ESAB Precision Plasmarc System Series "A" Instruction manual

F-15-456-F
November, 2010
INSTRUCTION MANUAL
PRECISION PLASMARC SYSTEM
SERIES "A"
This manual provides installation and operation instructions for the following components of the Precision Plasmarc
System starting with Ser. No. PORI818001:
Precision Plasmarc Console/Power Source, 208/230/400/460/575 V ac, 50/60 Hz, 3-phase, P/N 37357
Precision Plasmarc Flow Control Box P/N 37416
Precision Plasmarc Junction Box with HF Unit P/N 37400
PT-24 Torch 4.5 FT. (1.4 m) P/N 22362
PT-24 Torch 17 FT. (5.2 m) P/N 22363
Be sure this information reaches the operator.
You can get extra copies through your supplier.
caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENTS
SECTION
PARAGRAPH
TITLE
PAGE
SECTION 1
1.1
1.2
UNPACKING/HOISTING...............................................................................................17
Inspection...................................................................................................................................................17
Hoisting.......................................................................................................................................................17
SECTION 2 2.1
2.2
2.3
DESCRIPTION..............................................................................................................19
General........................................................................................................................................................19
Scope...........................................................................................................................................................19
Package Options Available...................................................................................................................19
SECTION 3
3.1
3.2
3.3
3.4
3.5
INSTALLATION........................................................................................................................................23
General........................................................................................................................................................23
Equipment Required..............................................................................................................................23
Location......................................................................................................................................................23
Primary Electrical Input Connections...............................................................................................23
Interconnecting Lines............................................................................................................................24
SECTION 4
4.1
4.2
4.3
4.4
OPERATION..................................................................................................................33
Power Source Controls/Indicators.....................................................................................................33
Operation...................................................................................................................................................34
Sample Procedure for Setting O2 Gas Flow Rates on Flow Control Box...............................35
Sample Procedure for Setting N2 Gas Flow Rates on Flow Control Box...............................35
Process Data Sheets................................................................................................................................37
SECTION 5
5.1
5.2
5.3
5.4
5.5
CUTTING QUALITY......................................................................................................63
Cut Angle....................................................................................................................................................63
Voltage and Cut Quality........................................................................................................................64
Top Dross....................................................................................................................................................66
Dross Formation.......................................................................................................................................66
Summary....................................................................................................................................................67
SECTION 6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
MAINTENANCE............................................................................................................69
General........................................................................................................................................................69
Inspection and Cleaning.......................................................................................................................69
Torch Consumable Parts.......................................................................................................................69
Gas Pressure Switch................................................................................................................................69
PT-24 Torch Description........................................................................................................................69
Torch Maintenance.................................................................................................................................70
PT-24 Consumable Removal, Inspection and Installation........................................................70
SECTION 7
7.1
7.2
7.3
TROUBLESHOOTING...................................................................................................73
Troubleshooting......................................................................................................................................73
Process Troubleshooting.......................................................................................................................73
Troubleshooting Procedures...............................................................................................................75
SECTION 8
8.1
8.2
REPLACEMENT PARTS.................................................................................................81
General........................................................................................................................................................81
Ordering......................................................................................................................................................81
3
TABLE OF CONTENTS
4
safety precautions
Safety Precautions
Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize precautionary information from the references
listed in Additional Safety Information section. Before performing any installation or operating
procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until
the work piece has been completely cleaned so that
there are no substances on the work piece which
might produce flammable or toxic vapors. Do not do
hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a fire hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protection Association, Battery march Park, Quincy, MA
02269.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy longsleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
5
safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
3. Welders should use the following procedures to
minimize exposure to EMF:
2. Connect the work piece to a good electrical
ground.
A.Route the electrode and work cables together.
Secure them with tape when possible.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
B. Never coil the torch or work cable around your
body.
C.Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
D.Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
Therefore:
9. Turn off the power before removing your gloves.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommendations. Do not mistake the work lead for a ground
cable.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
2. Exposure to EMF may have other health effects which
are unknown.
6
safety precautions
5.WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
safety precautions
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Meaning of symbols - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
sEGURIDAD
La seguridad - español
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan
producir gases inflamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable
como división.
6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.
9
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas,
de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.
sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
3.Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A.Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C.Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D.Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno. Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2.Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
10
sEGURIDAD
5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daños
a la persona.
12
sÉCURITÉ
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
La sûreté - français
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les fiches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inflammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de
plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur
lunettes de sécurité.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mortelles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
13
sÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A.Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C.Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D.Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conducteur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour
la santé.
14
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.
sÉCURITÉ
5.AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les fils de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
15
sÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.
16
section 1
UNPACKING/HOISTING
1.1 INSPECTION
1.2 hoisting
A. The Precision Plasmarc System will be shipped in four
separate containers. The power source, the junction box,
the flow control box and the PT-24 torch components
will all have their own containers. Remove all packing
material and inspect for evidence of concealed damage
which may not have been apparent upon receipt of the
four containers. All four components, the power source,
flow control box, junction box and PT-24 torch are fully
assembled with the exception of the fixed caster wheels
on the power source. Immediately notify the carrier of
any defects or damage.
The power source is equipped with one lifting eye that
enables the unit to be hoisted.
B. Check each container for any loose parts prior to disposing of shipping materials.
C. Check air louvers on the power source and junction box
and any other opening to ensure that any obstructions
are removed.
17
section 1
UNPACKING/HOISTING
18
section 2description
2.1 general
2.2 scope
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. The power source also provides control voltage
to the flow control box for precise control of the plasma
gas and shield gas to the PT-24 torch.
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
Table 2-1 lists Precision Plasmarc package options available through your ESAB dealer.
Table 2-1. Available Package Options
Precision Plasmarc Power Source (208/230/380/415/460/575) 3-phase 50/60 Hz (required)
P/N 37357
Flow Control Box (required)
P/N 37416
Junction Box with HF Unit (required)
P/N 37400
PT-24 Torch (one required)
4.5 ft. (1.4 m)
17 ft (5.2 m)
P/N 22362
P/N 22363
Power Bundle (one required)
25 ft (7.6 m)
60 ft (18 m)
100 ft (30 m
P/N 21905
P/N 21906
P/N 21907
Gas Line Bundle (one required)
10 ft (3 m)
20 ft (6 m)
30 ft (9 m)
60 ft (18 m)
100 ft (30 m)
P/N 21902
P/N 21903
P/N 21904
P/N 22334
P/N 22335
Control Lead Flow Control to Junction Box and Power Source to Flow Control Box (two
required)
10 ft (3 m)
20 ft (6 m)
30 ft (9 m)
60 ft (18 m)
100 ft (30 m)
P/N 21917
P/N 21918
P/N 21919
P/N 21920
P/N 21921
Torch Coolant 1 gallon (3.8 l) containers (4 gallons (15 l) required)
P/N 156F05
PT-24 Spare Parts Kit
P/N 37609
NOTE:
1. Control lead from the power source to customer CNC is supplied based on customer order. The gas supply hoses, work
lead and input primary cable are all supplied by the customer.
2. See Process Data Sheets for a list of torch consumable parts.
19
section 2description
Table 2‑2. Technical Specifications (Precision Plasma System)
Input Voltage
208/230/380/415/460/575 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
215 V dc
Duty Cycle
100%
Open Circuit Voltage
315 V dc
Power Source Size
22" (550 mm) W X 42" (1050 mm) D X 44" (1100 mm)
Power Source Weight
560 lbs. (254 kg)
Flow Control Box Size
11" (275 mm) W X 11" (275 mm) D X 16" (400 mm)
Flow Control Box Weight
35 lbs (16 kg)
Junction Box Size
17" (425 mm) L X 10" (250 mm) W X 7" (175 mm)
Junction Box Weight
27 Ibs (12 kg)
Junction Box
Power Source
Flow Control
Figure 2-1. Precision Plasma System
20
section 2description
Table 2‑3. Technical Specifications
(Plasma Gas)
Type
O2, N2, Air
Pressure
Flow
Purity Required
Recommend Liquid Cylinder
Service Regulators
Recommended Cylinder 2‑Stage
Regulators
Recommended Heavy‑Duty
Hi-FIow Station or Pipeline
Regulators
Recommended High‑Capacity
Station or Pipeline Regulators
125 psig (8.6 bars)
100 cfh (47 I/min) max (varies with application)
02-99.8%,N2-99.995%, Air‑clean, dry, 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‑77‑150‑590 (P/N 998348)
Oxygen: R‑76‑150‑024 (P/N 19151)
R‑6703 (P/N 22236)
Table 2‑4.Technical Specifications
(Starting Gas)
Type
N2, Air
Pressure
Flow
Purity Required
125 psig (8.6 bars)
60 cfh (28 I/min) max (varies with application)
99.995%, Dry, clean, free of oil and matter
Table 2‑5. Technical Specifications
(Secondary Gas)
Type
N2O2 H‑35, Methane
Pressure
Flow
Minimum Purity Required
100 psig (6.9 bars) H-35, Methane; 125 psig
(8.6 bars) N2, O2, Air
60 cfh (28 I/min) max (varies with application)
N2-99.995%; 02, 99.8% H‑35, Methane‑99.8%
Table 2‑6.Technical Specifications
(PT‑24 Torch)
Type
Water‑Cooled, Dual Gas
Rating
100 amps @ 100% duty cycle
Dimensions:
See Figure 8-9
21
section 2description
22
section 3installation
3.1 General
As shipped, the power source is configured for 575 V, 60
Hz input. If using 208, 230, 380, 415, or 460 V input, the
jumper input power cables located on the auto transformer must be repositioned to the desired input voltage
for safe operation. To gain access to the autotransformer,
remove the right side panel. (See Figure 3-1.)
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.
A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel (see Table
3-1 for fuse rating). The input power cable of the power
source may be connected directly to the disconnect
switch or a proper plug and receptacle may be purchased
from a local electrical supplier. If using plug/receptacle
combination, see Table 3-1 for recommended input
conductors for connecting receptacle to line disconnect
switch.
3.2 Equipment Required
A. 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 bars) to the Flow Control
(Gas Flowing).
B. Work Lead. No. 4 AWG (25 mm2) cable is recommended
for connecting workpiece to power source.
C. Primary Input Cable. See Section 3.4.
The following procedure explains the proper installation steps for connecting primary electrical power to the
power source. (See Figure 3-1.)
3.3 Location
Adequate ventilation is necessary to provide proper
cooling of the power source. Minimize the amount of
dirt, dust, and excessive heat to which the equipment is
exposed. There should be at least 2 feet (0.6m) of clearance between the power source and wall or any other
obstruction to allow freedom of air movement through
the power source.
A. Remove right side panel.
B. Ensure input power cable is disconnected from all electrical sources.
Table 3-1. Recommended Sizes For
Input Conductors and Line Fuses
Installing or placing any type of filtering device will restrict
the volume of intake air, thereby subjecting the power
source internal components to overheating. Use of any
type of filter device voids the warranty.
Input Requirements
3.4 Primary Electrical Input Connections (Figure 3-1)
ELECTRIC SHOCK CAN KILL! Precautionary measures
should be taken to provide maximum protection
against electrical shock. Be sure that all power is off
by opening the line (wall) disconnect switch and by
unplugging the power cord to the unit before any connections are made inside of the power source.
Volts
Phase
Amps
208
230
380
415
460
575
3
3
3
3
3
3
65
60
50
40
30
25
Input & Gnd
Conductor
CU/AWG/mm
No. 4
No. 6
No. 8
No. 10
No. 10
No. 10
2
25
16
10
6
6
6
Fuse
Ratings/
Phase,
Amps
100
80
80
60
50
40
*Sizes per National Electric Code for 75 °C rated conductors @
30 °C ambient. Not more than three conductors in raceway or
cable. Follow local codes if they specify sizes other than those
listed above.
C. Route input power cable through the strain relief located
at the rear panel.
D. 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.
Be sure that the power source is properly configured
for your input power supply. Do NOT connect a power
source configured for 230 V to a 460 V input power
supply. Damage to the machine may occur.
23
section 3installation
3.5 INTERCONNECTING LINES
E. Connect input power cable ground wire to the ground
lug provided on the base of the power source.
(Refer to Figure 3-2 or Figure 3-3 for the appropriate application.)
F. Connect three power leads of the input power cable to
the terminals located atop the main contactor. Secure
the leads by tightening each screw.
A. All interconnecting service lines supplied are numbered
on each end with corresponding numbers marked on
the cabinets next to the connection to be made.
G. 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.
B. Connect all five lines in gas bundle (Figure 3-4) to Flow
Control Box and Junction Box (Figure 3-5).
Ensure each input power jumper cable is connected
to the proper input voltage to be used on auto transformer.
H. Connect jumper wire to the proper input voltage connector located on the 7-position terminal block. (See
Figure 3-1.)
C. Connect power and coolant lines in power bundle (Figure 3-6) to junction box (Figure 3-7) and power source
(Figure 3-2 or 3-3).
D. Remove panel from rear of console and attach the
pilot-arc, torch and work lead. See Figure 3-8 to replace
panel.
E. Connect control lead (Figure 3-9) between the console
and the flow control and from the flow control to the
junction box. See Figure 3-2 or Figure 3-3 for the installation location.
GROUND CONNECTION
MAIN CONTACTOR
INPUT POWER CABLE
(Customer Supplied)
7-POSITION
TERMINAL BLOCK
Connect jumper to
proper input voltage
AUTO TRANSFORMER
Connect each jumper to
proper input voltage
Figure 3-1. Power Source Primary Power Connection Diagram
(Shown factory connected in 575 V position)
24
Figure 3-2. Precision Plasmarc Cutting Machine Interconnecting Diagram
25
Control Lead P/N’s
10 ft. (3m) P/N-21917
20 ft. (6m) P/N-21918
30 ft. (9m) P/N-21919
60 ft. (18m)P/N-21920
100 ft. (30m) P/N-21921
(Customer Supplied)
(Customer Supplied)
HEIGHT CONTROL
ARC VOLTAGE REMOTE
Power Bundle P/N’s
25 ft. (7.6m) P/N-21905
60 ft. (18m) P/N-21906
100 ft. (30m) P/N-21907
CNC
ARC VOLTAGE CONTROL
(Customer Supplied)
Gas Line Bundle
#1 Cut Gas O2 Plasma
#2 Cut Gas N2 Plasma
#3 Plasma Gas N2 Start
#4 Shield Gas
#5 Shield Gas, Preflow
Power Bundle
#6 Coolant to Torch
#7 Coolant Return from Torch
Torch Power Cable
Pilot Arc Lead
CONTROL LEAD
(Flow Control to Junction Box)
2
3 4
5
67
See Fig.3-7
WORK LEAD
(Customer Supplied)
PT-24 TORCH
4.5ft.(1.4m)P/N22362
17 ft. (5.2m) P/N 22363
BACK VIEW
N2
Alt
O2
Supplied by Customer
Alternate Gas
(Shield Addition)
N2
O2
PRIMARY CABLE
(Customer Supplied)
POWER SOURCE - P/N37357
AUTO TRANS.
CONTROL
POWER SOURCE
CONTROL LEAD - 14 Pin Connector
(Power source to Flow Control Box)
X
FLOW CONTROL BOX P/N-37416
CONTROL LEAD - 19 Pin Connector
(Power Source to CNC)
(Supplied based on Customer Order)
5
4
2
3
1
Gas Bundle P/N’s
10 ft. (3m) P/N-21902
20 ft. (6m) P/N-21903
30 ft. (9m) P/N-21904
60 ft. (18m) P/N-22334
100 ft. (30m) P/N-22335
(Customer Supplied)
CUTTING TABLE
JUNCTION BOX
with H.F. Unit
P/N-37400
1
Note:
All service lines have identification numbers stamped on connections
COOLER
W/4 Gal. (1.5L)
Tank
section 3installation
PT-24 TORCH
4.5 ft. (1.4m) P/N 22362
17 ft. (5.2m) P/N 22363
WORK
Power Bundle P/N’s
25 ft. (7.6m) P/N-21905
60 ft. (18m) P/N-21906
100 ft. (30m) P/N-21907
Consists of:
#6 Coolant to Torch
#7 Coolant Return from Torch
Torch Power Cable
Pilot Arc Lead
WORK LEAD
(Customer Supplied)
Figure 3-3. Precision Plasmarc Robotic Interconnecting Diagram
26
6
7
5
4
2
3
JUNCTION BOX
with H.F. Unit
P/N-37400
BACK VIEW
N2
Alt
O2
POWER BUNDLE
CONTROL LEAD
(Flow Control to Junction Box)
5
4
2
3
1
FLOW CONTROL BOX P/N-37416
Consists of:
#1 Cut Gas O2 Plasma
#2 Cut Gas N2 Plasma
#3 Plasma Gas N2 Start
#4 Shield Gas
#5 Shield Gas, Preflow
CONTROL LEAD - 19 Pin Connector
(Supplied based on Customer Order)
See Fig. 3-7
1
GAS LINE BUNDLE
Note:
All service lines have identification
numbers stamped on connections
Control Lead P/N’s
10 ft. (3m) P/N-21917
20 ft. (6m) P/N-21918
30 ft. (9m) P/N-21919
60 ft. (18m) P/N-21920
100 ft. (30m)P/N-21921
Gas Bundle P/N’s
10 ft. (3m) P/N-21902
20 ft. (6m) P/N-21903
30 ft. (9m) P/N 21904
60 ft. (18m) P/N 22334
100 ft. (30m) P/N 22335
Supplied by Customer
Alternate Gas
(Shield Addition)
N2
O2
PRIMARY CABLE
(Customer Supplied)
POWER SOURCE P/N-37357
AUTO TRANS.
CONTROL
POWER SOURCE
CONTROL LEAD - 14 Pin Connector
(Power source to Flow Control Box)
X
COOLER
W/4 Gal. (1.5L)
Tank
section 3installation
section 3installation
(2) adapters supplied
with bundle
BUNDLE P/N
#1
#2
#3
#4
#5
SHEATH
10 FT. (3m)
21902
21884
21875
21878
21887
21881
995832
20 FT. (6m)
21903
21885
21876
21879
21888
21882
995832
30 FT. (9m)
21904
21886
21877
21880
21889
21883
995826
60 FT. (18m)
22334
22337
22343
22345
22340
22347
995826
100 FT. (30m) 22335
22338
22344
22346
22341
22348
995826*
*2 required
Figure 3-4. Gas Line Bundle
1
2
3
4
5
Junction Box
with H.F. Unit
Figure 3-5. Gas Bundle Installation
27
section 3installation
No. 6 and No. 7
5/8-18 L.H.
(B-A/W)
6
6
7
7
No. 6 and No. 7
5/8-18 L.H.
(B-A/W)
PILOT ARC #16 AWG(YELLOW)
POWER CABLE#3 AWG
#6
#7
SHEATH
25 FT. (7.6m) P/N-21905
21911
21914
995832 (1)
60 FT. (18m) P/N-21906
21912
21915
995832 (2)
100 FT. (30m) P/N-21907
21913
21916
POWER BUNDLE
Figure 3-6. Power Bundle
Gas Tubing Bundle Connections:
Cut Gas (Yellow)
Shield Gas (Org. or Red)
Pilot Arc Cable
Pre-Cut Gas (Black)
Gas Tubing
Bundle
Start Gas (Blue)
Power
Cable
Torch Pilot Arc
Torch Assembly
Torch Electrical
(J2) Cable
Hose No. 6
Torch Negative
Power Bundle Assembly
Figure 3-7. Power Bundle/Junction Box Connections
28
Hose No. 7
section 3installation
F. Connect control lead (Figure 3-9) between the power
source and the flow control and from the flow control
to the junction box. See Figure 3-2 or Figure 3-3 for the
installation location.
CONTROL LEADS P/N’S
10 FT. (3m) P/N-21917
20 FT. (6m) P/N-21918
30 FT. (9m) P/N-21919
60 FT. (18m) P/N-21920
100 FT. (30m) P/N-21921
Figure 3-9. Available Control Leads
F. Torch Mounting Options.
1.
The torch is normally mounted by the sleeve.
2.
For more precise mounting, the torch can be
mounted by the 1.812" (46 mm) dia collar shown
(see Figure 3-10). This insulated collar and its shoulder are machined relative to the nozzle retainer
thread on the torch body and is held concentric
to the cutting nozzle within a total indicator reading of 0.010 inches (0.25 mm) or the nozzle bore
is within 0.005 inches of any point on the 1.812
dia.
NOTE
When mounting, be sure not to cover the small vent hole
in the side of the sleeve. This hole prevents coolant from
building inside the sleeve should a leak occur in a service
line.
Figure 3-10. Torch Mounting Options
Figure 3-8. Power Bundle/Power Source Rear Panel
Connection
29
section 3installation
Flow Control Box
G. Remove coolant fill cap at front of console and fill coolant
tank with 4 gallons (15 l) of plasma coolant. See Figure
3-11. Reinstall cap.
NOTE
O2
N2
Alt.
Due to the high electrical conductivity, use of tap water or
commercial antifreeze must NOT be used for torch cooling. A specially formulated torch coolant, P/N 156F05 (1
gallon (3.8 l) container) is available and recommended for
torch cooling. The coolant also provides freeze protection
down to -34° C.
NOTE
Operating the unit without coolant will cause permanent
damage to coolant pump.
X
Figure 3-11. Filling Coolant
Supplied by Customer
COOLANT
FILL CAP
Connect gas supply to flow control. See gas requirements
as listed in Tables 2-3, 2-4, and 2-5. (See Figure 3-12.)
Figure 3-12. Gas Supply Connection
J.
O2
Alternate Gas
Shield Addition)
H. Make all connections to the CNC and height control.
See instructions provided with equipment supplied.
I.
N2
1.
Close all valves on the gas flow control cabinet.
2.
Set all inlet gas pressures to 125 psig (8.6 bars).
3.
Turn the power source ON. The amber light to
the left of the switch will glow, the console fan
will operate and coolant will flow.
4.
Coolant pump pressure should be 80 to 90 psi (5.5
to 6.2 bars). See coolant pump pressure gauge on
front of console.
5.
Check for leaks on connections No. 6 and 7 on
the back of the console and in the junction box.
Check the torch power cable and pilot arc cable
connections in the junction box.
6.
Check the vent hole in the side of the torch sleeve
and the torch consumables.
7.
With console ON, use a solution of soap and water.
Check all gas connections for pressure tightness
as per following:
(a) Place the "plasma gas" select switch, SW-2, in
O2 position.
With installation complete, check for gas and coolant
leaks with a standard soap solution as follows (see Figures
3-13 and 3-14):
30
section 3installation
(b) Place the "shield gas" select switch, SW-3, in O2 +
N2 position.
(j) Close valves NV-1 (oxygen plasma gas valve) and
NV-5 (cut shield gas valve).
(c) Place the "test switch" SW-1 in START position.
(d) Open valve NV-3 (start gas valve) and NV-6 (shield
gas pre-flow valve) approximately two full turns.
(k) Place SW-1 in operate position to verify that O2
output pressure remains pressurized.
(e) Check all gas connections on lines 2 and 5 and torch
connections in junction box. Close valves NV-3 (start
gas valve) and NV-6 (shield gas pre-flow valve).
(f ) Place SW-1 in operate position to verify that N2
output pressure on right side of control remains
pressurized.
(g) Move switch SW-1 to CUT position.
(h) Open valves NV-1 (oxygen plasma gas valve) and
NV-5 (cut shield gas valve) approximately two full
turns.
(i)
(l)
Place plasma gas select switch SW-2 in N2 position.
(m) Open valve NV-2 (nitrogen plasma gas) approximately two full turns.
(n) Check all gas connections on line 2 for leaks.
Correct as needed.
(o) Place SW-1 in operate position to verify that N2
output pressure remains pressurized.
Check all gas connections on lines 1 and 4. Recheck torch connections in junction box. Correct
as needed.
SW-2
SW-3
NV-3
O2 Pressure
Out
NV-6
N2 Pressure
Out
SW-1
Plasma Start
Press. Out
NV-1
NV-5
NV-4
NV-2
Left Side View
Front View
Figure 3-13. Flow Control Controls
31
section 3installation
NOTE: The numbers in circles correspond with the steps needed to check gas and coolant leaks.
Flow Control Box
2
7
7
1
Alt.
N2
O2
7
6
7
5
6
7
6
Figure 3-14. Gas and Coolant Leak Check
32
3
section 4operation
4.1 POWER SOURCE CONTROLS/INDICATORS
E
D
C
F
B
A
G
H
I
J
K
L
M
Figure 4-1. Front Panel Controls
A. Main Power Switch - controls the input power to the
fan, water cooler, and the interface PCB. The amber light
to the left of the switch indicates power is ON.
G. Coolant Flow Fault Indicator - indicates low coolant
flow. The light will come on momentarily when the
console is turned on and then go out.
B. Output Current Dial - sets the cutting current when
current setting is made from the console front panel
(remote/panel switch in PANEL position).
H. Plasma Gas Pressure Fault Indicator - indicates low
plasma gas pressure.
C. Remote/Panel Switch.
I.
Start Gas Pressure Fault Indicators - indicates low
start gas pressure.
P/S Temp Fault Indicator - indicates over temperature
fault condition in the inverter power source.
1.
Panel Position - allows output current to be set
by the output current dial as described above.
J.
2.
Remote Position - allows output current to be set
by the CNC with an analog dc signal.
K. P/S Fault Indicator - indicates fault in the plasma control
PCB in the inverter power source.
D. Cutting Current Meter - displays the actual cutting
current.
L. Over/Under Voltage Fault Indicator - indicates input
voltage is above or below the tolerances of the PCU
console. Will latch until power is recycled by main power
switch.
E. Cutting Voltage Meter - displays the actual cutting
voltage.
M. Emergency Stop Fault Indicator - indicates CNC emergency condition.
F.
0-10 V dc = 0 - 100 Adc
Pilot Arc High/Low Switch - is used to select pilot arc
current.
33
section 4operation
4.2 OPERATION
A. Check consumables in torch for damage and be sure
they are correct for the material to be cut and gas to
be used (check against process data sheets starting on
page 25).
3.
If current is to be set from the cutting machine
CNC, place the remote panel switch in REMOTE
position. Consult the CNC instructions for setting
currents.
B. Set N2, O2, and Air inlet pressures to 125 psig (8.6 bars)
(flowing) and Methane and H-35 inlet pressure to 100
psig.
C. Gas Flow Control (Figure 4-2).
1.
Position PLASMA GAS select switch (SW-2) for
plasma gas to be used.
2.
Position SHIELD GAS select switch (SW-3) for shield
gas or gases to be used.
3.
Set SW-1 switch to start. Verify that N2 pressure is
125 psig (8.6 bars) while flowing.
4.
Set SW-1 switch to CUT. Verify that O2 pressure is
125 psig (8.6 bars) while flowing.
5.
Close any throttle valves not being used by turning
them clockwise.
SW-2
Figure 4-3. Coolant Level Indicator
SW-3
4.
Check coolant level (see Figure 4-3). Coolant level
must be checked with the console main power
switch in the OFF position. The coolant level must
fall within the SAFE OPERATING LEVEL indicated
(See Section 3.5.G).
5.
Place pilot arc high/low switch in the LOW position.
6.
Turn on the power source by placing the main
power switch in the ON position. The amber light
to the left of the switch will come on.
7.
Check coolant pressure. The pump pressure is
factory set between 80-90 psig (5.5 to 6.2 bars).
8.
Complete setting the gas flow rates by following
the two examples on the next two pages.
Figure 4-2. Gas Flow Control
D. Console.
1.
If current is to be set from console place the remote
panel switch in the PANEL position.
2.
Set the cutting current on the output current dial.
34
section 4operation
E. Set the arc voltage from the suggested arc voltage values
given in the process data sheets.
H. For setting shield and mixing shield cut gas.
(1) Adjust valve NV-5 (N2), read flow on flowmeter
FM-3.
NOTE
Arc voltage and piercing height will be set from the arc
voltage control or from the CNC. Consult instructions supplied with your equipment.
(2) Adjust valve NV-4 (O2), read flow on flowmeter
FM-4.
I.
With the completion of the above settings the system is
now ready for operation.
Move test switch SW-1 to OPERATE position. Flow control
is now set to operate.
4.4 SAMPLE PROCEDURE FOR SETTING n2
GAS FLOW RATES ON FLOW CONTROL
BOX (Figure 4-4)
4.3sample procedure for setting o2
gas flow rates on flow control
box (Figure 4-4)
NOTE
NOTE
This is a sample procedure only and the operator must
refer to the appropriate process data sheet.
This is a sample procedure only and the operator must
refer to the appropriate process data sheet.
SAMPLE SETUP:
SAMPLE SETUP:
Plasma - O2, Shield - N2 plus O2 Mix
Plasma - N2 or Air, Shield - N2 or Air plus Alternate gas
mix.
NOTE
A. Place PLASMA GAS select switch SW-2 in O2 position.
B. Place SHIELD GAS select switch SW-3 in O2 + N2 position.
To cut with air, connect the air source to the N2 inlet.
C. Place test switch SW-1 in START position.
A. Place PLASMA GAS select switch SW-2 in N2 position.
D. For setting plasma start gas adjust valve NV-3, read flow
on flowmeter FM-2.
B. Place SHIELD GAS select switch SW-3 in N2 + ALT position.
E. For setting shield preflow gas:
C. Place test switch SW-1 in START position.
Adjust valve NV-6, read flow on flowmeter FM-3.
F. Move test switch SW-1 to CUT position.
D. For setting plasma start gas adjust valve NV-3, read flow
on flowmeter FM-2.
G. For setting plasma cut gas adjust valve NV-1, read flow
on flowmeter FM-1.
E. For setting shield preflow gas, adjust valve NV-6, read
flow on flowmeter FM-3.
F. Move test switch SW-1 to CUT position.
35
section 4operation
G. For setting plasma cut gas adjust valve NV-2, read flow on flowmeter FM-2.
H. For setting shield and mixing shield cut gas.
(1) Adjust valve NV-5, read flow on flowmeter FM-3.
(2) Adjust valve NV-4, read flow on flowmeter FM-4.
I.
Move test switch SW-1 to OPERATE position. Flow control is now set to operate.
FM-1
FM-2
FM-3
FM-4
SW-2
SW-3
NV-3
NV-6
SW-1
NV-5
NV-1
NV-4
NV-2
Front View
Left Side View
Figure 4-4. Flow Control Box
36
(Sec.)
(IN)
.062
.075
.090
.125
.187
.250
(MM)
1.5
2
2.2
3
4
6
0
0
0
0
0
0
DELAY PIERCE
MATERIAL
THICKNESS
0
0
0
0
0
0
(Sec.)
PIERCE
ON
RISE

40
40
40
40
40
40
(FLOW READING)
START
PLASMA
P/N 21712
P/N 22531

INSULATOR SHIELD
RETAINER w/O-RING

55
55
55
55
55
55
(FLOW READING)
CUT
SHIELD
45
45
45
45
45
45
PRE
20
20
20
20
20
20
†
CUT †
VOLTAGE
ARC
10
10
10
10
10
10
150
152
153
158
170
185
ALT (FLOW READING)
SET‑UP PARAMETERS*
PLASMA
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
3810
3429
2667
1981
762
635
(MM/MIN)
150
135
105
78
30
25
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

30
NITROGEN
NITROGEN
METHANE
ELECTRODE

SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21541
NOZZLE "B"
NOTES:
3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
37
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
process data
section 4operation
THICKNESS
DELAY (Sec.)
0
0
0
0
(IN)
.062
.125
.187
.250
(MM)
1.5
3
4
6
PIERCE
MATERIAL
0
0
0
0
(Sec.)
PIERCE
ON
RISE
START
PLASMA


45
45
45
45
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


75
75
75
75
(FLOW READING)
CUT
PLASMA
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
55
55
55
55
PRE
20
20
20
20
†
CUT †
VOLTAGE
ARC
10
10
10
10
136
139
152
162
ALT (FLOW READING)
SHIELD
4318
3302
1981
1168
(MM/MIN)
170
130
78
46
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

55
NITROGEN
NITROGEN
METHANE
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21542
NOZZLE "C"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
38
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
process data
section 4operation
4
6
10
12
.187
.250
.375
.500
0
0
.1
.2
(Sec.)
(Sec.)
PIERCE
DELAY (MM) (IN)
0
0
.1
.1
ON
PIERCE
RISE
MATERIAL
THICKNESS
START
PLASMA


65
65
65
65
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

50
50
60
60
(FLOW READING)
CUT
SHIELD
45
45
45
45
PRE
20
20
20
20
†
CUT †
VOLTAGE
ARC
10
10
10
10
150
157
168
178
ALT (FLOW READING)
SET‑UP PARAMETERS*
PLASMA
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
2032
1651
1397
762
(MM/MIN)
80
65
55
30
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

70
NITROGEN
NITROGEN
METHANE
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21543
NOZZLE "D"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
39
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
process data
section 4operation
THICKNESS
.250
.375
.500
.625
0
0
.1
.3
(Sec.)
(IN)
(MM)
6
10
12
16
DELAY PIERCE
MATERIAL
0
0
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


80
80
80
80
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


100
100
100
100
(FLOW READING)
CUT
PLASMA
60
60
60
60
PRE
31
31
31
31
†
CUT †
VOLTAGE
ARC
10
10
10
10
150
162
166
176
ALT (FLOW READING)
SHIELD
2413
2032
1778
1270
(MM/MIN)
95
80
65
50
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
100
NITROGEN
NITROGEN
METHANE
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21923
NOZZLE "E"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
40
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
process data
section 4operation
0.9
1.3
1.5
1.9
2.7
3.4
20 GA
18 GA
16 GA
14 GA
12 GA
10 GA
0
0
0
.1
.1
.1
(Sec.)
(Sec.)
PIERCE
DELAY (MM) (IN)
0
0
0
0
0
0
ON
PIERCE
RISE
MATERIAL
THICKNESS
START
PLASMA


20
20
20
20
20
20
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

16
OXYGEN
NITROGEN
OXYGEN

11
11
11
11
11
11
(FLOW READING)
CUT
SHIELD
50
50
50
50
50
50
PRE
0
0
0
0
0
0
†
CUT †
VOLTAGE
ARC
5
5
5
5
5
5
114
117
118
123
124
129
ALT (FLOW READING)
SET‑UP PARAMETERS*
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
2540
2159
1778
1270
1016
914
(MM/MIN)
100
85
70
50
40
36
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
2 HOLE
(SEE NOTES)
P/N 21852
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21540
NOZZLE "A"
NOTES:
2 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
41
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
ALT. GAS:
11/30/99
CARBON STEEL
process data
section 4operation
(MM) (IN)
1.9 14 GA
3
.125
3.2
.135
4
.187
6
.250
THICKNESS
(Sec.)
0
0
0
.1
.1
0
0
0
.1
.2
PIERCE
ON
RISE
(Sec.)
DELAY PIERCE
MATERIAL
START
PLASMA


38
38
38
38
38
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


15
15
15
15
15
(FLOW READING)
CUT
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
50
50
50
50
50
PRE
0
0
0
0
0
†
CUT †
VOLTAGE
ARC
5
10
10
10
10
113
119
120
122
124
ALT (FLOW READING)
SHIELD
2032
1397
1320
1016
889
(MM/MIN)
80
55
52
40
35
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536
35
OXYGEN
NITROGEN
OXYGEN
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21541
NOZZLE "B"
NOTES:
3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
42
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
process data
section 4operation
(Sec.)
(IN)
.125
.135
.187
.250
.375 (MM)
3
3.2
4
6
10
0
0
.1
.2
.3
DELAY PIERCE
MATERIAL
THICKNESS
0
0
.1
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


50
50
50
50
50
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


20
20
20
20
20
(FLOW READING)
CUT
PLASMA
50
50
50
50
50
PRE
10
10
10
10
10
†
CUT †
VOLTAGE
ARC
0
0
0
0
0
119
121
127
130
136
ALT (FLOW READING)
SHIELD
1524
1270
1143
889
508
(MM/MIN)
60
50
45
35
20
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125PSI/8.6 BAR
PRESSURE:125PSI/8.6 BAR
PRESSURE:125PSI/8.6 BAR
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
45
OXYGEN
NITROGEN
OXYGEN
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21542
NOZZLE "C"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
43
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
process data
section 4operation
4
6
8
10
11
19
.187
.250
.312
.375
.500
.625 (MM) (IN)
THICKNESS
0
0
0
.1
.2
.3
(Sec.)
DELAY PIERCE
MATERIAL
0
0
0
.1
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


60
60
60
60
60
60
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


25
25
25
25
25
25
(FLOW READING)
CUT
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
60
60
60
60
60
60
PRE
20
20
20
20
20
20
CUT †
†
VOLTAGE
ARC
0
0
0
0
0
0
118
121
122
126
133
144
ALT (FLOW READING)
SHIELD
3048
2540
2032
1651
762
635
(MM/MIN)
120
100
80
65
30
25
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
70
OXYGEN
NITROGEN
OXYGEN
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21543
NOZZLE "D"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
44
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
process data
section 4operation
45
.312
.375
.500
.625
.750
0
0
.1
.2
.3
0
0
.1
.1
.1

80
80
80
80
80
(FLOW READING)
START
PLASMA

100
OXYGEN
NITROGEN
OXYGEN
30
30
30
30
30
(FLOW READING)
CUT
PLASMA
SHIELD
60
60
60
60
60
PRE
30
30
30
30
30
†
CUT †
VOLTAGE
ARC
0
0
0
0
0
132
137
140
143
146
ALT (FLOW READING)
SET‑UP PARAMETERS*
2290
2030
1270
760
630
(MM/MIN)
90
80
50
30
25
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21923
NOZZLE "E"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
8
10
12
16
19
(Sec.)
(Sec.)
PIERCE
DELAY (MM) (IN)
ON
PIERCE
RISE
MATERIAL
THICKNESS
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
process data
section 4operation
0.4
0.6
0.8
1.2
1.5 26 GA
24 GA
22 GA
18 GA
16 GA
0
0
0
0
0
(Sec.)
(MM)
DELAY (IN)
THICKNESS
PIERCE
MATERIAL
0
0
0
0
0
(Sec.)
PIERCE
ON
RISE
START
PLASMA


45
45
45
45
45
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

30
OXYGEN
AIR
OXYGEN
18
18
18
18
18
(FLOW READING)
CUT
PLASMA
SHIELD
40
40
40
40
40
PRE
20
20
20
20
20
†
CUT †
VOLTAGE
ARC
5
5
5
5
5
101
102
103
105
107
ALT (FLOW READING)
SET‑UP PARAMETERS*
6350
5080
4826
3556
2540
(MM/MIN)
250
200
190
140
100
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ELECTRODE

SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21541
NOZZLE "B"
NOTES:
3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
46
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
3
4
6
10
.125
.187
.250
.375
(MM) (IN)
0
0
.1
.2
(Sec.)
DELAY PIERCE
MATERIAL
THICKNESS
0
0
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


60
60
60
60
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


95
95
95
95
(FLOW READING)
CUT
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
45
45
45
45
PRE
55
35
35
35
†
CUT †
VOLTAGE
ARC
0
0
0
0
134
140
145
155
ALT (FLOW READING)
SHIELD
2286
1524
1016
711
(MM/MIN)
90
60
40
22
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536
50
AIR
AIR
AIR
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21542
NOZZLE "C"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
47
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
THICKNESS
.187
.250
.375
.500 .3
.4
.5
.6
(Sec.)
(IN)
(MM)
4
6
10
13
DELAY PIERCE
MATERIAL
.1
.1
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


70
70
70
70
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


95
95
95
95
(FLOW READING)
CUT
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
60
60
60
60
PRE
40
40
40
40
†
CUT †
VOLTAGE
ARC
0
0
0
0
131
154
159
162
ALT (FLOW READING)
SHIELD
2540
2270
711
609
(MM/MIN)
100
50
28
24
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
70
AIR
AIR
AIR
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21543
NOZZLE "D"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
48
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
.250
.375
.500
.625 .3
.4
.5
.6
(Sec.)
(IN)
(MM)
6
10
12
16
DELAY PIERCE
MATERIAL
THICKNESS
.1
.1
.1
.1
(Sec.)
PIERCE
ON
RISE

80
80
80
80
(FLOW READING)
START
PLASMA
P/N 21712
P/N 22531

INSULATOR SHIELD
RETAINER w/O-RING

65
65
65
65
(FLOW READING)
CUT
PLASMA
ELECTRODE
P/N 21539


60
60
60
60
PRE
35
35
35
35
†
CUT †
VOLTAGE
ARC
0
0
0
0
138
142
150
157 ALT (FLOW READING)
SHIELD
2030
1520
889
635
(MM/MIN)
80
60
35
25
(IPM)
TRAVEL SPEED
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
NOTES:
P/N 22007
1. Assemble swirl baffle into nozzle first.

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
100
AIR
AIR
AIR
SET‑UP PARAMETERS*

P/N 21923
NOZZLE "E"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
49
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
stainless steel
process data
section 4operation
3
4
6
10
.125
.187
.250
.375
0
0
.1
.2
(Sec.)
(Sec.)
PIERCE
DELAY (MM) (IN)
0
0
.1
.1
ON
PIERCE
THICKNESS
RISE
MATERIAL

60
60
60
60
(FLOW READING)
START
PLASMA
P/N 21712
P/N 22531

INSULATOR SHIELD
RETAINER w/O-RING

50
AIR
AIR
METHANE
95
95
95
95
(FLOW READING)
CUT
SHIELD
45
45
45
45
PRE
40
40
40
40
†
CUT †
VOLTAGE
ARC
7
7
7
7
135
146
157
175
ALT (FLOW READING)
SET‑UP PARAMETERS*
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
2286
1524
1041
558
(MM/MIN)
90
60
41
22
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21542
NOZZLE "C"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
50
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
.125
.187
.250
.375
.500
.2
.3
.4
.5
.6
(Sec.)
(IN)
(MM)
2
4
6
10
12
DELAY PIERCE
MATERIAL
THICKNESS
.1
.1
.1
.1
.1
(Sec.)
PIERCE
ON
RISE

70
70
70
70
70
(FLOW READING)
START
PLASMA
P/N 21712
P/N 22531

INSULATOR SHIELD
RETAINER w/O-RING


100
100
100
100
100
(FLOW READING)
CUT
PLASMA
P/N 21539
ELECTRODE


PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
60
60
60
60
60
PRE
50
40
40
40
40
†
CUT †
VOLTAGE
ARC
15
10
10
10
10
135
147
159
171
176
ALT (FLOW READING)
SHIELD
3048
2032
1270
762
609
(MM/MIN)
120
80
50
30
24
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21543
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
51
CUP SHIELD
w/RETAINER

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SHIELD CUP
INSULATOR
P/N 22010
NOZZLE "D"
70
AIR
AIR
METHANE
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
stainless steel
process data
section 4operation
.250
.375
.500
.625
.3
.4
.5
.6
(Sec.)
(Sec.)
6
10
12
16
PIERCE
DELAY (MM) (IN)
.1
.1
.1
.1
ON
PIERCE
THICKNESS
RISE
MATERIAL
START
PLASMA

80
80
80
80
(FLOW READING)
P/N 21712

INSULATOR SHIELD
RETAINER w/O-RING

100
AIR
AIR
METHANE
65
65
65
65
(FLOW READING)
CUT
PLASMA
SHIELD
60
60
60
60
PRE
40
40
40
40
†
CUT †
VOLTAGE
ARC
7
10
10
10
140
151
159
166
ALT (FLOW READING)
SET‑UP PARAMETERS*
2030
1524
889
635
(MM/MIN)
80
60
35
25
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21923
NOZZLE "E"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
52
P/N 22531
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
stainless steel
process data
section 4operation
.125
.187
.250
.375
0
0
.1
.2
(Sec.)
(IN)
(MM)
3
4
6
10
DELAY PIERCE
MATERIAL
THICKNESS
0
0
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


60
60
60
60
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING


85
85
85
85
(FLOW READING)
CUT
PLASMA

PT-24 TORCH
PRESSURE:125PSI/8.6 BAR
PRESSURE:125PSI/8.6 BAR
45
45
45
45
PRE
45
45
45
35
†
CUT †
VOLTAGE
ARC
0
0
0
0
128
133
144
155
ALT (FLOW READING)
SHIELD
2286
1524
1016
711
(MM/MIN)
90
60
40
22
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
50
NITROGEN
NITROGEN
SET‑UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21542
NOZZLE "C"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
53
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
(MM) (IN)
4
.187
6
.250
10
.375
13 .500
THICKNESS
(Sec.)
.1
.1
.1
.1
.3
.4
.5
.6
PIERCE
ON
RISE
(Sec.)
DELAY PIERCE
MATERIAL
START
PLASMA


70
70
70
70
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

70
NITROGEN
NITROGEN
95
95
95
95
(FLOW READING)
CUT
PLASMA
SHIELD
60 60 60 60 PRE
40
40
40
40
†
CUT †
VOLTAGE
ARC
0
0
0
0
132
150
159
162
ALT (FLOW READING)
SET‑UP PARAMETERS*
1905
1270
711
609
(MM/MIN)
75
50
28
24
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21543
NOZZLE "D"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
54
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
.250
.375
.500
.625
.3
.4
.5
.6
(Sec.)
(IN)
(MM)
6
10
12
16
DELAY PIERCE
MATERIAL
THICKNESS
.1
.1
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


80
80
80
80
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

100
NITROGEN
NITROGEN

95
95
95
95
(FLOW READING)
CUT
PLASMA
SHIELD
60
60
60
60 PRE
50
35
35
35 CUT †
†
VOLTAGE
ARC
0
0
0
0
138
145
153
157
ALT (FLOW READING)
SET‑UP PARAMETERS*
2032
1520
889
635 (MM/MIN)
80
60
35
25
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21923
NOZZLE "E"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
55
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
stainless steel
process data
section 4operation
THICKNESS
.187
.250
.375
.500
.3
.4
.5
.6
(Sec.)
(IN)
(MM)
4
6
10
13
DELAY PIERCE
MATERIAL
.1
.1
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


70
70
70
70
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

100
100
100
100
(FLOW READING)
CUT
SHIELD
60
60
60
60
PRE
65
65
65
70
†
CUT †
VOLTAGE
ARC
5
5
5
5
138
150
170
179
ALT (FLOW READING)
SET‑UP PARAMETERS*
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
1778
1143
762
609
(MM/MIN)
70
45
30
24
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

70
NITROGEN
NITROGEN
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692

NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21543
NOZZLE "D"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
56
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
process data
section 4operation
.250
.375
.500
.625 .3
.4
.5
.6
(Sec.)
(IN)
(MM)
6
10
12
16
DELAY PIERCE
MATERIAL
THICKNESS
.1
.1
.1
.1
(Sec.)
PIERCE
ON
RISE
START
PLASMA


80
80
80
80
(FLOW READING)
P/N 21712
P/N 22531
INSULATOR SHIELD
RETAINER w/O-RING

100
NITROGEN
NITROGEN
METHANE

95
95
95
95
(FLOW READING)
CUT
SHIELD
60
60 60 60 PRE
50
70
60
60
†
CUT †
VOLTAGE
ARC
5
5
5
5
133
158
170
177
ALT (FLOW READING)
SET‑UP PARAMETERS*
PLASMA

PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
1778
1524
965
660
(MM/MIN)
70
60
38
26
(IPM)
TRAVEL SPEED
1. Assemble swirl baffle into nozzle first.
2. To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a
very small amount of Krytox grease P/N73585064. Wipe the inner surface of the nozzle retainer that comes in contact
with the nozzle. Use care to apply a very thin film to ensure a proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install nozzle, electrode and water baffle.
NOTES:
P/N 21539
ELECTRODE

SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007

P/N 21923
NOZZLE "E"
NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
57
CUP SHIELD
w/RETAINER

SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
stainless steel
process data
section 4operation
KERF (INCHES)
1.016
0.080
2.024
0.090
2.276
0.100
2.528
0.110
2.78
3.284
58
46
MATERIAL THICKNESS (INCHES)
0.762
0.030
0.040
0.050
0.889
1.143
0.035
0.140
1.524
1.016
0.044in
0.130
0.058in
3.536
0.040
0.045
0.120
1.47mm
3.032
1.27
0.070
1.772
0.050
0.060
1.52
1.397
1.12mm
1.268
0.055
0.060
MATERIAL THICKNESS (mm)
PRECISION PLASMA PT-24 Carbon Steel 16 Amperes
section
SECTION4operation
4
OPERATION
KERF (mm)
KERF (INCHES)
59
48
1.168in
1.0668
1.1176
MATERIAL THICKNESS (INCHES)
0.040
1.016
0.040 0.055 0.070 0.085 0.100 0.115 0.130 0.145 0.160 0.175 0.190 0.205 0.220 0.235 0.250 0.265
0.042
0.044
1.1684
0.046mm
0.046
1.27
1.3208
1.2192
1.321in
0.052mm
1.3716
1.4224
0.048
0.050
0.052
0.054
0.056
1.4732
0.059mm
1.499in
0.058
6.35 6.731
1.524
2.54 2.921 3.302 3.683 4.064 4.445 4.826 5.207 5.588 5.969
0.060
1.016 1.397 1.778 2.159
MATERIAL THICKNESS (mm)
PRECISION PLASMA PT-24 Carbon Steel 35 Amperes
section
SECTION4operation
4
OPERATION
KERF (mm)
KERF (INCHES)
3.81
6.985
0.300
7.62
0.325
8.255
9.525
2.400mm
8.89
2.54
10.16
60
47
0.050
0.100
0.125
0.150
0.250
0.275
0.350
0.375
MATERIAL THICKNESS (INCHES)
1.27
0.400
1.397
0.055
1.651
1.778
1.905
1.524
0.064in
0.076in
2.032
0.060
0.065
0.070
0.075
0.080
2.159
1.930mm
6.35
0.085
0.225
5.715
2.286
0.200
5.08
0.090
0.175
4.445
0.095in 2.413
1.626mm
3.175
0.095
0.100
2.54
MATERIAL THICKNESS (mm)
PRECISION PLASMA PT-24 Carbon Steel 45 Amperes
section
SECTION4operation
4
OPERATION
KERF (mm)
KERF (INCHES)
61
49
0.050
0.063
0.060
0.070
0.080
0.090
0.100
0.110
1.5875
0.125
4.7625
0.188
0.062in
1.57mm
3.175
0.313
7.9375
0.375
0.080in
2.03mm
9.525
MATERIAL THICKNESS (INCHES)
0.250
0.070in
1.78mm
6.35
MATERIAL THICKNESS (mm)
0.438
11.1125
0.500
0.100in
2.54mm
12.7
1.27
0.563
1.524
1.778
2.032
2.286
2.54
2.794
14.2875
PRECISION PLASMA PT-24 Carbon Steel 70 Amperes
section
SECTION4operation
4
OPERATION
KERF (mm)
KERF (INCHES)
12.7
2.54mm
13.97
0.600
15.24
0.650
16.51
0.700
17.78
62
50
0.080
0.300
0.085
0.090
0.400
0.092in
0.550
MATERIAL THICKNESS (INCHES)
0.500
0.100in
2.032
0.800
2.159
2.286
2.413
2.54
0.100
0.095
2.667
0.105
0.750
0.120in
3.048
3.175
20.32
3.05mm
19.05
2.794
0.450
11.43
0.110
2.34mm
10.16
2.921
0.350
8.89
0.115
0.120
0.125
7.62
MATERIAL THICKNESS (mm)
PRECISION PLASMA PT-24 Carbon Steel 100 Amperes
section
SECTION4operation
4
OPERATION
KERF (mm)
section 5
CUTTING QUALITY
5.1 cut angle
Cut squareness is always a concern when using nitrogen
gas. The cut angle is referred to as either being positive
or negative (Figure 5-1). With a positive cut angle, the
top dimension of the part is slightly less than the bottom
dimension. With a negative cut angle, the top dimension
is slightly greater than the bottom dimension. The cut
angle is controlled by standoff (arc voltage), cutting speed,
and cutting amperage. If the cutting speed and amperage
are correct and the part has an excessive positive angle,
the standoff is too high. Begin lowering the arc voltage
in increments of 5 volts, observing cut squareness. There
will always be slight top edge rounding of the part when
using nitrogen.
The optimum torch height is just before the part begins to
develop a negative cut angle. To expand upon the other
two variables, if the torch standoff is correct, too fast of a
cutting speed will result in a positive cut angle; too slow of
a travel speed will result in a negative cut angle. Too high
or too low of current also produces a positive cut angle.
Oxygen plasma will also produce the same positive or
negative cut angle as nitrogen. The cut angle is controlled
by the torch standoff (arc voltage) cutting speed, and cutting amperage. The major difference is the sharp top edge
of the part. The positive angle changes but the sharp top
edge remains. If speeds and currents are correct, lower
the arc voltage in increments of 5 volts until the cut angle
begins to go negative or the cut face is under cut. At this
point, increase voltage until positive angle reappears. This
is the optimum cut squareness for these conditions.
B
POSITIVE (+) CUT ANGLE
Bottom dimension "A" is
greater than dimension "B"
A
B
NEGATIVE (-) CUT ANGLE
Bottom dimension "A" is
less than dimension "B"
A
Figure 5-1. Cut Angle
63
section 5
CUTTING QUALITY
ARC VOLTAGE/STANDOFF
Standoff and arc voltage are proportional.
The higher the torch above the plate (standoff), the higher the operating voltage and vice
versa.
Standoff
Arc Voltage
LAG LINES
These lines appear on the cut surface. They
are used to determine if your
process parameters are correct.
Figure 5-2. Cut Quality
If it has an excessive bevel or rounded top edge, it may
be the standoff (arc voltage) is set too high (Figure 5-3).
Lower the voltage until the excessive bevel or rounded
top edge disappears. On material thickness 1/4 inch (6
mm) and greater, a standoff too close may result in a negative cut angle (Figure 5-5).
5.2 voltage and cut quality.
Standoff (arc voltage) has a direct influence on cut
quality
and squareness. It is recommended that prior to cutting, all cutting parameters are set to the manufacturer's suggested conditions. A sample cut should be
made fol-lowed by a close examination of the part.
ARC VOLTAGE TOO HIGH
Correct Cutting Speed
Positive Cut Angle
Rounded Top Edge
More Dross
Top Dross
Cut Face Smooth
"S" Shaped Lag Lines
Arc Voltage
End View
(+) Cut Angle
Cut Face
Figure 5-3. Cut Quality (Arc Voltage Too High)
64
section 5
CUTTING QUALITY
ARC VOLTAGE CORRECT
Arc Voltage
End View
Optimum
Cut Angle
Correct Cutting Speed
Square Top Edge
No Top Dross
Little or No Bottom Dross
Cut Face Smooth
Uniform Lag Lines
Cut Face
Figure 5-4. Cut Quality (Arc Voltage Correct)
ARC VOLTAGE TOO LOW
Arc Voltage
End View
Correct Cutting Speed
Under Cut Top Edge
Negative Cut Angle
Dross
Cut Face Rough
Vertical Serrated Lag Lines
(-) Cut Angle
Cut Face
Figure 5-5. Cut Quality (Arc Voltage To Low With a Negative Cut Angle)
65
section 5
CUTTING QUALITY
ARC VOLTAGE TOO LOW
Arc Voltage
End View
Under Cut
Top Edge
-/+ Cut Angle
Correct Cutting Speed
Under Cut Top Edge
Negative Cut Angle
Dross
Cut Face Rough
Vertical Serrated Lag Lines
Cut Face
Figure 5-6. Cut Quality (Arc Voltage Too Low With An Under Cut Top Edge)
5.3top dross.
5.4 Dross formation.
Top dross usually appears as splatter near the top edge of
the kerf. This is a result of torch standoff (arc voltage) set
too high or a cutting speed set too fast. Use the parameter charts for recommended speed. The most common
problem is torch standoff or arc voltage control. Simply
lower the voltage settings in increments of 5 volts until
the top dross disappears. If an arc voltage control is not
being used, simply lower the torch manually until the top
dross disappears (Figure 5-7).
The correct cutting arc voltage also has an influence on
dross formation. If the arc voltage is set too high, the cut
angle becomes positive. In addition, dross forms on the
bottom edge of the part. This occurs because we are now
trying to cut the part with the feather tip of the plasma
arc. This dross is usually very tenacious and requires chipping and grinding for removal. Too low of a cutting voltage results in an undercutting of the parts or negative cut
angle. Dross formation usually occurs but in most cases
removes easily (Figure 5-6)
66
section 5
CUTTING QUALITY
TOP DROSS
Splatter appears on the top edge of both
pieces of the plate. Lower the voltage in
increments 5 V dc (maximum ) until top dross
disappears.
Figure 5-7. Top Dross
HIGH SPEED DROSS
Fine roll over dross that welds to
bot tom of edge. Cleaning requires
chipping or grinding.
Figure 5-8. High Speed Dross
LOW SPEED DROSS
Globular dross that forms in large
deposits. Comes off very easily.
Figure 5-9. Low Speed Dross
5.5summary.
Arc voltage is not an independent variable. It is dependent upon cutting amperage, nozzle size, torch standoff,
cut gas flow rate and cutting speed. An increase in arc
voltage can result from a decrease in cutting speed, an
increase in cutting amperage, a decrease in nozzle size,
an increase in gas flow, an increase in cut water flow or an
increase in torch standoff. Assuming that all of the variables are set to the manufacturer's settings, torch standoff
becomes the most influential variable to the process.
Good and accurate height control is a necessity in producing excellent cut quality.
67
section 5
CUTTING QUALITY
68
section 6
MAINTENANCE
6.1 General
G. With all input power disconnected, and with proper
eye and face protection on, blow out the inside of the
power source, the flow control, and the junction box
using low-pressure dry compressed air.
If this equipment does not operate properly, stop work
immediately and investigate the cause of the malfunction.
Maintenance work must be performed by an experienced
person, and electrical work by a trained electrician. Do
NOT permit untrained persons to inspect, clean, or repair
this equipment. Use only recommended replacement
parts.
6.3 Torch Consumable Parts
Make sure power switch on the Power Source is in OFF
position before working on the torch.
Spare parts kit P/N37609 is available for maintaining the
PT-24 torch. For contents and recommended uses, see
Figure 6-1 and Process Data Sheets.
Be sure that the wall disconnect switch or wall circuit
breaker is open before attempting any inspection or
work inside of the Power Source, the junction box, the
flow control box or the PT-24 torch.
6.4 gas pressure switch
6.2 Inspection and Cleaning
The pressure switches are factory set to provide precise
control of the cooling gas and plasma gas pressure. The
two switches are located in the junction box. The pressure
adjustment wheels on the pressure switches should not
be touched. Consult your ESAB representative if you have
determined that the pressure switches are not functioning
properly.
Frequent inspection and cleaning of the Precision Plasmarc System is recommended for safety and proper
operation. Some suggestions for inspecting and cleaning
are as follows:
A. Check work cable to workpiece connection.
6.5pt-24 torch description
B. Check safety earth ground at workpiece and at power
source chassis.
See Table 2-6 for overall size and general configuration.
C. Check heat shield on torch. It should be replaced if
damaged.
A. Mounting. The torch can be mounted by the sleeve
or by the 1.812 inches (46 mm) dia machined surface
shown (see Figure 3-10). This insulated surface and its
shoulder are machined relative to the nozzle retainer
thread on the torch body and is held concentric to the
cutting nozzle within a total indicator reading of 0.010
inches (0.25 mm) or the nozzle bore is within 0.005
inches of any point on the 1.812 dia. When mounting
be sure not to cover the small vent hole in the side of
the sleeve. This hole prevents coolant from building
inside the sleeve should a leak occur in a service line.
D. Check the torch electrode and cutting nozzle for wear
on a daily basis. Remove spatter, resharpen point, or
replace if necessary.
E. Make sure cable and hoses are not damaged or
kinked.
F. Make sure all plugs, fittings, and ground connections
are tight.
B. Service Lines. Both the 4.5 and 17 ft (1.4 m and 5.2 m)
long lines are shielded and connect to the junction box
by a friction fit grounded connection.
Water or oil occasionally accumulates in compressed
air lines. Be sure to direct the first blast of air away
from the equipment to avoid damage to the junction
box or flow control box.
C. Water Cooling. Coolant enters the torch through the
power cable (-), circulates through the torch body and
the electrode, crosses over to the nozzle (+) section of
the torch body through nonconductive bypass tubes,
travels back through the body and circulates between
the nozzle retainer and the nozzle, then back through the
torch body to the junction box via the pilot arc cable.
69
section 6
MAINTENANCE
D. Be especially careful not to get dirt or foreign matter in
the check valve fittings where the plasma cut and start
gases are attached. If however dirt or other foreign matter gets into the check valves, they can be dismantled,
then cleaned and replaced.
D. 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. See Figure 6-2 for further explanation of this system.
E. Shield Gas. Shield preflow, cut shield and postflow
enter the torch through one connection, pass through
the torch body, through the shield gas diffuser and then
out of the orifice in the shield cap that surrounds the
plasma jet.
F.
The seat, ball and spring must not be damaged when
handling. Also, Do NOT substitute any other spring or
ball. If they are dropped, lost, or damaged they must
be replaced with genuine ESAB replacement parts.
Changes, substitutions or damaged parts will affect
set pressures and cause poor starting and piercing.
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.
6.6 TORCH MAINTENANCE
6.7 PT-24 CONSUMABLE REMOVAL,
INSPECTION AND INSTALLATION
Make sure power switch on the console is in the OFF
position and primary input power is disconnected.
Make sure power switch on the console is in the OFF
position and primary input power is disconnected.
A. Always check the three O-rings on the torch body before
each day's operation and replace if any damage or wear
is noted. Apply a thin coat of silicone grease to O-rings
before assembling to torch. The O-ring P/N 638797
inside the torch body that seals the nozzle is especially
critical. Because of its location, damage or wear is not
readily apparent. Replacing this ring on a daily basis is
recommended. Be careful not to scratch or damage the
inside surface of the torch. A toothpick works well for
removing the O-ring. The ring can be replaced without
removing the water baffle P/N 21725, if however the
baffle is to be removed, always use a 3/16 inch (5 mm)
hex wrench or nut driver.
B. Water leaks, moisture, or coolant dripping from the vent
hole in the sleeve indicates service line damage. If service
lines have to be replaced always use two wrenches to
avoid twisting the metal tubes.
NOTE
When changing consumables, if the nozzle retainer/diffuser seems especially stubborn and difficult to remove,
the console is probably still on. With the console on, the
pump will be running and coolant pressure behind the
retainer will prevent it from turning freely. Check the
console before making further attempts to remove the
nut. Notice also that a small amount of coolant will be lost
each time consumables are removed. This is normal and
eventually the coolant will have to be replaced. Check the
coolant before each operation.
A. Removal and Inspection
C. The torch sleeve P/N 21757 is threaded onto the torch
body. If the sleeve is too tight to be readily removed by
hand, use a large adjustable wrench on the flats located
on the body or lightly tighten these flats in a vise. With
the body secured in this manner, the use of two hands
on the sleeve may break the sleeve free, if not, use a
strap wrench. Always check service line connections
for leaks before replacing the sleeve.
70
1.
Unscrew the shield cup retainer. The cup may
come free with the retainer or stay on the torch.
If on the torch, pluck it free with your thumbnail.
Inspect the cup for damage around the orifice,
if the edge of the orifice is damaged, it must be
replaced. Straight cuts cannot be produced if this
orifice is distorted.
2.
The shield cup insulator is sandwiched between
the insulator shield retainer and the nozzle retainer/diffuser and may stay attached to nozzle
retainer because of the very close fit-up between
these members.
section 6
3.
4.
5.
6.
MAINTENANCE
B. Installation
Unscrew the nozzle retainer/diffuser. Inspect for
any damage especially where the retainer contacts
the nozzle. The innerface 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 and poor cutting will result. Replace
as necessary, do not attempt to repair. Check the
small gas passages for blockages. Clear blockages
with an air stream.
1.
Electrode - Apply a thin film of silicone grease to
the O-ring, just enough to produce a shiny surface,
thread the electrode in place and snug tight with
the tool provided. Do NOT overtighten.
2.
The nozzle is removed with the aid of the tool
provided. Place the slot around the groove in the
nozzle and pull the nozzle free.
Nozzle & Swirl Baffle - Place the swirl baffle into
the nozzle being careful not to get grease in the
small gas passages. Push this assembly into the
torch.
3.
Remove the swirl baffle from the nozzle. If the
baffle remains in the torch, it will come free with
the removal of the electrode. Check the small gas
passages for blockage. Clear blockages with an air
stream, if blockages cannot be cleared, replace the
baffle. Do NOT insert anything in these holes in
an effort to clear them. Distortion of these holes
will impair cutting performance.
Nozzle Retainer/Diffuser - To prevent leakage
between the nozzle and nozzle retainer, moisten
the corner of a clean, dry, lint-free cloth with a very
small smount of Krytox grease P/N 73585064.
Wipe the inner surface of the nozzle retainer that
comes in contact with the nozzle. Use care to apply a very thin film to ensure a proper seal. Thread
the nozzle retainer onto torch and hand tighten.
4.
Shield Cup Insulator - Push the shield cup insulator
on the nozzle retainer.
Unscrew the electrode with the aid of the tool
provided.
5.
Shield Cup and Retainer - Screw this assembly
onto the torch and hand tighten.
CUP SHIELD
w/ RETAINER
22531
SHIELD CUP
INSULATOR
22010
NOZZLE
"A" (15A) - 21540
"B" (30A) - 21541
"C" (50A) - 21542
"D" (70A) - 21543
"E" (100A) - 21923
SWIRL BAFFLE
21852 (15A) - 2 HOLES
21536 (30A) - 3 HOLES
21692 (50/70/100A) - 4 HOLES
O-RING
98W18
O-RING
638797
O-RING
86W62
O-RING
950715
INSULATOR SHIELD
RETAINER W/ O-RING
C-21712
NOZZLE RETAINER/
DIFFUSER - D-22007
Slot for
removing
nozzle
Assemble
swirl ring
into nozzle
first
For removing
and replacing
water baffler
ELECTRODE
(15/30/50/70A)
21539
ELECTRODE &
NOZZLE TOOL
C-21765
Hex for
installing
electrode
71
WATER
BAFFLE
C-21725
TORCH ASSEMBLY
D-21530
section 6
MAINTENANCE
NOTE:
Schematics and Wiring Diagrams on 279.4mm x 431.8mm
(11” x 17”) paper are included inside the back cover of this manual.
72
section 7
TROUBLESHOOTING
7.1 Troubleshooting
7.2 PROCESS TROUBLESHOOTING
A.
Programmable Logic Controller (PLC).
The PLC is located in the Precision Plasma Power
Source. It is a device capable of providing predefined
outputs depending on state of the inputs. The precise
conditions are programmed and permanently stored
in the PLC. The PLC is visible through the plexiglass
window on the left side panel of the power source.
The PLC will provide predefined outputs in response
to input signals from external devices. 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; Input (0-15) and
Output (0-11). Input LEDs light when the corresponding signal is detected by the PLC. Output LEDs light
when the PLC issues a signal to an external device.
LEDs are 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.
The signal exchange between the PLC and external
devices are both time 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.
ELECTRIC SHOCK CAN KILL! Be sure that all primary
power to the machine has been externally disconnected. Open the line (wall) disconnect switch or circuit
breaker before attempting inspection or work inside
the power source.
Capacitors can store high voltages even when power
is disconnected or unit is deenergized. Ensure power
supply capacitors are grounded prior to performing
maintenance.
73
section 7
TROUBLESHOOTING
Figure 7-1. Programmable Logic Controller (PLC)
Table 7-1. PLC Input/Output LEDs
INPUT
LED
OUTPUT
FUNCTION
LED
FUNCTION
0
START/STOP
0
TRAVEL
1
PREFLOW
1
HI FREQUENCY
2
ARC-ON
2
PILOT ARC RELAY
3
O2 PRESSURE
3
POWER SOURCE
4
N2 PRESSURE
4
START PRESSURE SWITCH FAULT
5
PILOT ARC
5
CUT GAS PRESS. SWITCH FAULT
6
FAULT
6
FAULT OUTPUT
7
7
8
8
START GAS ON N2
9
CUT GAS ON N2
10
FULL SHIELD
11
REGULATED SHIELD
74
section 7
TROUBLESHOOTING
7.3 troubleshooting procedures
Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite
simple. If the cause cannot be quickly located, shut off
the input power, open up the appropriate component,
and perform a simple visual inspection of all the components and wiring. Check for secure terminal connections,
loose or burned wiring or components, bulged or leaking
capacitors, or any other sign of damage or discoloration.
Voltages in plasma cutting equipment are high
enough to cause serious injury or possibly death. Be
particularly careful around equipment when the covers are removed.
NOTE
The cause of control malfunctions can be found by
referring to the sequence of operations (Figure 7-1) and
electrical schematic diagram (Figure 7-2, 7-3, 7-5 and 7-8)
and checking the various components. A volt-ohmmeter
will be necessary for some of these checks.
Before checking voltages in the circuit, disconnect the
power from the high frequency generator to avoid damaging your voltmeter.
Table 7-2. Troubleshooting Guide
PROBLEM
Reduced consumable
(electrode) life
POSSIBLE CAUSE
ACTION
Skeleton cutting
Cutting skeletons to facilitate their removal from
the table can adversely affect electrode life by:
1. Causing the torch to run off the work.
2. Continuous Pilot Arc edge starts.
3.
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.
4. Increased 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.
See crashing/diving in Item 2 below.
Height control problems
Increase piercing standoff.
Piercing standoff too low
Starting on edges with continuous pilot arc
75
Position torch more carefully or use a waster plate
to start on.
section 7
TROUBLESHOOTING
Table 7-2. Troubleshooting Guide
PROBLEM
Reduced nozzle life
POSSIBLE CAUSE
ACTION
Diving is usually caused by a change in arc voltage when an automatic height control is in use.
Diving can damage the nozzle. Usually the voltage change is the result of a change of direction
or speed to negotiate a corner or as a result of
plate falling away from the arc. These problems
can be dealt with by disabling the height control
in such situations and by extinguishing the arc
earlier when finishing the cut on falling plate.
Contacting work
diving
Diving may also be caused by a problem with
the height control or the signals fed to it.
The nozzle may sometimes be damaged if the
torch hits a flipped up part. This is difficult to
avoid entirely but careful part programming can
minimize the problem.
Work flipping
This refers to crashes or nozzle damage caused
by the front end of the torch catching on top
spatter after a pierce. Hold the torch at a high
standoff or start with a longer lead-in to avoid
this problem.
Catching on piece
Reduce speed to prevent rooster tailing during
cut. Reduce speed around corners if rooster tailing occurs only coming out of corners.
Excessive speed
Same as for electrode above.
Process factors
Increases delay time.
Inadequate initial delay.
Pierce not complete before starting
Poor cut quality
Gas selection
O2 carbon steel - best cut quality minimal dross.
N2/Air -Stainless steel best cut quality when used
with CH4 or H-35 alternate gas.
N2/Aluminum - best cut quality when using CH4
alternate gas.
Verify and correct torch alignment (vertical).
Torch alignment to work
Verify correct current. Refer to perimeter tables.
Incorrect current
Cutting over slats will cause some bottom dross.
If the cut runs along the slat, it can produce
other cut quality problems. The only solution is
to avoid running along the slats.
Cutting over slats
76
section 7
TROUBLESHOOTING
Table 7-2. Troubleshooting Guide
PROBLEM
Poor cut quality
(cont.)
POSSIBLE CAUSE
ACTION
Cutting machine or torch vibrates
Make sure brackets and height control are
rigid and properly adjusted.
Bevel angle
Wrong travel direction (good angle on
scrap side)
Same as dross and cut surface above except
varying characteristics of material being cut
and cutting machine or torch vibrations.
Standoff and speed have considerable effect
on bevel angle.
With standard swirl parts the most square
side of the cut is on the right side of the
direction of travel.
Plate shifting while being cut
Small, thin or lightweight plates can shift
while cutting. Clamp them down.
Slag buildup on cut table
Clean slag from cut table.
No pilot arc
Contaminated electrode
Clean or replace electrode.
Insufficient spark gap setting (in plumbing box
Set spark gap to 0.040 IN (1.0 mm).
Pilot Arc Contactor (PAC) malfunctioning
Replace contactor.
Blown pilot arc fuses
Replace fuses.
Pressure switches
N2 pressure switch, switch faulty or not
adjusted properly.
No arc transfer
Cutting current setting may be too low
Raise cutting current (see Process Data).
Torch may be too high above the workpiece
Lower the torch standoff slightly.
Work lead may be dis-connected from
cutting table
N2 or O2 check valve in torch body may
be stuck open
77
Make sure work lead is firmly connected to
workpiece or cutting table.
Unscrew torch sleeve. Then disassemble
two copper adapters from torch body and
remove debris. Do not lose ball and string.
section 7
TROUBLESHOOTING
Table 7-2. Troubleshooting Guide
PROBLEM
Torch fails to fire
POSSIBLE CAUSE
ACTION
Start gas
Lower start gas flow.
Cooling water flow
Pump pressure too low; should be 80/90 PSI
(5.5/6.2 bars).
Faulty cooling water flow switch CWFS
Obstruction in torch limiting cooling
water flow
Nozzle life extremely short
Coolant flow through torch should be
greater than 0.5 gal/min.
Pilot arc high/low switch is in high position
Place switch in low position.
Nozzle pitting/arcing inside bore
Nitrogen quality too low, requires 99.995%
pure for longest nozzle life.
Start gas flow too low
Short electrode life
Replace CWFS switch.
Check cutting parameters.
Insufficient cooling
Check pump for 80/90 PSI (5.5/6.2 bars)
output pressure.
Start gas quality
Gas quality needs to be 99.995% minimum.
Cut gas quality
Oxygen gas needs to be 99.8% minimum.
Short electrode/
nozzle life
Water leak on torch front end
Check nozzle retainer for tightening.
Positive cut angle
Arc voltage too high
Lower arc voltage in small increments
Cutting speed too fast
If cutting speed is too fast, simply lower
speed
Cutting current too high
Wrong nozzle being used or lower current
into correct operating range
Cutting current too low
Negative cut angle
Raise current if nozzle is designed for it.
Arc voltage too low
Raise the arc voltage in small increments.
Cutting speed too slow
Slowly increase cutting speed.
78
section 7
TROUBLESHOOTING
Table 7-3. PT-24 Torch Leak Procedure
Front end of torch leaking
Remove:
shield cup
insulator shield retainer
insulator ring
nozzle retaining cup
nozzle
swirl baffle
electrode
Visually inspect nozzle sealing o-ring and electrode o-ring
Are o-rings
damaged?
yes
Replace
o-ring
no
Visually inspect nozzle and retaining cup metal-to-metal seat
Are seats
damaged?
yes
Replace
parts
no
Reassemble electrode, swirl baffle, nozzle and retaining cup
Still
Leaking?
yes
Replace nozzle
Still
Leaking?
no
no
Let’s cut!
79
yes
Replace Retaining cup
section 7
TROUBLESHOOTING
80
section 8replacement parts
8.0 Replacement Parts
8.1General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
8.2
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.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
81
section 8replacement parts
8, 9
10 16 12
1
15
3
5
4
6
6
7, 8
3
3
6
5
13
13
16
12
12
15
Figure 8-1. Flow Control Box, P/N 37416 (Left, Front and Right Side Views)
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Qty.
Req.
1
1
3
1
6
6
1
3
2
1
2
4
2
1
2
2
Part
No.
Description
32189
35862
21898
952140
21711
22228
952220
951474
634518
6271128
672528
08030281
23101300
1006733
11Z93
952202
Circuit
Symbol
BOX, FLOW CONTROL
COVER, FLOW CONTROL BOX (NOT SHOWN)
FLOW METER W/TUBE 1/4-33-G-5
FLOW METER W/TUBE 1/4-15-G-5
GAUGE 1.50 #160PSI
VALVE ASSY
SWITCH TOGGLE 3PDT 3 POS 15A 125V
SEAL SWITCH BLACK
SWITCH TOGGLE DPDT 2 POS15A 125V
CONN BOX RCPT 14MP SHELL 20
SPACER .26 ID x .38D x 1.50 LG STL
ADAPTOR B/I-G F 1/8 NPTM
SPACER .28ID x .50D x .38 LG NYL
CONN BOX RCPT 19FS SHELL 22
ADAPTOR B/ACETM 1/8 NPTM
ADAPTOR B/OXY M 1/8 NPTM
82
SW1
SW2, 3
J1
J2
14
section 8replacement parts
25
DETAIL ’B’
(See Fig. 8-3.)
26
25
DETAIL ’C’
(See Fig. 8-3.)
22
21
A
23
24
24
23
23
A
23, 27, 28
23
SECTION A-A
Figure 8-2. Flow Control Box, P/N 37416 (Top and Inside Views)
Item
No.
21
22
23
24
25
26
27
28
Qty.
Req.
1
1
12
4
2
2
1
1
Part
No.
Description
950760
635686
952087
952172
952086
952084
21897
44151300
Circuit
Symbol
RELAY ENCLOSED DPDT 24VAC 10A
TERM. BLOCK 8 POS
FITTING 1/8 NPTM SWIVEL ELBOW
FITTING 1/4 NPTM STRAIGHT
FITTING 1/4 NPTM SWIVEL ELBOW
FITTING 1/4 NPTM SWIVEL TEE
VALVE CHECK ASSEMBLY
COUPLING PIPE BND 1/8 BRS
83
ICR
TB1
section 8replacement parts
49
35
45
34
38
32
33
37
33
40
34
35
34
35, 46
33
39
32
41
35, 45
36, 35
46
44
34
40
35
DE TAIL 'B '
43
48
35, 46
35, 45
42
46
47
34
35, 46
DE TAIL 'C '
43
37
34
31
Figure 8-3. Flow Control Box, P/N 37416 (Inlet and Outlet Manifold Assemblies)
Item
No.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
Qty.
Req.
1
2
7
8
14
3
2
1
1
6
1
1
3
1
5
5
1
1
1
Part
No.
Description
35867
21897
44151300
952087
67100030
950390
952083
952697
11Z93
21711
08030281
952202
951982
35868
92140024
952703
952085
672528
0558007539
Circuit
Symbol
BLOCK INLET MANIFOLD
VALVE CHECK
COUPLING PIPE BND 1/8 BRS
FITTING 1/8 NPTM SWIVEL ELBOW
NIPPLE PIPE 1/8 x .75 LG
TEE BRASS 1/8 NPTF
FITTING 1/8 NPTM STRAIGHT
VALVE SOLENOID 3 WAY
ADAPTOR B/ACET M 1/8NPTM
GAUGE 1.50 160 PSI
ADAPTOR B/I-G F 1/8NPTM
ADAPTOR B/OXY M 1/8 NPTM
SWITCH PRESSURE 10 - 100PSI
BLOCK OUTLET MANIFOLD
ELBOW PIPE ST 90° 1/8 BRS
VALVE SOLENOID
FITTING 1/8 NPTM SWIVEL TEE
SPACER .26 ID x .380 x 1.50 LG STL
FITTING, EXHAUST, M5 1/8 NPTF
84
SOL1
PS1, 2, 3
SOL2, 3, 4, 5, 6
section 8replacement parts
PLASTIC TUBING, .250 OD x .040 WALL (TYP.)
90858003 (14.5’ TOTAL)
Figure 8-4. Flow Control Box, Tubing Network
TUBING 90858003
FROM
TO
LENGTH
FM1(OUT)
NV1(IN)
10.50
FM4(OUT)
NV4(IN)
10.50
FM2(OUT)R
NV2(IN)
12.50
FM3(OUT)L
NV5(IN)
12.50
FM1(IN)
O2 (OUT)BOT
8.00
FM2(IN)
N2 (OUT)TOP
8.00­
FM3(IN)
N2 (OUT)BOT
8.00
FM4(IN)
SOL1 01
10.50
FM2(OUT)L
NV3(IN)
10.50
FM3(OUT)R
NV6(IN)
8.00
NV6(OUT)
SOL6 01
12.50
NV3(OUT)
SOL4 01
10.50
NV1 OUT)
SOL3 01
12.50
NV2(OUT)
SOL2 01
12.50
NV5(OUT)
SOL5 01
10.50
NV4(OUT),
SOL5 01
10.50
02(OUT)
SOL1 03
6.00
85
section 8replacement parts
67
66
68
74
65
80
64
71
72
73
WORK
61
62
63
75
76
Figure 8-5. Junction Box, P/N 37400 (Inlet View)
ITEM
NO.
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
QTY
REQ.
PART
NO.
DESCRIPTION
1
6271128
1
11Z93
1
11Z62
1
674969
1
677905
1
37250
1
37387
1
951188
1
37386
1
1
37385
1
37391
1
2062119
1
37392
1
993426
1
23610197
1
32288
1
35861
1
37384
1
950256
CONN. BOX RECPT. 14MP SHELL 20
ADAPTOR B/FG M X 1/8 NPTM SPEC
ADAPTOR B/OXYM X 1/8 NPTM SPEC
PCB FILTER ASS'Y
SPARK GAP ASS'Y
TRANSFORMER H.F. AUTO
BUSBAR TORCH CABLE
LOCKNUT CONDUIT 2 NPT
COVER KYDEX (NOT SHOWN)
HOSE FEED THROUGH
BAFFLE KYDEX
BULKHEAD 1/8 NPTF LHX 1/4 NPTF LH
CONN 9 POS AMP
BULKHEAD 1/4 NPTF LH X 1/4 NPTM
GROMMET RUBBER 1.5 ID X 1.75 OD
PLUG HOLE .875DH .125 CT NYBLK
CABINET JUNCTION BOX SCREENED
COVER JUNCTION BOX HINGED
BASE KYDEX JUNCTION BOX
CAP MICA .002 mf 10KWV
86
CIRCUIT
SYMBOL
J1
PCB1
SG1
T1
J2
section 8replacement parts
84
G ND
85
84
83
89
86
87
91
81
82
86
88
Figure 8-6. Junction Box (Outlet View)
ITEM
NO.
QTY
REQ.
81
82
83
84
85
86
87
88
89
90
91
1
1
1
2
4
2
1
1
1
1
1
PART
NO.
DESCRIPTION
952697
952083
37382
21711
22364
951982
37388
37361
951179
950116
0558007539
CIRCUIT
SYMBOL
VALVE SOLENOID 3-WAY
CONNECTOR MALE 1/8 NPT
MANIFOLD
GAUGE 1.50 160 PSI
COUPLING 1/8 FLOW 1/4 NPT
SWITCH PRESSURE 10 - 100 PSI
BUSBAR PILOT ARC
TORCH CONNECTION SHIELD
HV TRANSFORMER
EMI FILTER
FITTING, EXHAUST, M5 1/8 NPTF
87
SOL1
PS1, 2
T2
section 8replacement parts
TOP VIEW
LEFT SIDE VIEW
RIGHT SIDE VIEW
Figure 8-7. Precision Plasma Console/Power Source P/N 37357, Overall View
ITEM
NO.
QTY
REQ.
131
132
133
134
135
136
137
1
1
1
2
1
1
1
PART
NO.
DESCRIPTION
2091514
995227
35925YL
13734588
35924YL
34941
35923YL
CIRCUIT
SYMBOL
LABEL WARNING
LABEL WARNING EXPOSED HIGH VOLT
COVER TOP
LOGO ESAB CLEAR
PANEL SIDE RIGHT
LENS CLEAR
PANEL SIDE LEFT
88
section 8replacement parts
SILICONE
RUBBER
151
147
146
148
SILICONE
RUBBER
142
150
141
151
See Meter
Assy. Detail
146
148
143
144
AM1 & VM1
147 TYP. REF.
PBC1
REF,
146
149
154
155
156
152
See Detail
"Y"
Figure 8-7C
Figure 8-7A. Power Source Front View
ITEM
NO.
141
142
143
144
146
147
148
149
150
151
152
154
155
156
QTY
REQ.
1
1
1
1
3
2
2
1
1
4
1
1
3
1
PART
NO.
DESCRIPTION
32286GY
954751
2234589
2234587
951474
951061
634518
672508
37345GY
952095
952182
950518
182W82
598481
CIRCUIT
SYMBOL
PANEL FRONT
OVERLAY PRECISION PLASMA
POT 10K 10 TURN
DIAL, DIGITAL TURNS COUNTING
SEAL SWITCH BLACK
METER LED 5 VDC
SWITCH TOGGLE DPDT 2 POS 15A
SWITCH TOGGLE 3PST 2 POS 15A
CONTROL PANEL PRECISION PLASMA
SPACER LED
SPOUT REMOTE FILLER WITH CAP (See Fig. 8-7C)
GROMMET RUBBER 2.12 ID x 2.50 OD x.06W
ELBOW 90° 1/4 NPT
GAUGE 200 PSI
89
R2
AM1, VM1
S2, S3
S1
section 8replacement parts
161 (MOD1-P1)
168 (PLC1 P1)
169 (PLC1 J1)
165
168 (MOD1-P3)
170, 171
161 (PLC1 P2)
163 (PLC1 J2)
166 (J3)
167 (P3)
164
162
163 (J4)
161 (P4)
172
Figure 8-7B. Power Source, P/N 37357 (Inside Front View)
ITEM
NO.
161
162
163
164
165
166
167
168
169
170
171
172
QTY
REQ.
3
1
2
2
1
1
1
2
1
2
1
1
PART
NO.
2234521
635686
2234519
17750020
673458
2234518
2234520
2234891
2234877
951161
37448
647065
DESCRIPTION
CIRCUIT
SYMBOL
PLUG 16 POS
TERMINAL STRIP 8 POS (MARKER 647343)
RECEPTACLE 16 POS
RESISTOR 20 OHM 50W NI
CONTACTOR PILOT ARC 3P 40A
RECEPTACLE 8 POS
PLUG 8 POS
PLUG 10 POS
RECEPTACLE 10 POS
CAP METPOLY 20 uf 400VDC
BUSBAR DIODE
CHOKE SIGNAL #CH12
90
MOD1-P1, PLC1-P2 & P4
TB6
PLC1-J2 & J4
R11, 12
K2
J3
P3
PLC1-P1, MOD1-P3
PLC1-J1
C1, 2
L1
section 8replacement parts
191, 191A
181
195
182, 182A, 182B, 182C,
182D, 182E, 183
152 (REF.)
TYWRAP
186
190
192
194
(11")
BASE
192
189
194
(4")
"Y" DETAIL
188
187
186
185
193
.50"
192
End of level indicator tube
must be sealed with a porous
material that lets air through,
keeps water in and dirt out.
Use foam protector provided
with pump. Secure with
TyWrap.
184
Figure 8-7C. Power Source Left Side View (Cover Removed)
ITEM
NO.
181
182
182A
182B
182C
182D
182E
183
184
185
186
187
188
189
190
191
191A
192
193
194
195
QTY
REQ.
1
1
1
1
3
1
1
6
1
2
1
1
2
1
5
1
1
5
1
1.25FT
3.67FT
PART
NO.
DESCRIPTION
951209
38103
950096
952034
952030
952032
952205
952053
35920GY
952013
952179
35682
952012
13735308
950760
38131
951009
994471
952181
90858007
90858625
CIRCUIT
SYMBOL
PLC CONTROLLER (REQUIRES (1) 99513607 EPROM)
PCB ISOLATION AMP (See Fig. 8-7A, Meter Detail)
HOUSING CONTACT CRIMP 3 PIN
PLUG 5 POS (COVER 952035)
PLUG 18 POS (COVER 952031)
PLUG 16 POS (COVER 952033)
RECEPTACLE P/C 4 POS
STANDOFF #6-32 x 7/8 LG
BASE PRECISION PLASMA
CASTER SWIVEL
TANK WATER
XFMR AUTO
CASTER FIXED
RELAY ENCLOSED DPDT 120 VAC 20 A
RELAY ENCLOSED DPDT 24 VAC 10A
BOARD P/C START UP
RECEPTACLE P/C 6 POS 10A 300V
CLAMP HOSE W/D .50D - 1.06D SS
PLASTIC "Y" PIPE FOR 5/8IN TUBING
BRAIDED TUBING 5/8 ID
TUBING CLEAR VINYL 5/8 ID
91
PLC
PCB1
PCB1-P7, P9
PCB1-P10
PCB1-P1, 3, 4
PCB1-P2
PCB1-P5
T2
K7
K3-6, 8
PCB2
PCB2-P1
section 8replacement parts
201
211
202
210
203
204
213
205
208, 209
206, 212
207
Figure 8-7D. Power Source, Rear View
ITEM
NO.
201
202
203
204
205
206
207
208
209
210
211
212
213
QTY
REQ.
1
1
1
1
1
1
1
2
2
2
1
1
1
PART
NO.
DESCRIPTION
35928GY
952209
952210
97W63
23610197
952571
32202GY
58V75
951568
950829
950937
952136
0558954156
CIRCUIT
SYMBOL
DOOR ACCESS REAR
CONN BOX RECEPTACLE 19 FS SH
J1
CONN BOX RECEPTACLE 14 FS SH
J2
STRAIN RELIEF
PLUG HOLE .875 DIA .125 CT NYL BK
FUSE 7A 600VAC FAST ACTING
F4
PANEL REAR
ADAPTOR B/A-W F 1/4 NPTM BKHD
PLUG & CHAIN 5/8-18 LH W/NUT
CIRCUIT BREAKER 3 AMP
CB1,2
STRAIN RELIEF
FUSE HOLDER PANEL MOUNT
LABEL RATING PRECISION PLASMA
92
section 8replacement parts
224, 225
226
227
228
223
222
234
235
232, 233
229, 230, 231
Figure 8-7E. Power Source, Right Side, Top View (Cover Removed)
ITEM
NO.
222
223
224
225
226
227
228
229
230
231
232
233
234
235
QTY
REQ.
1
1
1
1
1
1
1
1
1
2
1
1
1
1
PART
NO.
DESCRIPTION
952144
37359
2062334
672058
672002GY
673502
952026
951347
951068
68100126
951215
951346
35679
36417GY
CIRCUIT
SYMBOL
GASKET
MODULE POWER (See Fig. 8-8)
MOD1
MOTOR FAN
M1
BLADE FAN
SHROUD FAN
CONTACTOR 3 POLE 75A
K1
TERMINAL BLOCK 7 POS 25A 12-18 AWG
TB2
PUMP CARB W/STRAINER (See Fig. 8-7F)
CLAMP V-BAND 1.91D x .41W
REDUCER 3/8 NPT TO 1/4 NPT
MOTOR CARB 1/3 H/P
M2
BLADE FAN 8.75 DIA
XFMR CONTROL
T1
SHROUD FAN 9.5 OD
93
section 8replacement parts
243
246
245
CHECK VALVE DETAIL
243
241
242
243
241
243
244
PUMP DETAIL
245
FLOW SWITCH DETAIL
Figure 8-7F. Power Source, Flow Switch, Check Valve, Pump Detail
ITEM
NO.
QTY
REQ.
241
3
242
1
243
5
244
1
245
2
246
1
PART
NO.
DESCRIPTION
182W82
950179
10Z30
950001
58V75
21124
CIRCUIT
SYMBOL
ELBOW 90° 1/4 NPT
TEE PIPE BRANCH 1/4 NPT BRS
ADAPTOR B/A-W M 1/4 NPTM
SWITCH FLOW .25 GPM SPST
ADAPTOR B/A-W F 1/4 NPTM BKHD
VALVE CHECK ASSY
94
FS1
section 8replacement parts
267
252 (2)
265
251
252
266
255
263
264
258
252
253
256
257
254
259
260
261
262
261
Figure 8-7G. Power Source, Front View, Tob View (Cover Removed)
ITEM
NO.
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
QTY
REQ.
1
4
1
1
1
1
3
1
1
1
2
1
1
1
5IN
1
1
PART
NO.
DESCRIPTION
36418
13734871
36539
36538
950487
35919
35929
995103
950167
950823
92W57
13735961
96W10
2017483
90858009
2234891
36423
CIRCUIT
SYMBOL
HOSE ASSY (TANK BOTTOM-PUMP INLET)
CLAMP HOSE W/D .25D - .62D
HOSE ASSY (FLOW SWITCH TO CORE)
HOSE ASSY (PUMP OUTLET - TORCH OUT)
TERM BLOCK 2 POS
MOD1-TB2
BOARD TERMINAL OUTPUT
TB5
BUSBAR INPUT
TERMINAL BLOCK 24 POS 15A (MARKER STRIP 950238)
TB3
GROMMET RUB 1.12 ID x 1.50 OD x .06W
BUSHING SNAP
GROMMET RUB .63 ID x .88 GD x .06W
HEAT EXCHANGER
HOLDER FUSE
FUSE 1A 250V FAST ACTING
F3
TUBING NYLOBRADE 3/8 ID 5/8 OD
PLUG 10 POS
MOD1-P4
HOSE ASSY (PUMP OUT TO GAUGE)
95
section 8replacement parts
273
271
313
309
299
274
288
307
308
274
272
309
275
276
277
312
278
279
317
315
280
281
311
298
297
282
283
314
294
293
284
285
296
295
312
293
294
286
292
312
291
310
290
289
312
288
287
306
301
305
302
304
303
Figure 8-8. Power Module, P/N 37359, Top and Back View
96
section 8replacement parts
ITEM
NO.
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
QTY
REQ.
1
1
2
2
2
2
2
2
2
1
1
1
3
1
1
1
1
2
1
1
2
1
4
4
2
2
1
1
1
2
1
1
1
1
1
1
2
2
1
4
4
1
1
1
1
PART
NO.
DESCRIPTION
35792
35793
951940
951983
38052
951194
17750020
951980
951191
951979
951196
35794
951321
951978
951192
35940
35790
950711
32958
36872
952255
36873
951193
17721020
951518
951185
35788
35918
35844
951981
2234877
674156
2234518
38047
2234519
17250005
99512068
951028
2062282
951313
647345
950823
639533
17140310
951828
CIRCUIT
SYMBOL
BUSBAR IGBT (+)/CAPACITOR
BUSBAR IGBT (-)/CAPACITOR
CAPACITOR 1uf 600VDC
C6,7
CAPACITOR 3300uf 450VDC
C4,5
P/C BRD ASSY IGBT DRIVER
PCB2,3
PAD THERMAL POWER RESISTOR 50W
RESISTOR 20 OHM 50W NI
R4,5
IGBT 300A 600V
Q1,2
PAD THERMAL IGBT 1200V
SCR 90A
SCR1
PAD THERMAL SCR MODULE
BUSBAR INPUT BRIDGE /SCR
VARISTOR METAL OXIDE 275V
MOV1,2,3
BRIDGE DIODE 3 PH 130A
BR1
PAD THERMAL BRIDGE
TRANSFORMER CONTROL
T1
BUSBAR JUMPER
SWITCH TERMINAL 194°F
TS1,2
TRANSFORMER CURRENT
T2
BUSBAR CAPACITOR
CAPACITOR FILM 40uf 400VDC
C8,9
BUSBAR CAPACITOR/GBT
PAD THERMAL POWER RESISTOR 25W
RESISTOR 20 OHM 25W NI
R6,7,8,9
PAD THERMAL DIODE MODULE
MODULE DIODE 100A 600V
D1,2
BUSBAR OUTPUT BRIDGE
BUSBAR SHUNT
NOMEX INSULATOR 3 x 5
HEATSINK
BLOCK TERMINAL 10 POS
J3
ADAPTOR
TB3
BLOCK TERMINAL 8 POS
J2
SHUNT FEEDBACK
SH1
BLOCK TERMINAL 16 POS
J1
RESISTOR 5 OHM 50W
R1
BRACKET MTG #9 RESISTOR
CAP FILM 1mf 630VDC
C2,3
CAPACITOR .22mf 1000VDC
C1
CAPACITOR .01mf 630VDC/200VAC
C12,13,14,15
BUSHING SNAP 1.31 ID 1.50 MH .44L
BUSHING SNAP .687
BUSHING SNAP .857ID 1.093MH
RESISTOR CM FILM AL 2W 10K
R3
CAPACITOR .033uf 1000VDC
C11
Figure 8-8. Power Module, P/N 37359, Top and Back View - (Cont)
97
section 8replacement parts
325
324
321, 322, 323
320
M1
REF.
L1
REF.
Figure 8-8A. Power Module Assembly
ITEM
NO.
320
321
322
323
324
325
QTY
REQ.
1
1
2
2
2
1
PART
NO.
DESCRIPTION
37102
38148
951339
951340
951469
35800
CIRCUIT
SYMBOL
BRACKET PCB KYDEX
PCB ASSY PCM CONT BRD PWR MOD
PLUG FEMALE 12 POS
PLUG FEMALE 14 POS
CAPACITOR .022uf 250VAC
INSULATOR NOMEX
98
PCB1
PCB1 P1, 5
PCB1 P2, 6
C16, 17
section 8replacement parts
349
348
342
345
346
343
350
351
SECTION "A-A"
Figure 8-8B. POWER MODULE, BOTTOM VIEW
ITEM
NO.
342
343
345
346
348
349
350
351
QTY
REQ.
1
1
1
1
1
1
1
1
PART
NO.
DESCRIPTION
951182
2234877
950487
950823
17280215
35700
35681
35680
CIRCUIT
SYMBOL
FAN AXIAL
BLOCK TERMINAL 10 POS
TERMINAL STRIP 2 POS
BUSHING SNAP .687
RESISTOR 1.5K OHM 100W
INDUCTOR POWER FACTOR
TRANSFORMER ASSY MAIN
INDUCTOR ASSY OUTPUT
99
M1
J4
TB2
R2
L1
T3
L2
section 8replacement parts
S TAR T
409
S HIE LD 1
C UT
S HIE LD 2
410
C OM/C OM
C OM/C OM
S HIE LD2
S HIE LD1
C UT
S TAR T
403
S IL
409
404
OR N
404
OR N
402
401
408
407
405
B LU
406
YE L
405
B LU
406
YE L
410
401
410
S HIE LD 1
S TAR T G AS
S OLE NOID
S HIE LD 2
401
C UT G AS
S OLE NOID
S HIE LD G AS S OLE NOIDS
Figure 8-9A. SOLENOID ASSEMBLY, PT-24, P/N 22376
ITEM NO.
QTY REQ.
PART NO.
DESCRIPTION
401
3
952697
SOLENOID 3-WAY
402
1
952703
SOLENOID 2-WAY
403
1
22364
CONNECTOR QUICK DISCONNECT SILVER
404
2
22365
CONNECTOR QUICK DISCONNECT ORANGE
405
2
22366
CONNECTOR QUICK DISCONNECT BLUE
406
2
22367
CONNECTOR QUICK DISCONNECT YELLOW
407
1
952931
PLUG BLOCK 6 POS
408
1
593985
O-RING 1.42 ID X .103 NEOP 70A
409
1
0558007539
FITTING, EXHAUST, M5 1/8 NPTF
410
2
0558006291
ELBOW STREET 90 DEG 1/8 BRS
100
CIRCUIT SYMBOL
section 8replacement parts
1
2
3
1 2 3 4 5 6 7 8
Relay 24 VAC Common
Shield 2 and Relay NC
Plasma 1 and 2 Common
Shield 1 and 2 Common
Shield 1 and 2 Relay 24VAC
Relay NC
Plasma 2
Plasma 1
Solenoid
and
Relay
Wires
5
4
6
7
Figure 8-9B. T GAS SHUT-OFF VALVE, PT-24, P/N 0558001335
ITEM
NO.
QTY
REQ.
1
2
3
4
5
6
7
2
2
1
2
2
2
1
PART
NO.
0558001458
9852921
0558001502
593986
REF
REF
REF
CIRCUIT
SYMBOL
DESCRIPTION
SOLENOID 3-WAY
SOLENOID 2-WAY
FLANGE
O-RING 1.42 ID X .103 NEOP 70A
PLUG CONNECTOR, 8 POSITION
PLUG, 8 POSITION
RELAY
101
section 8replacement parts
27
20
23
7
15
21
5
6
22
24
29
4
2
25
13
1
26
20
9
11
10
NOTE:
Torch is supplied with 70 amp consumables assembled in place.
12
8
102
14
3
section 8replacement parts
Table 8-9. Precision Plasma PT-24 Torch Assembly
ITEM NO.
QTY
PART OR CODE NO
1
1
21758
BODY & TUBE AY PT-24 TORCH
2
1
22568
SLEEVE TORCH PT-24
3
1
21761
POWER CABLE 4.5FT (1,4m) PT-24
1
22424
POWER CABLE 12FT (3,7m) PT-24
1
22398
POWER CABLE 17FT (5,2m) PT-24
1
21762
CABLE PILOT ARC 4.5FT (1,4m) PT-24
1
22425
CABLE PILOT ARC 12FT (3,7m) PT-24
4
DESCRIPTION
1
22396
CABLE PILOT ARC 17FT (5,2m) PT-24
5
1
22381
GAS LINE START (BLU)
6
1
22380
GAS LINE CUT (YEL)
7
1
REF
8
1
21539
ELECTRODE
9
1
21692
SWIRL BAFFLE 50/70 AMP
10
1
21543
NOZZLE
11
1
22007
RETAINER/DIFFUSER NOZZLE PT-24
12
1
22010
INSULATOR SHIELD CUP PT-24
13
1
21712
SHIELD RETAINER
14
1
77500101
15
1
21765
TOOL ELECTRODE & NOZZLE PT-24
20
1
22531
CUP SHIELD PT-24
21
1
22376T
SHUT-OFF GAS VALVE ASS'Y (See Fig. 8-9B)
22
1
22375
PROTECTOR GORTIFLEX SENSOR 7IN LG
23
1
2234133
24
1
22382
GASLINE SHIELD (ORN)
25
1
22378
CABLE SOLENOID 4.5FT (1,4m) PT-24
1
22427
CABLE SOLENOID 12FT (3,7m) PT-24
1
22389
CABLE SOLENOID 17FT (5,2m) PT-24
1
37663
GAS TUBING ASS'Y QUICK DISC 4.5FT (1,4m) PT-24
1
0558001878
GAS TUBING ASS'Y QUICK DISC 12FT (3,7m) PT-24
1
37664
GAS TUBING ASS'Y QUICK DISC 17FT (5,2m) PT-24
26
SHROUD SHIELDING PT-24
LUB GREASE DOW DC-111
CLAMP WORM DRIVE
27
1
951168
CLAMP BAND-IT
29
1
8996565
CLAMP HOSE
NOT SHOWN -- CABLE BUNDLE, INCLUDES ITEMS 3,4,25, AND 26
30
1
0558001503
CABLE ASSEMBLY BUNDLE 4.5FT (1,4m) PT-24
1
0558001876
CABLE ASSEMBLY BUNDLE 12FT (3,7m) PT-24
1
0558001504
CABLE ASSEMBLY BUNDLE 17FT (5,2m) PT-24
103
notes
104
revision history
1. Revision “D” of 02/2005 - updated schematic 35798 (Precision Plasmarc System Series “A”)
per change notice #043269.
2. Revision "E" of 07/2007 - Updated replacement parts per CN #073135.
3. Revision "F" - Updated p.27 gas bundle illustration to show new configuration with adapters.
105
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]
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