PT-24 Precision Plasmarc System

PT-24 Precision Plasmarc System
F15-800
November, 2003
Installation, Operation and Maintenance for the
PT-24 Precision Plasmarc System
Series “B”
411 South Ebenezer Road
Florence, SC 29501-0545
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total
customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15800
.
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
©
ESAB Cutting Systems, 2003
Printed in U.S.A.
Table of Contents
SECTION
PARAGRAPH
TITLE
PAGE
SECTION 1
1.1
1.2
SECTION 2
2.1
2.2
2.3
SECTION 3
3.1
3.2
3.3
3.4
3.5
SECTION 4
4.1
4.2
4.3
4.4
SECTION 5
5.1
5.2
5.3
5.4
5.5
SECTION 6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
SECTION 7
7.1
7.2
7.3
7.4
SECTION 8
8.1
8.2
Safety ................................................................................................................................... 4
UNPACKING/HOISTING...................................................................................................... 18
Inspection ............................................................................................................................ 18
Hoisting................................................................................................................................ 18
DESCRIPTION...................................................................................................................... 19
General................................................................................................................................. 19
Scope ................................................................................................................................... 19
Package Options Available ................................................................................................ 19
INSTALLATION.................................................................................................................... 23
General................................................................................................................................. 23
Equipment Required........................................................................................................... 23
Location ............................................................................................................................... 23
Primary Electrical Input Connections............................................................................... 23
Interconnecting Lines......................................................................................................... 24
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
KERF .................................................................................................................................... 58
CUTTING QUALITY ............................................................................................................. 71
Cut Angle ............................................................................................................................. 71
Voltage and Cut Quality ..................................................................................................... 72
Top Dross ............................................................................................................................ 74
Dross Formation ................................................................................................................. 74
Summary.............................................................................................................................. 75
MAINTENANCE ................................................................................................................... 77
General................................................................................................................................. 77
Inspection and Cleaning .................................................................................................... 77
Torch Consumable Parts ................................................................................................... 77
Gas Pressure Switch .......................................................................................................... 77
PT-24 Torch Description and Maintenance ...................................................................... 77
Torch Maintenance ............................................................................................................. 78
PT-24 Consumable Removal, Inspection and Installation.............................................. 78
TROUBLESHOOTING ......................................................................................................... 81
Troubleshooting.................................................................................................................. 81
Process Troubleshooting................................................................................................... 81
Troubleshooting Procedures............................................................................................. 83
Schematics and Wiring ...................................................................................................... 88
REPAIR PARTS ................................................................................................................... 97
General................................................................................................................................. 97
Ordering ............................................................................................................................... 97
REPLACEMENT PARTS LISTS .......................................................................................... 98
1
Table of Contents
This page intentionally left blank.
2
SECTION 1
SAFETY
1.1 Introduction
The process of cutting metals with plasma
equipment provides industry with a valuable and
versatile tool. ESAB cutting machines are
designed to provide both operation safety and
efficiency. However, as with any machine tool,
sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or
as an observer, compliance with established
precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious personnel injury
or severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the field
of cutting and welding apparatus, obtain and read
the publications listed in the Recommended
References.
1-1
SECTION 1
SAFETY
1.2 Safety Notations And Symbols
!
! DANGER
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
! WARNING
Used to call attention to potential hazards that
could result in personal injury or loss of life.
! CAUTION
1-2
The following words and symbols are used
throughout this manual. They indicate different
levels of required safety involvement.
ALERT or ATTENTION. Your safety is
involved or potential equipment failure exists.
Used with other symbols and information.
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
CAUTION
Used to call attention to minor hazards to
equipment.
NOTICE
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
SECTION 1
SAFETY
1.3 General Safety Information
! WARNING
! WARNING
Machinery often starts automatically.
This equipment moves in various directions and
speeds.
•
Moving machinery can crush.
•
Only qualified personnel should operate or
service this power source.
•
Keep all personnel, materials, and
equipment not involved in production
process clear of entire system area.
•
Fence off entire work cell to prevent
personnel from passing through area or
standing in the working envelope of the
equipment.
•
Post appropriate WARNING signs at every
work cell entrance.
•
Follow lockout procedure before servicing
any equipment.
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual
before using machine.
•
Read entire procedure before operating or
performing any system maintenance.
•
Special attention must be given to all hazard
warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
•
All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
•
Read all safety publications made available
by your company.
1-3
SECTION 1
! WARNING
SAFETY
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety warning labels
on machine.
Refer to operator’s manual for additional safety
information.
1.4 Installation Precautions
! WARNING
Improperly Installed Equipment Can
Cause Injury Or Death.
Follow these guidelines while installing machine:
1-4
•
Contact your ESAB representative before
installation. He can suggest certain
precautions regarding piping installation and
machine lifting, etc. to ensure maximum
security.
•
Never attempt any machine modifications or
apparatus additions without first consulting
a qualified ESAB representative.
•
Observe machine clearance requirements
for proper operation and personnel safety.
•
Always have qualified personnel perform
installation, troubleshooting and
maintenance of this equipment.
•
Provide a wall mounted disconnect switch
with proper fuse sizes close to the power
supply.
SECTION 1
SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper
machine operation and SAFETY. Refer to this
manual’s Installation section for detailed grounding
instructions.
! WARNING
Electric shock hazard.
Improper grounding can cause severe injury or
death.
Machine must be properly grounded before put
into service.
1.6 Operating A Plasma Cutting Machine
! WARNING
! WARNING
Flying debris and loud noise
hazards.
•
Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and
flying debris generated during operation.
•
Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.
•
Noise from plasma arc can damage hearing.
Wear correct ear protection when cutting
above water.
Burn hazard.
Hot metal can burn.
•
Do not touch metal plate or parts
immediately after cutting. Allow metal time
to cool, or douse with water.
•
Do not touch plasma torch immediately after
cutting. Allow torch time to cool.
1-5
SECTION 1
! WARNING
SAFETY
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
• Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
• Always turn power off to plasma power
supplies before servicing any system
component.
•
Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Wear insulating gloves, shoes and clothing
to insulate yourself from workpiece and
electrical ground.
•
Keep gloves, shoes, clothing, work area,
and equipment dry.
•
! WARNING
Replace worn or damaged cables.
Fume hazard.
Fumes and gases generated by the plasma
cutting process can be hazardous to your
health.
•
Do NOT breathe fumes.
• Do not operate plasma torch without fume
removal system operating properly.
• Use additional ventilation to remove fumes if
necessary.
•
Use approved respirator if ventilation is not
adequate.
•
Provide positive mechanical ventilation when
cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe
these fumes.
•
Do not operate near degreasing and
spraying operations. Heat or arc rays can react
with chlorinated hydrocarbon vapors to form
phosgene, a highly toxic gas and other irritant
gases.
1-6
SECTION 1
! WARNING
SAFETY
Radiation hazard.
Arc rays can injure eyes and burn skin.
•
Wear correct eye and body protection.
• Wear dark safety glasses or goggles with
side shields. Refer to following chart for
recommended lens shades for plasma cutting:
Arc Current
Lens Shade
Up to 100 Amps
Shade No. 8
100-200 Amps
Shade No. 10
200-400 Amps
Shade No. 12
Over 400 Amps
Shade No. 14
• Replace glasses/goggles when lenses are
pitted or broken
• Warn others in area not to look directly at
the arc unless wearing appropriate safety
glasses.
• Prepare cutting area to reduce reflection
and transmission of ultraviolet light.
Use special paint on walls to absorb
UV light.
Install protective screens or curtains to
reduce ultraviolet transmission.
1-7
SECTION 1
! WARNING
SAFETY
Burn Hazard.
Heat, spatter, and sparks cause fire and burns.
•
Do not cut near combustible material.
• Do not have on your person any
combustibles (e.g. butane lighter).
• Pilot arc can cause burns. Keep torch
nozzle away from yourself and others when
activating plasma process.
•
Wear correct eye and body protection.
•
Wear gauntlet gloves, safety shoes and hat.
• Wear flame-retardant clothing covering all
exposed areas.
• Wear cuffless trousers to prevent entry of
sparks and slag.
• Have fire extinguishing equipment available
for use.
! WARNING
Explosion hazard.
•
Certain molten aluminum-lithium (Al-Li)
alloys can cause explosions when plasma cut
OVER water.
These alloys should only be dry cut on
a dry table.
DO NOT dry cut over water.
Contact your aluminum supplier for
additional safety information regarding
hazards associated with these alloys.
•
Do not cut in atmospheres containing
explosive dust or vapors.
•
Do not carry any combustibles on your
person (e.g. butane lighter)
•
Do not cut containers that have held
combustibles.
1-8
SECTION 1
SAFETY
1.7 Service Precautions
! WARNING
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
• Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
• Always turn power off to plasma power
supplies before removing covers or panels to
service any system component.
•
Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
•
Keep gloves, shoes, clothing, work area,
and equipment dry.
•
Inspect power and ground leads cables for
wear or cracking. Replace worn or damaged
cables. Do not use if damaged.
! WARNING
•
Never bypass safety interlocks.
•
Follow lock-out procedures.
Hot Torch can cause skin burns.
Allow torch to cool before servicing.
1-9
SECTION 1
! DANGER
SAFETY
Danger of Electric Shock.
Torch may be electrically active.
Turn off Plasma Power Console before
servicing.
CAUTION
Establish and adhere to preventive
maintenance. A composite program can be
established from recommended schedules.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical
damage could occur to equipment or machine.
! CAUTION
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter.
Integrated circuits are susceptible to over
voltage damage. Power off before using test
probes to prevent accidental shorting of
components.
All circuit boards securely seated in sockets, all
cables properly connected, all cabinets closed
and locked, all guards and covers replaced
before power is turned on.
1-10
SECTION 1
SAFETY
1.8 Safety References -- Regulations, Standards, Guidelines
The following recognized publications on safety in welding and cutting
operations are recommended. These publications have been prepared
to protect persons from injury or illness and to protect property from
damage, which could result from unsafe practices. Although some of
these publications are not related specifically to this type of industrial
cutting apparatus, the principles of safety apply equally.
1.8.1 USA
•
“Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
•
“Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
•
“Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
•
“Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
•
“Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
•
“Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
•
“Safe Practices” - AWS SP, American Welding Society.
•
“Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
•
“Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
•
“Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
•
"Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
•
“Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.
1-11
SECTION 1
SAFETY
1.8.2 International
Accident Prevention
VBG- Unfallverhütungsvorshriften
General Provisions
VBG 1
Allgemeine Unfallverhütungsvorshriften
Electrical Equipment and operating Equipment
VBG 4
Elektrische Anlagen
Welding, Cutting and related working methods
VBG 15
Schweißen un Schneiden un verwandte Verfahren
Shot Blasting Works
VBG 48
Strahlarbeiten
Gases
VBG 61
Gase
Oxygen
VBG 62
Sauerstoff
Operating liquid jet cutting machines
VBG 87
Arbeiten mit Flüssigkeitsstrahlem
Laser beams, accident prevention and Electrotechnology
VBG 93
Laserstrahlung, Unfallverhütungs-vorschriften für
Feinmechnik und Elektrotechnik
Noise
VBG 121
Lärm
1-12
SECTION 1
SAFETY
VDE Regulations
VDE - Vorschriften
VDE 0100
Erection of power installations with normal voltages up to
1000 volts
Bestimmungen für das Errichten von Stakstromanlagen
mit Nennspannungen bis 1000 Volt
Electrical equipment of industrial machines
VDE0113
Elektrishe Ausrüstung von Industriemaschinen
VDE 0837
VDE 083750
Radiation safety of laser products; users guide (DIN EN
60825)
Strahlungssicherheit von Lasereinrichtungen und
Benutzungsrichtlinen (DIN EN 60825)
Specification for laser guards
Anforderung an Lasershcutzwänden
TRAC Technical Rules for Acetylene and Carbide Stores
TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager
Acetylene lines
TRAC-204
Azetylenleitungen
Acetylene cylinder battery systems
TRAC-206
Azetylenflaschenbatterieanlagen
Safety devices
TRAC-207
Sicherheitseinrichtungen
1-13
SECTION 1
SAFETY
TRG Technical Rules for Pressure gases
TRG – Technische Regein für Druckgase
General regulations for pressure gases
TRG 100
Allgemeine Bestimmungen für Druckgase
Pressure gases
TRG 101
Druckgase
Technical gas mixtures
TRG 102
Technishe Gasgemische
Pressure gases; alterative use of compressed gas tanks
TRG 104
1-14
Druckgase, wahlweise Verwendung von
Druckgasbehältem
SECTION 1
SAFETY
TRGS – Technische Richtlinien für Gefahrstoffe
TRGS-102
Techn. Richtkonzentration (TRK) für gefährliche Stoffe
TRGS-402
Ermittlung u. Beurteilung der Konzentration gefährlicher
Stoffe in der Luft im Arbeitsbereich
TRGS-900
Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)
TA
TA-Luft un TA-Lärm (BLm SchV)
DIN Standards
DIN-Normen
DIN 2310
Part 1
Teil 1
DIN 2310
Part 2
Teil 2
DIN 2310
Part 4
Teil 4
DIN 2310
Part 5
Teil 5
DIN 2310
Part 6
Teil 6
DIN 4844
Part 1
Teil 1
Thermal cutting; terminology and nomenclature
Thermsiches Schneiden, Allgemeine Begriffe und
Bennungen
Thermal cutting; determination of quality of cut faces
Thermsiches Schneiden, Ermittein der Güte von
Schnittflächen
Thermal cutting; arc plasma cutting; process principles,
quality, dimensional tolerances
Thermsiches Schneiden, Plasmaschneiden,
Verfahrensgrundlagen, Güte, Maßtoleranzen
Thermal cutting; laser beam cutting of metallic materials;
process principles
Laserstrahlschneiden von metallischen Werkstoffen,
Verfahrensgrundlagen, Güte, Maßtoleranzen
Thermal cutting; Classification, processes
Einführung, Verfahren
Safety markings (DIN EN 7287)
Sicherheitskennzeichen (Siehe EN 7287)
1-15
SECTION 1
SAFETY
DIN EN ISO Harmonized Standards
DIN EN ISO-Harmonisierte Normen
DIN EN
292/1 and 2
Safety of machinery
Sicherheit von Maschinen, Geräten und Anlagen
Hoses for welding, cutting and allied processes
DIN EN 559
DIN EN 560
Schläuche für Schweißen, Schneiden und verwandte
Verfahren
Hose connections and hose couplings for equipment for
welding, cutting and allied processes
Schlauchanschlüsse und Schlauchverbindungen für
Geräte zum Schweißen, Schneiden und verwandte
Verfahren
Gas welding equipment hose couplings
DIN EN 561
Gasschweißgeräte, Kupplungen
DIN EN
626-1
DIN EN
848-1
DIN EN
1829
Sichereit von Maschinen, Reduzierung des
Gesundheitsrisikos
Single spindle vertical milling machines
Fräsmaschine für einseitige Bearbeitung mit drehendem
Werkzeug
High pressure water jet machines
Hochdruckwasserstrahlschneidmaschine
DIN EN
9013
Thermal cutting, oxygen cutting, process principles,
dimensional tolerances
Thermisches Schneiden, Autogenes Brennschneiden,
Verfahrensgrundlagen, Güte, Maßtoleranzen
DIN EN
12584
Imperfections in oxy/fuel flame cuts, laser beam cuts and
plasma
Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und
Plasmaschnitten
DIN EN
12626
1-16
Safety of machines, reduction of risks to health
Laser processing machines
Laserbearbeitungsmaschinen
SECTION 1
SAFETY
DIN EN
28206
DIN EN
31252
DIN EN
31553
Acceptance testing for oxygen cutting machines
Abnahmeprüfung für Brennschneidmaschinen
Laser Equipment
Lasergeräte
Laser and laser related equipment
Laser und Laseranlagen
DIN EN
60204-1
Electrical equipment of machines
DIN EN
60825
Radiation safety of laser products
Elekrische Ausrüstung von Maschinen
Strahlensicherheit von Laseranlagen
Arrangement of protection devices
DIN EN 999
Anordnung von Schutzeinrichtungen
VDI Guidelines
VDI 2906
Quality of cut faces on metallic workpieces; abrasive
water jet cutting and arc plasma cutting
Schnittflächenqualität beim Schneiden von Werkstücken
aus Metall, Abrasiv- Wasserstrahischneiden und
Plasmastrahischneiden
Room air; Technical systems for welding workshops
VDI 2084
Raumluft techn. Anlagen für Schweißwerkstätten
1-17
SECTION 1B
UNPACKING/HOISTING
B. Check each container for any loose parts prior to
disposing of shipping materials.
1.1 INSPECTION
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.
Immediately notify the carrier of any defects or damage.
C. Check air louvers on the power source and junction
box and any other opening to ensure that any obstructions are removed.
1.2 HOISTING
The power source is equipped with one lifting eye that
enables the unit to be hoisted.
18
SECTION 2
DESCRIPTION
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 (200/230/380/415/460/575) 3-phase 50/60
Hz (required)
P/N 0558003587
Flow Control Box (required)
P/N 37416
Junction Box with HF Unit (required)
P/N 37400
Pt-24 Torch (one required)
4.6 ft.
12 ft.
17 ft.
P/N 0558001460
P/N 0558001874
P/N 0558001461
Power Bundle (one required)
25 ft.
60 ft.
100 ft.
P/N 21905
P/N 21906
P/N 21907
Gas Line Bundle (one required)
10 ft.
20 ft.
30 ft.
60 ft.
100 ft.
P/N
P/N
P/N
P/N
P/N
Control Lead-Flow Control to Junction Box and Power Source to Flow Control
Box (two required)
10 ft.
20 ft.
30 ft.
60 ft.
100 ft.
P/N 21917
P/N 21918
P/N 21919
P/N 21920
P/N 21921
Torch Coolant 3.8 l containers (15 l required)
21902
21903
21904
22334
22335
P/N 156F05
PT-24 Spare Par ts Kit
P/N 37609
NOTES: 1. Control lead from the power source to customer CNC is supplied based on customer order.
Gas supply, hoses, work lead and input primary cable are all supplied by the customer.
2. See Process Data Sheets for a list of torch consumable parts.
19
SECTION 2
DESCRIPTION
Table 2-2. Technical Specifications
(Precision Plasma System)
Input Voltage
200/230/380/415/460/575 V 3 phase 50/60 Hz
Input Current
70/60/50/40/30/25 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
PRECISION PLASMA
JUNCTION BOX
PRECISION PLASMA
POWER SUPPLY
PILO T
AR C
C ON TRO L
6.75"
(171mm)
P OWER
CU RR ENT
N PLA SMA
REC ISIO
RC
44"
(1118mm)
10.62"
(270mm)
19.75"
(502mm)
WEIGHT = 26.5 lbs.(12 kg)
42"
(1067mm)
22" (559mm)
Flow Control
WEIGHT = 560 lbs. (254 kg)
400 mm
275 mm
275 mm
WEIGHT = 27 lbs. (12kg)
Figure 2-1. Precision Plasma System
20
SECTION 2
DESCRIPTION
Table 2-3. Technical Specifications
(Plasma Gas)
Type
Pressure
O2, N2, Air
125 psig (8.6 bar)
Flow
Purity Required
100 cfh (47 I/min) max (varies with application)
O2-99.8%,N2-99.995%, Air-clean, dry, oil-free
Recommend Liquid Cylinder
Service Regulators
Recommended Cylinder 2-Stage
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)
Regulators
Hydrogen, Methane: R-77-150-350 (P/N 998342)
Nitrogen: R-77-150-580 (P/N 998344)
Recommended Heavy-Duty
Industrial Air: R-77-150-590 (P/N 998348)
Oxygen: R-76-150-024 (P/N 19151)
Hi-FIow Station or Pipeline
Regulators
Recommended High-Capacity
Non-Corrosive, Non-Toxic Industrial Gas:
Station or Pipeline Regulators
R-6703 (P/N 22236)
Table 2-4.Technical Specifications
(Starting Gas)
Type
N2, Air
Pressure
Flow
Purity Required
125 psig (8.6 bar)
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
Pressure
N2O2 H-35, Methane
100 psig (6.9 bar) H-35, Methane
Flow
125 psig (8.6 bar) N2, O2, Air
60 cfh (28 I/min) max (varies with application)
Purity Required
N2-99.995%; O2-99.8%, 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 2
DESCRIPTION
22
SECTION 3
INSTALLATION
3.1 GENERAL
! CAUTION
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.
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.
3.2 EQUIPMENT REQUIRED
As shipped, the power source is configured for 575 V, 60
Hz input. If using 200, 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.)
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 bar) to the Flow
Control (gas flowing).
B. Work Lead. No. 4 AWG cable is recommended for
connecting workpiece to power source.
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.
C. Primary Input Cable. See Section 3.4.
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 two feet of clearance between the
power source and wall or any other obstruction to allow
freedom of air movement through the power source.
Table 3-1 Recommended Sizes For
Input Conductors and Lline Fuses
Input Requirements
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.
3.4 PRIMARY ELECTRICAL INPUT
CONNECTIONS (Figure 3-1)
Volts
Phase
200
230
380
415
460
575
3
3
3
3
3
3
Input & Gnd
Conductor
Amps CU/AWG
70
60
50
40
30
25
No. 4
No. 6
No. 8
No. 10
No. 10
No. 10
Fuse Ratings/
Phase, Amps
mm2
25
16
10
6
6
6
100
80
80
60
50
40
*Sizes per National Electric Code for 75°C rated conductors @ 30°Cambient. Not
more than three conductors in raceway or cable. Follow local codes if they specify
sizes other than those listed above.
! WARNING
The following procedure explains the proper installation
steps for connecting primary electrical power to the power
source. (See 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.
A. Remove right side panel.
B. Ensure input power cable is disconnected from all
electrical sources.
C. Route input power cable through the strain relief
located at the rear panel.
23
SECTION 3
INSTALLATION
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.
H. Connect jumper wire to the proper input voltage
connector located on the 7-position terminal block.
(See Figure 3-1.)
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)
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.
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.
B. Connect all five lines in gas bundle (Figure 3-4) to Flow
Control Box and Junction Box (Figure 3-5).
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.
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).
! CAUTION
D. Remove panel from rear of console and attach the
pilot-arc, torch and work lead. See Figure 3-8 to
replace panel.
Ensure each input power jumper cable is connected to
the proper input voltage to be used on auto transformer.
Ground
Connection
TB2
K1
200
230
380
415
460
575
200
230
380
415
460
575
Main Contactor
PHASE 1
TB1
Input Power Cable
(customer supplied)
200
230
380
415
460
575
PHASE 2
200
230
380
415
460
575
7 Position Terminal Block
Auto Transformer
PHASE 3
Factory wired for
575 volts
Figure 3-1. Power Source Primary Power Connection Diagram
(Shown factory connected in 575 V position)
24
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
CNC
1
3
4
5
JUNCTION BOX
with H.F. Unit
P/N-37400
2
Power Bundle P/N’s
25 ft. (7.6m) P/N-21905
60 ft. (18m) P/N-21906
100 ft. (30m) P/N-21907
1
6 7
BACK
VIEW
N2
14 pin
Control Lead P/N’s
30 ft. (9,1m)
P/N-57002248
50 ft. (15,2m) P/N-57002249
75 ft. (22,9m) P/N-57002250
100 ft. (30,5m) P/N-57002251
160 ft. (48,8m) P/N-57002252
CONTROL LEAD - 14 Pin Connector
(Supplied based on Customer Order)
WORK LEAD
(Customer Supplied)
19 pin
FLOW CONTROL BOX P/N-37416
PT-24 TORCH
4.5 ft. (1,4m) P/N 0558001460
12 ft. (3,7m) P/N 0558001874
17 ft. (5,2m) P/N 0558001461
See Fig. 3-7
Alt
4
5
O2
3
2
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
CUTTING TABLE
(Customer Supplied)
HEIGHT CONTROL
(Customer Supplied)
ARC VOLTAGE REMOTE
(Customer Supplied)
ARC VOLTAGE CONTROL
(Customer Supplied)
Gas 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)
Note:
All service lines have identification
numbers stamped on connections
O2
Supplied by Customer
Alternate Gas
(Shield Addition)
N2
PRIMARY CABLE
(Customer Supplied)
POWER SOURCE P/N-37358
AUTO TRANS.
CONTROL
POWER SOURCE
CONTROL LEAD - 14/19 Pin Connector
(Power Source to Flow Control Box)
X
W/4 Gal. (1.5L)
Tank
COOLER
SECTION 3
INSTALLATION
Figure 3-2. Precision Plasmarc Cutting Machine Interconnecting Diagram
SECTION 3
INSTALLATION
BUNDLE P/N
10 FT. (3m)
21902
20 FT. (6m)
21903
30 FT. (9m)
21904
60 FT. (18m) 22334
100 FT. (30m) 22335
* 2 REQUIRED.
#1
21884
21885
21886
22337
22338
#2
21875
21876
21877
22343
22344
#3
21878
21879
21880
22345
22346
#4
21887
21888
21889
22340
22341
#5
21881
21882
21883
22347
22348
SHEATH
995832
995832
995826
995826
995826*
Figure 3-4. Gas Line Bundle
1
2
3
4
5
Flow Control
Box
1 2 3 4 5
Junction Box
with H.F. Unit
Figure 3-5. Gas Bundle Installation
26
SECTION 3
INSTALLATION
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
995832 (3)
POWER BUNDLE
(1) One 25 ft. piece Reqd.
(2) Three 25 ft. pieces Reqd.
(3) Four 25 ft. pieces Reqd.
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 Connection
27
Hose No. 7
SECTION 3
INSTALLATION
E. 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 Lead
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.
1.812" (46mm)
Diameter Collar
2.0" (51mm)
Diameter Sleeve
Vent Hole
Figure 3-10. Torch Mounting Options
Figure 3-8. Power Bundle/Power Source Rear
Panel Connection
28
COOLA
FILL CA
SECTION 3
INSTALLATION
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.
Flow Control Box
O2
N2
NOTE
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.
PI LOT
ARC
X
CONTR OL
N2
O2
POWER
CURRE NT
RE CIS ION
PLASMA RC
Alternate Gas
(Shield Addition)
Supplied by Customer
ANT
AP
Figure 3-12. Gas Supply Connection
1. Close all valves on the gas flow control cabinet.
2. Set all inlet gas pressures to 125 psig (8.6 bar).
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.
Figure 3-11. Filling Coolant
4. Coolant pump pressure should be 80 to 90 psi (5.5
to 6.2 bar). See coolant pump pressure gauge on
front of console.
H. Make all connections to the CNC and height control.
See instructions provided with equipment supplied.
I.
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.
Connect gas supply to flow control. See gas requirements as listed in Tables 2-3, 2-4, and 2-5. (See
Figure 3-12.)
6. Check the vent hole in the side of the torch sleeve
and the torch consumables.
J. With installation complete, check for gas and coolant
leaks with a standard soap solution as follows (see
Figures 3-13 and 3-14):
7. With console ON, use a solution of soap and
water. Check all gas connections for pressure
tightness as per following:
29
SECTION 3
INSTALLATION
(a) Place the "plasma gas" select switch, SW-2,
in O2 position.
(h) Open valves NV-1 (oxygen plasma gas valve)
and NV-5 (cut shield gas valve) approximately two full turns.
(b) Place the "shield gas" select switch, SW-3,
in O2 + N2 position.
(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.
Check all gas connections on line 1 and 4.
Recheck torch connections in junction box.
Correct as needed.
(j)
Close valves NV-1 (oxygen plasma gas
valve) and NV-5 (cut shield gas valve).
(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)
(i)
(l)
Place SW-1 in operate position to verify that
N2 output pressure on right side of control
remains pressurized.
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.
(g) Move switch SW-1 to CUT position.
(o) Place SW-1 in operate position to verify that
N2 output pressure remains pressurized.
SW-2
SW-3
NV-3
O2 Pressure
Out
PLASMA GAS
O2
O2+N2
NV-6
N2 Pressure
Out
SW-1
Plasma Start
Press. Out
NV-1
N2
SHIELD GAS
N2+ALT
NV-5
NV-4
NV-2
Left Side View
Front View
Figure 3-13. Flow Control Controls
30
SECTION 3
INSTALLATION
Flow Control Box
2
7
7
1
Alt.
N2
O2
7
6
7
5
6
7
6
NOTE: The numbers in circles correspond with the steps
needed to check gas and coolant leaks.
Figure 3-14. Gas Coolant Leak Check
31
3
SECTION 3
INSTALLATION
32
SECTION 4
OPERATION
4.1 POWER SOURCE CONTROLS/
INDICATORS
C
D
E
F
G
B
H
I
J
L
K
M
A
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.
F. Pilot Arc High/Low Switch is used to select pilot arc
current.
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 settings are 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.
1. Panel Position - allows output current to be set by
the output current dial as described above.
I.
2. Remote Position - allows the output current to be
set by the CNC with an analog dc signal.
J. P/S Temp Fault Indicator - indicates over temperature fault condition in the inverter power source.
0-10 V dc = 0 - 100 Adc
Start Gas Pressure Fault Indicators - indicates low
start gas pressure.
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.
33
SECTION 4
OPERATION
4.2 OPERATION
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.
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 23).
B. Set N2, O2 and Air inlet gas pressures to 125 psig (8.6
bar) (flowing). Set H-35, methane inlet pressures to
100 psi.
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.
Figure 4-3. Coolant Level Indicator
5. Close any throttle valves not being used by
turning them clockwise.
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).
PLASMA GAS
SW-2
O2
N2
SHIELD GAS
O2+N2
5. Place pilot arc high/low switch in the LOW position.
N2+ALT
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.
SW-3
7. Check coolant pressure. The pump pressure is
factory set between 80-90 psig (5.5 to 6.2 bar).
8. Complete setting the gas flow rates by following
the two examples on the next two pages.
E. Set the arc voltage from the suggested arc voltage
values given in the process data sheets.
Figure 4-2. Gas Flow Control
NOTE
D. Console.
Arc voltage and piercing height will be set from the arc
voltage control or from the CNC. Consult instructions
supplied with your equipment.
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 4
OPERATION
With the completion of the above settings the system is
now ready for operation.
4.4 SAMPLE PROCEDURE FOR
SETTING N2 GAS FLOW RATES ON
FLOW CONTROL BOX (Figure 4-4)
4.3 SAMPLE PROCEDURE FOR
SETTING O2 GAS FLOW RATES ON
FLOW CONTROL BOX (Figure 4-4)
NOTE
This is a sample procedure only and the operator must
refer to the appropriate process data sheet.
NOTE
SAMPLE SETUP:
This is a sample procedure only and the operator must
refer to the appropriate process data sheet.
Plasma - N2 or Air, Shield - N2 or Air plus Alternate
gas mix.
SAMPLE SETUP:
NOTE
Plasma - O2, Shield - N2 plus O2 Mix
To cut with air, connect the air source to the N2 inlet.
A. Place PLASMA GAS select switch SW-2 in O2
position.
A. Place PLASMA GAS select switch SW-2 in N2
position.
B. Place SHIELD GAS select switch SW-3 in O2 + N2
position.
B. Place SHIELD GAS select switch SW-3 in N2 + ALT
position.
C. Place test switch SW-1 in START position.
C. Place test switch SW-1 in START position.
D. For setting plasma start gas adjust valve NV-3, read
flow on flowmeter FM-2.
D. For setting plasma start gas adjust valve NV-3, read
flow on flowmeter FM-2.
E. For setting shield preflow gas:
Adjust valve NV-6, read flow on flowmeter FM-3.
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.
F. Move test switch SW-1 to CUT position.
G. For setting plasma cut gas adjust valve NV-1, read
flow on flowmeter FM-1.
H. For setting shield and mixing shield cut gas.
G. For setting plasma cut gas adjust valve NV-2, read
flow on flowmeter FM-2.
(1) Adjust valve NV-5 (N2), read flow on flowmeter
FM-3.
H. For setting shield and mixing shield cut gas.
(2) Adjust valve NV-4 (O2), read flow on flowmeter
FM-4.
I.
(1) Adjust valve NV-5, read flow on flowmeter FM-3.
(2) Adjust valve NV-4, read flow on flowmeter FM-4.
Move test switch SW-1 to OPERATE position. Flow
control is now set to operate.
I.
35
Move test switch SW-1 to OPERATE position. Flow
control is now set to operate.
SECTION 4
FM-1
OPERATION
FM-2
FM-3
FM-4
SW-2
SW-3
PLASMA GAS
NV-3
O2
NV-6
SHIELD GAS
O2+N2
N2
N2+ALT
SW-1
NV-5
NV-1
NV-4
NV-2
Front View
Left Side View
Figure 4-4. Flow Control Box
36
37
.062
.075
.090
.125
.187
.250
1.5
2
2.2
3
4
6
0
0
0
0
0
0
(Sec.)
0
0
0
0
0
0
(Sec.)
START
ð
ð
CUT
PLASMA
55
55
55
55
55
55
45
45
45
45
45
45
20
20
20
20
20
20
CUT
†
10
10
10
10
10
10
ALT
† CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
40
40
40
40
40
40
PRE
†
(FLOW READING)
SHIELD
P/N 21539
150
152
153
158
170
185
VOLTAGE
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.
PT-24 TORCH
AL30
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
NOTES:
ð
30
NITROGEN
NITROGEN
METHANE
ELECTRODE
ð
SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536
SET-UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
ð
P/N 21541
NOZZLE "B"
(FLOW READING) (FLOW READING)
NOTES:
3 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
38
.062
.125
.187
.250
1.5
3
4
6
0
0
0
0
(Sec.)
0
0
0
0
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
75
75
75
75
55
55
55
55
20
20
20
20
CUT
10
10
10
10
ALT
136
139
152
162
VOLTAGE
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.
PT-24 TORCH
AL50
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
NOTES:
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
45
45
45
45
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
55
NITROGEN
NITROGEN
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21542
NOZZLE "C"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
39
.187
.250
.375
.500
(IN)
0
0
.1
.2
(Sec.)
0
0
.1
.1
(Sec.)
START
ð
ð
CUT
PLASMA
50
50
60
60
45
45
45
45
20
20
20
20
CUT
10
10
10
10
ALT
†
150
157
168
178
VOLTAGE
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.
PT-24 TORCH
AL70
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
NOTES:
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
65
65
65
65
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
70
NITROGEN
NITROGEN
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
ð
P/N 21543
NOZZLE "D"
(FLOW READING) (FLOW READING)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
4
6
10
12
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
40
.250
.375
.500
.625
(IN)
0
0
.1
.3
(Sec.)
0
0
.1
.1
(Sec.)
START
ð
ð
CUT
PLASMA
100
100
100
100
60
60
60
60
31
31
31
31
CUT
10
10
10
10
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
80
80
80
80
PRE
†
(FLOW READING)
SHIELD
P/N 21539
150
162
166
176
VOLTAGE
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.
PT-24 TORCH
AL100
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
ELECTRODE NOTES:
ð
ð
100
NITROGEN
NITROGEN
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
ð
P/N 21923
NOZZLE "E"
(FLOW READING) (FLOW READING)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
6
10
12
16
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
ALUMINUM
41
20 GA
18 GA
16 GA
14 GA
12 GA
10 GA
0.9
1.3
1.5
1.9
2.7
3.4
0
0
0
.1
.1
.1
(Sec.)
0
0
0
0
0
0
(Sec.)
START
ð
ð
CUT
PLASMA
11
11
11
11
11
11
50
50
50
50
50
50
0
0
0
0
0
0
CUT
†
5
5
5
5
5
5
ALT
† CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
20
20
20
20
20
20
PRE
†
(FLOW READING)
SHIELD
P/N 21539
114
117
118
123
124
129
VOLTAGE
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.
PT-24 TORCH
CB15
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
ð
16
OXYGEN
NITROGEN
OXYGEN
ELECTRODE
ð
SWIRL BAFFLE
2 HOLE
(SEE NOTES)
P/N 21852
SET-UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
ð
P/N 21540
NOZZLE "A"
(FLOW READING) (FLOW READING)
NOTES:
2 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
ALT. GAS:
11/30/99
CARBON STEEL
42
14 GA
.125
.135
.187
.250
1.9
3
3.2
4
6
0
0
0
.1
.2
(Sec.)
0
0
0
.1
.1
(Sec.)
NOTES:
3 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
15
15
15
15
15
50
50
50
50
50
PRE
0
0
0
0
0
CUT
†
†
5
10
10
10
10
ALT
† CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
38
38
38
38
38
SHIELD
(FLOW READING)
SET-UP PARAMETERS*
P/N 21539
113
119
120
122
124
VOLTAGE
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.
PT-24 TORCH
CB30
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
ð
35
OXYGEN
NITROGEN
OXYGEN
ELECTRODE
ð
SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21541
NOZZLE "B"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
43
.125
.135
.187
.250
.375
3
3.2
4
6
10
0
0
.1
.2
.3
(Sec.)
0
0
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
20
20
20
20
20
50
50
50
50
50
10
10
10
10
10
CUT
0
0
0
0
0
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
50
50
50
50
50
PRE
†
(FLOW READING)
SHIELD
P/N 21539
119
121
127
130
136
VOLTAGE
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.
PT-24 TORCH
CB50
PROCESS DATA
PRESSURE:125PSI/8.6 BAR
PRESSURE:125PSI/8.6 BAR
PRESSURE:125PSI/8.6 BAR
ARC
NOTES:
ð
45
OXYGEN
NITROGEN
OXYGEN
ELECTRODE
ð
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21542
NOZZLE "C"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
44
.187
.250
.312
.375
.500
.625
4
6
8
10
11
19
0
0
0
.1
.2
.3
(Sec.)
0
0
0
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
25
25
25
25
25
25
60
60
60
60
60
60
20
20
20
20
20
20
CUT
0
0
0
0
0
0
ALT
118
121
122
126
133
144
VOLTAGE
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.
PT-24 TORCH
CB70
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
60
60
60
60
60
60
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
70
OXYGEN
NITROGEN
OXYGEN
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21543
NOZZLE "D"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
45
.312
.375
.500
.625
.750
8
10
12
16
19
0
0
.1
.2
.3
(Sec.)
0
0
.1
.1
.1
(Sec.)
START
ð
ð
CUT
PLASMA
30
30
30
30
30
60
60
60
60
60
30
30
30
30
30
CUT
0
0
0
0
0
ALT
†
132
137
140
143
146
VOLTAGE
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.
PT-24 TORCH
CB100
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
80
80
80
80
80
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
100
OXYGEN
NITROGEN
OXYGEN
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
ð
P/N 21923
NOZZLE "E"
(FLOW READING) (FLOW READING)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
CARBON STEEL
46
26 GA
24 GA
22 GA
18 GA
16 GA
0.4
0.6
0.8
1.2
1.5
0
0
0
0
0
(Sec.)
0
0
0
0
0
(Sec.)
NOTES:
3 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
18
18
18
18
18
40
40
40
40
40
20
20
20
20
20
CUT
5
5
5
5
5
101
102
103
105
107
VOLTAGE
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.
PT-24 TORCH
SS30A
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
†
ALT
† CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
45
45
45
45
45
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
30
OXYGEN
AIR
OXYGEN
SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21541
NOZZLE "B"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
47
.125
.187
.250
.375
(IN)
0
0
.1
.2
(Sec.)
0
0
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
3
4
6
10
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
95
95
95
95
45
45
45
45
PRE
55
35
35
35
CUT
†
†
0
0
0
0
ALT
(FLOW READING)
SHIELD
P/N 21539
134
140
145
155
VOLTAGE
2286
1524
1016
558
(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.
PT-24 TORCH
SS50A
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
ð
ELECTRODE
ð
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
60
60
60
60
50
AIR
AIR
AIR
SWIRL BAFFLE
3 HOLE
(SEE NOTES)
P/N 21536
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21542
NOZZLE "C"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
48
.187
.250
.375
.500
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
4
6
10
13
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
95
95
95
95
60
60
60
60
PRE
40
40
40
40
CUT
†
†
0
0
0
0
ALT
(FLOW READING)
SHIELD
P/N 21539
131
154
159
162
VOLTAGE
2540
1270
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.
PT-24 TORCH
SS70A
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
ð
ELECTRODE
ð
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
70
70
70
70
70
AIR
AIR
AIR
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21543
NOZZLE "D"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
49
.250
.375
.500
.625
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
6
10
12
16
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
65
65
65
65
60
60
60
60
PRE
35
35
35
35
CUT
†
0
0
0
0
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
80
80
80
80
SHIELD
P/N 21539
138
142
150
157
VOLTAGE
2030
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.
PT-24 TORCH
SS100A
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
ð
ELECTRODE
ð
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
100
AIR
AIR
AIR
(FLOW READING)
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21923
NOZZLE "E"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
50
.125
.187
.250
.375
3
4
6
10
0
0
.1
.2
(Sec.)
0
0
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
(IN)
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
95
95
95
95
45
45
45
45
PRE
40
40
40
40
CUT
†
7
7
7
7
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
60
60
60
60
SHIELD
P/N 21539
135
146
157
175
VOLTAGE
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.
PT-24 TORCH
SS50A4
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
NOTES:
ð
ELECTRODE
ð
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
50
AIR
AIR
METHANE
(FLOW READING)
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21542
NOZZLE "C"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
51
.125
.187
.250
.375
.500
(IN)
.2
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
2
4
6
10
12
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
100
100
100
100
100
60
60
60
60
60
50
40
40
40
40
CUT
15
10
10
10
10
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
70
70
70
70
70
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ARC
135
147
159
171
176
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.
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
SS70A4
PROCESS DATA
VOLTAGE
ELECTRODE NOTES:
ð
ð
70
AIR
AIR
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21543
NOZZLE "D"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
52
.250
.375
.500
.625
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
6
10
12
16
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
65
65
65
65
60
60
60
60
40
40
40
40
CUT
7
10
10
10
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
80
80
80
80
PRE
†
(FLOW READING)
SHIELD
P/N 21539
PT-24 TORCH
140
151
159
166
VOLTAGE
2030
1524
889
635
(MM/MIN)
80
60
35
25
(IPM)
TRAVEL SPEED
SS100A4
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
PROCESS DATA
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.
ARC
NOTES:
ð
100
AIR
AIR
METHANE
ELECTRODE
ð
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21923
NOZZLE "E"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
53
.125
.187
.250
.375
(IN)
0
0
.1
.2
(Sec.)
0
0
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
3
4
6
10
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
85
85
85
85
45
45
45
45
45
45
45
35
CUT
0
0
0
0
ALT
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
60
60
60
60
PRE
†
(FLOW READING)
SHIELD
P/N 21539
128
133
144
155
VOLTAGE
2286
1524
1016
558
(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.
PT-24 TORCH
SS50N
PROCESS DATA
PRESSURE:125PSI/8.6 BAR
PRESSURE:125PSI/8.6 BAR
ARC
NOTES:
ð
50
NITROGEN
NITROGEN
ELECTRODE
ð
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21542
NOZZLE "C"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
54
.187
.250
.375
.500
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
4
6
10
13
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
95
95
95
95
60
60
60
60
40
40
40
40
CUT
0
0
0
0
ALT
†
ARC
132
150
159
162
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.
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
SS70N
PROCESS DATA
VOLTAGE
NOTES:
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
70
70
70
70
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
70
NITROGEN
NITROGEN
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21543
NOZZLE "D"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
55
.250
.375
.500
.625
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
6
10
12
16
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
95
95
95
95
60
60
60
60
50
35
35
35
CUT
†
0
0
0
0
138
145
153
157
VOLTAGE
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.
PT-24 TORCH
SS100N
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
ARC
NOTES:
ALT
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
80
80
80
80
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
100
NITROGEN
NITROGEN
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21923
NOZZLE "E"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
56
.187
.250
.375
.500
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
4
6
10
13
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
100
100
100
100
60
60
60
60
65
65
65
70
CUT
5
5
5
5
ALT
†
138
150
170
179
VOLTAGE
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.
PT-24 TORCH
SS70NM
PROCESS DATA
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
NOTES:
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
70
70
70
70
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
70
NITROGEN
NITROGEN
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21543
NOZZLE "D"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
57
.250
.375
.500
.625
(IN)
.3
.4
.5
.6
(Sec.)
.1
.1
.1
.1
(Sec.)
NOTES:
4 Hole Baffle - *Set flow reading with valves.
6
10
12
16
(MM)
ON
THICKNESS PIERCE
DELAY PIERCE
RISE
ð
CUT
PLASMA
95
95
95
95
60
60
60
60
50
70
60
60
CUT
5
5
5
5
ALT
PROCESS DATA
133
158
170
177
VOLTAGE
1778
1524
965
660
(MM/MIN)
70
60
38
26
(IPM)
TRAVEL SPEED
SS100NM
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.
PT-24 TORCH
PRESSURE:125 PSI/8.6 BAR
PRESSURE:125 PSI/8.6 BAR
PRESSURE:100 PSI/6.9 BAR
ARC
NOTES:
†
† CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
80
80
80
80
PRE
†
(FLOW READING)
SHIELD
P/N 21539
ELECTRODE
ð
ð
100
NITROGEN
NITROGEN
METHANE
SWIRL BAFFLE
4 HOLE
(SEE NOTES)
P/N 21692
SET-UP PARAMETERS*
ð
(FLOW READING) (FLOW READING)
START
ð
P/N 21923
NOZZLE "E"
NOZZLE RETAINER/
DIFFUSER
(SEE NOTES)
P/N 22007
ð
PLASMA
P/N 21712
P/N 22531
MATERIAL
INSULATOR SHIELD
RETAINER w/O-RING
ð
CUP SHIELD
w/RETAINER
ð
SHIELD CUP
INSULATOR
P/N 22010
AMPERAGE:
PLASMA GAS:
SHIELD GAS:
SHIELD MIX GAS:
11/30/99
STAINLESS STEEL
SECTION 4
OPERATION
Aluminum Kerf Values N2/N2/CH4
Aluminum N2/N2/CH4 30 Amperes
Material Thickness (mm)
1.575
1.905
2.286
3.175
4.750
6.350
0.140
3.556
0.120
3.048
2.540
0.100
0.080
0.087
1.524
0.060
0.040
1.270
1.270
1.524
0.065
1.270
0.060
0.050
0.050
2.032
1.651
0.050
Kerf (mm)
Kerf (inches)
2.210
1.016
0.508
0.020
0.000
0.000
0.062
0.075
0.090
0.125
0.187
0.250
Material Thickness (inches)
Aluminum N2/N2/CH4 50 Amperes
Material Thickness (mm)
3.175
4.775
0.140
3.556
0.120
3.048
2.362
0.100
2.032
Kerf (inches)
6.350
0.080
1.524
0.060
0.060
0.093
2.540
2.032
0.080
1.651
1.524
0.065
0.040
1.016
0.020
0.508
0.000
0.000
0.062
0.125
0.188
Material Thickness (inches)
58
0.250
Kerf (mm)
1.575
SECTION 4
OPERATION
Aluminum N2/N2/CH4 70 Amperes
Material Thickness (mm)
6.350
9.525
12.700
0.190
4.826
0.170
4.318
0.150
3.810
0.130
3.048
3.302
2.845
0.110
0.090
2.540
2.540
0.112
0.100
0.120
0.100
2.794
Kerf (mm)
Kerf (inches)
4.750
2.286
1.778
0.070
1.270
0.050
0.187
0.250
0.375
0.500
Material Thickness (inches)
Aluminum N2/N2/CH4 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
0.190
4.826
0.170
4.318
0.150
3.810
3.302
2.921
0.110
0.090
2.540
0.100
2.667
0.130
2.794
0.115
0.105
2.286
0.070
1.778
0.050
1.270
0.250
0.375
0.500
Material Thickness (inches)
59
0.625
Kerf (mm)
Kerf (inches)
3.302
0.130
SECTION 4
OPERATION
Carbon Steel Kerf Values O2/N2/O2
Carbon Steel O2/N2/O2 16 Amperes
Material Thickness (mm)
3.404
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.473
0.060
1.118
0.040
1.524
0.058
Kerf (mm)
Kerf (inches)
1.219
1.016
0.044
0.508
0.020
0.000
0.000
0.048
0.134
Material Thickness (inches)
Carbon Steel O2/N2/O2 35 Amperes
Material Thickness (mm)
3.175
6.350
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.499
0.060
1.168
0.040
1.524
1.321
0.059
0.052
1.016
0.046
0.508
0.020
0.000
0.000
0.060
0.125
Material Thickness (inches)
60
0.250
Kerf (mm)
Kerf (inches)
1.524
SECTION 4
OPERATION
Carbon Steel O2/N2/O2 45 Amperes
Material Thickness (mm)
6.350
9.525
0.140
3.556
0.120
3.048
2.413
Kerf (inches)
0.100
0.095
1.930
0.080
1.626
0.060
2.540
2.032
0.076
1.524
0.064
0.040
1.016
0.020
0.508
Kerf (mm)
3.175
0.000
0.000
0.125
0.250
0.375
Material Thickness (inches)
Carbon Steel O2/N2/O2 70 Amperes
Material Thickness (mm)
3.429
6.350
9.525
12.700
0.140
3.556
0.120
3.048
2.540
2.540
0.100
0.080
2.032
1.778
0.080
1.575
0.060
0.100
0.070
1.524
0.062
0.040
1.016
0.020
0.508
0.000
0.000
0.135
0.250
0.375
Material Thickness (inches)
61
0.500
Kerf (mm)
Kerf (inches)
2.032
SECTION 4
OPERATION
Carbon Steel O2/N2/O2 100 Amperes
Material Thickness (mm)
9.525
12.700
19.050
3.556
0.140
3.048
3.048
0.120
0.120
2.540
0.100
2.540
2.337
0.080
0.092
2.032
0.060
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.375
0.500
Material Thickness (inches)
62
0.750
Kerf (mm)
Kerf (inches)
0.100
SECTION 4
OPERATION
Stainless Steel Kerf Values O2/N2/O2
Stainless Steel O2/N2/O2 30 Amperes
Material Thickness (mm)
0.584
0.726
1.207
1.588
0.140
3.556
0.120
3.048
0.100
2.540
0.080
2.032
1.524
0.060
1.143
0.040
0.889
0.035
0.889
0.035
0.889
0.035
0.889
0.045
1.016
0.035
0.508
0.020
0.000
0.000
26GA
24GA
22GA
Material Thickness (inches)
63
18GA
16GA
Kerf (mm)
Kerf (inches)
0.457
SECTION 4
OPERATION
Stainless Steel Kerf Values Air/Air/CH4
Stainless Steel Air/Air/CH4 70 Amperes
Material Thickness (mm)
3.175
4.775
6.350
9.525
12.700
3.556
0.140
2.921
0.120
0.115
2.540
2.032
0.080
0.060
2.540
2.286
1.778
0.100
0.090
2.032
0.080
0.070
1.524
0.040
1.016
0.020
0.508
Kerf (mm)
Kerf (inches)
0.100
3.048
0.000
0.000
0.125
0.188
0.250
0.375
0.500
Material Thickness (inches)
Stainless Steel Air/Air/CH4 100 Amperes
Material Thickness (mm)
9.525
12.700
0.190
4.826
0.170
4.318
0.150
Kerf (inches)
15.875
3.556
0.130
3.048
0.140
0.120
0.110
2.286
3.302
2.794
2.540
0.090
3.810
0.100
2.286
0.090
1.778
0.070
1.270
0.050
0.250
0.375
0.500
Material Thickness (inches)
64
0.625
Kerf (mm)
6.350
SECTION 4
OPERATION
Stainless Steel Kerf Values N2/N2/CH4
Stainless Steel N2/N2/CH4 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
3.556
0.140
2.921
0.120
3.048
2.667
2.540
0.105
0.095
2.032
0.080
0.080
0.060
1.524
0.040
1.016
0.020
0.508
Kerf (mm)
2.032
Kerf (inches)
0.115
2.413
0.100
0.000
0.000
0.187
0.250
0.375
0.500
Material Thickness (inches)
Stainless Steel N2/N2/CH4 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
0.190
4.826
0.170
4.318
3.810
3.810
0.150
0.150
3.302
0.130
0.130
2.794
0.110
0.090
2.540
2.794
0.110
0.100
2.286
1.778
0.070
1.270
0.050
0.250
0.375
0.500
Material Thickness (inches)
65
0.625
Kerf (mm)
Kerf (inches)
3.302
SECTION 4
OPERATION
Stainless Steel Kerf Values N2/N2
Stainless Steel N2/N2 50 Amperes
Material Thickness (mm)
3.175
4.750
6.350
9.525
0.140
3.556
0.120
3.048
0.100
2.540
2.032
1.778
1.524
0.060
0.060
0.080
1.651
0.070
0.065
1.524
0.040
1.016
0.020
0.508
Kerf (mm)
Kerf (inches)
2.032
0.080
0.000
0.000
0.125
0.187
0.250
0.375
Material Thickness (inches)
Stainless Steel N2/N2 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
0.140
3.556
0.120
3.048
2.540
0.080
0.060
2.286
2.286
1.778
0.090
2.540
0.100
0.090
2.032
0.070
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.187
0.250
0.375
Material Thickness (inches)
66
0.500
Kerf (mm)
Kerf (inches)
0.100
SECTION 4
OPERATION
Stainless Steel N2/N2 100 Amperes
Material Thickness (mm)
9.525
12.700
0.190
4.826
0.170
4.318
0.150
Kerf (inches)
15.875
3.556
0.130
3.048
2.794
0.110
0.090
2.540
0.140
0.120
3.810
3.302
2.794
0.110
0.100
2.286
1.778
0.070
1.270
0.050
0.250
0.375
0.500
Material Thickness (inches)
67
0.625
Kerf (mm)
6.350
SECTION 4
OPERATION
Stainless Steel Kerf Values Air/Air
Stainless Steel Air/Air 50 Amperes
Material Thickness (mm)
4.750
6.350
0.140
3.556
0.120
3.048
2.413
0.100
2.032
Kerf (inches)
9.525
2.540
0.095
2.032
0.080
1.524
0.060
0.060
0.080
1.651
1.524
0.065
0.040
1.016
0.020
0.508
Kerf (mm)
3.175
0.000
0.000
0.125
0.187
0.250
0.375
Material Thickness (inches)
Stainless Steel Air/Air 70 Amperes
Material Thickness (mm)
4.750
6.350
9.525
12.700
3.556
0.140
2.921
Kerf (inches)
0.115
0.110
0.100
0.080
2.921
2.794
3.048
0.115
2.540
1.905
2.032
0.075
0.060
1.524
0.040
1.016
0.020
0.508
0.000
0.000
0.187
0.250
0.375
Material Thickness (inches)
68
0.500
Kerf (mm)
0.120
SECTION 4
OPERATION
Stainless Steel Air/Air 100 Amperes
Material Thickness (mm)
6.350
9.525
12.700
15.875
4.826
0.170
4.064
0.150
3.556
Kerf (inches)
3.302
0.140
0.130
2.921
0.110
0.160
4.318
3.810
3.302
0.130
2.794
0.115
0.090
2.286
0.070
1.778
1.270
0.050
0.250
0.375
0.500
Material Thickness (inches)
69
0.625
Kerf (mm)
0.190
SECTION 4
OPERATION
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70
SECTION 5
CUTTING QUALITY
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.
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.
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
71
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 followed by a close examination of the part.
ARC VOLTAGE TOO HIGH
Arc Voltage
End View
(+) Cut Angle
Correct Cutting Speed
Positive Cut Angle
Rounded Top Edge
More Dross
Top Dross
Cut Face Smooth
"S" Shaped Lag Lines
Cut Face
Figure 5-3. Cut Quality (Arc Voltage Too High)
72
SECTION 5
CUTTING QUALITY
ARC VOLTAGE CORRECT
Arc Voltage
End View
Correct Cutting Speed
Square Top Edge
No Top Dross
Little or No Bottom Dross
Cut Face Smooth
Uniform Lag Lines
Optimum
Cut Angle
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)
73
SECTION 5
CUTTING QUALITY
ARC VOLTAGE TOO LOW
Arc Voltage
Under Cut
Top Edge
-/+ Cut Angle
End View
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)
5.3 TOP 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)
74
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
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.
5.5 SUMMARY.
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,
75
SECTION 5
CUTTING QUALITY
76
SECTION 6
MAINTENANCE
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.
6.1 GENERAL
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
! WARNING
! WARNING
Make sure power switch on the Power Source is in OFF
position before working on the torch.
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.
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.
6.2 INSPECTION AND CLEANING
6.4 GAS PRESSURE SWITCH
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:
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.
A. Check work cable to workpiece connection.
B. Check safety earth ground at workpiece and at power
source chassis.
6.5 PT-24 TORCH DESCRIPTION
C. Check heat shield on torch. It should be replaced if
damaged.
See Table 2-6 for overall size and general configuration.
D. Check the torch electrode and cutting nozzle for wear
on a daily basis. Remove spatter, resharpen point, or
replace if necessary.
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.
E. Make sure cable and hoses are not damaged or
kinked.
F. Make sure all plugs, fittings, and ground connections
are tight.
! CAUTION
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.
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.
77
SECTION 6
MAINTENANCE
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.
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.
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.
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.
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.
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.
! CAUTION
F. 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.
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.
6.6 TORCH MAINTENANCE
! WARNING
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.
! WARNING
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.
Make sure power switch on the console is in the OFF
position and primary input power is disconnected.
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
78
SECTION 6
MAINTENANCE
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.
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.
6. Unscrew the electrode with the aid of the tool
provided.
B. Installation
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.
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.
3. 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.
2. Nozzle & Swirl Baffle - Place the swirl baffle into
the nozzle being careful not to get anything in the
small gas passages. Push this assembly into the
torch.
3. 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. 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.
5. 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
CUP SHIELD
w/ RETAINER
22531
SHIELD CUP
INSULATOR
22010
4. Shield Cup Insulator - Push the shield cup insulator on the nozzle retainer.
NOZZLE
"A" (15A) - 21540
"B" (30A) - 21541
"C" (50A) - 21542
"D" (70A) - 21543
"E" (100A) - 21923
5. Shield Cup and Retainer - Screw this assembly
onto the torch and hand tighten.
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
WATER
BAFFLE
C-21725
Figure 6-1. Front End Parts, PT-24 Torch
79
TORCH ASSEMBLY
D-21530
MAINTENANCE
C-22388-A
SECTION 6
Figure 6-2. Schematic Gas Flow
80
SECTION 7
TROUBLESHOOTING
7.1 TROUBLESHOOTING
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.
! WARNING
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.
! WARNING
Capacitors can store high voltages even when power
is disconnected or unit is deenergized. Ensure
power supply capacitors are grounded prior to performing maintenance.
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.
81
SECTION 7
TROUBLESHOOTING
1
2
3
4
1
PA202
POWER
omron
RUN
SYSMAC
ERR/ALM IA111
CJ1M
INH
0
PROGRAMMABLE
PRPHL
CONTROLLER
COMM
8
CPU12
BKUP
OC201
1 2 3 4 5 6 7
9 10 11 12 13 14 15
0
0
L
OC201
SW SETTING
BATTERY
AC100
-240V
INPUT
MCPWR
BUSY
2
L
C2
3
C3
4
C4
5
C5
13
C5
6
C6
C6
7
7
C7
15
COM
C7
NC
COM
NC
NC
AC100V
7mA 50Hz
8mA 60Hz
7
C1
6
14
6
2
C4
11
5
CO
5
12
4
0
C3
9
3
1
4
10
2
1
C2
7
1.
2.
3.
4.
5.
0
3
8
5
7
C1
L2/N
PORT
6
2
5
NC
5
1
6
NC
4
CO
4
PERIPHERAL
3
0
3
L1
2
1
1
OPEN
2
NC
AC250V 2A
DC24V 2A
AC250V 2A
DC24V 2A
Power Supply
CPU
AC Input Module
Relay Output Module
Flash Memory
Figure 7-1 Programmable Logic Controller (PLC)
Table 7-1 PLC Input/Output LEDs
INPUT
OUTPUT
LED
Function
LED
Function
0
1
2
3
4
5
6
7
8
Start/Stop
Preflow
Arc-On
O2 Pressure
N2 Pressure
Reserved
Fault
1-0
1-1
1-2
1-3
1-4
1-5
1-6
---2-0
2-1
2-3
2-4
Travel
Hi-Frequency
Pilot Arc Relay
Power Source
Start Pressure Switch Fault
Cut Gas Pressure Switch Fault
Fault Output
82
Start Gas On
Cut Gas On
Full Shield
Regulated Shield
SECTION 7
TROUBLESHOOTING
7.3 TROUBLESHOOTING PROCEDURES
! WARNING
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
Before checking voltages in the circuit, disconnect the
power from the high frequency generator to avoid damaging your voltmeter.
The cause of control malfunctions can be found by
referring to the sequence of operations (Figure 7-1) and
electrical schematic diagram (Figures 7-2, 7-3, 7-5 and 78) and checking the various components. A voltohmmeter will be necessary for some of these checks.
Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e
PROB L EM
1.
Reduced consumable
(electrode) life
POSSIB L E CAUSE
Skeleton cutting
ACTION
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 star ts.
3. Greatly increasing the frequency of star ts
T h i s i s m a i n l y a p r o b l e m fo r O 2 c u t t i n g
and can be alleviated by choosing a path
with a minimum number of star ts.
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.
Height control problems
See crashing/diving in Item 2 below.
Piercing standoff too low
Increase piercing standoff.
Star ting on edges with
continuous pilot arc
Position torch more carefully or use a waster
plate to star t on.
83
SECTION 7
TROUBLESHOOTING
Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e
PROB L EM
2.
Reduced nozzle life
POSSIB L E CAUSE
Contacting work
diving
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.
Diving may also be caused by a problem with
the height control or the signals fed to it.
3.
Poor cut quality
Work flipping
The nozzle may sometimes be damaged if the
torch hits a flipped up par t. This is difficult to
avoid entirely but careful par t programming
can minimize the problem.
Catching on piece
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 star t with a longer lead-in to
avoid this problem.
Excessive speed
Reduce speed to prevent rooster tailing during
cut. Reduce speed around corners if rooster
tailing occurs only coming out of corners.
Process factors
Same as for electrode above.
Inadequate initial delay.
Pierce not complete before
star ting
Increases delay time.
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.
Torch alignment to work
Verify and correct torch alignment (ver tical).
Incorrect current
Verify correct current. Refer to perimeter
tables.
Cutting over slats
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.
84
SECTION 7
TROUBLESHOOTING
Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e
PROB L EM
3.
4.
5.
6.
Poor cut quality (cont.)
No pilot arc
No arc transfer
No preflow
POSSIB L E CAUSE
ACTION
Cutting machine or torch
vibrates
Make sure brackets and height control are rigid and
properly adjusted.
Bevel angle
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.
Wrong travel direction (good
angle on scrap side)
With standard swirl par ts 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.
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.
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 disconnected from cutting table
Make sure work lead is firmly connected to workpiece
or cutting table.
N2 or O2 check valve in torch
body may be stuck open
Unscrew torch sleeve. Then disassemble two copper
adapters from torch body and remove debris. Do not
lose ball and string.
No star t signal
Check input O LED on PLC. Should be lit. This
verifies a star t commend has been given.
Emergency stop signal open
Check for continuity between TB3-18 and TB3-19.
(Also see NOTE in Schematic Diagram, Fig 7-6).
Shor ted, closed or jumpered out
CWFS
Check cooling water LED on front panel. Should be lit.
No cooling water
Check reservoir. Add coolant until full.
N2 pressure switch not activated
With gas supply on, check LED 4 on PLC. Should be
lit when switch is positioned in START GAS TEST or
START condition.
85
SECTION 7
TROUBLESHOOTING
Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e
PROB L EM
7.
Torch fails to fire
POSSIB L E CAUSE
Star t gas
Lower star t 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
8.
9.
Nozzle life extremely
shor t
Shor t electrode life
ACTION
Replace CWFS switch.
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.
Star t gas flow too low
Check cutting parameters.
Insufficient cooling
Check pump for 80/90 PSI (5.5/6.2 bars) output
pressure.
Star t gas quality
Gas quality needs to be 99.995% minimum.
Cut gas quality
Oxygen gas needs to be 99.8% minimum.
10.
Shor t electrode/nozzle
life
Water leak on torch front
end
Check nozzle retainer for tightening.
11.
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
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.
12.
Negative cut angle
86
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 yes
damaged?
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
Turn on coolant flow and check for leaks
Still
Leaking?
yes
Replace nozzle
Still
Leaking?
no
no
Let’s cut!
87
yes
Replace Retaining cup
D-37414
Figure 7-2. Flow Control Schematic
SECTION 7
TROUBLESHOOTING
88
D
D-37399-D
Figure 7-3. Junction Box Schematic and Wiring Diagram
SECTION 7
TROUBLESHOOTING
89
D-37413
Figure 7-4. Flow Control Wiring Diagram
SECTION 7
TROUBLESHOOTING
90
SECTION 7
TROUBLESHOOTING
92
SECTION 7
TROUBLESHOOTING
93
TROUBLESHOOTING
MOD1
WHT
8
TB7
OC201
0
8
1 2
3
9 10 11
4
5
6
7
12 13 14 15
0
0
E
6
3
4
5
6
7
POR T
3
C3
SEE DETAIL
C3
4
C4
5
C5
C5
6
C6
C6
P3
1
7
C7
C7
NC
NC
AC100V
7m A 50Hz
8m A 60Hz
AC250V 2A
DC24V 2A
NC
AC250V 2A
DC24V 2A
PLC1
K2-L3 (BLU)
TB8
10 1
C1
2
P2
16
J2
2
2
SEE CHART
BLU
BLU
1
1
1
1
R7
R9 R8
R1
1
F
K8
1
4
7
A
3
6
9
B
K6
K7
1
4
7
A
1
4
7
A
3
6
9
B
K5
1
4
7
A
3
6
9
B
3
6
9
B
K4
1
4
7
A
3
6
9
B
K3
1
4
7
A
SEE DETAIL
TB4
3
6
9
B
1
A
L1
L2
L3
B
C2
TB5
2
1 2 3 4 5 6 7 8
C1
C4
5
7
NC
COM
F
S2-3 (BLK)
2
CO
2
6
14
15
S2-6 (ORN)
1
0
1
4
9
11
13
R10
0
L
3
7
8
10
12
BLU
7
C2
COM
1
6
2
5
PER IPHER A L
2
5
C1
3
4
NC
BLU
4
BUS Y
NC
2
3
1
2
S W S E TTING
BATTE RY
MCP W R
2
CO
WHT
PLC MOD
16
C2
R13
MOD1 SH1-1 (GRY)
OP E N
L1
A C 100
-240V
IN PUT
L2/N
TB6
OC 201
1
0
L
1
PLC1 P2-9 (VIO)
IA 111
C1-1 (BLU)
S2-2 (BLU)
RUN
E RR/ALM
INH
P RP HL
COMM
BKUP
1
R11
P OW E R
R12
omr on
S YS MAC
CJ1M
P ROGRAMMABLE
CONTROLLE R
CPU12
PA 202
1
SEE CHART
PCB2
P1
K2
ZD2
L1-H1 (BLU)
PLC1 P2-10 (RED)
J1
BLU
T1
T2
T3
P1
E
C2-2 (WHT)
TB5-PA (YEL)
C2-1 (YEL)
SECTION 7
2
SH1
K2-T1(YEL)
K2-T3(WHT)
1
R14-1 (GRY)
TB6-2(RED)
TB5-TORCH(BLK) D1
8
R15-2 (RED)
1
P2
P3
TB3
1
8
1
P4
16
MOD1 TB3-1 (RED)2
2
R15
1
R14 1
FRONT VIEW
WITH FRONT
PANEL REMOVED
PLC TB4-4(BRN)
PLC1 J2-12(ORN)
PLC1 J2-11(WHT)
ZD3
PLC TB4-4(BRN)
PLC1 J2-13(GRY)
PLC1 J2-14(YEL)
PLC TB7-15(YEL)
1 3
4 6
7 9
A B
PLC TB4-4(BRN)
PLC TB8-5(ORN)
PLC TB4-1(WHT)
PLC TB7-19(VIO)
K3
1 3
4 6
7 9
A B
PLC TB4-4(BRN)
PLC TB8-6(YEL)
PLC TB4-1(WHT)
J1-G (BLK)
K4
1 3
4 6
7 9
A B
J1-K (YEL)
K5
1 3
4 6
7 9
A B
TB3-22 (WHT)
PLC TB4-2(WHT)
K6
1 3
4 6
7 9
A B
TB3-23 (BLK)
K7
1 3
4 6
7 9
A B
PLC TB8-2(BRN)
K8
PLC TB4-4(BRN)
TB3-20 (BLU)
TB3-21 (GRY)
PLC TB7-16(BLU)
T2
1
2
3
4
5
6
7
8
PLC TB4 (SEE DETAIL-SHT 4)
PS-L1
PS-L2
PS-LG
PS-GR
PLC TB7-10 (BLK)
PLC TB7-2 (WHT)
PLC TB8-14 (GRN)
PLC TB8-14 (GRN)
J1
P2
J2
1 PLC TB7-14(ORN) 1 PLC CB3-1(BLK)
1 P4-10(VIO)
2 PLC TB7-13(ORN) 2 PLC TB7-2(WHT)
2 P4-9(VIO)
PLC1 P2-7 (VIO)
PLC TB7-7 (VIO)
PLC TB7-8 (VIO)
PLC TB7-9 (BRN)
PLC TB7-12 (BLK)
PLC TB7-11 (RED)
PLC TB7-12 (BLK)
PLC TB7-14 (ORN)
PLC TB7-13 (ORN)
PLC TB7-15 (YEL)
PLC TB4-6 (GRY)
PLC TB7-19 (VIO)
PLC TB4-8 (GRY)
PLC TB7-16 (BLU)
PLC TB4-8 (GRY)
OUT2-0
OUT2-C0
OUT2-1
OUT2-C1
OUT2-2
OUT2-C2
OUT2-3
OUT2-C3
PLC TB7-20 (VIO)
PLC TB7-17 (GRY)
PLC TB7-21 (BRN)
PLC TB4-8 (GRY)
PLC TB7-22 (RED)
PLC TB4-6 (GRY)
PLC TB7-23 (ORN)
PLC TB4-6 (GRY)
IN1-0
IN1-1
IN1-2
IN1-3
IN1-4
IN1-5
IN1-6
IN1-7
IN1-8
IN1-9
IN1-10
IN1-11
IN1-12
IN1-13
IN1-14
IN1-15
IN1-COM
IN1-COM
PLC TB8-1 (WHT)
PLC TB8-2 (BRN)
PLC TB8-4 (RED)
PLC TB8-5 (ORN)
PLC TB8-6 (YEL)
4 PLC TB8-4(RED)
5 TB3-5 (BLK)
6 TB3-6(VIO)
7
8 PLC TB8-8(BLU)
9
10
P1
1 PCB1 P4-1(BRN)
POWER MOD1
2 PCB1 P4-2(GRY)
P1
3 PCB1 P4-7(YEL)
PCB1 P4-9(YEL)
PLC1 P2-9 (VIO)
3 PLC TB7-2(WHT)
OUT1-0
OUT1-C0
OUT1-1
OUT1-C1
OUT1-2
OUT1-C2
OUT1-3
OUT1-C3
OUT1-4
OUT1-C4
OUT1-5
OUT1-C5
OUT1-6
OUT1-C6
P4
PLC1 MODULE
PLC1 MODULE
PLC
P2
1 PCB1 P1-16(VIO)
1
1 PCB1 P4-3(RED)
1 R10-1 (GRY)
2 TB5-WORK(BLK)
3 PLC TB7-24(GRY)
3 P4-2(BLU)
2 PCB1 P1-15(BLU) 2
2 PCB1 P4-4(YEL)
4 J1-C(ORN)
5 TB5-WORK(RED)
6
5 PCB1 P5-1 (BLK)
4 P4-1(BLU)
PLC1 P2-15(BLU) 6 PCB1 P5-2(VIO)
5 PCB1 P7-1(BLK) 7
6
8 PCB1 P4-8(ORN)
3 PCB1 P3-12(ORN) 3
4 PCB1 P3-13(WHT) 4
3 PCB1 P4-15(BLU)
4 PCB1 P4-16(ORN)
5 PCB1 P1-13(BLK) 5
5 TB6-6(BRN)
6 PCB1 P1-14(RED) 6
6 TB6-8(GRY)
7 PLC1 P2-1 (VIO)
9
7 PCB1 P3-18(BLU) 7
8
10
7
8
9 J1-N(GRY)
4 PCB1 P4-10(WHT)
S3-4(BLU)
10 PLC TB7-11(RED)
9 PLC1 P2-2 (VIO)
11 K3-6(WHT)
10 K2-B(RED)
10
12 K3-9(ORN)
11 PCB1 P1-7(WHT)
11
13 K4-9(GRY)
12 PCB1 P1-8(ORN)
14 K4-6(YEL)
13 PCB1 P1-9(GRY)
14 PCB1 P1-10(YEL)
12
13
15 TB4-4(BRN)
16
15 PLC1 P2-4(BLU)
15 PCB1 P9-3(BLK)
16
16
K2-A (VIO)
NOT USED
8
7 PCB1 P4-11(RED)
8 PCB1 P4-12(BLK)
8 PCB-TB P1-1(YEL)
9 PCB1 P4-13(VIO)
9 R2-1(ORN)
10 PCB1 P4-14(YEL)
PCB1 P2-14(BLU)
2
PLC1 P2-4(BLU)
PCB1 P2-13(BLU)
3
PCB1 P2-12(BRN)
4
PCB1 P2-11(BRN)
PLC1 P2-3(BLU)
SH1
P3
1
5
6
7
PCB1 P2-5(ORN)
8
PCB1 P2-4(ORN)
9
PCB1 P2-2(VIO)
PLC1 P2-2(VIO)
10 PCB1 P2-1(VIO)
PLC1 P2-1(VIO)
11 PCB1 P3-1(GRY)
12 PCB1 P3-2(BLU)
13 PCB1 P1-3(RED)
14 PCB1 P1-2(BRN)
15
14 PCB1 P9-1(RED)
16
PCB2
TB5
P3
1
2
PCB1 P2-16(YEL)
3
PCB1 P2-8(GRY)
4
PCB1 P2-9(RED)
5
PLC TB8-8 (BLU)
PCB1 P2-15(YEL)
PCB1 P2-10(GRY)
6
PCB1 P10-4(WHT)
7
PCB1 P10-3(BLK)
8
PCB1 P10-5(WHT)
PCB2-PA(YEL)
R3
PCB1 P7-3(RED)
MOD1-TB3-1 (RED)
MOD1 SH1-2(BLK)
R4
PA
WORK
TB6 1 2 3 4 5 6 7 8
R5
R6
MOD1 P3-6(GRY)
S3-6(GRY)
S3-3(ORN)
MOD1 TB3-1(BLK)
TB5-PA(YEL)
K2-T1 (YEL)
PLC1 J2-5(RED)
PCB2 P1-1 (RED)
PCB2 P1-6 (BLK)
TORCH
VIEW F-F
MOD1 P3-5(BRN)
PCB2 - P1
PLC TB8-23 (BLK)
PLC TB8-18 (BLK)
P1-1
P1-2
P1-3
P1-6
TB5-WORK(RED)
TB3-13(ORN)
TB3-14(BRN)
TB5-TORCH(BLK)
VIEW E-E
0558003589
SHEET 3 OF 4
94
D1(-) GRY
PLC
TB7
1 PLC CB3-2 (BLK)
PLC TB7-10 (BLK)
PLC TB7-12 (BLK)
TB8
1 PLC CB1-2 (BLK)
TB3-1 (WHT)
PLC IN1-0 (WHT)
2 PLC J2-2 (WHT)
PLC PS-L2 (WHT)
PLC J1-3 (WHT)
PLC TB4-1 (WHT)
2 K7-4 (BRN)
PLC IN1-1 (BRN)
3
3
4 K3-B(BRN)
K4-B(BRN)
K5-B(BRN)
K6-B(BRN)
K8-B(BRN)
PLC J2-15(BRN)
4
4 PLC J1-4 (RED)
PLC IN1-2 (RED)
5
5
5 K5-9 (ORN)
PLC IN1-3 (ORN)
2 TB3-2 (WHT)
K7-6 (WHT)
PLC TB8-24 (WHT)
TB4-1 (WHT)
3
6 PLC OUT2-C3 (GRY)
PLC OUT1-C4 (GRY) 6
PLC TB4-7 (GRY)
PLC OUT2-C2 (GRY)
7 TB3-4 (VIO)
PLC OUT1-0 (VIO)
7 PLC TB7-24 (GRY)
PLC TB4-8 (GRY)
J1-D (GRY)
PLC TB4-6 (GRY)
8 TB3-3 (VIO)
PLC OUT1-C0 (VIO)
8 PLC TB4-7 (GRY)
PLC OUT2-C1 (GRY)
9 J1-M (BRN)
PLC OUT1-C6 (GRY)
PLC OUT1-1 (BRN)
PLC OUT1-C5 (GRY)
10 PLC TB7-18 (BLK)
PLC PS-L1 (BLK)
PLC J1-2 (ORN)
PLC TB7-1(BLK)
PLC J2-1 (BLK)
TB4
1 K5-6 (WHT)
K6-6 (WHT)
PLC TB4-2 (WHT)
PLC TB7-2 (WHT)
TROUBLESHOOTING
PLC TB7-1 (BLK)
SECTION 7
1
2
PLC CB3
6 K6-9 (YEL)
PLC IN1-4 (YEL)
7
8 PLC IN1-6 (BLU)
PLC J1-8 (BLU)
9
10
11 PLC J2-10 (RED)
PLC OUT1-2 (RED)
11
12 PLC OUT1-C1 (BLK)
PLC OUT1-C2 (BLK)
12
PLC TB7-1(BLK)
13 PLC J1-2 (ORN)
PLC OUT1-C3 (ORN) 13
14PLC PS-LG (GRN)
14 PLC J1-1 (ORN)
PLC PS-GR (GRN)
PLC OUT1-3 (ORN)
GND1 (GRN)
15 K3-A (YEL)
PLC OUT1-4 (YEL)
16 K8-A (BLU)
PLC OUT1-6 (BLU) 15
17 PLC OUT2-C0 (GRY)
PLC TB7-24 (GRY) 16
17
18 PLC IN1-COM (BLK)
PLC TB7-10 (BLK) 18
19 PLC OUT1-5 (VIO) 19
PLC TB7-24 (GRN)
20
K4-A (VIO)
20 J1-B (VIO)
PLC OUT2-0 (VIO)
21
22
21 J1-F (BRN)
PLC OUT2-1 (BRN)
22 PLC OUT2-2 (RED)
23 PLC IN1-15 (BLK)
J1-J (RED)
23 PLC OUT2-3 (ORN)
24 PLC TB7-18 (BLK)
J1-L (ORN)
PLC TB4-2 (WHT)
24 PLC J2-3 (GRY)
PLC TB4-7 (GRY)
PLC TB7-17 (GRY)
95
0558003589
SHEET 4 OF 4
SECTION 7
TROUBLESHOOTING
0558003591
2
H4
380V
H3
230V
H2
200V
H1
1
TB2
2
3
FNT PNL
ON/OFF
1
11
P3-1
12
P3-2
6
2
ZD1,220
1
1
M1
120VAC
LED2
LED5
LED8
34
33
32
5
6
31
30
29
LED3
LED6
LED9
14
P1-7
11
P1-8
START GAS
9
12
A
A
A
5
ØB
460V
17
CH5
415V
16
CH4
380V
15
CH3
230V
14
CH2
200V
13
CH1
MOV3
BH7
610V
BH8
L2 T2
575V
12
BH6
460V
11
BH5
415V
10
BH4
380V
BH3
230V
200V
9
8
7
9
P1 J1
A
7
9
10
1
2
3
P4-9
P4-1
P4-2
P4-7
A
575V
460V
415V
380V
230V
200V
6
5
4
3
2
1
TB1
27
TB8-23
6
B
K8
6
B
26
25
24
23
22
21
20
6
B
PLC1
PLC MODULE #1
19
18
17
16
6
A
K2
L1
B
T1
L2
T2
L3
T3
15
120VAC RELAY
6
1
AH6
NOT USED ON
PRECISION PLASMA CONSOLE
J2
P1
1 2 3 4 5 6 7 8
C2
R11
20uf
400V
10K
8W
FRONT PNL LOCAL
CURRENT SETTING POT
R2
10K
MIN
MAX
1 3
2
R3
R4
4.99K 4.99K
P3-17(+)
P9-3
P9-1
P1-14
P1-13
P3-13
P3-12
P1-15
P1-16
BH1
AH4
EFC
SEL
ZD2 220VAC
BH2
AH5
TB8-24
P4-14
P4-13
P4-12
P4-11
P10-1
P10-2
P4-16
P4-15
P4-4
P4-3
P3-18(-)
AH8
610V
6
B
P1-17
AH7
L1 T1
K6
9
8
4
5
P4-8
P4-10
P5-1
P1-12
P5-2
P1-11
P1-18
MOV1
ØA
K5
6
B
TB6-6
610V
CH6
K4
9
V1
VOLTMETER
CB1
3A 2
575V
18
K3
9
13
P1-9
AUTO XFMR
L3 T3
28
TB4-2
PLASMA GAS
P1-10
CH8
ØC
MOV2
6
36
35
8
10
P7-1
P7-3
T2
CH7
A K1 B
4
LED7
AM1
AMMETER
S1
5
LED4
P1-3
P1-2
13
14
15
16
J4 P4
NC
C
NO FS1
1 F4 2
15A
2
TB4-4
9
3
PCB TRIM POT
838193
6
1
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10
14
TB6-8
3
H5
415V
40
39
38
37
TB4-1
TB6-7
4
H6
460V
LED1
P8
5
575V
PCB1
ISOLATION AMPLIFIER AND
FAULT SIGNAL PCB
38103
+
+
6
41
2
P1-5
P1-6
1
7
1
3A
7
J3 P3
P10-5
8
18VAC
P10-3
7
18VAC
P10-4
6
5
P2-10
18VAC
4
P2-9
18VAC
3
P2-8
2
P2-16
24VAC
1
P2-15
P2-14
24VAC
P2-13
P2-12
24VAC
P2-11
P2-7
P2-6
P2-5
12VAC
P2-4
P2-2
120VAC
P2-1
P6
T3
H7
T1
X13
X12
X11
X16
X15
H7 X14
X6
H6 X5
X8
1
H5 X7
2
X4
3
H4 X3
4
5
H3
6
X10
7
H2 X9
8
X2
9
H1 X1
10
CB3
+
+
PUMP
MOTOR
M2
1
CB2
2
7A
4
P2 J2
1
1
2
3
4
15
4
FRONT PNL
CURRENT
SETTING
LOCAL/REMOTE
DPDT S3
5
P3
P4
AH3
10
AH2
9
AH1
8
TB2-2
TB2-1
BR1-A
BR1-B
BR1-C
7
6
5
MOD1
POWER MODULE #1
4
3
2
1
SH1-2
SH1-1
TB3-1
96
13
12
11
10
9
8
7
6
5
4
3
2
1
SECTION 7
TROUBLESHOOTING
0558003591
41
40
39
38
37
36
35
28
27
POWER SUPPLY
MODULE
OUTPUT
MODULE
#2
L2
L1
LG
GR
NC
NC
0
C0
1
C1
2
C2
3
C3
4
5
6
C4
C5
0
1
2
3
C3
B
C
D
E
F
G
H
J
K
L
TRAVEL
M
N
FC HF
PAC
P
R
S
T
START
START GAS FLT
CUT GAS FLT
FAULT TO CNC
U
V
START GAS ON, NITROGEN
CUT GAS ON, OXYGEN
FULL SHIELD
REGULATED SHIELD
1
2
3
4
5
6
26
25
24
23
22
21
20
7
8
9
10
11
PLC1
PLC MODULE #1
N
M
1
F3 2
1A
R6
39K
2W TB6-4
R5
39K
2W TB6-2
START SIGNAL FROM
CNC TO P.S., RELAY CLOSING
I ARC ON SIGNAL FROM P.S.
G TO CNC, RELAY CLOSING
ARC ON SIGNAL
FROM P.S. TO CNC,
TRANSISTOR
START SIGNAL FROM
CNC TO P.S., 120VAC
START SIGNAL FROM
CNC TO P.S., 24VAC
L +10VDC REMOTE CURRENT
J SETTING FROM CNC TO P.S.
C VOLTAGE DIVIDER, (+)
12
13
TB6-5
15
J2
TB3
COMMON TB4 7&8
120VAC RELAY
19
18
17
16
TO FLOW
CONTROL BOX
J1
29
CNC START
0
CNC PREFLOW
1
ARC ON TO CNC
2
O2 PS
3
N2 PS
4
5
FAULT
6
7
8
9
10
11
12
13
14
15
COM
ZD3
COM
220 VAC
C6
C0
A
B
C1
K7
C2
4
6
PLC
INPUT
MODULE
31
30
A
OUTPUT MODULE
#1
34
33
32
J1
14
15
16
17
H VOLTAGE DIVIDER, (-)
18
19
20
21
22
E
F
A
B
K
23
D
EMERGENCY STOP FROM CNC TO P.S.
RELAY/CONTACTOR NORMALLY CLOSED
OPEN IN CASE OF EMERGENCY
FAULT SIGNAL FROM P.S. TO CNC
RELAY CLOSING, DRY CONTACT
120VAC PREFLOW SIGNAL
FROM CNC TO P.S.
24
14
L1
H1
FRONT PNL
PILOT ARC
SELECTOR
S2 6
5 HI
4
2
R7
10K
OHM
20uf
400V 8W
D1
R7
10K
OHM
8W
TO CUTTING MACHINE CNC
CONNECTOR CHASSIS GND SUPPLIED
BY CUTTING MACHINE GROUP
R7
20 OHM 300W
R8
20 OHM
300W
3 R1
LO
20 OHM 300W
R9
1
C1
R14
20 OHM
50W
R15
20 OHM
50W
3
2
1
97
P1-2
P1-1
START UP
PA
P1-3 PCB2
838131
P1-6
13
12
11
10
9
8
7
6
5
4
20 OHM 300W
R10
3.1 OHM
300W
WORK
PILOT ARC
TORCH
TO JUNCTION BOX J1
H2
SECTION 8
REPLACEMENT PARTS
8.1 General
Always provide the serial number of the unit on
which the parts will be used. The serial number is
stamped on the unit nameplate.
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 or from:
ESAB Welding and Cutting Products
ATTN: Customer Service Department
PO Box 100545 Ebenezer Road
Florence, SC USA 29501-0545
Phone (843) 664-4405
(800) ESAB-123 (372-3123)
ESAB Cutting Systems - Canada
6010 Tomken Road
Mississauga, Ontario, Canada L5T 1X9
Phone (905) 670-0220
Fax
(905) 670-4879
ESAB Cutting Systems GMBH
Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Phone 011-49-6039-400
Fax 011-49-6039-403-02
http://www.esab.de
Be sure to indicate any special shipping instructions
when ordering replacement parts.
Refer to the Communications Guide located on the
last page of this manual for a list of customer
service phone numbers.
99
SECTION 8
REPLACEMENT PARTS
8.3 Plasmarc Power Source-Exterior Components
2
3
1
4
6
8
OUTPUTS
START-STOP 0
PREFLOW 1
ARC-ON 2
O2 PRESSURE 3
N2 PRESSURE 4
PILOT 5
FAULT 6
7
8
INPUTS
1-0
1-1
1-2
1-3
1-4
1-5
1-6
1-7
2-0
2-1
2-2
2-3
TRAVEL
HI FREQUENCY
PILOT ARC RELAY
POWER SOURCE
START GAS PRESS SWI FAULT
CUT GAS PRESS SWI FAULT
OUTPUT FAULT
5
START GAS ON N2
CUT GAS ON O2
FULL SHIELD
REGULATED SHIELD
7
100
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
35925YL
Cover-Top
2
995227
Label Warning-Exposed High Volt
3
2091514
Label Warning
4
34941
5
13734588
Logo ESAB Clear
6
35924YL
Panel Right Side
7
32403Y
Panel Left Side
8
61328087
Lens Clear
Screw, HMH ¼-20 X .50 L
101
SECTION 8
REPLACEMENT PARTS
6
5
4
3
2
1
7
8
9
11
10
See
"TEE"
Detail
Page 7-12
102
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
672508
Symbol
(Elec-Ay)
S1
Switch Toggle 2PST 2 Pos 15A
2
634518
S2,3
Switch Toggle DPDT 2 Pos 15A
3
951061
AM1,VM1
Meter LED 5VDC
4
951061
AM1,VM1
Meter LED 5VDC
5
634518
S2,3
6
2234589
R2
7
954751
8
32286GY
Panel Front
9
See Below
Gauge 200 PSI
10
952182
11
36346GY
NOTICE
Description
Switch Toggle DPDT 2 Pos 15A
POT 10K 10 Turn
Overlay Precision Plasma
Spout Remote Filler w/Cap
BRKT, Remote Filler
Refer to Console Serial Number to determine
which gauge to order. Gauges require
different hole sizes in front panel and are not
interchangeable.
• Console with serial number in PxxJ348xx
format require gauge P/N 0558004488
• All others use P/N 598481
P/N 598481
P/N 0558004488
103
SECTION 8
REPLACEMENT PARTS
1
11
2
10
13
9
3
12
4
8
5
6
7
104
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
952209
J1
Conn Box Recpt 19 FS SH
3
952210
J2
Conn Box Recpt 14 FS SH
4
97W6
5
23610197
6
952571
7
32202GY
8
58V75
Adaptor B/A-W F ¼ NPTM BKHD
9
954599
Label Rating Precision Plasma
10
950829
11
950937
Strain Relief
12
13730763
Plate, Serial
13
950874
Door Access Rear
35928GY
3 Strain Relief
Plug Hole .875 Dia. .125 CT Nyl BK
Fuse 7A 600 VAC Fast Acting
F4
Panel Rear
Circuit Breaker 3 AMP
CB1
Circuit Breaker 7 AMP
CB2
105
SECTION 8
REPLACEMENT PARTS
8.4 Plasmarc Power Source-Internal Components
18
17
Reference: PCB1
Isolation Amp
Reference:
Meter LED
AM1,VM1
4
20
5
3
3
6
7
19
8
PA202
POWER
omron
SYSMAC
CJ1M
PROGRAMMABLE
CONTROLLER
CPU12
OC201
IA111
RUN
ERR/ALM
INH
PRPHL
COMM
BKUP
0
8
1 2 3 4 5 6 7
10 11 12 13 14 15
9
0
0
L
2
SW SETTING
BATTERY
2
CO
1
C1
3
MCPWR
2
4
BUSY
C2
5
3
6
L2/N
C3
7
8
PERIPHERAL
9
10
11
12
13
14
NC
15
COM
4
PORT
AC100V
7mA 50Hz
8mA 60Hz
C4
5
C5
6
7
C6
C7
NC
COM
NC
3
4
5
6
7
0
L
1
2
3
4
5
6
7
0
CO
1
2
3
4
5
6
7
C1
C2
C3
C4
C5
C6
C7
NC
NC
AC250V 2A
DC24V 2A
15
OC201
1
0
1
OPEN
AC100
L1
-240V
INPUT
NC
AC250V 2A
DC24V 2A
2
10
1
13
12
11
106
14
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
635686
TB4
3
838103
950096
952053
952034
952030
952032
952205
PCB1
PCB1 P9,7
Base, Precision Plasma
35920GY
Term Block 8 pos
PCB1 P10
PCB1 P1,3,4
PCB1 P2
PCB1 P5
PCB Isolation AMP
Housing Contact, Crimp 3 pin
Standoff #6-32 X .88 L
Plug 5 Pos
Plug 18 Pos
Plug 16 Pos
Receptacle P/C 4 Pos
Box PLC
4
0558003595G
5
0558003578
PLC
6
38131
PCB2
Board, PC Startup
7
950760
K3-6,8
Relay Enclosed DPDT 24VAC
8
17300020
R1,7,8,9
10
13735308
K7
11
952012
12
35682
13
952179
Tank, Water
14
952013
Caster Swivel
15
639533
Bushing, Snap .88 I.D. X 1.09 MH X .45 L
16
17300931
17
952095
18
71200732
19
950829
CB3
20
0558003577
TB7, TB8
PLC Controller
Resistor 300W 20ohm 10%
Relay Enclose DPDT 120VAC 20A
Caster Fixed
XFMR Auto
T2
Resistor, 300W 3.1ohm 10%
Spacer, LED
Adhesive, SIRBR Clr
Circuit Breaker, 3 AMP
Terminal Block, 24 POS, 300V
107
SECTION 8
REPLACEMENT PARTS
4
3
2
1
14
11
5
12
6
7
13
10
7
9
8
108
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
952026
Symbol
(Elec-Ay)
TB2
Description
2
673502
K1
3
672002GY
4
2062334
5
36417GY
6
951215
7
951347
Pump, Carb w/Strainer
8
950179
Tee, Pipe Branch ¼ Brs
9
10Z30
Adaptor, B/A-W M ¼ NPTM
10
182W82
11
37348
Kit, Wire Primary
12
33551
BRKT, Water Tank
13
37805
14
32203GY
Terminal Block
Contactor 3 Pole 75A
Shroud, Fan
Motor, Fan
M1
Shroud, Fan
Motor, Carb 1/3 Hp
M2
Elbow 90 DEG. ¼ NPT
Auto XFMR
T3
BRKT, Auto XFMR
109
SECTION 8
REPLACEMENT PARTS
5
6
8
9
4
1
7
9
8
2
2
3
7
9
3
12
13
11
“TEE” Detail
10 X5
110
7
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
950001
3
21124
Valve, Check Assy
4
36539
Hose, Assy Flowswitch To Core
5
90858009
TBG, Nylobrade 3/8 I.D X .625 O.D.
6
36418
Hose Assy Tank Bottom- Pump Inlet
7
58V75
Adaptor, B/A-W F ¼ NPTM BKHD
8
182W82
9
10Z30
Adaptor, B/A-W M ¼ NPTM
10
994471
Clamp, Hose W/D .50 Dia X 1.06 SS
11
952179
Tank, Water
12
952182
Spout, Remote Filler w/Cap
13
952181
Tee, Plastic Pipe
Hose, Assy Pump Outlet- Torch out
36538
Switch, Flow .25 GPM SPSTB
FS1
Elbow 90 Deg. ¼ NPT
111
SECTION 8
REPLACEMENT PARTS
10
6
5
4
3
7
2
9
7
1
8
112
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
13735961
Heat Exchanger
2
950823
Bushing, Snap
3
950167
Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W
4
995103
TB3
Terminal Block 24 POS 15A
5
36919
TB5
Board, Terminal Output
6
96W10
Holder, Fuse
7
92W57
Grommet, Rub .63 I.D. X .88 O.D. X .06 W
8
639533
Bushing, Snap .88 I.D. X 1.09 MH X .45 L
9
35930GY
BRKT, Heat Exchanger
10
2234891
Plug, 10 Pos
113
SECTION 8
REPLACEMENT PARTS
6
13
5
7
8
4
9
3
10
2
11
1
12
114
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
2
17750020
3
36527GY
4
951161
C1,2
Cap, Metpoly 20uf 400VDC
5
673458
K2
Contactor, Pilot Arc 3P 40A
6
2234521
P4,MOD1
P1,PLC1 P2
Plug, 16 Pos
7
2234891
MOD1 P3, 4,
PLC1 P1
Plug, 10 Pos
8
2234518
J3
9
2234521
P1,PLC1 P2
Plug, 16 Pos
10
2234519
J4, PLC1 J2
Receptacle, 16 Pos
11
635686
TB6
Terminal Strip, 8 Pos
12
647065L1
13
38193
Bushing, Snap
950823
Res 20 ohm 50W
R11,12
Cover, Terminal Board
Receptacle, 8 Pos
Choke Signal #Ch12
Printed Circuit Board Trim Pot
PCB-TB
115
SECTION 8
REPLACEMENT PARTS
8.5 PLC Precision Plasma CJIM P/N 0558003578
1
3
2
4
1
PA202
POWER
omron
RUN
OC201
SYSMAC
ERR/ALM IA111
CJ1M
INH
0 1
0 1 2 3 4 5 6 7
PROGRAMMABLE
PRPHL
CONTROLLER
COMM
8 9 10 11 12 13 14 15
CPU12
BKUP
0
L
OPEN
SW SETTING
BATTERY
MCPWR
BUSY
2
7
0
1
0
CO
C1
C2
C2
3
C3
C3
7
4
8
4
C4
C4
9
5
10
11
5
C5
6
12
13
C5
6
C6
7
14
15
C6
7
C7
C7
COM
NC
COM
NC
NC
AC100V
7mA 50Hz
8mA 60Hz
AC250V 2A
DC24V 2A
5
116
2
2
3
L2/N
PORT
6
C1
5
NC
5
1
2
6
NC
4
L
1
4
PERIPHERAL
3
CO
3
L1
AC100
-240V
INPUT
OC201
2
0
1
2
NC
AC250V 2A
DC24V 2A
3
4
5
6
7
SECTION 8
REPLACEMENT PARTS
Item
Number
Part Number
Quantity
Description
1
0558003755
1
OMRON Power supply
2
0558003756
1
CPU
3
0558003758
1
AC Input Module
4
0558003757
2
Relay Output Module
5
0558003633
1
Flash Memory
117
SECTION 8
REPLACEMENT PARTS
8.6 Power Source Power Module
4
3
2
5
6
1
7
118
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
Symbol
(Elec-Ay)
Description
35914GY
Base Power Module
2
37102
Bracket, PCB KYDEX
3
35799
Wire Kit, Power Module
4
951339
951340
5
37101GY
6
951981
7
35700
PCB1 P1, 5
PCB1 P2, 6
Plug, Female 12 Position
Plug, Female 14 Position
Deck, Power Module
Heat Sink
Inductor, Power Factor
L1
119
SECTION 8
REPLACEMENT PARTS
A
2
3
4
1
5
A
6
8
7
Section A-A
120
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
2234877
Symbol
(Elec-Ay)
J3,4
Description
2
951182
M1
Fan, Axial
3
950487
TB2
Terminal Strip 2 Position
4
950823
5
35700
L1
Inductor, Power Factor
6
17280215
R2
Resistor 1.5K OHM 100W
7
35680
L2
Inductor Assembly Output
8
35681
T3
Transformer Assembly, Main
Block Terminal 10 Position
Bushing, Snap
121
SECTION 8
REPLACEMENT PARTS
3
4
5
2
1
6
7
122
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
2234518
Symbol
(Elec-Ay)
J2
Description
2
38047
SH1
3
2234519
J1
4
35917GY
5
951981
6
2234877
J3, 4
Block Terminal, 10 Position
7
674156
TB3
Adaptor
Block Terminal, 8 Position
Shunt, Feedback
Block Terminal, 16 Position
Baffle Heatsink
Heatsink
123
SECTION 8
REPLACEMENT PARTS
14
12
13
10
11
8
9
10
7
6
15
5
16
4
17
3
18
19
2
20
1
19
21
22
21
23
24
21
124
25
26
27
SECTION 8
REPLACEMENT PARTS
Item
Number
1
Part Number
2
951978
951192
3
35794
4
951979
951196
SCR1
SCR 90A
Pad Thermal SCR Module
5
951980
Q1,2
IGBT 300A 600V
6
17750020
951194
R4,5
Resistor 20OHM 50W NI
Pad Thermal Power Resistor 50W
7
647345
8
17250005
9
951940
C6,7
Capacitor 1uf 600VDC
10
951983
C4,5
Capacitor 3300 uf
11
35793
Busbar IGBT (-)/Capacitor
12
950823
Bushing Snap .687
13
35792
Busbar IGBT (+)/Capacitor
14
5844
Nomex Insulator
15
951191
Pad Thermal IGBT 1200V
16
35799
Wire Kit Module
17
35918
Busbar Shunt
18
639533
Bushing Snap .875 I.D. X 1.093 MH
19
17721020
R6,7,8,9
Resistor 20 OHM 25W NI
20
951185
D1,2
Module Diode 100A 600V
21
647345
Bushing Snap 1.31 I.D. X 1.5 MH .44 L
22
36873
Busbar Capacitor/IGBT
23
952255
24
36872
25
32958
T2
26
950711
TS1,2
27
35790
35940
Symbol
(Elec-Ay)
T1
Description
Transformer Control
BR1
Bridge Diode 3PH 130A
Pad Thermal Bridge
Busbar Input Bridge
Bushing Snap 1.31 I.D. X 1.5 MH .44 L
Resistor 5OHM 50W
C8,9
Capacitor Film 40uf 400VDC
Busbar Capacitor
Transformer, Current
Switch Thermal 194 Deg. F.
Busbar Jumper
125
SECTION 8
REPLACEMENT PARTS
8, 9
1
10 16 12
15
Figure
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
8-1.
3
5
Flow
Qty.
Req.
Part
No.
1
1
3
1
6
6
1
3
2
1
2
4
2
1
2
2
32189
35862
21898
952140
21711
22228
952220
951474
634518
6271128
672528
08030281
23101300
1006733
11Z93
952202
53A61
4
6
6
Control
Box,
7, 8
3
3
5
6
P/N 37416
Views)
13
13
(Left,
Front
and
16
12
12
15
Right
14
Side
Circuit
Symbol
Description
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
STAINLESS STEEL INDICATOR BALL (not shown)
126
SW1
SW2, 3
J1
J2
SECTION 8
REPLACEMENT 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
Item
No.
Qty.
Req.
Part
No.
21
22
23
24
25
26
27
28
1
1
12
4
2
2
1
1
950760
635686
952087
952172
952086
952084
21897
44151300
Control
Box,
P/N
37416
(Top
and
Inside
Views)
Circuit
Symbol
Description
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
127
ICR
TB1
SECTION 8
REPLACEMENT PARTS
35,38
45
34
32
33
37
33
40
34
35
34
35, 46
33
39
32
41
35, 45
36, 35
46
44
34
40
35
48
35, 46
35, 45
42
46
47
34
35, 46
DETAIL 'B'
DETAIL 'C'
43
43
37
34
31
Figure
8-3.
Flow
Control
Item
No.
Qty.
Req.
Part
No.
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
1
2
7
8
14
3
2
1
1
6
1
1
3
1
5
5
1
1
35867
21897
44151300
952087
67100030
950390
952083
952697
11Z93
21711
08030281
952202
951982
35868
92140024
952703
952085
672528
Box,
P/N 37416
semblies)
(Inlet
and
Outlet
Manifold
As-
Circuit
Symbol
Description
BLOCK INLET MANIFOLD
VALVE CHECK
COUPLING PIPE BND 1/8 BRS
FITTING 1/8NPTM 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
128
SOL1
PS1, 2, 3
SOL2, 3, 4, 5, 6
SECTION 8
REPLACEMENT PARTS
PLASTIC TUBING, .250 OD x .040 WALL (TYP.)
90858003 (14.5' TOTAL)
Figure
8-4.
Flow
Control
TUBING
Box,
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
129
Network
SECTION 8
REPLACEMENT PARTS
67
66
68
74
65
80
64
71
72
73
WORK
61
62
63
75
76
Figure
8-5.
ITEM
NO.
QTY
REQ.
PART
NO.
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6271128
11Z93
11Z62
674969
677905
37250
37387
951188
37386
37385
37391
2062119
37392
993426
23610197
32288
35861
37384
950256
Junction
Box,
P/N
37400
DESCRIPTION
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
130
(Inlet
View)
CIRCUIT
SYMBOL
J1
PCB1
SG1
T1
J2
SECTION 8
REPLACEMENT PARTS
84
85
GND
84
83
89
86
87
81
82
86
88
Figure
ITEM
NO.
QTY
REQ.
PART
NO.
81
82
83
84
85
86
87
88
89
1
1
1
2
4
2
1
1
1
952697
952083
37382
21711
22364
951982
37388
37361
951179
8-6.
Junction
Box
(Outlet
DESCRIPTION
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
131
View)
CIRCUIT
SYMBOL
SOL1
PS1, 2
T2
SECTION 8
REPLACEMENT PARTS
START
SHIELD 1
CUT
SHIELD 2
COM/COM
COM/COM
SHIELD2
SHIELD1
CUT
START
407
403
SIL
404
ORN
404
ORN
402
401
SHIELD 1
401
405
BLU
406
YEL
405
BLU
406
YEL
401
SHIELD 2
START GAS
SOLENOID
SHIELD GAS SOLENOIDS
Figure
408
8-9A.
SOLENOID
ASSEMBLY,
PT-24,
CUT GAS
SOLENOID
P/N
ITEM
NO.
QTY
REQ.
PART
NO.
DESCRIPTION
401
402
403
404
405
406
407
408
3
1
1
2
2
2
1
1
952697
952703
22364
22365
22366
22367
952931
593985
SOLENOID 3-WAY
SOLENOID 2-WAY
CONNECTOR QUICK DISCONNECT SILVER
CONNECTOR QUICK DISCONNECT ORANGE
CONNECTOR QUICK DISCONNECT BLUE
CONNECTOR QUICK DISCONNECT YELLOW
PLUG BLOCK 6 POS
O-RING 1.42 ID X .103 NEOP 70A
132
22376
CIRCUIT
SYMBOL
SECTION 8
REPLACEMENT 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
7
6
Figure
8-9B.
T
ITEM
NO.
QTY
REQ.
PART
NO.
1
2
3
4
5
6
7
2
2
1
2
2
2
1
0558001458
9852921
0558001502
593986
REF
REF
REF
GAS
SHUT-OFF
VALVE,
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
133
PT-24,
P/N
0558001335
CIRCUIT
SYMBOL
20
4
13
1
20
26
9
11
10
8
12
14
NOTE:
Torch is supplied with 70 amp
consumables assembled in place.
27
23
7
15
21
5
6
22
24
29
3
2
25
Table
ITEM
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
20
21
22
23
24
25
26
27
29
8-9.
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Precision
PART OR
CODE NO.
21758
22568
21761
22424
22398
21762
22425
22396
22381
22380
REF
21539
21692
21543
22007
22010
21712
77500101
21765
22531
22376
22375
2234133
22382
22378
22427
22389
37663
0558001878
37664
951168
8996565
Plasma
PT-24
Torch
DESCRIPTION
BODY & TUBE AY PT-24 TORCH
SLEEVE TORCH PT-24
POWER CABLE 4.5FT (1,4m) PT-24
POWER CABLE 12FT (3,7m) PT-24
POWER CABLE 17FT (5,2m) PT-24
CABLE PILOT ARC 4.5FT (1,4m) PT-24
CABLE PILOT ARC 12FT (3,7m) PT-24
CABLE PILOT ARC 17FT (5,2m) PT-24
GAS LINE START (BLU)
GAS LINE CUT (YEL)
SHROUD SHIELDING PT-24
ELECTRODE
SWIRL BAFFLE 50/70 AMP
NOZZLE
RETAINER/DIFFUSER NOZZLE PT-24
INSULATOR SHIELD CUP PT-24
SHIELD RETAINER
LUB GREASE DOW DC-111
TOOL ELECTRODE & NOZZLE PT-24
CUP SHIELD PT-24
T SHUT-OFF GAS VALVE ASS'Y (See Fig. 8-9B)
PROTECTOR GORTIFLEX SENSOR 7IN LG
CLAMP WORM DRIVE
GASLINE SHIELD (ORN)
CABLE SOLENOID 4.5FT (1,4m) PT-24
CABLE SOLENOID 12FT (3,7m) PT-24
CABLE SOLENOID 17FT (5,2m) PT-24
GAS TUBING ASS'Y QUICK DISC 4.5FT (1,4m) PT-24
GAS TUBING ASS'Y QUICK DISC 12FT (3,7m) PT-24
GAS TUBING ASS'Y QUICK DISC 17FT (5,2m) PT-24
CLAMP BAND-IT
CLAMP HOSE
NOT SHOWN -- CABLE BUNDLE, INCLUDES ITEMS 3,4,25, AND 26
30
1
1
1
0558001503
0558001876
0558001504
CABLE ASSEMBLY BUNDLE 4.5FT (1,4m) PT-24
CABLE ASSEMBLY BUNDLE 12FT (3,7m) PT-24
CABLE ASSEMBLY BUNDLE 17FT (5,2m) PT-24
Assembly
ESAB
Welding
&
Cutting
Products,
COMMUNICATION
GUIDE
-
A. CUSTOMER SERVICE QUESTIONS:
Order Entry
Product Availability
Order Changes
Saleable Goods Returns
Florence,
SC
CUSTOMER
Welding
SERVICES
Equipment
Pricing
Delivery
Shipping Information
Eastern Distribution Center
Telephone: (800)362-7080 / Fax: (800) 634-7548
Central Distribution Center
Telephone: (800)783-5360 / Fax: (800) 783-5362
Western Distribution Center
Telephone: (800) 235-4012/ Fax: (888) 586-4670
B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns
Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications
Equipment Recommendations
D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates
Repair Status
Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 / Fax: (843) 664-4454
Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 5:00 PM EST
IF
YOU
DO
NOT
KNOW
WHOM
TO
CALL
Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
F-15-800
03/03
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