040
0.889
0.035
0.889
0.035
0.889
0.035
0.889
0.045
1.016
0.035
0.020
0.508
0.000
0.000
26GA
24GA
22GA
Material Thickness (inches)
4-81
18GA
16GA
Kerf (mm)
Kerf (inches)
0.457
SECTION 4
OPERATION
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4
Stainless Steel Air/Air/CH 4 70 Amperes
Material Thickness (mm)
3.175
4.775
6.350
9.525
12.700
0.140
3.556
2.921
0.120
0.115
2.540
0.100
2.032
0.080
2.540
2.286
0.090
1.778
2.032
0.080
0.060
0.070
1.524
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
0.100
3.048
0.000
0.125
0.188
0.250
0.375
0.500
Material Thickness (inches)
Stainless Steel Air/Air/CH 4 100 Amperes
Material Thickness (mm)
9.525
12.700
0.190
4.826
0.170
4.318
0.150
Kerf (inches)
15.875
3.556
0.130
3.048
0.140
0.120
0.110
3.810
3.302
2.794
2.540
2.286
0.100
0.090
2.286
0.090
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
4-82
0.625
Kerf (mm)
6.350
SECTION 4
OPERATION
4.4.3.5 Stainless Steel Kerf Values N 2 /N 2/CH4
Stainless Steel N 2/N2/CH4 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
2.921
0.120
3.048
2.667
2.540
0.105
0.095
0.080
2.032
0.080
0.060
1.524
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
2.032
Kerf (inches)
0.115
2.413
0.100
0.000
0.187
0.250
0.375
0.500
Material Thickness (inches)
Stainless Steel N 2/N2/CH4 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
0.190
4.826
0.170
4.318
3.810
0.150
3.810
0.150
0.130
3.302
0.130
2.794
0.110
0.090
2.540
2.794
0.110
0.100
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
4-83
0.625
Kerf (mm)
Kerf (inches)
3.302
SECTION 4
OPERATION
4.4.3.6 Stainless Steel Kerf Values N 2/N 2
Stainless Steel N 2/N2 50 Amperes
Material Thickness (mm)
4.750
6.350
9.525
0.140
3.556
0.120
3.048
0.100
2.540
2.032
0.080
2.032
1.778
1.524
0.060
0.080
1.651
0.070
0.065
1.524
0.060
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
Kerf (inches)
3.175
0.000
0.125
0.187
0.250
0.375
Material Thickness (inches)
Stainless Steel N 2/N2 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
0.120
3.048
2.540
0.100
2.540
2.286
2.286
0.080
0.060
0.090
1.778
2.032
0.070
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.187
0.250
0.375
Material Thickness (inches)
4-84
0.500
Kerf (mm)
Kerf (inches)
0.100
0.090
SECTION 4
OPERATION
Stainless Steel N 2/N2 100 Amperes
Material Thickness (mm)
9.525
12.700
0.190
4.826
0.170
4.318
0.150
Kerf (inches)
15.875
3.556
0.130
3.048
2.794
0.110
0.140
0.120
2.540
3.810
3.302
2.794
0.110
0.090
0.100
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
4-85
0.625
Kerf (mm)
6.350
SECTION 4
OPERATION
4.4.3.7 Stainless Steel Kerf Values Air/Air
Stainless Steel Air/Air 50 Amperes
Material Thickness (mm)
4.750
6.350
0.140
3.556
0.120
3.048
2.413
0.100
Kerf (inches)
9.525
2.032
2.540
0.095
0.080
2.032
1.524
0.060
0.080
1.651
1.524
0.065
0.060
0.040
1.016
0.020
0.508
0.000
Kerf (mm)
3.175
0.000
0.125
0.187
0.250
0.375
Material Thickness (inches)
Stainless Steel Air/Air 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
2.921
0.120
0.115
0.110
0.100
3.048
0.115
2.540
1.905
0.080
2.032
0.075
0.060
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.187
0.250
0.375
Material Thickness (inches)
4-86
0.500
Kerf (mm)
Kerf (inches)
2.921
2.794
SECTION 4
OPERATION
Stainless Steel Air/Air 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
4.826
0.170
4.064
0.150
3.556
Kerf (inches)
3.302
0.140
0.130
2.921
0.110
0.160
4.318
3.810
3.302
0.130
2.794
0.115
0.090
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
4-87
0.625
Kerf (mm)
0.190
SECTION 4
OPERATION
Page intentionally left blank.
4-88
SECTION 5
MAINTENANCE
5.1 General
If this equipment does not operate properly, stop work
immediately and investigate the cause. Qualified
personnel must perform maintenance work. Do NOT
permit untrained persons to inspect, clean or repair
equipment. Use only recommended replacement
parts.
! WARNING
Electric Shock Can Kill!
Before attempting any inspection or repair inside
any of the components of the Precision Plasma,
open wall disconnect or wall circuit breaker.
5.2 Inspection And Cleaning
Frequent inspection and cleaning of the Precision
Plasmarc System is recommended for safety and
proper operation. Consider the following during
inspection and cleaning:
Location of pump
filter
! WARNING
•
Check work cable to workpiece connection.
•
Check safety earth ground at workpiece and at
power source chassis.
•
Check heat shield on torch. Replace if damaged.
•
Check torch electrode and cutting nozzle for wear
daily.
•
Ensure cable and hoses are not damaged or
kinked.
•
Ensure all plugs, fittings, and ground connections
are tight.
•
Check screen filter in coolant pump located inside
Power Source periodically and flush as required.
Flying Debris Hazard.
Flying Debris Can Seriously Injure Eyes
Wear protective eyewear whenever cleaning with
compressed air.
5-1
SECTION 5
MAINTENANCE
CAUTION
Avoid Potential Equipment Damage
Water and/or oil can accumulate in compressed
air lines. Be sure to direct the first air blast away
from equipment to avoid damaging the junction
box or flow control box.
•
With all input power disconnected and with proper
eye and face protection, blow out the inside of the
power source, flow control, and junction box using
low-pressure, clean/dry compressed air.
•
Occasionally, bleed all water from the filter below
the air filter-regulator.
•
Mounting. The torch can be mounted by the 2"
(51 mm) dia. sleeve or by the 1.812" (46 mm) dia
machined surface shown. This insulated surface
and its shoulder are machined relative to the
nozzle retainer thread on the torch body. They are
held concentric to the cutting nozzle within a total
indicator reading of 0.010" (0.25 mm) or the nozzle
bore is within 0.005" of any point on the 1.812"
dia. When mounting, do not to cover the small
vent hole in the side of the sleeve. This hole
prevents coolant from building inside the sleeve if a
leak occurs.
•
Service Lines. 4.5 ft. (1.4m), 12 ft. (3.7m), 17ft.
(5.2m) and 20 ft. (6.1m) lines are shielded and
connect to the junction box by a friction fit
grounded connection.
5.3 Pt-24 Torch Description
1.812" (46 mm)
Diameter Collar
2.0" (51 mm)
Diameter Sleeve
Vent Hole
5-2
SECTION 5
MAINTENANCE
•
Plasma Cut and Start Gas. These gases enter the
torch through connections that house check valves
within the torch body. The valves acting in
conjunction with solenoid valves control the back
and forth switching of start and cut gases.
Argon
Process
Air
O2
125 psi
N2
125 psi
H35
100 psi
CH4
100 psi
Gas In from supply
Ar
AIR-1
O2-1
N2-1
PS1
AIR-2
N2-2
METH
Process Air
Pressure Switch
O2-2
GAS FLOW SCHEMATIC
N2-3
METH
O2
N2
Air
Ar
Solenoid Valve
Pressure Switch
PS5
PS4
PS2
PS3
Sentronic Valve
Flow Meter
Check Valve
Interface
Board
VALVE 4
6-BAR
SENTRONIC
VALVE 3
6-BAR
SENTRONIC
VALVE 2
9-BAR
SENTRONIC
VALVE 1
9-BAR
SENTRONIC
Check Valve
2 Way Solenoid Valve
SG2
BLK
SG1
ORG
PG2
YEL
PG1
BLU
Gas Quick Coupling
EFC J-Box
SG2
SG1
PG2
PG1
Electronic
Manifold
Assembly
Note: Shop air should not be
used for process air.
PT-24 Torch
5-3
SECTION 5
MAINTENANCE
•
Shield Gas. Shield preflow, cut shield and
postflow enter the torch through one connection.
These gases pass through:
§
the torch body,
§
the shield gas diffuser,
§
•
out the orifice in the shield cap surrounding
the plasma jet.
Power and Pilot Arc Lines. Coolant IN to the torch
is through the power cable (-). Coolant OUT from
the torch is through the pilot arc (+) line.
Water Cooling.
1. Coolant enters the torch through the power cable
(-),
Coolant In via
Power Cable
Coolant Out via
Pilot Arc Cable
Crossover
Tube
2. circulates through the torch body and the
electrode,
3. crosses over to the nozzle (+) section of the torch
body through nonconductive crossover tubes,
4. travels back through the body and circulates
between the nozzle retainer and the nozzle,
5. back through the torch body to the junction box
via the pilot arc cable.
Electrode Body
Pilot Arc Body
Water Baffle
Swirl Baffle
Electrode
Nozzle Retainer
Nozzle
5-4
SECTION 5
MAINTENANCE
5.4 Torch Maintenance
! WARNING
Electric Shock Can Kill
Before performing torch maintenance:
•
Turn power switch on the console to the OFF
position.
•
Disconnect primary input power.
Torch Body O-Rings
O-ring
P/N 950714
•
Each day before starting operation, check O-rings
on the torch body . Replace if damaged or worn.
•
Apply a thin coat of silicone grease to O-rings
before assembling to torch. Do not use Krytox.
•
The O-ring, P/N 638797, inside the torch body that
seals the nozzle is especially critical.
O-ring
P/N 86W62
O-ring
P/N 638797
§
Damage or wear is not readily apparent because
of its location,
§
We recommend replacing this O-ring on a daily
basis.
§
Be careful not to scratch or damage the torch
surface.
§
A wooden toothpick works well for removing Orings.
§
The O-ring can be replaced without removing
the water baffle P/N 21725; however if the baffle is
removed, always use a 3/16" (5 mm) hex wrench
or nut driver.
Torch Sleeve Vent
•
Water leaks, moisture or coolant dripping from the
sleeve vent hole indicates service line damage.
•
If service lines must be replaced, always use two
wrenches to avoid twisting the metal tubes.
Vent Hole
5-5
SECTION 5
MAINTENANCE
Sleeve
P/N 822568
CAUTION
Check Valve Body P/N 821739
Torch Sleeve
•
The torch sleeve P/N 822568 is threaded onto the
torch body.
•
If the sleeve is too tight for hand removal, use a
large adjustable wrench on the body flats or lightly
tighten these flats in a vise. With the body
secured, using two hands on the sleeve may break
it free. If not, use a strap wrench.
•
Before replacing sleeve, always check service line
connections for leaks.
Damaged Or Incorrect Torch Check Valve
Parts Will Affect Cutting Performance.
•
Do not damaged the check valve seat, ball and
spring when handling.
•
Do not substitute any other spring or ball. If they
are lost, dropped, or damaged, they must be
replaced with factory replacement parts.
•
Using non-authorized or damaged torch check
valve parts will affect set pressures and cause poor
starting and piercing.
Ball P/N 821740
Spring P/N 821741
CAUTION
Improperly Seated Fittings Will Cause Leaks
And Poor Performance.
•
Keep threads and seat surfaces clean when reassembling check valves.
•
If dirt or foreign matter contaminates check valves,
valves,
disassemble, clean or replace.
5-6
SECTION 5
MAINTENANCE
5.5 PT-24 Consumable Disassembly And Inspection
! WARNING
Electric Shock Can Kill!
•
Turn power switch on the console OFF.
•
Disconnect primary input power.
If the nozzle retainer/diffuser is difficult to remove, the
console may be on.
PT-24 Front End
NOTE:
If the console is on, the pump will be running and
coolant pressure behind the retainer will prevent it from
turning freely. Check the console before attempting to
remove the nut. Notice that a small amount of coolant
is lost each time consumables are removed. This is
normal and the coolant will eventually have to be
replaced. Check coolant before each operation.
1. Unscrew the cup shield/retainer. Inspect around
orifice for damage. Replace orifice edge if nicked
or damaged. A distorted orifice will not produce
straight cuts.
cuts
Shield Cup
Insulator
2. Unscrew and remove insulator shield
Insulator Shield
Retainer
Cup Shield
w/Retainer
3. The shield cup insulator is sandwiched between
the cup and the nozzle retainer/diffuser. It may
remain attached to nozzle retainer because of the
very close fit between these members.
5-7
SECTION 5
MAINTENANCE
4. Unscrew the nozzle retainer/diffuser. Inspect for
damage, especially where the retainer contacts the
nozzle. The surface between the retainer and the
nozzle creates a metal to metal seal for the
coolant. Any damage to this sealing surface will
cause a leak resulting in poor cutting. Replace as
necessary, but do not attempt to repair. Check
small gas passages for blockages. Clear
blockages with an air stream.
Nozzle
Nozzle
Retainer
No damage to the
contact area.
Nozzle
5. Use the tool provided to remove the nozzle. Place
the slot around the nozzle groove and pull it free.
Electrode and Nozzle Tool P/N 21765
6. Remove the swirl baffle from the nozzle. If the
baffle remains in the torch, it will come free when
removing the electrode. Check the small gas
passages of the swirl baffle for blockage and clear
blockages with an air stream. If blockages cannot
be cleared, replace baffle. Do NOT insert anything
in these holes when trying to clear them. Distorting
these holes will impair cutting performance.
Electrode
Swirl Baffle
Nozzle
5-8
SECTION 5
MAINTENANCE
7. Use the electrode and nozzle tool provided to
unscrew the electrode. (P/N 21765).
5.6 PT-24 Torch Tip Re-assembly
1. Electrode
Apply a thin film of silicone grease to the O-ring, just
enough to produce a shiny surface. Thread electrode
in place and tighten snugly with tool provided. DO
NOT OVER TIGHTEN.
Nozzle Retainer
2. Nozzle & Swirl Baffle
Nozzle
Small Amount
of Krytox
Place swirl baffle into nozzle with the grooved end of
the baffle going inside nozzle.
When properly assembled, the small spherical tip of
nozzle makes a metal to metal coolant seal with the
nozzle retainer. Apply a small amount of Krytox (antiseizing compound) on the small diameter of the nozzle
retainer as shown. This grease prevents possible
galling/seizing between the nozzle and retainer. It also
facilitates a watertight seal. Do not put Krytox on
nozzle.
3. Nozzle Retainer/Diffuser
Thread the nozzle retainer onto torch and hand
tighten.
Water Seal
5-9
SECTION 5
MAINTENANCE
4. Shield Cup Insulator
Shield Cup
Insulator
Push the shield cup insulator on the nozzle retainer.
This component is a press fit and may remain
assembled when the assembly was taken apart.
Nozzle Retainer
5. Insulator Shield Retainer
Apply a thin coat of silicone grease to the O-ring and
thread insulator shield retainer on to Shield Cup.
Hand tighten.
NOTICE
Do not attach Insulator to the torch
body first.
Threading Insulator on to torch body first will not allow
shield gases to flow properly. Thread insulator onto
the Shield Cup first and then attach both pieces onto
the torch body.
6. Shield Cup And Retainer
Screw this assembly (Insulator/Shield Cup and
Retainer) onto the torch and hand tighten.
CAUTION
O-Ring Inspection & Lubrication
•
Inspect O-rings often for nicks and wear. Worn or
damaged O-rings will affect starting and cut
quality.
•
Applying a thin coat of silicone grease to the torch
tip O-rings during service assembly will facilitate
future disassembly.
•
Do not use Krytox on O-rings. Krytox is an antiseize lubricant and will dissipate over time.
Disassembly will be difficult.
5-10
SECTION 6
TROUBLESHOOTING
6.1 General Safety
! WARNING
Electric Shock Can Kill!
! WARNING
High Voltages Can Be Stored In
Capacitors.
Externally disconnect all primary power to
the machine before servicing.
Open the line (wall) disconnect switch or
circuit breaker before attempting
inspection or work inside the power
source.
Even when power is disconnected or unit
is de-energized, capacitors can store high
voltages. Assure power supply capacitors
are grounded prior to performing
maintenance.
6.2 Programmable Logic Controller (PLC)
•
Located in the Precision Plasma Power Source.
•
Capable of providing predefined outputs
depending on state of the inputs. The precise
conditions are programmed and permanently
stored in the PLC.
•
Visible through the plexiglas window on the left
side panel of the power source.
•
Provides predefined outputs in response to
input signals from external devices.
•
The signal exchange between the PLC and
external devices are both time dependent and
condition dependent. If a required signal is not
received in the proper sequence, the PLC will
discontinue the process and generate a fault
signal to the CNC.
6-1
SECTION 6
TROUBLESHOOTING
6.2.1 PLC LEDs (Light Emmiting Diode)
OUTPUT
Highly reliable indicators. It is not likely that one will
"burn out". However, if the technician is not
confident that the LEDs are working, the presence
of a signal can be confirmed by using a meter and
taking a measurement on the appropriate pin.
Refer to the schematic and wiring diagrams.
1 CH
0 1 2 3 4 5 6 7
8 9 10 11
•
This exchange of signals can be confirmed by
observing the LEDs on the top of the PLC while
troubleshooting. These indications are useful in
isolating a system failure to the most likely
device.
•
The LEDs are divided into two groups;
POWER
RUN
ALARM
ERROR
INPUT
0 CH
§
Input (0-15) light when the corresponding
signal is detected by the PLC.
§
Output (0-11) light when the PLC issues a
signal to an external device.
0 1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
6.2.2 PLC LED Functions
INPUT
OUTPUT
LED
Function
LED
Function
0
Start/Stop
0
Not Used
1
Not Used
1
Hi-Frequency
2
Arc-On
2
Pilot Arc Relay
3
Not Used
3
Power Source
4
Not Used
4
Not Used
5
Fault
5
Fault Output
6
Not Used
6
Not Used
7
Not Used
7
Not Used
8
Not Used
8
Not Used
9
Not Used
9
Not Used
10
Not Used
10
Not Used
11
Not Used
11
Not Used
12
Not Used
13
Not Used
14
Not Used
15
Not Used
6-2
SECTION 6
TROUBLESHOOTING
6.3 Troubleshooting Guide
6.3.1 Reduced Consumable Life
Cutting Up Skeletons Cutting skeletons (discarded material left after all
pieces have been removed from a plate) to facilitate
their removal from the table can adversely affect
electrode life by:
•
Causing the torch to run off the work.
•
Continuous Pilot Arc edge starts
•
Greatly increasing the frequency of starts. This
is mainly a problem for O2 cutting and can be
alleviated by choosing a path with a minimum
number of starts.
•
Increase likelihood that the plate will spring up
against the nozzle causing a double arc. This
can be mitigated by careful operator attention
and by increasing standoff and reducing cutting
speeds.
If possible, use a gas torch for skeleton cutting.
Height Control Problems •
•
Torch diving is usually caused by a change in
arc voltage when an automatic height control is
in use. Usually the voltage change is the result
of plate falling away from the arc. These
problems can effectively be eliminated by
disabling the height control and extinguishing
the arc earlier when finishing the cut on a falling
plate.
Diving can also be caused by a faulty height
control.
Piercing Standoff Too Low Increase pierce standoff
Starting on edges with Position torch more carefully or start on adjacent
continuous pilot arc scrap material.
Work Flipping The nozzle may be damaged if the torch hits a
flipped up part.
Catching on Pierce Spatter Increase standoff or start with longer lead-in
Pierce not complete before starting Increase initial delay time.
6-3
SECTION 6
TROUBLESHOOTING
See Cut Quality In Section 4
6.3.2 Poor Cut Quality
6.3.3 No Pilot Arc
Contaminated Electrode Clean or replace electrode
Insufficient spark gap setting Set spark gap to 0.040”
in plumbing box.
Pilot Arc Contactor (PAC) Replace contactor
malfunctioning
6.3.4 No Arc Transfer
Cutting current Raise cutting current (see Process Data)
setting too low.
Torch too high Lower torch standoff (see Process Data)
above workpiece
Work lead not Ensure work lead is firmly connected to workpiece
connect to cutting table or cutting table
N2 or O2 check valve in torch
body may be stuck open
See maintenance section for check valve repair.
6.3.5 No Preflow
No start signal Check input 0 LED on PLC. Should be lit. This
verifies a start command has been given
Emergency stop signal open Check for continuity between TB3-18 and TB3-19
Shorted, closed or jumpered out Check cooling water LED on front panel. Should be
Cooling Water Flow Switch lit.
No Cooling Water Check reservoir. Add coolant until full.
6.3.6 Torch Fails To Fire
Start Gas Lower start gas flow
Cooling water Flow Pump pressure too low. Should be 115/130 psi.
Faulty cooling water flow switch Replace CWFS switch
(CWFS)
Obstruction in torch Coolant flow through torch should be greater than
limiting cooling water flow 0.5 gal/min
6-4
SECTION 6
TROUBLESHOOTING
6.3.7 Nozzle Life Extremely Short
Pilot Arc H/L switch Refer to Process Data
in wrong position
Nozzle arcing inside bore Nitrogen quality too low. Requires 99.995 % purity
Start gas flow too low Check Process Data cutting parameters
6.3.8 Short Electrode Life
Insufficient cooling Check pump for 115/130 psi output pressure
Start gas quality Gas quality needs to be 99.995 % purity minimum
Cut gas quality Oxygen gas needs to be 99.8 % purity
6.3.9 Short Electrode And Nozzle Life
Water leak on torch front-end Follow torch leak procedure
6-5
SECTION 6
TROUBLESHOOTING
1
2
2
PLASMA GAS 2
SHIELD GAS 1
3
3
SHIELD GAS 1
4
SHIELD GAS 2
COMMON
P4
SHIELD GAS 2
5
PLASMA GAS 1
PLASMA GAS 2
4
PLASMA GAS 1
1
6.4 Flow Control Schematic
5
6
7
A. C. COMMON
8
CHASSIS
P5
COMMON
120 vac (11 ne)
6
4
7
1
2
3
8
9
9
10
10
4 amp
7
8
5
6
FUSED 24vac TO CNC
24vac COMMON
VALVE 1 SHIELD (SH)
1
CHASSIS GROUND
VALVE 1 GND (GN)
2
24 vdc GROUND
3
VALVE 1 SET PT.
VALVE 1 SET PT. (SP)
4
VALVE 1 + 24 VDC
VALVE 2 SET PT. (SP)
5
VALVE 2 SET PT.
VALVE 2 +24V (PR)
6
VALVE 1 +24 VALVE (PR)
VALVE 2 +24 VDC
}
PLASMA GAS 1
VALVE 2 SHIELD (SH)
VALVE 2 GND (GN)
}
PLASMA GAS 2
}
SHIELD GAS 1
}
SHIELD GAS 2
VALVE 3 SHIELD (SH)
P1
VALVE 3 GND
VALVE 3 SET PT.
8
VALVE 3 +24 VDC
9
VALVE 4 SET PT.
10
VALVE 4 +24 VDC
1
PRES. SW. 15 V. SOURCE (SR1)
2
PRES. SW 24 V. SOURCE (SR2)
3
VALVE 3 +24 V (PR)
7
VALVE 3 SET PT. (SP)
PS5 (SHIELD GAS 2)
VALVE 4 SHIELD (SH)
VALVE 4 GND (GN)
VALVE 4 SET PT. (SP)
VALVE 4 +24V (PR)
{
{
{
{
{
PS5
JP1
(SHIELD GAS 2)
PS5
PS4
JP2
(SHIELD GAS 1)
4
PS4
5
PS3
6
PS2 (PLASMA GAS 1)
7
PS1
PS1 (PROCESS AIR)
SELECTOR VALVE COMMON
1
METHANE
2
H-35 NOT USED
3
N2-3
4
N2-2
5
N2-1
RC1
8
1
METH
2
H-35
3
SOLENOID
METH
H.F 120 V FROM POWER SUPPLY
H.F. 120 V TO J-BOX
JP5
PS1
10
PS2
(PROCESS AIR)
PS3 (PLASMA GAS 2)
P2
JP4
PS2
(PLASMA GAS 1)
PS4 (SHIELD GAS 1)
H.F. 120 V FROM POWER SUPPLY
H.F. 120 V TO J-BOX
JP3
(PLASMA GAS 2)
9
PS3
1 amp
N-3
RC2
4
5
SOLENOID
H-35
1 amp
RC3
6
N-2
7
SOLENOID
N-3
1 amp
RC4
8
N-1
9
N-1
10
O-2
11
O-2
12
O-1
13
SOLENOID
N-2
1 amp
RC5
SOLENOID
1 amp
P3
RC6
6
7
O2-1
8
AIR-2
9
AIR-1
10
SOLENOID
O2-2
ARGON
1 amp
15
AIR-2
16
AIR-1
17
AIR-1
18
AR
19
RC7
14
SOLENOID
O-1
AIR-2
1 amp
RC8
SOLENOID
1 amp
RC9
SOLENOID
1 amp
RC10
20
SOLENOID
1 amp
TB1
6-6
SECTION 6
TROUBLESHOOTING
Process Air
125 psi
Argon
125 psi
O2
125 psi
N2
125 psi
H35
100 psi
CH4
100 psi
6.5 Gas Flow Schematic
Ar
AIR-1
O2-1
N2-1
PS1
AIR-2
N2-2
METH
O2-2
N2-3
METH
N2
O2
Air
Solenoid Valve
Ar
Pressure Switch
PS5
PS4
PS2
PS3
Sentronic Valve
Flow Meter
Check Valve
Interface
Board
VALVE 4
6-BAR
SENTRONIC
VALVE 3
6-BAR
SENTRONIC
VALVE 2
9-BAR
SENTRONIC
VALVE 1
9-BAR
SENTRONIC
Check Valve
2 Way Solenoid
Valve
SG2
BLK
SG1
ORG
PG2
YEL
PG1
BLU
Gas Quick Coupling
EFC Junction
Box
Electronic
Manifold
Assembly
PT-24 Torch
6-7
SECTION 6
TROUBLESHOOTING
6.6 Junction Box Wiring Diagram
T1-X1 RED
PILOT ARC BLU
1
2
GND1 GRN
3
PCB1
J1-M GRY
X2
J1
GND1
J1
PILOTARC
J1-A GRN
PCB1-3 GRN
PCB1-2 BLU
J2
J1
SPLICE
J2-5
J2-6
J2-7
J2-8
A
B
C
D
E
F
G
H
I
J
K
L
M
N
WHT
WHT
WHT
WHT
J1-C WHT
DENOTES IN-LINE SPLICE
DENOTES SELF LEAD
6-8
GRN GND1
BLU J2-2
WHT SPLICE
YEL J2-1
BLK J2-3
ORN J2-4
GRY T3-H1
BLK T3-H2
1
2
3
4
5
6
7
8
9
YEL
BLU
BLK
ORN
WHT
WHT
WHT
WHT
---
J1-F
J1-B
J1-J
J1-L
SPLICE
SPLICE
SPLICE
SPLICE
---
J2
C2
2
C1
SG1-1 RED
X3
1
SG1-2 BLU
T1
X1
1
PCB1-1 RED
C1-1 BLU
BLU
SG1-1 RED
X2
2
X1
X2
T1-X2 BLU
SG1-2 BLU
T3
X3
T3-X1 RED
T3-X2 BLU
T1-X1 RED
H1 H2
T2
SG1
X1
C1-2 BLU
J1-N BLK
SECTION 6
TROUBLESHOOTING
6.7 Junction Box Schematic
J1
A
B
C
D
E
TO FLOW
CONTROL
J2
YEL
J2
PLASMA-1
SOLENOID COMMON
GND1
PLASMA-2
F
G
H
J
K
L
M
N
I
SHIELD GAS 1
SHIELD GAS 2
H2
T3
6
5
3
3
1
4
9
2
4
ORG
BLK
SG-1
MANIFOLD
EFC A/M
SG1
1
X1
2
C1
.002 uf
10KV
C2
2500pf
15KV
1
NEG
X1 X2
PCB1
1
2
X3
T1
X1
NEG
X2
3
CABLE
CONNECTIONS
TO CONSOLE
X3
T2
TORCH
CONNECTIONS
GND1
PILOT
ARC
PILOT
ARC
WORK
SCHEMATIC DIAGRAM
6-9
PG-2
PG-1
X2
2
H1
2
5
6
7
8
1
BLU
SG-2
TROUBLESHOOTING
6.8 Power Module Wiring Diagram
PCB2 P1
PCB3 P1
PCB1 P3
PCB1 P4
NEXT PAGE
P3
4 1
P3
C17
C16
P4
1
SECTION 6
4
P4
P5
1
P1
1
PCB1
*
*
*
1
J1
1 TS2-2(SPLICE)(VIO)
2 TS1-1(VIO)
3 PCB1 P5-1(ORN)
4 PCB1 P5-2(WHT)
5 PCB1 P5-5(BLK)
6 PCB1 P5-6(RED)
7 PCB1 P6-12(BLU)
8 PCB1 P6-14(BRN)
9 PCB1 P6-13(ORN)
10PCB1 P2-12(YEL)
11PCB1 P2-12(YEL)
12PCB1 P2-13(GRY)
13PCB1 P2-13(GRY)
14PCB1 P6-10(BLK)
15PCB1 P6-11(RED)
16
J1
R2
+
C3
C5
J1-2(VIO)
TS2-1(VIO)
L1
SEE NOTE 3
H1
C4(-)
*
*
BR1-F
C9(+) BUSS (BLK)
GND1
C6
R4
1
R5
C7
D2
C9
*
1
X1
X2
TS2
**
H1
1
10
MOV1
2
*
BR1
*
*
**
1
MOV3
TB2-1(RED)
*
J2
T3-X2
G
TB2-2(GRY)
C8
L2-X1
PCB1 P1-8(ORN)
PCB1 P1-7(ORN)
PCB1 P2-6(BRN)
R9
C15
R7
C13
R3
R5-2(BLK)
T3-H1
T3-H2
J2
* T3-X1
J4
MOV2
+
X1
T2
10
SCR1
X2
C1
R8
C14
C12
BUSS TO
SH1
R6
J3
1
-
SEE NOTE 3
BLK R1-1 (YEL)
R1-2 (YEL)
H3
H1
8
L2
T3
X2
X1
T1
BOTTOM
H2
*
Q1-C2E1
C9(+) BUSS
D1-3
D2-3
**
**
PCB1 P1-4(BRN)
PCB1 P2-11(VIO)
PCB1 P2-14(VIO)
PCB1 P1-3(BRN)
PCB1 P2-4(ORN)
PCB1 P2-1(ORN)
7
8
9
11
10
12
7
T1
TOP
1
6
J3
1 J4-1(BLK)
2 J4-2(WHT)
3 J4-3(RED)
4 J4-4(ORN)
5 J4-5(BLU)
6 J4-6(YEL)
7 J4-7(BRN)
8 J4-8(GRY)
9 J4-9(VIO)
10J4-10(BLK)
D1/D2-2 BUSS
TB3
12
*
* PCB1 P6-10(BLK)
D1
TS1-2(VIO)
J1-1(SPLICE)(VIO)
PCB1 P2-5(YEL)
L1-H1
SH1
+
PCB1 P6-11(RED)
Q1
C4(+)(WHT)
Q2
1
1
C11
2
TS1
1
2
3
4
5
6
7
8
H2
PCB2
2
PCB3
16
2
C2
C4
-
-
R1
1
2
+
1
SCR1(+) (YEL)
SCR1(-) (YEL)
2
PCB3 P1
L1-H2
R2-1(BLK)
SCR1(+)(WHT)
R2-2(RED)
C4(+)(RED)
PCB1
C4(-)(BLK)
PCB2 P1
P4
P2
P6
14
P1
P1
14
12J1-10(YEL)
J1-11(YEL)
13J1-12(GRY)
J1-13(GRY)
14T1-X12(VIO)
PCB1 P6-7(VIO)
P5
1
P6
5 SCR1-G (YEL)
6 SCR1(+) (BRN)
7
8
9
10
11T1-X11(VIO)
P6
1
2 J1-16(WHT)
3
4
5
6
7 PCB1 P2-14 (VIO)
8
9
10 J1-14(BLK)
SH1 (-) (BLK)
11 J1-15(RED)
SH1(+) (RED)
12 J1-7 (BLU)
13 J1-9(ORN)
14 J1-8(BRN)
12
**
GND1
P5
1 J1-3(ORN)
2 J1-4(WHT)
3 T1-X1(YEL)
4 T1-X2(YEL)
5 J1-5(BLK)
6 J1-6(RED)
7
8
9
10
11
12
1 T1-X7(ORN)
2
3
4 T1-X8(ORN)
1
PCB1 P1-2(BLK)
PCB1 P1-1(BLK)
T1-X9(BRN)
T1-X10(BRN)
T1-X5(BLU)
T1-X6(BLU)
T2-X2(ORN)
T2-X1(ORN)
T1-X3(WHT)
T1-X4(WHT)
PCB1 P1-12(BLK)
PCB1 P1-11(BLK)
P2
1
2
3
4
5
6
7
8
9
10
11
12
P2
12
P1
6
PCB1 P1-6(BLU)
PCB1 P1-5(BLU)
PCB1 P1-10(WHT)
6-10
5
4
3
2
1
PCB1 P5-3(YEL)
PCB1 P5-4(YEL)
PCB1 P1-9(WHT)
SECTION 6
TROUBLESHOOTING
Power Module Wiring Diagram Part 2
Previous Page
2
+
C2
C4
-
*
T1-H1(RED)
2
PCB2
T1-H3(GRY)
*
C11
C6
1
1
2
Q1
M1
TB2
* BLK
* BLK
1
2
J4
J4
1
+
G
T2
10
1 J3-1(BLK)
2 J3-2(WHT)
3 J3-3(RED)
4 J3-4(ORN)
5 J3-5(BLU)
6 J3-6(YEL)
7 J3-7(BRN)
8 J3-8(GRY)
9 J3-9(VIO)
10J3-10(BLK)
H1
T3
H2
NOTES:
DENOTES SELF LEADS.
12DENOTES SPLICE
3- TP DENOTES TWISTED PAIR
4. SOLDERING AND CRIMPING WIRES AND TERMINALS ARE
VERY IMPORTANT TO THE OPERATION AND RELIABILITY
OF THIS POWER MODULE. ADDITIONAL INSPECTION
MUST BE DONE.
*
6-11
J4
1
6
SECTION 6
TROUBLESHOOTING
C1
E1
G1
Q(x) C2E1
G2
E2
E2
C(x)
6.9 Precision Plasma Power Module Schematic
DETAIL
4
6-12
SECTION 6
TROUBLESHOOTING
6.10 Precision Plasma Power Source Wiring Diagram
Part 1
PCB1
P1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P4-14(BRN)
P4-13(RED)
PCB1 P1-6(BLK)
PCB1 P1-5(BLK)
PLC1 P2-11(WHT)
PLC1 P2-12(ORN)
PLC1 P2-13(GRY)
PLC1 P2-14(YEL)
PCB1 P1-12(BLK)
PCB1 P1-11(BLK)
MOD1 P1-5 (BLK)
MOD1 P1-6 (RED)
MOD1 P1-2 (BLU)
MOD1 P1-1 (VIO)
PCB1 P1-18(BLK)
PCB1 P1-17(BLK)
P2
1 P4-10(VIO)
2 P4-9(VIO)
3
4 P4-8(ORN)
5 P4-7(ORN)
6
7
8 P3-3(GRY)
9 P3-4(RED)
10 P3-5(GRY)
11 P4-4(BRN)
12 P4-3(BRN)
13 P4-2(BLU)
14 P4-1(BLU)
15 P3-1(YEL)
16 P3-2(YEL)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P3
P4-11(GRY)
P4-12(BLU)
MOD1 P1-3(ORN)
MOD1 P1-4(WHT)
PCB-TB P1-6(YEL)
MOD1 P1-7(BLU)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
P4
PLC1 P1-1(BRN)
PLC1 P1-2(GRY)
MOD1 P3-1(RED)
MOD1 P3-2(YEL)
P5
1 PLC1 P1-5 (BLK)
2 PLC1 P1-6 (VIO)
P7
1 PLC1 P2-5(BLK)
2
3 TB6-5(RED)
P9
1 MOD1 P1-14(RED)
2
3 MOD1 P1-15(BLK)
1
2
3
4
5
P10
S3-5(VIO)
S3-2(RED)
P3-7(BLK)
P3-6(WHT)
P3-8(WHT)
PLC1 P1-3(YEL)
PLC1 P1-8(ORN)
PLC1 P1-3(YEL)
PLC1 P1-4(WHT)
MOD1 P3-7(RED)
MOD1 P3-8(BLK)
MOD1 P3-9(VIO)
MOD1 P3-10(YEL)
MOD1 P3-3(BLU)
MOD1 P3-4(ORN)
J1
2
1 3
MOD1 P1-9 (ORN)
S3-4 (BLU)
VIEW OF R2
S3-1 (BRN)
1
P1
18
4
P5
1
H2
H1
S2-5 (BLK)
PLC-COMM6 (BLU)
F
PLC-0109 (GRY)
G
K5-A (BLK)
J
PLC-0110 (WHT)
K
K6-A (YEL)
L
PLC-0111 (BRN)
M
PLC-0101 (VIO)
N
PLC1 J2-9 (GRY)
S
K2-L3(BLU)
T
U
18
3
P7
1
PLC1 J2-4 (ORN)
D
R
L1
P2
1
PCB4
PLC-0108 (YEL)
C
P
16
4
P9
1
B
H
SEE
VIEW
OF R2
R2-3(BLU) 4 5 6
1,3
S3
R2-2(BRN) 1 2 3
2
PCB1 P10-2(RED)
R2
TB6-7(ORN)
GND2 (GRN)
E
PCB1 P10-1(VIO)
TB6-8(GRY)
MOD1 P1-7(BLU)
A
V
P3
J2
1
18
1
J1-A (GRN)
K1-L2 (BLU)
F4-1 (YEL)
*
12
S1 3 4
56
K1-L1 (BRN)
14
25
36
S2
P4
M1-GND (GRN)
GND2
MOD1 TB2-1 (RED)
T3-H1 (RED)
P10
1
5
L1-H2 (BLK)
BLK
S2
A
TB3-20 (BLU)
B
TB3-21 (GRY)
C
TB3-13 (ORN)
D
TB3-23 (BLK)
E
TB3-18 (VIO)
F
TB3-19 (YEL)
G
TB3-4 (WHT)
H
TB3-14 (BRN)
I
TB3-3 (ORN)
J
TB3-12 (VIO)
K
TB3-22 (WHT)
L
TB3-11 (RED)
M
TB3-2 (GRY)
N
TB3-1 (BRN)
K2-L3 (BLU)
J2
CB1-1 (BLK)
TB2-3 (RED)
M2-4 SPLICE (WHT)
CB2-1 (BLK)
M1-2 (WHT)
MOD1 TB2-2(GRY)
3
J1
*
TB2-1(BLU)
6
2
R1-2 (BLK)
S1-2(YEL)
4
5
1
R7-2 (ORN)
12
F4
12
CB2
12
CB1
MOD1 TB2-1(BLK)*
1
*
GND2 (GRN)
GND
M1
2
CB1-1 (WHT)
*
NC RED
*
FS1C BLK
*
ORN
NO
J4-14(BRN)
J4-13(RED)
6-13
*
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
A
MOD1
T2-AH2
MOVB
T2-BH2
J4-1(BLU)
J4-11(GRY)
X8
X5 J3-1(YEL)
X6 J3-2(YEL)
X7 J4-2(BLU)
X1 J4-10(VIO)
X2 J4-9(VIO)
X3 J4-4(BRN)
X4 J4-3(BRN)
T2-CH2
TB2
SEE
DETAIL
L1
T1
H1
H3
H2
T1
J4-12(BLU)
T3
TB1
MOV1
T3-H1(GRY)
(BLK)
T2
L3
B
K1
SEE
DETAIL
MOD1 BR1-A
(YEL)
T3-H3(GRY)
H7
(VIO)
H6
H5
H4
TOP
L2
ZD1
A
T1
(ORN)
(BRN)
J3-8(WHT)
X14 J3-3(GRY)
X15 J3-4(BLK)
X16 J3-5(GRY)
X12
X13
J4-8(ORN)
X9
X10
X11
J4-7(ORN)
J3-6(WHT)
J3-7(RED)
MOVC
MOV
F4-2(BLU)
T3-H2(BLK)
T3-H3(GRY)
CB2-1(RED)
T3-H4(YEL)
T3-H5(BRN)
T3-H6(ORN)
T3-H7(VIO)
S1-1 (BLU)
BR1
S1-5 (BRN)
Part 2
AH2
SEE T3
DETAIL
T3
BH2
M2
MOD1 BR1-B
SEE DETAIL
MOD1 BR1-C
CH2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
MOV2
MOV3
BLK
BLK
BLK
T2
SPLICE
M2
1
3
2
GRN
6
MOD1 TB2-1(RED)
WHT (INTERNAL)
RED (INTERNAL)
TB2-4 (YEL)
4
CB2-2 (WHT)
BRN (INTERNAL)
H4
H1
S1-6 (RED)
T1-H1 (RED)
TB2-5 (BRN)
H5
T3
TB2-6 (ORN)
SPLICE
TB2-7 (VIO)
H6
H2
H7
H3
TB2-2 (BLK)
TB2-3 (GRY)
T1-H3 (GRY)
6-14
TB2
1
2
3
4
5
6
7
BLK
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
Part 3
MOD1
TB2
CB1-2(GRY)
M1-1(BLK)
2
1
S1-6(RED)
M2-1 SPLICE (RED)
MOD1
MOD1
P4
1
TB3-7(RED)
2
TB3-8(YEL)
3
TB3-9(BLU)
4
TB3-10(ORN)
5
TB3-11(RED)
6
TB3-12(VIO)
7
F3-1(RED)
8
TB3-16(BLK)
9
TB3-18(VIO)
MOD1 P4-7 (RED)
1
2 TB3-15 (RED)
F3
TB4
SEE DETAIL
TB2
TB3
TB3
1
PA
P4
1
2
3
WORK
10
4
5
10 TB3-19(YEL)
TORCH
6
7
J3
8
1
T1-X5(YEL)
2
T1-X6(YEL)
9
3
T1-X14(GRY)
10
4
T1-X15(BLK)
5
T1-X16(GRY)
6
T1-X11(WHT)
1
13
7
T1-X12(RED)
J4
14
8
T1-X13(WHT)
J3
11
1
12
8
15
16
1
T1-X8(BLU)
2
T1-X7(BLU)
3
T1-X4(BRN)
4
18
19
20
21
T1-X3(BRN)
22
5
23
6
7
T1-X10(ORN)
8
T1-X9(ORN)
9
T1-X2(VIO)
10
T1-X1VIO)
11
K1-A(GRY)
12
K1-B(BLU)
13
FS1-NO(RED)
14
FS1-C(BRN)
15
16
16
17
J4
24
REAR VIEW
WITH REAR PANEL
REMOVED
6-15
PLC-0000 (BRN)
J2-N (BRN)
PLC(-24VDC) (GRY)
J2-M (GRY)
J2-I(ORN)
PLC-COMM 2 (ORN)
J2-G(WHT)
PLC-0100 (WHT)
PLC1 J1-5 (BLK)
PLC1 J1-6 (VIO)
MOD1 P4-1(RED)
MOD1 P4-2(YEL)
MOD1 P4-3(BLU)
MOD1 P4-4(ORN)
MOD1 P4-5(RED)
J2-L(RED)
MOD1 P4-6(VIO)
J2-J(VIO)
PCB2 P1-2(ORN)
J2-C(ORN)
PCB2 P1-3(BRN)
J2-H(BRN)
F3-2 (RED)
MOD1 P4-8(BLK)
MOD1 P4-9(VIO)
J2-E(VIO)
MOD1 P4-10(YEL)
J2-F (YEL)
K8-9 (BLU)
J2-A (BLU)
K8-6 (GRY)
J2-B(GRY)
K7-B (WHT)
J2-K(WHT)
K7-A (BLK)
J2-D(BLK)
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
Part 4
PLC1 MODULE
PLC
TB4-1(VIO)
L2
PLC1 J2-1(BLK)
PLC-COMM1(BLK)
TB3-4 (WHT)
TB3-3 (ORN)
J1-M (VIO)
PLC1 J2-7 (BLU)
PLC-COMM4 (BLU)
PLC1 J2-10(RED)
PLC-COMM3 (BLU)
PLC1 J1-1(BRN)
PLC1 J1-2(GRY)
K3-A (VIO)
K4-A (WHT)
K8-A (ORN)
0100
COMM 2
0101
COMM 3
0102
COMM 4
0103
COMM 5
0104
0105
0106
0107
COMM 6
TB5
PCB2-PA(YEL)
PCB2
K2-T1 (YEL)
PA
PLC1 J2-5(RED)
MOD1 SH1-2(BLK)
PCB2 P1-1 (RED)
0108
0109
0110
0111
COMM 7
WORK
PCB2 P1-6 (BLK)
MOD1 TB3-1(BLK)
TORCH
VIEW F-F
J1
L1
J2
1
PLC-0103(BRN)
1
PLC-L2(BLK)
2
PLC-COMM5(GRY)
2
TB4-1 (VIO)
3
TB4-1(VIO)
3
PLC-COMM7(BLU)
4
PLC-0002(WHT)
4
J1-C(ORN)
5
TB3-5 (BLK)
5
TB5-WORK(RED)
6
TB3-6 (VIO)
6
7
7
8
9
PLC-COMM3 (BLU)
8
PLC-0006(ORN)
9
10
J1-N(GRY)
10 PLC-0102(RED)
11 K3-6(WHT)
12 K3-9(ORN)
13 K4-9(GRY)
PLC-COMM 7 (BLU)
J1-D(BLU)
J1-B (YEL)
J1-F (GRY)
J1-J (WHT)
J1-L (BRN)
PLC1 J2-3(BLU)
PLC-COMM 6 (BLU)
14 K4-6(YEL)
15 TB4-2(BRN)
16
TB5-PA(YEL)
0000
0001
HS COMM
0002
0003
0004
0006
COMM 1
+24VDC
-24VDC
PCB2 - P1
P1-1
TB5-WORK(RED)
P1-2
TB3-13(ORN)
P1-3
TB3-14(BRN)
P1-6
TB5-TORCH(BLK)
VIEW E-E
TB3-1 (BRN)
K7-4 (BLU)
PLC-(+24VDC) (VIO)
PLC1 J1-4(WHT)
K5-9 (YEL)
K6-9 (RED)
PLC1 J1-8(ORN)
PLC-L2(BLK)
PLC-HS COMM (VIO)
TB3-2 (GRY)
K7-6 (GRY)
E
J1
L1
L2
0100
COMM 2
0101
COMM 3
0102
COMM 4
0103
COMM 5
0104
0105
0106
0107
COMM 6
0108
0109
0110
0111
COMM 7
PCB2
2
2
BLU
BLU
1
BLU
K8
1
1
1 3
46
7
A9
B
R7
R10
R9
R8
+24VDC
-24VDC
J2
F
1
1
COMM 1
TB5
2
2
0006
0007
BLU
2
0000
0001
HS COMM
0002
0003
0004
BLU
PLC
S2-3 (BLK)
S2-6 (ORN)
F
K6
K7
1 3
46
7
A9
B
1 3
46
79
AB
K5
K4
1 3
1 3
46
7
A9
B
46
7
A9
B
K3
1 3
46
7
A9
B
TB4
PLC1 J2-2(VIO)
R1
PLC1 J2-15(BRN)
K3-B(BRN)
PLC-L1(VIO)
K5-6(VIO)
K4-B(BRN)
1
2
TB4
K6-6(VIO)
K5-B(BRN)
PLC1 J1-3(VIO)
K6-B(BRN)
K8-B (BRN)
K4
K3
1 3
4 6
7 9
A B
1 3
4 6
7 9
A B
1 3
4 6
7 9
A B
6-16
PLC1 J2-11(WHT)
K5
1 3
4 6
7 9
A B
TB4-2(BRN)
K6
TB4-2(BRN)
PLC1 J2-13(GRY)
PLC1 J2-14(YEL)
PLC-0104 (VIO)
J1-K (YEL)
ZD3
TB3-22 (WHT)
TB3-23 (BLK)
PLC-0001 (BLU)
TB4-2(BRN)
TB3-20 (BLU)
TB3-21 (GRY)
PLC-0106 (ORN)
1 3
4 6
7 9
A B
TB4-2(BRN)
PLC-0003 (YEL)
TB4-1(VIO)
PLC-0105 (WHT)
K7
1 3
4 6
7 9
A B
TB4-2(BRN)
PLC-0004 (RED)
TB4-1(VIO)
J1-G (BLK)
K8
PLC1 J2-12(ORN)
T2
PLC-(-24VDC) (GRY)
MOD1 SH1-1 (GRY)
E
SECTION 6
TROUBLESHOOTING
Wiring Diagram – Precision Plasma Power Source
Part 5
MOD1
P3
P1
P2
PCB1 P4-3(RED)
1
1
PCB1 P1-16(VIO)
1
R10-1 (GRY)
2
PCB1 P4-4(YEL)
2
2
PCB1 P1-15(BLU)
2
TB5-WORK(BLK)
3
PCB1 P4-15(BLU)
3
3
PCB1 P3-12(ORN)
4
PCB1 P4-16(ORN)
4
4
PCB1 P3-13(WHT)
5
TB6-6(BRN)
5
5
PCB1 P1-13(BLK)
6
TB6-8(GRY)
6
6
PCB1 P1-14(RED)
7
PCB1 P4-11(RED)
7
7
PCB1 P3-18(BLU)
8
PCB1 P4-12(BLK)
8
9
PCB1 P4-13(VIO)
8
PCB-TB P1-1(YEL)
10 PCB1 P4-14(YEL)
9
R2-1(ORN)
NOT USED
S3-4(BLU)
10
11
12
13
14 PCB1 P9-1(RED)
15 PCB1 P9-3(BLK)
16
R3
PCB1 P7-3(RED)
MOD1-TB3-1 (RED)
R4
1 2 3 4 5 6 7 8
MOD1 P3-6(GRY)
S3-6(GRY)
S3-3(ORN)
R5
R6
MOD1 P3-5(BRN)
C2-2 (WHT)
TB5-PA (YEL)
C2-1 (YEL)
TB6
MOD1
WHT
T1
T2
T3
P1
8
P1
1
K2
ZD2
A
L1
L2
L3
B
1
P3
1
K2-L3 (BLU)
16
L1-H1 (BLU)
PLC1 P2-10 (RED)
SEE DETAIL
S2-2 (BLU)
1 23 4567 8
C1-1 (BLU)
PLC1 P2-9 (VIO)
WHT
TB6
P3
1
PCB1 P2-15(YEL)
2
PCB1 P2-16(YEL)
3
PCB1 P2-8(GRY)
4
PCB1 P2-9(RED)
5
PCB1 P2-10(GRY)
6
PCB1 P10-4(WHT)
7
PCB1 P10-3(BLK)
8
PCB1 P10-5(WHT)
P4
1
PCB1 P2-14(BLU)
16
2
PCB1 P4-1(BRN)
2
PCB1 P4-2(GRY)
3
PCB1 P4-7(YEL)
1
P4-10(VIO)
PLC1 P2-7 (VIO)
2
P4-9(VIO)
1
4
PCB1 P4-10(WHT)
3
P4-2(BLU)
5
PCB1 P5-1 (BLK)
4
P4-1(BLU)
6
PCB1 P5-2(VIO)
PLC1 P2-15(BLU)
7
5
8
6
9
7
10
8
9
PCB1 P7-1(BLK)
PLC1 P2-1 (VIO)
2
R11
1
2
SH1
K2-T1(YEL)
K2-T3(WHT)
R14-1 (GRY)
TB6-2(RED)
TB5-TORCH(BLK)
1
D1
8
R15-2 (RED)
1
PLC MOD
P3
PLC1 P2-9 (VIO)
PCB1 P4-9(YEL)
PCB1 P4-8(ORN)
R13
P2
P1
1
C1
16
PLC1 MODULE
1
R12
C2
10
P2
SH1
1
1
P2
TB3
8
1
P4
PLC1 P2-4(BLU)
MOD1 TB3-1 (RED)
2
2 R15
1
PLC1 P2-2 (VIO)
R14 1
PCB1 P2-13(BLU)
PLC1 P2-3(BLU)
D1(-) GRY
3
PCB1 P2-12(BRN)
4
PCB1 P2-11(BRN)
5
K2-A (VIO)
6
10 K2-B(RED)
7
11 PCB1 P1-7(WHT)
12 PCB1 P1-8(ORN)
13 PCB1 P1-9(GRY)
PCB1 P2-5(ORN)
8
PCB1 P2-4(ORN)
9
PCB1 P2-2(VIO)
10
PCB1 P2-1(VIO)
11
PCB1 P3-1(GRY)
12
PCB1 P3-2(BLU)
13
PCB1 P1-3(RED)
14
PCB1 P1-2(BRN)
PLC1 P2-2(VIO)
14 PCB1 P1-10(YEL)
15 PLC1 P2-4(BLU)
PLC1 P2-1(VIO)
16
FRONT VIEW
WITH FRONT
PANEL REMOVED
6-17
15
16
SECTION 6
TROUBLESHOOTING
6.11 Schematic- Precision Plasma Power Source
Part 1
P2 J2
1
2
3
4
15
460V
H5
5
415V
H4
4
380V
H3
3
230V
H2
2
200V
H1
1
11
P3-1
12
P3-2
13
P1-3
14
15
16
J4 P4
P1-2
TB2
1 F4 2
1 5A
NC
NO FS1
2
3
FNT PNL
ON/OFF
1
S1
LED2
LED5
LED8
LED3
LED6
LED9
M1
5
P7-3
6
PLASMA GAS
P1-10
14
11
P1-8
START GAS
PLC1
PLC MODULE #1
12
13
P1-9
AM1
AMMETER
V1
VOLTMETER
P1 J1
7
9
10
1
2
3
P4-9
P4-1
P4-2
P4-7
1
120VAC
A K1 B
T2
CH7
CH8
575V
460V
415V
380V
MOV2
230V
610V
200V
18
17
16
15
14
13
MOV3
5
L2 T2
P4-8
P4-10
P5-1
P1-12
P5-2
P1-11
CH5
CH4
CH3
CH2
460V
415V
380V
230V
200V
12
11
10
9
8
7
BH6
BH5
BH4
BH3
BH1
AH8
575V
460V
415V
380V
230V
200V
6
5
4
3
2
1
TB1
Z D 2
180V AC
A
B
K2
L1
T1
6
PCB TRIM POT
1 838193
AH6
AH5
AH4
NOT USED ON
PRECISION PLASMA CONSOLE
J2
P1
1 2 3 4 5 6 7 8
L2
T2
L3
T3
120VAC RELAY
P3-17(+)
P9-3
P9-1
P1-14
P1-13
P3-13
P3-12
P1-15
P1-16
BH2
AH7
L1 T1 610V
6
P4-14
P4-13
P4-12
P4-11
P10-1
P10-2
P4-16
P4-15
P4-4
P4-3
P3-18(-)
MOV1
ØA
5
CH1
BH8
575V
8
4
P1-18
P1-17
BH7
610V
ØB
CH6
3
1 2 3 4 5 6 7 8 9 10
6
1
P3
P4
AH3
10
AH2
9
AH1
8
TB2-2
TB2-1
BR1-A
BR1-B
BR1-C
7
6
5
MOD1
POWER MODULE #1
4
3
2
1
SH1-2
SH1-1
TB3-1
6-18
R11
10K
8W
FRONT PNL LOCAL
CURRENT SETTING POT
R2
10K
MIN
MAX
1 3
2
R3
R4
4.99K 4.99K
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C2
20uf
400V
T B 6 -8
L3 T3
AUTO XFMR
ØC
T B 6 -7
4
6
P7-1
P1-7
CB1
1 3A 2
2
ZD1,180V
LED7
C
6
5
LED4
8
10
T B 6-6
2
LED1
9
P 1 -5
P 1 -6
H6
6
PCB1
ISOLATION AMPLIFIER AND
FAULT SIGNAL PCB
38103
P10-5
18VAC
P10-3
18VAC
P10-4
P2-10
18VAC
P2-9
18VAC
P2-8
P2-16
24VAC
P2-15
P2-14
24VAC
P2-13
P2-12
24VAC
P2-11
P2-7
P2-6
P2-5
12VAC
P2-4
P2-2
120VAC
P2-1
P6
575V
8
7
6
5
4
3
2
1
+
+
H7
1
7
1
T3
7
J3 P3
P8
CB2
7A
2
T1
X13
X12
X11
X16
X15
H7 X14
X6
H6 X5
X8
1
H5 X7
2
X4
3
H4 X3
4
5
H3
6
X10
7
H2 X9
8
X2
9
H1 X1
10
+
+
PUMP
MOTOR
M2
1
4
4
FRONT PNL
CURRENT
SETTING
LOCAL/REMOTE
DPDT S3
5
SECTION 6
TROUBLESHOOTING
Schematic- Precision Plasma Power Source
Part 2
CNC
I/O
P2 J2
1
2
3
4
15
TB4-1
TB4-2
J1
7
9
A
8
B
EFC
10
C
Ref. 6.4
P5
D
E
1
0001 2
HSCOMM 3
0002 4
0003 5
0004 6
7
0006 8
0007 9
10
11 PLC
12
13
14
15
16
17
COMM1 18
19
20
21
22
24VDC 23
-24VDC 24
0000
5
6
14
11
9
6
A
13
K3
9
6
A
K4
B
K5
B
9
6
A
9
P1 J1
B
6
A
K6
ZD3
180VAC
A
K7
B
4
6
F
5
S
6
T
7
U
8
JUNCTION
BOX
Ref. 6.7
V
J2
TB3
N START SIGNAL FROM
M CNC TO P.S., RELAY CLOSING
1
2
I ARC ON SIGNAL FROM P.S.
G TO CNC, RELAY CLOSING
ARC ON SIGNAL
FROM P.S. TO CNC,
TRANSISTOR
START SIGNAL FROM
CNC TO P.S., 120VAC
3
4
7
8
6
START SIGNAL FROM
CNC TO P.S., 24VAC
10
12
L +10VDC REMOTE CURRENT
J SETTING FROM CNC TO P.S.
13
C VOLTAGE DIVIDER, (+)
14
H VOLTAGE DIVIDER, (-)
11
PLC1
PLC MODULE #1
6
F3 2
1
P7-3
PCB
Isolation Amplifier And
Fault Signal PCB
15
1A
TO CUTTING MACHINE CNC
CONNECTOR CHASSIS GND SUPPLIED
BY CUTTING MACHINE GROUP
16
17
E EMERGENCY STOP FROM CNC TO P.S.
RELAY/CONTACTOR NORMALLY CLOSED
F OPEN IN CASE OF EMERGENCY
A FAULT SIGNAL FROM P.S. TO CNC
B RELAY CLOSING, DRY CONTACT
18
19
K2
5
R
120VAC RELAY
A
10
P
UNUSED
CIRCUITS
9
8
4
9
H.F.
N
B
B
4
M
6
K8
3
L
5
A
2
J
K
7
9
10
1
2
3
9
1
H
H.F.
1
5
2
3
4
P2
G
B
TB6-5
R6
39K
2W TB6-4
R5
39K
2W TB6-2
120VAC RELAY
20
21
22
K 120VAC PREFLOW SIGNAL
D FROM CNC TO P.S.
23
24
FRONT PNL
PILOT ARC
SELECTOR
S2 6
5 HI
4
H2
L1
H1
R7
20 OHM 300W
R8
20 OHM
300W
3 R1
2
R7
10K
OHM
20uf
400V 8W
LO
20 OHM 300W
R9
1
C1
D1
10
9
R14
20 OHM
50W
8
7
MOD1
POWER MODULE #1
R7
10K
OHM
8W
6
R15
20 OHM
50W
5
4
3
2
1
SH1-2
SH1-1
TB3-1
6-19
20 OHM 300W
P1-1
P1-2
START UP
PA
PCB2
P1-3
838131
P 1 -6
12
1 L 1
2 L 2
3
4
5
6
7 01 00
8 COMM2
9 01 01
10 COMM3
11 0 1 0 2
12 COMM4
13 0 1 0 3
14 COMM5
15 0 1 0 4
16 0 1 0 5
17 0 1 0 6
18 0 1 0 7
19 COMM6
20 0 1 0 8
21 0 1 0 9
22 0 1 1 0
23 0 1 1 1
24 COMM7
J1
A
B
C
D
E
F
G
H
J
K
L
M
N
I
R10
3.1 OHM
300W
WORK
TO JUNCTION BOX J1
PILOT ARC
TORCH
SECTION 6
TROUBLESHOOTING
6.12 Technical Guide To Using And
Understanding The Operation Of The
Electronic Flow Control
Introduction
The following information is a guide for
troubleshooting The Precision Plasma Electronic
Flow Control. Knowledge of machine and control
operation is required.
6-20
SECTION 6
TROUBLESHOOTING
6.12.1 Precision Process Timers
Timer
Description
Plasma Preflow Time
The minimum interval of time between the receipt of a
plasma process start signal and the issuance of the signal
to turn the plasma power supply on. Plasma process start
gas flows are in effect during this time.
Line Purge Time
The interval of time allowed to purge the plasma process
gas lines. Plasma process purge/fill gas flows are in effect
during this time.
Plasma Firing Time
The maximum interval of time allowed for receipt of an arcon signal from the issuance of the signal to turn the plasma
power supply on. Plasma process start gas flows are in
effect during this time.
Plasma Pierce Time
The interval of time allowed for piercing the work piece
after receipt of the arc-on signal. Plasma process cut gas
flows are in effect during this time. (Torch stationary, AHC
disabled, machine stationary).
Plasma AHC Delay
The interval of time allowed after expiration of the PLASMA
PIERCE TIME timer before enabling AHC. Plasma process
cut gas flows are in effect during this time. (Torch
stationary, AHC disabled, machine moving).
Plasma Arc Delay
The interval of time for filtering the arc-on signal to allow
the signal to assume a stable mode / condition. Plasma
process cut gas flows are in effect during this time.
Master Up
The interval of time allowed to raise the plasma torch after
receipt of a plasma process off signal. Plasma process
start gas flows are in effect during this time.
Analog Channel Disable
The interval of time allowed before enabling the plasma
process idle flow analog values. Plasma process start gas
flow analog values are in effect during this time.
Line Fill Time
The interval of time allowed to fill the plasma process gas
lines. Plasma process purge/fill gas flows are in effect
during this time.
Plasma Postflow
The interval of time allowed for plasma process gases to
flow after expiration of the MASTER UP timer. Plasma
process start gas flows are in effect during this time.
Line Vent Time
The interval of time allowed to vent the plasma process
gas lines. Plasma process idle gas flows are in effect
during this time.
Flow Control Vent Time
The interval of time allowed to vent the flow control gas
lines. Plasma process purge/fill gas flows are in effect
during this time.
6-21
SECTION 6
TROUBLESHOOTING
6.12.2 Process Timer Values For Vision Cutting Record File PARAM.CUT
Vision Interpretation Data File DEF.TEC
V
(Hidden Flag)
DEF .TEC
Qx
(Upper Editing
Limit)
Ux
(Lower Editing
Limit)
Wx
(Preset Value)
PARAM.CUT
V = Hidden Flag Enabled
TIMERS
Plasma Preflow Time
0.6
0.5
50.0
V
Line Purge Time
1.0
1.0
50.0
V
Plasma Firing Time
6.0
4.0
6.0
V
Plasma Pierce Time
0.0
0.0
50.0
Plasma Ahc Delay
0.0
0.0
50.0
Plasma Arc Delay
0.3
0.0
0.5
Master Up
2.0
0.0
50.0
600.0
600.0
600.0
V
Line Fill Time
5.0
5.0
50.0
V
Plasma Postflow
5.0
5.0
50.0
V
Line Vent Time / Flow Control Vent Time
2.0
2.0
50.0
V
Analog Channel Disable
6-22
V
SECTION 6
TROUBLESHOOTING
6.12.3 Process Window Key Functions
Key Function
Description
•
Plasma AHC Allow Icon
•
•
(F2 Push-Button)
•
•
Plasma AHC Icon
•
(F3 Push-Button)
•
Icon permits the machine operator to allow or
disallow plasma AHC.
Icon does not turn plasma AHC on.
Plasma AHC is allowed if the icon is highlighted
(darkened).
Plasma AHC is not allowed if the icon is not
highlighted.
Icon permits machine operator to manually turn
plasma AHC on or off.
Icon also permits the operator to perform a
plasma IHS cycle if the plasma process is not
active.
The plasma AHC allow icon must be highlighted.
highlighted
Plasma Start Parameter Test Icon
•
Icon permits the machine operator to manually
test/adjust the plasma process start parameters
with the exception of the plasma gas 2 start flow.
•
Icon permits the machine operator to manually
test/adjust the plasma gas 2 start flow.
The plasma start parameter test icon must be
highlighted.
highlighted
(F4 Push-Button)
Plasma Gas 2 Test Icon
•
(F5 Push-Button)
Plasma Cut Parameter Test Icon
•
•
Icon permits the machine operator to manually
test/adjust the plasma process cut parameters.
The plasma start parameter test icon must be
highlighted.
highlighted
(F6 Push-Button)
Plasma Start Icon
•
•
(F6 Push-Button)
6-23
Icon permits the machine operator to manually
start or stop the plasma process.
The plasma start parameter test icon must not be
highlighted.
highlighted
SECTION 6
TROUBLESHOOTING
6.12.4 Proportional Valve Analog Flow Values
For Param.Cut And Def.Tec
Analog Flow Values
Jx
(Upper
Channel Limit)
Ix
(Lower
Channel Limit)
Yy
(Upper
Parameter
Limit)
Xx
(Lower
Parameter
Limit)
V
(Hidden Flag)
DEF.TEC
Qx
(Upper Editing
Limit)
Ux
(Lower Editing
Limit)
Wx
(Preset Value)
PARAM.CUT
V = Hidden Flag Enabled
Plasma Gas 1 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 1 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 2 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 2 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 1 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 1 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 2 Start Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Shield Gas 2 Cut Flow Analog Out
0.0
0.0
100.0
0.0
100.0
0.0
255.0
Plasma Gas 1 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Plasma Gas 1 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Plasma Gas 1 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Plasma Gas 2 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Plasma Gas 2 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Plasma Gas 2 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Shield Gas 1 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Shield Gas 1 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Shield Gas 1 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
Shield Gas 2 Soft Flow Analog Out
10.0
10.0
10.0
V
0.0
100.0
0.0
255.0
Shield Gas 2 Purge/Fill/Vent Flow
Analog Out
100.0
100.0
100.0
V
0.0
100.0
0.0
255.0
Shield Gas 2 Idle Flow Analog Out
0.0
0.0
0.0
V
0.0
100.0
0.0
255.0
6-24
SECTION 6
TROUBLESHOOTING
6.12.5 Process Gas Selection Requirements
•
Plasma process gas selection is accomplished
with activation of the appropriate SDP file.
•
The correct CUTTING RECORD FLAG must be in
each SDP file.
•
Selection is keyed to the value in the CUTTING
RECORD FLAG.
•
Please refer to the ATAS description of the
cutting package for a detailed explanation of The
cutting record flag.
Material Type
Plasma Gas
Shield Gas
Abbreviation
Cutting Record Flag
Carbon steel
O2
N2
CS1-O2-N2
M1000000000000000
Carbon steel
O2
N2 with O2 mix
CS2-O2-N2/O2
M0100000000000000
Carbon steel
O2
O2
CS3-O2-O2
M0000000000010000
Stainless steel
N2
N2
SS1-N2-N2
M0010000000000000
Stainless steel
N2
N2 with CH4 mix
SS2-N2-N2/CH4
M0001000000000000
Stainless steel
Air
Air
SS4-Air-Air
M0000010000000000
Stainless steel
Air
Air with CH4 mix
SS5-Air-Air/CH4
M0000001000000000
Aluminum
N2
N2
Al1-N2-N2
M0000000010000000
Aluminum
N2
N2 with CH4 mix
Al2-N2-N2/CH4
M0000000001000000
Plasma marking
Argon
Air
PM1-Argon-Air
M0000000000100000
6-25
SECTION 6
TROUBLESHOOTING
6.12.6 EFC Process Gas Flow Chart
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
Error
condition?
yes
no
no
Line fill
4
Station on?
no
no
yes
ready
5
Plasma stop
7
yes
Plasma
test?
10
yes
Error
condition?
yes
no
yes
yes
no
no
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-26
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
no
Station on?
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
no
yes
no
SECTION 6
TROUBLESHOOTING
Finish
16 Milliseconds
0.5 Seconds
1.0 Second
0.5 Seconds
1.5 Seconds
2.0 Seconds
Start
16 Milliseconds
6.12.7..Station On, Flush/Pressurize Cycle
PG-N2,O2 SG-N2
X = OPEN / ENABLED, BLANK = CLOSED / DISABLED,
ANALOG VALUE = 0 - 10 VDC
SOLENOID VALVES
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
Plasma Gas 2 Torch Solenoid Valve
Shield Gas 1 Torch Solenoid Valve
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
Shield Gas 1 Cut Flow Analog Out
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Idle Flow Analog Out
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
6-27
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
(O2)
Test (Start)
Process Post
Flow
Process
Cut
Process
Start
Ready
Line
Fill
Line
Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓
Test (Cut)
6.12.8 Solenoid And Proportional Valve Requirements
Carbon Steel PG-O2, SG-N2
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
SOLENOID VALVES
X
Plasma Gas 1 Supply Solenoid Valve N2-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
X
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
X
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
X
X
X
Plasma Gas 2 Cut Flow Analog Out
X
Shield Gas 1 Start Flow Analog Out
X
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
6-28
SECTION 6
TROUBLESHOOTING
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
O
X
X
X
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
Station on?
Error
condition?
yes
yes
no
no
4
Station on?
no
no
yes
ready
5
no
7
Plasma stop
New SDP file
selected?
Error
condition?
no
Plasma
test?
10
yes
yes
no
no
yes
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
Station on?
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
Plasma test
(start O2)?
no
no
Station on?
yes
yes
yes
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-29
Plasma
test cut?
no
Test (start O2)
yes
no
yes
Plasma test?
yes
Plasma test
(start O2)?
yes
no
New
SDP file
selected?
no
yes
Station on?
yes
yes
yes
no
no
Station on?
yes
yes
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
no
yes
no
yes
Station on?
New
SDP files
selected?
no
yes
Line fill
Test (cut)
yes
yes
no
no
Station on?
yes
no
12
13
Idle (Station
Off)
Test (Cut)
Test (Start)
(O2)
Test (Start)
Process
Post Flow
Process Cut
Ready
Process Start
X
1
Vision Shift/Start
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Fill
Line Purge
Flow Control Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓
Idle (Station
On)
6.12.9 Gas Error Monitoring
Carbon Steel PG-O2, SG-N2
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
Off)
11
Test (Cut)
Test (Start)
(O2)
Test (Start)
Process Post
Flow
Process
Cut
Process
Start
Ready
Line
Fill
Line
Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓
Idle (Station
On)
6.12.10
Solenoid And Proportional Valve Requirements
Carbon Steel PG-O2, SG-N2/O2
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
SOLENOID VALVES
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Supply Solenoid Valve O2-2
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve O2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
X
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
X
X
X
Plasma Gas 2 Cut Flow Analog Out
X
Shield Gas 1 Start Flow Analog Out
Shield Gas 1 Cut Flow Analog Out
X
X
Shield Gas 2 Start Flow Analog Out
X
X
X
X
X
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
6-30
X
SECTION 6
TROUBLESHOOTING
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
Shield Gas 2 Pressure Switch
X
X
O
X
X
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
no
Plasma stop
yes
yes
7
yes
yes
Plasma test
(start O2)?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-31
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
no
Station on?
yes
Plasma test?
Plasma test
cut?
no
New SDP file
selected?
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
Station on?
no
yes
no
12
13
Idle (Station
Off)
Test (Cut)
Test (Start)
(O2)
Test (Start)
Process
Post Flow
Process Cut
Process Start
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Ready
Line Fill
Line Purge
Line Vent
Flow Control Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓
Idle (Station
On)
6.12.11
Gas Error Monitoring
Carbon Steel PG-O2, SG-N2/O2
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
(O2)
Test (Start)
Process Post
Flow
Process
Cut
Process
Start
Ready
Line
Fill
Line
Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓
Test (Cut)
6.12.12
Solenoid And Proportional Valve Requirements
Carbon Steel PG-O2, SG-O2
X = Open / Enabled, Blank = Closed / Disabled,,
Analog Value = 0 - 10 Vdc
SOLENOID VALVES
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Supply Solenoid Valve O2-2
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve O2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
X
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
X
X
X
Plasma Gas 1 Cut Flow Analog Out
Plasma Gas 2 Start Flow Analog Out
X
X
X
Plasma Gas 2 Cut Flow Analog Out
X
Shield Gas 1 Start Flow Analog Out
Shield Gas 1 Cut Flow Analog Out
X
X
Shield Gas 2 Start Flow Analog Out
X
X
X
X
X
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
X
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
X
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
Shield Gas 2 Soft Flow Analog Out
X
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
6-32
X
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
Shield Gas 2 Pressure Switch
X
X
O
X
X
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
no
Plasma stop
yes
yes
7
yes
yes
Plasma test
(start O2)?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-33
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
no
Station on?
yes
Plasma test?
Plasma test
cut?
no
New SDP file
selected?
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
Station on?
no
yes
no
11
12
13
Idle (Station
Off)
Test (Start)
(O2)
Test (Start)
Process
Post Flow
Process Cut
Process Start
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Ready
Line Fill
Line Purge
Flow Control Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓
Line Vent
6.12.13
Gas Error Monitoring
Carbon Steel PG-O2, SG- O2
Idle (Station
On)
TROUBLESHOOTING
Test (Cut)
SECTION 6
SECTION 6
TROUBLESHOOTING
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.14
Solenoid And Proportional Valve Requirements
Stainless Steel PG-N2, SG-N2
X = OPEN / ENABLED, BLANK = CLOSED / DISABLED,
ANALOG VALUE = 0 - 10 VDC
Solenoid Valves
Plasma Gas 1 Supply Solenoid Valve N2-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve CH4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-34
12
13
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Fill
Line Purge
Flow Control
Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Line Vent
6.12.15
Gas Error Monitoring
Stainless Steel PG-N2, SG-N2
Idle (Station
On)
TROUBLESHOOTING
Test (Cut)
SECTION 6
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
yes
yes
no
yes
yes
Plasma test
(start O2)?
no
New SDP file
selected?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-35
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
7
Station on?
yes
Plasma test?
Plasma test
cut?
Plasma stop
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
Station on?
11
no
yes
no
SECTION 6
TROUBLESHOOTING
SOLENOID VALVES
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.16
Solenoid And Proportional Valve Requirements
Stainless Steel PG-N2, SG-N2/CH4
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve CH4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-36
X
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
On)
Idle (Station)
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
X
X
O
X
X
Shield Gas 2 Pressure Switch
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.17
Gas Error Monitoring
Stainless Steel PG-N2, SG-N2/CH4
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-37
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
11
no
yes
no
SECTION 6
TROUBLESHOOTING
Solenoid Valves
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.18
Solenoid And Proportional Valve Requirements
Stainless Steel PG-Air, SG-Air
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-38
SECTION 6
TROUBLESHOOTING
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
O
12
13
Idle (Station
On)
Idle (Station)
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.19
Gas Error Monitoring
Stainless Steel PG-Air, SG-Air
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
yes
New SDP file
selected?
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-39
Plasma
test cut?
no
yes
no
Analog
disable
timing?
no
Plasma test?
yes
Plasma test
(start O2)?
yes
yes
New
SDP file
selected?
no
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
11
no
yes
no
SECTION 6
TROUBLESHOOTING
Solenoid Valves
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.20
Solenoid And Proportional Valve Requirements
Stainless Steel PG-Air, SG-Air/CH4
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-40
X
12
13
Idle (Station)
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Purge
Flow Control
Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Line Vent
6.12.21
Gas Error Monitoring
Stainless Steel PG-Air, SG-Air/CH4
Idle (Station
On)
TROUBLESHOOTING
Test (Cut)
SECTION 6
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
yes
yes
no
yes
yes
Plasma test
(start O2)?
no
New SDP file
selected?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-41
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
7
Station on?
yes
Plasma test?
Plasma test
cut?
Plasma stop
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
Station on?
11
no
yes
no
SECTION 6
TROUBLESHOOTING
Solenoid Valves
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.22
Solenoid And Proportional Valve Requirements
Aluminum PG-N2, SG-N2
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
Plasma Gas 2 Soft Flow Analog Out
X
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
X
Plasma Gas 2 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-42
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
12
13
Idle (Station)
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Purge
Flow Control
Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Line Vent
6.12.23
Gas Error Monitoring
Aluminum PG-N2, SG-N2
Idle (Station
On)
TROUBLESHOOTING
Test (Cut)
SECTION 6
X
X
O
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
Station on?
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
Plasma stop
yes
yes
7
yes
yes
Plasma test
(start O2)?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-43
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
no
Station on?
yes
Plasma test?
Plasma test
cut?
no
New SDP file
selected?
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
no
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
no
11
no
yes
no
SECTION 6
TROUBLESHOOTING
Solenoid Valves
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.24
Solenoid And Proportional Valve Requirements
Aluminum PG-N2, SG-N2/CH4
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
X
X
X
X
X
X
X
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
X
X
X
X
X
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-44
X
SECTION 6
TROUBLESHOOTING
12
13
Idle (Station
On)
Idle (Station)
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.25
Gas Error Monitoring
Aluminum PG-N2, SG-N2/CH4
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
X
X
Shield Gas 2 Pressure Switch
O
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
4
Station on?
no
no
yes
ready
5
no
Plasma stop
yes
yes
no
yes
yes
Plasma test
(start O2)?
Plasma
test?
10
no
Error
condition?
no
yes
yes
no
yes
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-45
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
no
7
Station on?
yes
Plasma test?
Plasma test
cut?
no
New SDP file
selected?
no
yes
no
Station on?
yes
yes
no
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
yes
Station on?
Test (cut)
no
yes
yes
Line fill
Station on?
yes
yes
no
Station on?
no
yes
no
SECTION 6
TROUBLESHOOTING
Solenoid Valves
11
12
13
Idle (Station
On)
Idle (Station
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
6.12.26
Solenoid And Proportional Valve Requirements
Marking PG-Argon, SG-Air
X = Open / Enabled, Blank = Closed / Disabled,
Analog Value = 0 - 10 Vdc
X
Plasma Gas 1 Supply Solenoid Valve N2-2
Plasma Gas 1 Supply Solenoid Valve Air-2
Plasma Gas 1 Supply Solenoid Valve Argon
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Supply Solenoid Valve O2-2
Shield Gas 1 Supply Solenoid Valve O2-1
Shield Gas 1 Supply Solenoid Valve N2-1
X
Shield Gas 1 Supply Solenoid Valve Air-1
Shield Gas 2 Supply Solenoid Valve N2-3
X
Shield Gas 2 Supply Solenoid Valve Ch4
Plasma Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Torch Solenoid Valve
X
X
Shield Gas 1 Torch Solenoid Valve
X
X
X
X
X
X
X
X
X
Shield Gas 2 Torch Solenoid Valve
X
X
X
X
X
Analog Flow Values
Plasma Gas 1 Start Flow Analog Out
X
X
Plasma Gas 1 Cut Flow Analog Out
X
X
Plasma Gas 2 Start Flow Analog Out
Plasma Gas 2 Cut Flow Analog Out
Shield Gas 1 Start Flow Analog Out
X
Shield Gas 1 Cut Flow Analog Out
X
X
X
X
X
Shield Gas 2 Start Flow Analog Out
Shield Gas 2 Cut Flow Analog Out
Plasma Gas 1 Soft Flow Analog Out
Plasma Gas 1 Purge/Fill/Vent Flow Analog Out
Plasma Gas 1 Idle Flow Analog Out
X
X
X
X
X
X
X
X
X
X
X
X
Plasma Gas 2 Soft Flow Analog Out
Plasma Gas 2 Purge/Fill/Vent Flow Analog Out
Plasma Gas 2 Idle Flow Analog Out
X
X
Shield Gas 1 Soft Flow Analog Out
Shield Gas 1 Purge/Fill/Vent Flow Analog Out
Shield Gas 1 Idle Flow Analog Out
X
X
X
X
Shield Gas 2 Soft Flow Analog Out
Shield Gas 2 Purge/Fill/Vent Flow Analog Out
Shield Gas 2 Idle Flow Analog Out
X
X
X
6-46
SECTION 6
TROUBLESHOOTING
Plasma Gas 2 Pressure Switch
O
O
Shield Gas 1 Pressure Switch
O
Shield Gas 2 Pressure Switch
O
12
13
Idle (Station
On)
Idle (Station)
Off)
Test (Start)
Process Post
Flow
Process Cut
Process Start
Ready
Line Fill
11
X = Monitored For Pressure Present,
O = Monitored For Absence Of Pressure
X
X
Process Gas Pressure Switches
Plasma Gas 1 Pressure Switch
Line Purge
Flow Control
Vent
Line Vent
➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒
Test (Cut)
Gas Error Monitoring --Marking PG-Argon, SG-Air
X
X
1
Vision Shift/Start
Numbers
Line vent
Flow control vent
2
Idle (Station off)
13
#
correspond to columns on solenoid/
proportional valve requirement charts
and gas error monitoring charts
9
no
Station
on?
Test (start)
11
yes
Section 6.7.7
for details
Line Purge
6
Process start.
Station on Flush/
Pressure cycle
Plasma
stop?
3
no
yes
Error
condition?
no
no
Line fill
4
Station on?
no
no
yes
ready
5
no
Plasma stop
no
Plasma
test?
10
yes
no
Error
condition?
no
yes
yes
no
yes
yes
Plasma test
(start O2)?
Station on?
no
Plasma
start?
yes
8
no
Process
Postflow
Test (start O2)
Station on?
New
SDP file
selected?
no
Plasma test?
yes
no
Analog
disable
timing?
no
yes
New SDP file
selected?
Plasma test
cut?
yes
no
no
12
Idle (Station On)
Station on?
no
no
no
Station on?
yes
yes
yes
Plasma test
(start O2)?
New SDP file
selected?
no
Plasma
test?
yes
no
Plasma
start?
no
yes
6-47
Plasma
test cut?
no
yes
yes
New
SDP file
selected?
no
Plasma test?
yes
yes
no
New SDP file
selected?
no
yes
yes
no
7
Station on?
yes
yes
Station on?
yes
yes
no
Plasma test?
Plasma test
cut?
Arc
established
?
yes
Process cut
New
SDP files
selected?
yes
no
yes
Station on?
Test (cut)
no
yes
yes
Station on?
yes
yes
no
Station on?
no
yes
no
SECTION 6
TROUBLESHOOTING
This page intentionally left blank.
6-48
SECTION 7
REPLACEMENT PARTS
7.1 General
Always provide the serial number of the unit on
which the parts will be used. The serial number is
stamped on the unit nameplate.
7.2 Ordering
To ensure proper operation, it is recommended that
only genuine ESAB parts and products be used
with this equipment. The use of non-ESAB parts
may void your warranty.
Replacement parts may be ordered from your
ESAB Distributor or from:
ESAB Welding and Cutting Products
ATTN: Customer Service Department
PO Box 100545 Ebenezer Road
Florence, SC USA 29501-0545
Phone (843) 664-4405
(800) ESAB-123 (372-3123)
ESAB Cutting Systems - Canada
6010 Tomken Road
Mississauga, Ontario, Canada L5T 1X9
Phone (905) 670-0220
Fax
(905) 670-4879
ESAB_HANCOCK GmbH
Cutting Technologies
P.O. Box 1128
D-61174 Karbon
Robert-Bosch-Strasse 20
D-61184 Karbon
Phone + 49 60 39 40-0
Fax
+49 60 39 40 301+302
http://www.esab.de
Be sure to indicate any special shipping instructions
when ordering replacement parts.
Refer to the Communications Guide located on the
last page of this manual for a list of customer
service phone numbers.
7-1
SECTION 7
REPLACEMENT PARTS
7.3 Plasmarc Power Source-Exterior Components
1
3
2
6
8
4
5
7
7-2
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
A-995227
Label Warning-Exposed High Volt
3
B-2091514
Label Warning
4
A-34941
5
A-13734588
Logo ESAB Clear
6
C-35924YL
Panel Right Side
7
D-35923YL
Panel Left Side
8
61328087
Screw, HMH ¼-20 X .50 L
Cover-Top
D-35925YL
Lens Clear
7-3
SECTION 7
REPLACEMENT PARTS
6
5
4
3
2
1
7
8
9
11
10
See
"TEE"
Detail
Page 7-12
7-4
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
A-8672508
Symbol
(Elec-Ay)
S1
Description
Switch Toggle 2PST 2 Pos 15A
2
A-8634518
S2,3
Switch Toggle DPDT 2 Pos 15A
3
A-8951061
AM1,VM1
Meter LED 5VDC
4
A-8951061
AM1,VM1
Meter LED 5VDC
5
A-8634518
S2,3
6
A-2234589
R2
7
B-954751
8
D-32286GY
Panel Front
9
A-8598481
Gauge 200 PSI
10
C-952182
Spout Remote Filler w/Cap
11
C-36346GY
Switch Toggle DPDT 2 Pos 15A
POT 10K 10 Turn
Overlay Precision Plasma
BRKT, Remote Filler
7-5
SECTION 7
REPLACEMENT PARTS
1
11
2
10
13
9
3
12
4
8
5
6
7
7-6
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
A952209
J1
Conn Box Recpt 19 FS SH
3
A-952210
J2
Conn Box Recpt 14 FS SH
4
A-897W6
5
A-23610197
6
A-8952571
7
D-32202GY
8
A-858V75
Adaptor B/A-W F ¼ NPTM BKHD
9
A-954599
Label Rating Precision Plasma
10
A-8950829
11
A-950937
Strain Relief
12
A-13730763
Plate, Serial
13
A-8950874
Door Access Rear
C-35928GY
3 Strain Relief
Plug Hole .875 Dia. .125 CT Nyl BK
Fuse 7A 600 VAC Fast Acting
F4
Panel Rear
Circuit Breaker 3 AMP
CB1
Circuit Breaker 7 AMP
CB2
7-7
SECTION 7
REPLACEMENT PARTS
7.4 Plasmarc Power Source-Internal Components
18
17
Reference: PCB1
Isolation Amp
Reference:
Meter LED
AM1,VM1
4
3
5
3
6
7
8
15
2
16
10
1
13
12
11
7-8
14
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
A-950487
TB4
3
D-838103
A-950096
A-952053
A-952034
A952030
A-952032
A-952205
PCB1
PCB1 P9,7
Base, Precision Plasma
D-35920GY
Term Block 2 pos
PCB1 P10
PCB1 P1,3,4
PCB1 P2
PCB1 P5
PCB Isolation AMP
Housing Contact, Crimp 3 pin
Standoff #6-32 X .88 L
Plug 5 Pos
Plug 18 Pos
Plug 16 Pos
Receptacle P/C 4 Pos
Box PLC
4
D-37345GY
5
A-951209
PLC
6
C-838131
PCB2
Board, PC Startup
7
A-8950760
K3-6,8
Relay Enclosed DPDT 24VAC
8
17300020
R1,7,8,9
10
A-13735308
K7
11
A952012
12
C-35682
13
B-8952179
Tank, Water
14
A-952013
Caster Swivel
15
A-639533
Bushing, Snap .88 I.D. X 1.09 MH X .45 L
16
17300931
Resistor, 300W 3.1ohm 10%
17
A-952095
Spacer, LED
18
71200732
Adhesive, SIRBR Clr
PLC Controller
Resistor 300W 20ohm 10%
Relay Enclose DPDT 120VAC 20A
Caster Fixed
XFMR Auto
T2
7-9
SECTION 7
REPLACEMENT PARTS
4
3
2
1
14
11
5
12
6
7
13
10
7
9
8
7-10
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
A-8952026
Symbol
(Elec-Ay)
TB2
Description
2
A-8673502
K1
3
672002GY
4
A82062334
5
C-36417GY
6
A951215
7
A8951347
Pump, Carb w/Strainer
8
A8950179
Tee, Pipe Branch ¼ Brs
9
A-810Z30
Adaptor, B/A-W M ¼ NPTM
10
A-182W82
Elbow 90 DEG. ¼ NPT
11
A-37348
Kit, Wire Primary
12
B-33551
BRKT, Water Tank
13
C-837805
14
C-32203GY
Terminal Block
Contactor 3 Pole 75A
Shroud, Fan
Motor, Fan
M1
Shroud, Fan
Motor, Carb 1/3 Hp
M2
Auto XFMR
T3
BRKT, Auto XFMR
7-11
SECTION 7
REPLACEMENT PARTS
5
6
8
9
4
1
7
9
8
2
2
3
7
9
3
12
13
11
“TEE” Detail
10 X5
7-12
7
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
A-8950001
3
C-821124
Valve, Check Assy
4
B-36539
Hose, Assy Flowswitch To Core
5
90858009
TBG, Nylobrade 3/8 I.D X .625 O.D.
6
B-36418
Hose Assy Tank Bottom- Pump Inlet
7
A-858V75
Adaptor, B/A-W F ¼ NPTM BKHD
8
A-182W82
Elbow 90 Deg. ¼ NPT
9
A-810Z30
Adaptor, B/A-W M ¼ NPTM
10
A-8994471
Clamp, Hose W/D .50 Dia X 1.06 SS
11
A-8952179
Tank, Water
12
C-952182
Spout, Remote Filler w/Cap
13
A-952181
Tee, Plastic Pipe
Hose, Assy Pump Outlet- Torch out
B-36538
FS1
Switch, Flow .25 GPM SPSTB
7-13
SECTION 7
REPLACEMENT PARTS
10
6
5
4
3
7
2
9
7
1
8
7-14
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
C-13735961
Heat Exchanger
2
A-8950823
Bushing, Snap
3
A-950167
Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W
4
A-995103
TB3
Terminal Block 24 POS 15A
5
A-36919
TB5
Board, Terminal Output
6
A-896W10
Holder, Fuse
7
A-92W57
Grommet, Rub .63 I.D. X .88 O.D. X .06 W
8
A-639533
Bushing, Snap .88 I.D. X 1.09 MH X .45 L
9
D-35930GY
BRKT, Heat Exchanger
10
A-2234891
Plug, 10 Pos
7-15
SECTION 7
REPLACEMENT PARTS
6
13
5
7
8
4
9
3
10
2
11
1
12
7-16
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
17750020
3
C-36527GY
4
A-8951161
C1,2
Cap, Metpoly 20uf 400VDC
5
A-8673458
K2
Contactor, Pilot Arc 3P 40A
6
A-2234521
P4,MOD1
P1,PLC1 P2
Plug, 16 Pos
7
A-2234891
MOD1 P3, 4,
PLC1 P1
Plug, 10 Pos
8
A-2234518
J3
9
A-2234521
P1,PLC1 P2
Plug, 16 Pos
10
A-2234519
J4, PLC1 J2
Receptacle, 16 Pos
11
A-635686
TB6
Terminal Strip, 8 Pos
12
A-647065L1
13
C-838193
Bushing, Snap
A-8950823
Res 20 ohm 50W
R11,12
Cover, Terminal Board
Receptacle, 8 Pos
Choke Signal #Ch12
Printed Circuit Board Trim Pot
PCB-TB
7-17
SECTION 7
REPLACEMENT PARTS
7.5 Power Source Power Module
4
3
2
5
6
1
7
7-18
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
35914GY
Base Power Module
2
37102
Bracket, PCB KYDEX
3
35799
Wire Kit, Power Module
4
8951339
8951340
5
37101GY
Deck, Power Module
6
8951981
Heat Sink
7
835700
PCB1 P1, 5
PCB1 P2, 6
Plug, Female 12 Position
Plug, Female 14 Position
Inductor, Power Factor
L1
7-19
SECTION 7
REPLACEMENT PARTS
A
2
3
4
1
5
A
6
8
7
Section A-A
7-20
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2234877
Symbol
(Elec-Ay)
J3,4
Description
2
8951182
M1
Fan, Axial
3
950487
TB2
Terminal Strip 2 Position
4
8950823
5
835700
L1
Inductor, Power Factor
6
17280215
R2
Resistor 1.5K OHM 100W
7
835680
L2
Inductor Assembly Output
8
835681
T3
Transformer Assembly, Main
Block Terminal 10 Position
Bushing, Snap
7-21
SECTION 7
REPLACEMENT PARTS
3
4
5
2
1
6
7
7-22
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2234518
Symbol
(Elec-Ay)
J2
Description
2
838047
SH1
3
2234519
J1
4
35917GY
Baffle Heatsink
5
8951981
Heatsink
6
2234877
J3, 4
Block Terminal, 10 Position
7
8674156
TB3
Adaptor
Block Terminal, 8 Position
Shunt, Feedback
Block Terminal, 16 Position
7-23
SECTION 7
REPLACEMENT PARTS
14
12
13
10
11
8
9
10
7
6
15
5
16
4
17
3
18
19
2
20
1
19
21
22
21
23
24
21
7-24
25
26
27
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
2
8951978
8951192
3
835794
4
8951979
8951196
SCR1
SCR 90A
Pad Thermal SCR Module
5
8951980
Q1,2
IGBT 300A 600V
6
17750020
8951194
R4,5
Resistor 20OHM 50W NI
Pad Thermal Power Resistor 50W
7
647345
8
17250005
9
8951940
C6,7
Capacitor 1uf 600VDC
10
8951983
C4,5
Capacitor 3300 uf
11
835793
Busbar IGBT (-)/Capacitor
12
8950823
Bushing Snap .687
13
835792
Busbar IGBT (+)/Capacitor
14
35844
Nomex Insulator
15
8951191
16
35799
Wire Kit Module
17
35918
Busbar Shunt
18
639533
Bushing Snap .875 I.D. X 1.093 MH
19
17721020
R6,7,8,9
Resistor 20 OHM 25W NI
20
8951185
D1,2
Module Diode 100A 600V
21
647345
Bushing Snap 1.31 I.D. X 1.5 MH .44 L
22
836873
Busbar Capacitor/IGBT
23
952255
24
836872
25
832958
T2
26
8950711
TS1,2
27
835790
835940
Symbol
(Elec-Ay)
T1
Description
Transformer Control
BR1
Bridge Diode 3PH 130A
Pad Thermal Bridge
Busbar Input Bridge
Bushing Snap 1.31 I.D. X 1.5 MH .44 L
Resistor 5OHM 50W
Pad Thermal IGBT 1200V
C8,9
Capacitor Film 40uf 400VDC
Busbar Capacitor
Transformer, Current
Switch Thermal 194 Deg. F.
Busbar Jumper
7-25
SECTION 7
REPLACEMENT PARTS
7.6 Precision Plasma Junction Box Replacement Parts
2
1
A
2 REF
8
7
3
6
5
4
Section A-A
A
7-26
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
674969
PCB1
PCB Assembly Filter
3
837250
T2,3
XFMR H.F. Auto
4
82062119
J2
Conn ( Pos
5
37391
BKHD A/A-W*F B/A-W*F
6
37392
BKHD A/A-W*F B/A-W*F
7
8950256
C1
Cap Mica .002uf 10 KwV
8
8677905
SG1
Spark Gap Assy
Wire Kit, Junction Box Precision Plasma
37515
7-27
SECTION 7
REPLACEMENT PARTS
4
B
2
1
C
C
B
5
6
3
7
Section B-B
7-28
8
Section C-C
SECTION 7
Item
Number
REPLACEMENT PARTS
Part Number
Symbol
(Elec-Ay)
Description
Conn Box Recpt 14 MP Shell 20
J1
1
6271128
2
37522
Base Kydex J Box
3
37523
Cover Kydex J Box
4
Ref
5
Ref
Torch Cable Conn Reference
6
Ref
Torch Conn NEG Reference
7
Ref
Pilot Arc Torch Reference
8
Ref
PCB1
J2
7-29
SECTION 7
REPLACEMENT PARTS
1
2
3
4
5
7-30
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
954075
Name Plate
2
37361
Torch Conn Shield
951188
Locknut, Conduit 2NPT
3
954509
Label Warning High Volt Symbol
4
952928
Coupling, Quick Disconn F 14 Hose
5
950518
Grommet RBR 2.12 I.D. X 2.50 O.D. X .06W
7-31
SECTION 7
REPLACEMENT PARTS
7.7 Electronic Flow Control Box
➀ P/N 952920
1
3
2
TB1
O-2
AIR1
SP
V1
SH
GN
ASSY. 000-005-0007
PS1
PR
PR
GN
SH
V2 SP
PS2
PS3
PS4
PS5
RC7
RC8
AR
SR2
SR2
SR1
SR2
SR1
1
RC10
P1
SR2
SR1
SR2
SR1
GN
SP
PR
SP
SH
V3
V4
SH
JP1
GN
PR
JP2
6
JP3
7
JP4
4
JP5
SR1
RC9
1
P2
AIR2
O-1
RC4
RC5
P3
1
RC6
N-1
N-2
1
N-3
P4
H35
METH
RC1
RC2
1
RC3
P5
➂ P/N 952921
5
➅ P/N 952922
➁ P/N 952868
Process
Air
Argon
Air
Air
N2
Air-2
Air-1
Argon
Oxygen
Nitrogen
Argon
Argon
O2
Air
O2
N2
O2-2
N2-3
N2-2
Oxygen
O2-1
Nitrogen
N2-1
H-35
Methane
Meth
H-35
N2
H-35
H-35
➆ P/N 953914
Methane
Methane
➃ P/N 952913
7-32
➄ P/N 952915
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
952920
Switch, Pressure 50 PSI Non-Adj
2
952686
PCB Prec Flow Control Interface Board
3
952921
Valve Sol 2-Way 02
4
952913
Manifold Assembly Complete Prec Flow
5
952915
XMFR Control 115/230V 50/60 HZ
6
952922
Lamp Pilot 28V Green
7
952914
Manifold Assembly w/Check Valves ONLY
7-33
SECTION 7
REPLACEMENT PARTS
Plasma Gas 1
Plasma Gas 2
6
Shield Gas 1
7
Shield Gas 2
Vent 1
Vent 2
Vent 3
Valve 1
Valve 2
Valve 3
Vent 4
Valve 4
1
5
4
3
➁➂➃➄ P/Ns 952916,952917, 952918, 952919
7-34
2
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
Purchase Locally
2
952916
Valve, Analog 0-6 Bar 0-10 VDC Valve4 SG2
3
952917
Valve, Analog 0-6 Bar 0-10 VDC Valve3 SG1
4
952918
Valve, Analog 0-9 Bar 0-10 VDC Valve2 PG2
5
952919
Valve, Analog 0-9 Bar 0-10 VDC Valve 1 PG1
6
639571
Flow Meter Tube ONLY
¼-33-G-5 PG1
7
0558002392
Flow Meter Tube ONLY
SG2
¼ -15-G-5 PG2, SG1,
Fuse, Glass Body, Slow Acting 3AG 4A
7-35
SECTION 7
REPLACEMENT PARTS
7.8 PT-24 Torch Assembly EFC Series A/M P/N 0558001462
Notes:
1* = Plasma 2 in Yellow
2* = Plasma 2 Out Yellow
3* = Plasma 1 in Blue
4* = Plasma 1 Out Blue
5* = Shield 2 In Black
6* = Shield 2 Out Black
7* = Shield 1 In Orange/Red
8* = Shield 1 Out Orange/Red
20
18
7*
6*
13
5*
4*
3*
16
2*
1*
10
14
19
6
9
8
11
2
7
12
4
3
5
1
21
22
5/8 - 18
L.H. (Ref)
3/8 - 24
L.H. (Ref)
23
7-36
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
821758
Body & Tube Assembly PT-24 Torch
2
822568
Sleeve, Torch PT-24
3
22381
Gas Line Start Blue
4
22380
Gas Line Cut Yellow
5
22382
Gas Line Shield Orange/Red
6
See Process Data
Swirl Baffle (See Process Data)
7
See Process Data
Nozzle (see Process Data)
8
822007
Retainer/Diffuser
9
822010
Insulator Shield Cup
10
821712
Insulator Shield Retainer
11
821539
Electrode
12
822531
Cup Shield w/Retainer
13
0558001336
14
22375
Protector Gortiflex Sensor 7LG
15
821765
Tool Electrode & Nozzle (NOT Shown)
16
0558001447
Quick Disconnect 90 Deg. Elbow 1.18 L
17
77500101
LUB Grease DOW DC-111 (NOT Shown)
18
2234133
Clamp, Worm Drive
19
8996565
Clamp, Hose
20
80558001470
PT-24 Cable Bundle Assembly 4.5 Ft.
80558001875
PT-24 Cable Bundle Assembly 12 Ft.
80558001471
PT-24 Cable Bundle Assembly 17 Ft.
T Gas Shutoff VLV Assembly EFC
21
821739
Check Valve Body
22
821740
Ball
23
821741
Spring
7-37
SECTION 7
REPLACEMENT PARTS
7.9 T Gas Shut-off Valve Assembly EFC Series A/M
3
2
1
2
3
4
5
6
1
7-38
Plasma 1 & 2 Common
Shield 1 & 2 Common
Shield 1
Shield 2
Plasma 2
Plasma 1
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
0558001502
Flange
2
8952921
2 Way Solenoid Valves
3
593985
O-Ring
7-39
SECTION 7
REPLACEMENT PARTS
7.10 PT-24 Torch EFC Version 1
16
18
14
10
13
19
6
9
8
11
7
12
Detail Torch Front End
2
15
17
4
3
5
21
20
22
1
23
24
7-40
Not Shown
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
821758
Body & Tube Assembly PT-24 Torch
2
822568
Sleeve, Torch PT-24
3
22381
Gas Line Start Blue
4
22380
Gas Line Cut Yellow
5
22382
Gas Line Shield Orange/Red
6
See Process Data
Swirl Baffle (See Process Data)
7
See Process Data
Nozzle (see Process Data)
8
822007
Retainer/Diffuser
9
822010
Insulator Shield Cup
10
821712
Insulator Shield Retainer
11
821539
Electrode
12
822531
Cup Shield w/Retainer
13
22422
Solenoid Assembly Electronic Flow Control V1
14
22375
Protector Gortiflex Sensor 7LG
15
821765
Tool Electrode & Nozzle (NOT Shown)
16
951168
Clamp, Band-it
17
77500101
LUB Grease DOW DC-111 (NOT Shown)
18
2234133
Clamp, Worm Drive
19
8996565
Clamp, Hose
20
80558001470
PT-24 Cable Bundle Assembly 4.5 Ft.
80558001875
“
80558001471
21
“
“
“
“
“
22378
Cable, Solenoid 4 ft.
22427
Cable, Solenoid 12 ft.
22389
Cable, Solenoid 17 ft.
22
821739
Check Valve Body
23
821740
Ball
24
821741
Spring
7-41
“
12 Ft.
“
17 Ft.
SECTION 7
REPLACEMENT PARTS
7.11 Solenoid Assembly Torch, Electronic Flow Control Version 1
4
1
2
8
6
6
3
7
8
7
COM/COM
COM/COM
Shield 2
Shield 1
Plasma 2
Plasma 1
10
5
9
9
5
7-42
SECTION 7
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
22422
Solenoid Assembly Electronic Flow Version 1
2
596985
O-Ring, 1.42 X .103 NEOP 70A
3
952931
Plug Block 6 Pos
4
22421
Bracket, Solenoid EFC
5
952703
Solenoid, 2 Way
6
22367
Quick Disconnect Connector, Yellow
7
952697
Solenoid, 3 Way
8
22366
Quick Disconnect Connector, Blue
9
22365
Quick Disconnect Connector, Orange/Red
10
22364
Quick Disconnect Connector, Silver
7-43
SECTION 7
REPLACEMENT PARTS
Notes:
7-44
Customer // Technical Support
(843) 664-4405
(800) ESAB-123 (372-2123)
ESAB Welding and Cutting Products
PO BOX 100545 Ebenezer Road
Florence, SC 29501-0545
http://www.esab.com
ESAB Cutting Systems – Canada
6010 Tomken Road
Mississauga, Ontario Canada L5T 1X9
Phone: (905) 670-0220
Fax: (905) 670-4879
ESAB-Hancock GmbH
Cutting Technologies
P.O Box 1128
D-61174 Karben
Robert-Bosch-Strasse 20
D-61184 Karben
Phone + 49 60 39 40-0
Fax
+ 49 60 39 40 301_302
http://www.esab.com
[email protected]
Printed in U.S.A
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