ESAB m3® Plasma Integrated Gas Control (IGC) System - ICH Instruction manual
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Integrated Gas Control (IGC) System - ICH
no t r el ea se d p rel imi na ry
Instruction Manual
(use with EPP-202/362 Power Sources)
for cut data see manual: 0558010300
0558012266 07/2014
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Integrated Gas Control (IGC) System - ICH
Integrated Gas Control (IGC) System - ICH
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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Integrated Gas Control (IGC) System - ICH
Integrated Gas Control (IGC) System - ICH
Table of Contents
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Integrated Gas Control (IGC) System - ICH
Integrated Gas Control (IGC) System - ICH
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Integrated Gas Control (IGC) System - ICH
Integrated Gas Control (IGC) System - ICH
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Integrated Gas Control (IGC) System - ICH
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Safety
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SAFETY
SAFETY
Safety - English
WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety
Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.
2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below.
Make certain that such openings are protected from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors.
Do not do hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", available from the National
Fire Protection Association, Battery march Park,
Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling.
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SAFETY
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work cables. Route cables on the same side of your body.
D. Connect the work cable to the work piece as close as possible to the area being welded.
E. Keep welding power source and cables as far away from your body as possible.
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
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5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.)
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:
1.
Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are qualified to perform such work.
SAFETY
2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
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SAFETY
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
DANGER
CAUTION
WARNING
Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.
Means potential hazards which could result in personal injury or loss of life.
Means hazards which could result in minor personal injury.
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be used outside during precipitation unless sheltered.
CAUTION This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage.
If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and
/ or significant damage to equipment is possible.
Maximum
Tilt Allowed
15 °
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To avoid personal injury and/or equipment damage, lift using method and attachment points shown here.
SAFETY
Safety - Spanish
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección
"Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las
Precauciones de Seguridad puede resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS--
Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división.
6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de las flamas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones.
Por lo tanto:
1 . Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.
7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of
Cutting and Welding Processes", disponible a través de la
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo.
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SAFETY
1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.
8. Use guantes secos y sin agujeros antes de energizar el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETI-
COS - Son peligrosos. La corriente eléctrica fluye através de cualquier conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.
Por lo tanto:
HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno.
1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.
2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.
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5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code
§25249.5 et seq.)
MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte.
Por lo tanto:
1.
Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.
SAFETY
2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.
6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form
52-529.
Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los
MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo.
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
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SAFETY
SIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos
Significan ¡Atención! ¡Esté Alerta! Se trata de su seguridad.
PELIGRO
Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.
ADVERTENCIA
CUIDADO
Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.
Significa el posible riesgo que puede resultar en menores daños a la persona.
Clase de envolvente
El código IP indica la clase de envolvente, es decir, el grado de protección contra la penetración de objetos sólidos o agua. Se provee protección contra el toque con un dedo, penetración de objetos sólidos de un tamaño superior a 12 mm y contra rocío de agua de hasta 60 grados de la vertical. El equipo marcado IP21S se puede almacenar, pero no se debe usar en el exterior durante periodos de precipitaciones a menos que esté protegido.
ADVERTENCIA
Este producto sólo se debe usar para corte por plasma Cualquier otro uso puede causar lesiones físicas y/o daños en los equipos.
ADVERTENCIA
Si el equipo se coloca sobre una superficie con una inclinación superior a 15°, se puede producir un volcamiento. Es posible que se produzcan lesiones físicas y/o daños importantes en los equipos.
Inclinación máxima permitida
15 °
ADVERTENCIA
Para evitar lesiones físicas y/o daños en los equipos, levante mediante el método y los puntos de sujeción que se indican en esta ilustración.
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SAFETY
Safety - French
AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection.
Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les fiches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive.
L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures
à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise épaisse
à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes
étanches par dessus leur lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent :
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif.
Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.
7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire
Protection Association, Batterymarch Park, Quincy, MA
02269.
CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.
21
SAFETY
1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de terre électrique.
3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel.
4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porte-
électrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.
7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.
3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :
A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps.
LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation.
Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.
22
SAFETY
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer.
(California Health & Safety Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES --
La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1.
Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur.
Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez CGA
Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis
Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualifié.
N'effectuez aucune réparation électrique à moins d'être qualifié à cet effet.
2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation
électrique.
3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des flaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.
6. Utilisez l'équipement conformément à son usage prévu et n'effectuez aucune modification.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA
SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal
Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
23
SAFETY
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.
DANGER Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraîner des blessures corporelles mineures.
Classe de protection de l’enveloppe
L’indice de protection (codification IP ) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale. Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.
AVERTISSEMENT
Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.
AVERTISSEMENT
L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante.
Angle d’inclinaison maximal
15 °
24
AVERTISSEMENT
Soulevez à l’aide de la méthode et des points d’attache illustrés afin d’éviter de vous blesser ou d’endommager l’équipement.
System Diagrams
26 system diagrams
Below are some abbreviations used throughout this manual.
ABBREVIATIONS:
A/C - Air Curtain
ACC - Air Curtain Control
AHC - Automatic Height Control
CGC - Combined Gas Control
ICH - Interface Control Hub
IGC - Integrated Gas Control
PDB - Power Distribution Box
RAS - Remote Arc Starter
WIC - Water Injection Control
system diagrams
System Diagrams
The following illustration shows configurations available on the Integrated Gas Control (IGC) System. With this system, ESAB offers a variety of configurations to meet customer’s requirements. Below are the descriptions of each configuration.
1.
Base System
This system is the basic configuration for the IGC Plasma System. It contains major components, such as the Power
Supply, PT-36 Torch, Remote Arc Starter (RAS), Combined Gas Control (CGC), Power Distribution Box (PDB) and
Automatic Height Control (AHC). This system will meet most customers’ needs in cutting carbon steel, stainless steel, and aluminum. It also has the functionality of marking on carbon steel and stainless steel with the same torch and the same consumables. By simply alternating cutting and marking mode on the go, this system is capable of cutting and marking in the same part program without changing the consumables.
2.
Base System + ACC
This system includes the above Base System and ESAB Air Curtain Control (ACC). Air Curtain is a device used to improve the performance of plasma arc when cutting underwater. The Air Curtain output is triggered from the AHC electrical cabinet.
3.
Base System + AHC
This system includes the Base System plus the ESAB AHC, called a “B4 lifter”. In this configuration, ICH will control plasma sequence, and also the AHC sequence. Customer CNC needs to provide the start signal and corner signal for normal cutting.
4.
Base System + WIC
This system is configured to introduce the Water Injection Control (WIC), a module used to regulate cut water flow to shield the cutting process. This configuration is to meet needs of a customer who wants to cut stainless steel without using H35. This system still uses the standard PT-36 torch, but a different set of consumables. Similar to the dry system, this WIC system can also do marking with water shield.
5.
Base System + WIC + ACC (diagram shows all options)
This complete system gives the opportunity for customer to cut carbon steel, stainless steel, and aluminum.
Customer has the capability to cut stainless steel with Water Injection Control (WIC), and underwater with the help of Air Curtain Control (ACC).
27
Base System (EPP-202/362)
Height Control)
THREE PHASE POWER
P/S-CAN
PS-W
(customer supplied) CNC-PWR
CNC-IO
Work Table
CNC-WIC-PWR
CNC-ESTOP
ICH-AUX
ICH-PDB-PWR
ICH-WIC-CAN
ICH-AHC-CAN
ICH-AHC-PWR
Descriptions
30
Description
Description
Power Supplies
The IGC system can use different plasma power supplies. ESAB provides the EPP-202/362, with various input voltages and current output for your requirements. For details about our power supplies, please refer to the power supply’s specific manual.
380/400V Power Supplies
460/575V Power Supplies
Part Number
Output
(100 % duty cycle)
Voltage
Current range DC (marking)
Current range DC (cutting)
Power
Open Circuit Voltage (OCV)
Voltage (3-phase)
Current (3- phase)
Input
Frequency
KVA
Power
Power Factor
Input Fuse (recommended)
Weight - lbs (kg)
EPP-202,
200/230/460V,
60Hz,
0558011310
360 VDC
200/230/460 V
115/96/50 A RMS
60 Hz
39.5 KVA
35.5 KW
90%
150/125/70 A
941 (427)
EPP-202,
380/400V CCC,
50Hz,
0558011311
160 VDC
10A to 36A
EPP-202,
400V CE,
50Hz,
0558011312
30A to 200A
32KW
342/360 VDC
380/400 V
60/57 A RMS
50 Hz
39.5 KVA
35.5 KW
90%
80/75 A
939 (426)
360 VDC
400 V
57 A RMS
50 Hz
39.5 KVA
35.5 KW
90%
75 A
957 (434)
EPP-202,
575V,
60Hz,
0558011313
366 VDC
575 V
43 A RMS
60 Hz
39.5 KVA
35.5 KW
90%
60 A
1085 (492)
31
Description
The IGC system can use different plasma power supplies. ESAB provides the EPP-202/362, with various input voltages and current output for your requirements. For details about our power supplies, please refer to the power supply’s specific manual.
380/400V Power Supplies
460/575V Power Supplies
Part Number
Output
(100 % duty cycle)
Voltage
Current range DC (marking)
Current range DC (cutting)
Power
Open Circuit Voltage (OCV)
Voltage (3-phase)
Current (3- phase)
Frequency
KVA Input
Power
Power Factor
Input Fuse (recommended)
Weight - lbs (kg)
EPP-362,
460V,
60Hz,
0558011314
360 VDC
460 V
109 A RMS
60 Hz
88.7 KVA
83.7 KW
94%
150 A
1130 (514)
EPP-362,
380V CCC,
50Hz,
0558011315
200 VDC
10A to 36A
30A to 360A
72KW
364 VDC
380 V
134 A RMS
50 Hz
88.5 KVA
85.1 KW
96%
175 A
1130 (514)
EPP-362,
400V CE,
50Hz,
0558011316
360 VDC
400 V
128 A RMS
50 Hz
88.6 KVA
84.7 KW
96%
175 A
1140 (518)
EPP-362,
575V,
60Hz,
0558011317
360 VDC
575 V
88 A RMS
60 Hz
87.7 KVA
84.0 KW
96%
125 A
1125 (512)
32
Description
Interface Control Hub (ICH) p/n 0558009607
The Interface Control Hub (ICH) provides the plasma process control including current, gas and torch height (if applicable). It also serves as the interface between the customer CNC and the ESAB IGC plasma system. At the same time, it functions as a hub for CAN communication.
Specifications
Dimensions: 7.50” (190.5 mm) high x 10.125” (257.2 mm) wide x 6.50” (165.1 mm) deep
Weight: 8.5 lbs. (3.9 kg)
Operating Temperature
Max Humidity
Enclosure Degree of Protection
5-40°C (41-104°F)
95% non-condensing
IP54
Input Power Reduction
230 VAC, 5 Amps
120 VAC, 3 Amps
ICH Mounting Dimensions
0.28”
(7.1 mm)
11.50”
(292.1 mm)
3.00”
(76.2 mm)
33
Description
CNC Direct Board
p/n 0558009991
The CNC Direct board is the control and interface board inside the ICH. It provides the process control, interface to customer CNC, system setup, panel interface, etc. Below is a skeleton of this CNC board. It shows the major components and the major connectors on the board. The table below gives the functions of these connections.
34
Port
X1
X2
X3
X4
X6
X7
X8
X9
XS1
Function
CNC Control, DB37
RS232
CAN1 and 24VDC input
CAN2
Spare I/O
Reserved
Aux Control, DB25
ASIOB1 Communication
Switches: Plasma Start, Gas Test
Port
XS2
XP1
XP2
S2, S3
V12
V13
V41
J1
Function
Switches: Local/Remote, Station Select and Screen Select
Programming port 1
Programming port 2
ID switches, by default S2=1, S3=4
IC, Main processor
EEPROM, Save data for system configuration, error history, etc.
IC for ASIOB1
DIP switches:
1- 120R for CAN1, 2- 120R for CAN2,
3- VCC to ASIOB1, 4- GND to ASIOB1
Default: 1 - ON, 2 - ON, 3 - OFF, 4 - OFF
Description
Combined Gas Control (CGC) p/n 0558010241
The Combined Gas Control regulates the output of the plasma gas (PG) selected from the three plasma gas inlets (N2/Air, O2/H35 and Argon) and controls the flow of shield gas (SG). It is powered by 24 Volts (AC and DC) from the RAS Box and receives commands via the CAN-bus directly from the ICH.
Like the Shield Gas Box and the Plasma Gas Box, the gas output of the
Combined Gas Control is monitored and fed back through the CAN-bus to ICH for self-diagnosis.
There are four gas inputs (three plasma gases, one shield gas), two gas outputs (SG, PG), and one outboard connection (air curtain). The four inputs are fitted with porous bronze filters and "G-1/4" (BSPP) female right-hand thread. Either of two adaptor fitting kits are available to adapt standard metric or CGA hose connections. The gas fittings and adaptors are listed in the following tables.
Specifications
Dimensions: 8.5” (215.9 mm) long x 6.0” (152.4 mm) wide x 4.5” (114.3 mm) high
Weight: 8.65 lbs. (3.9 kg)
Power Input: 24 VAC/DC
* 6.25”
(158.8 mm)
NOTE:
CAN cable must be routed separate from torch leads.
* 8.50” (215.9 mm) including fittings on front and back
4.75”
(120.7 mm)
4.50”
(114.3 mm)
35
Description
PT-36 m3 G2
Plasma
Torch
Component Locator Designation
(See following component illustrations)
RAS Box
Customer
Supplied
Gases
Power
N2/Air
O2/H35
Air
N2/Air
Argon
CAN
D
J
F
E
A
B
C
G
H
Combined
Gas Control
J
CNC or
Process
Controller
Combined Gas Control Component Locator Designations
Note:
Refer to enclosed tables for all available hoses and cables.
Connections
There are two cables connected to the Combined Gas Control: one is 24V power, the other is CAN. There are four gas inputs (N2/Air, O2/H35, Argon and SG) and two gas outputs (PG and SG). The gas fittings are listed below.
Note:
Chassis must be connected to the machine ground.
Inputs
Output
Gas
N2/Air
O2/H35
Argon
SG
PG
SG
Fitting
1/8” NPT x “A” Inert Gas RH Female
1/4” NPT x “B” Fuel LH Male
1/4” NPT x “B” Inert Gas RH Female
1/4” NPT x “B” Oxygen RH Male
Connection, Male
0.125NPT to "A" Size
ESAB
P/N
631475
83390
74S76
83389
2064113
36
A
Description
B
C D E F J
J H G
37
Description
CAUTION
When connecting fuel gas lines to the oxygen plasma gas input, or reconnecting oxygen after fuel gas use, extra care must be taken to assure that all lines from input through the torch are completely purged.
It is recommended to purge the system and torch lines with nitrogen for 60 seconds prior to reconnection, then purge the nitrogen for 60 seconds with the new supply gas before cutting.
Outputs
Gas
Plasma
Metric
Input
Adaptors
Shield
Air Curtain
Plasma
CGA
Input
Adaptors
Shield
Air Curtain
Fitting
Argon
N2/Air
O2/H35/F5*
N2/Air
Air
G-1/4” right hand male x G-1/4” right hand male
G-1/4” right hand male x G-1/4” right hand male
G-1/4” right hand male x G-1/4” right hand male
G-1/4” right hand male x G-1/4” right hand male
G-1/4” right hand male x “B” Air/Water right hand male
* Another adapator is required when connecting H35/F5.
Part Number - 0558010246 (G-1/4” right hand female x G-1/4” left hand male)
Argon
N2/Air
O2/H35/F5*
N2/Air
Air
G-1/4” right hand male x “B” Inert Gas right hand female
G-1/4” right hand male x “B” Inert Gas right hand female
G-1/4” right hand male x “B” Oxygen right hand male
G-1/4” right hand male x “B” Air/Water right hand male
G-1/4” right hand male x “B” Air/Water right hand male
* Another adapator is required when connecting H35/F5.
Part Number - 0558010245 (“B” Oxygen right hand female x “B” Fuel Gas left hand male)
SG
PG
Air Curtain
1/4” NPT x 5/8"-18 LH male
1/4” NPT x “B” Inert Gas right hand female
1/8” NPT x “B” Inert Gas left hand female
ESAB
P/N
0558010163
0558010163
0558010163
0558010163
0558010165
0558010166
0558010166
0558010167
0558010165
0558010165
10Z30
2064113
08030280
Note:
The PT-36 Torch is shipped with hose lengths that will not allow the Combined Gas Control to be mounted more than two meters (6.6 feet) away from the torch. Please make sure the routing of the standard hoses will allow them to bend and connect properly before permanently mounting the Combined Gas Control.
If additional distance between the torch and box is required, the standard torch hose assembly will need extension hoses to create longer lengths. Extension hoses can be ordered to connect to the existing hose assembly.
BOTH HOSES MUST BE ORDERED
Extension Hose, Plasma Gas, 1M (3.3 ft.) ESAB P/N 0558008996
Extension Hose, Shield Gas, 1M (3.3 ft.) ESAB P/N 0558008997
The longer hose lengths will require that the pierce time be increased and a longer lead-in time must be specified. This is due to the additional time required to purge the N
2
start gas from the hose before the O
2
cut gas becomes affective. This condition occurs when cutting carbon steel with oxygen.
38
Description
Each gas has a requirement for maximum flow and pressure as shown in chart below:
Plasma
Shield
Air Curtain
Gas
Argon
O2/H35/F5
N2/Air
N2/Air
Air
Gas &
Pressure
Air (85psi / 5.9bar)
Process
Nitrogen
(125psi / 8.6bar)
Oxygen
(125psi / 8.6bar)
CGC Flow Diagram
Pressure
125 psi (8.6 bar), 200 SCFH (5.7 SCMH)
125 psi (8.6 bar) for O2, 75 psi (5.2 bar) for H35/F5, 255 SCFH (7.2 SCMH)
125 psi (8.6 bar), 255 SCFH (7.2 SCMH)
125 psi (8.6 bar), 353 SCFH (10.0 SCMH)
80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)
Maximum Gas Flow Rates - CFH (CMH)
With PT-36 Torch
269
(7.6)
385
(10.9)
66
(1.9)
Gas Purity
Clean, Dry, Oil Free
Filtered to 25 microns
99.99%, Filtered to 25 microns
99.5%, Filtered to 25 microns
39
40
Description
Combined Gas Control Plumbing Schematic
Ar
V1
PT1
O2/H35/F5
V2
PV1 PT3
Plasma Gas
N2/Air
V3
P
1
∆P
P
2
PT2
PV2
N2/Air
PT = Pressure Transducer
PV = Proportional Valve
Shield Gas
Description
Combined Gas Control Electrical Schematic
6
7
8
Con 1
3
4
5
1
2
CAN H Out
CAN L Out
CAN Gnd
CAN H In
CAN L In
NC
NC
NC
Con 2
3
4
1
2
24VAC In
24VAC In
-24VDC In
+24VDC In
11
13
15
5
7
9
1
CO 1
3
2
4
6
8
10
12
14
16
LED 1
LED 2
41
CGC Mounting Dimensions
p/n 0558008459
Description
0.313”
(8.0mm)
0.281
(7.1mm)
CGC Bottom View
0.37”
(9.5mm)
7.50”
(190.5mm)
4.72”
(120.0mm)
4.00”
(101.6mm)
0.37”
(9.5mm)
M6
0.90”
(22.9mm)
2.52”
(64.0mm)
42
Description
Troubleshooting
The Combined Gas Control has two visible LEDs that indicate its’ status. When the GREEN LED is on, this indicates power is applied to the unit and the rate at which it is flashing shows the operational status of the unit (refer to the chart below). If the Green LED is not ON, check the power cable, which should carry 24VDC and 24VAC from the Control Power Box.
If the Yellow LED is not ON, either there is no power to the unit or the station is not selected.
The Combined Gas Control is highly integrated and is treated as a “Black Box”. If one or more functions of the unit stop working, the unit must be returned for repair. Contact technical support for troubleshooting and RMA assistance.
LED
Green
Yellow
Status
OFF
10% ON, 90% OFF
50% ON, 50% OFF
90% ON, 10% OFF
ON
Meaning
Power OFF
Boot loader is running
Application is running
Application is running, CAN is available
Station is selected
Replacement Parts
NOTE:
Additional Parts lists, Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm
(11” x 17”) paper are included inside the back cover of this manual.
43
Description
Power Distribution Box (PDB) p/n 0558010242
The Power Distribution Box (PDB) takes 230 VAC or
115 VAC depending on the switch setup. Outputs of 24 VDC and 24 VAC are to supply power to the
Combined Gas Control (CGC). The PDB also recieves commands from the ICH via the A/C CTRL port. This is for controlling the air curtain outputs. By default, the PDB can control one CGC and one air curtain. If needed, a second CGC and air curtain can be controlled after putting another power block and necessary connectors inside. Power block and connectors kit part number is 0558010247.
Specifications
Dimensions: 10” (254 mm) long x 9.5” (241.3 mm) wide x 4.25” (108 mm) high
Weight: 9.0 lbs. (4.1 kg)
Input Power
230 VAC, 2 Amps
115 VAC, 3 Amps
Output Power 24 V AC/DC
PDB Mounting Dimensions
8.00”
(203.2 mm)
6.50”
(165.1 mm)
M6
.875”
(22.2 mm)
3.00”
(76.2 mm)
4.25”
(108.0 mm)
10.00”
(254.0 mm)
44
Description
PDB Mounting Plate Dimensions
p/n 0558008794
5.75”
(146.0mm)
0.281
(7.1mm)
0.313”
(8.0mm) 0.50”
(12.7mm)
9.50”
(241.3mm)
PDB Schematic
From the factory, the PDB’s 230/115VAC switch is set to 230VAC. If the customer requires a different input voltage, then change the switch to 115 VAC. For more information see fold-out schematics included with this manual.
45
Description
Remote Arc Starter (RAS) p/n 0558012260
The Remote Arc Starter is more commonly referred to as the RAS
Box. The RAS box provides a voltage feedback to the plasma torch lift. This voltage is used to regulate the torch height while cutting, maintaining the proper height of the torch above the work piece.
Within the RAS box there is a High Frequency/Voltage Divider circuit board which provides pilot arc ionization and voltage divider functions to regulate torch height.
Coolant connections and torch power connections are made within the RAS box and provide an interface between the power supply, coolant circulator and the torch.
Specifications
Dimensions: 8.75” (222.3 mm) high x 7.50” (190.5 mm) wide x 17.00” (431.8 mm) deep
Weight: 28.5 lbs. (12.9 kg)
46
8.75”
(222.3 mm)
7.50”
(190.5 mm)
17.00”
(431.8 mm)
G, H
Description
Remote Arc Starter Connections
Note:
Chassis must be connected to the machine ground.
A
F E
D
C
J
Letter
A
C
D
E
F
G, H
I
J
Description
3 Pin Voltage Divider Connection to the Lift
14 Pin Amphenol Power Supply Connection
Power Supply Enable
Coolant Inlet - Flowing to the Torch
Coolant Return - Flowing back to the Coolant Circulator from the Torch
Strain Relief Fittings
Torch Shroud Connection
Machine Ground Connection
I
47
48
Description
Power
Supply
Control
Box
Component Locator Designation
(See following component illustrations)
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Coolant Return Hose
H
E
F
C
G
I
Power, Pilot Arc, Coolant
Remote
Arc
Starter
A
VDR Cable
Power Supply Enable
D
AHC / Lift
( Optional )
PT-36 m3 CAN
Plasma
Torch
Remote Arc Starter Box Component Locator Designations
NOTE: Refer to enclosed tables for all available hoses and cables.
Description
RAS Box Mounting Dimensions
The box has four M6 x 1 threaded mounting holes shown in pattern below.
CAUTION
If fasteners are threaded into the box from below, the length of the fasteners must not allow them to extend more than 0.25” beyond the edge of the internal female threads. If fasteners are too long they can interfere with the components inside the box.
5.00”
(127.00 mm)
1.00”
(2.54 mm)
2.75”
(69.85 mm)
13.75”
(349.25 mm)
RAS Box Mounting Plate Dimensions
p/n 0558008461 18.50"
(469.9 mm)
17.50"
(444.5 mm)
8.75"
(222.3 mm)
3.25"
(82.6 mm)
7.50"
(190.5 mm)
6.50"
(165.1 mm)
49
Air Curtain Control (ACC)
Description p/n 37440 p/n 0558010243
Specifications
Dimensions: 6.00” high (152.4 mm) x 9.56” wide (242.8 mm) x 2.50” deep (63.5 mm)
Weight: 4.00 lbs. (1.81 kg)
Input Power: 24 VAC
The Air Curtain is a device used to improve the performance of plasma arc when cutting underwater. The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone to reduce noise, fume, and arc radiation, even though the torch has been submerged.
The Air Curtain requires a source of compressed air that needs to be clean, dry and oil-free. It should be delivered at 80 psi @ 1200 cfh (5.5 bar @ 34 CMH).
50
ACC Mounting Dimensions
Description
9.31”
(236.5 mm)
5.81”
(147.6 mm)
2.91”
(74.0 mm)
.312” x .500” slots
1.16”
(29.5 mm)
ACC Component Connections
7.00”
(177.8 mm)
A
NOTE:
Cables “A” and “B” are listed in the ACC
Component Connections, INSTALLATION section of this manual.
Compressed Air
B
51
Description
Water Injection Control (WIC) p/n 0558009370
The Water Injection Control (WIC) regulates the flow of cut water supplied to the plasma torch. This water is used as a shield in the cutting process. This shield assists in forming the plasma arc and also cools the cut surface. The selection and output of cut water is performed and controlled by the ICH. The WIC consists of a water regulator, pump and a closed feedback loop between proportional valve and flow sensor. This is controlled by a local
Process Control Unit (PCU). The PCU communicates via CAN to the ICH while controlling the proportional and solenoid valves.
The WIC is monitored and sends feedback signals through the CAN bus to the ICH for diagnostic purposes.
For more detailed information on the Water Injection Control (WIC), see manual #0558009491.
Dimensions (Electrical module)
Dimensions (Pump Module)
Weight (Electrical module)
Weight (Pump Module)
Water Requirements
Air Supply (anti-freezing function)
Pump
Motor
Pressure Regulator
Pressure Transducer
Proportional Valve
Flow Sensor
Air Solenoid
Specifications
163 mm x 307 mm x 163 mm (6.4 in x 12.1 in x 6.4 in)
465 mm x 465 mm x 218 mm (18.3 in x 18.3 in x 8.6 in)
15 lb. dry (6.8 kg)
60 lb. dry (27.2 kg)
Tap water with an allowable water hardness of <2 ppm as CaCO3 and Conductivity:
>200,000 ohms per inch, filtered at 5 microns. 1 gpm (3.8 l/min) minimum flow rate @ 20 psi (1.4 bar).
250 CFH @ 80 psi (7.1 cmh @ 5.5 bar)
Positive displacement, rotary vane with adjustable by-pass valve (250 psi / 17.2 bars maximum), CW rotation, Capacity: 1.33 GPM @ 150 psi (5.04 l/min @ 10.3 bar),
Nominal speed: 1725 rpm, Temperature rating: 150 o F (66 o C)
1/2 HP, 230 VAC single phase, 60 Hz, 1725 RPM, 3.6A current,
Temperature rating: 150 o F (66 o C)
Inlet water pressure: 100 psi (6.9 bar) maximum
Outlet water pressure: 20 psi (1.4 bar) factory set
Maximum pressure range: 0 - 200 psi (0 - 13.8 bar)
Temperature range: -40
Supply voltage: 24 VDC o - 257 o F (-40 o - 125 o C)
Pressure signal output: 4 mA for 0 psi, 20 mA for 200 psi (13.8 bar). Regulated to 1 to 5 VDC with 250 ohm resistor.
Supply voltage: 24 VDC
Full load current: 500 mA, Input control signal: 0-10 VDC.
Coil: Standard Voltage: 24 VDC, Operating current: 100-500 mA,
Valve: Orifice size: 3/32”, Cv:0.14 (fully open)
Operating differential pressure: 115 psi (8.0 bar) ; Max. flow 1.5 gpm
Maximum fluid temperature: 150 o F (66 o C)
Maximum operating pressure: 200 psi (13.8 bar),
Operating temperature: -4 o - 212 o F (-20 o - 100 o C), Input power: 5 - 24 VDC @ 50 mA maximum, Output signal: 58 - 575 Hz, Flow range: 0.13 - 1.3 gpm
Supply voltage: 24 VDC, Maximum operating pressure: 140 psi (9.7 bar) , Operating temperature: 32 o - 77 o F (0 - 25 o C)
52
Description
Automatic Height Control (AHC) p/n 0560947166
The B4 lift assembly provides vertical motion for the PT-36 plasma torch, using a typical motor, screw, and slide configuration. The motor turns an enclosed spindle screw, which in turn raises/lowers the lifting plate along linear rails. Directional commands given from the plasma controller determine the direction of the travel. Fixed limit switches are included to prevent upper and lower lift’s over travel.
The lift assembly also contains components necessary to control height over work surfaces; initial, piercing, and cutting heights are encoder controlled during the plasma cycle. During part production, height is automatically controlled by taking voltage measurements between the torch electrode and work surface.
The B4 lifts utilize an Omni Soft Touch® assembly to protect the system during station crashes. Proximity switches monitor torch position in the torch holder. If the torch is jarred in any direction, the process will stop and an error report will be sent to the controller.
Specifications
Dimensions:
6.0” (152.4 mm) wide x 8.5” (215.9 mm) deep x 31.5” (800.1 mm) high
Lift Speed: 315 IPM [8.0m per minute]
Vertical Travel: 8.00” [200.0 mm]
Approximate Weight including torch holder: 85 lbs. [38.5 kg]
Torch Barrel Size: 85.7 mm
IHS Accuracy: ± 0.5 mm
Component Tolerances Encoder Accuracy: ± 0.25 mm
Voltage Accuracy: ± 1 volt
53
Description
B4 Mounting Dimensions
B4 lift hole patterns are provided below to aid end users in mounting the plasma station. An optional plasma bracket/nut plate is available. For more specific details, please refer to the B4 Lift manual.
54
(6) M8 x 1.25 x 40
Socket Head Cap Screws
4.13” [104.9mm]
3.64” [92.4mm]
0.49” [12.4mm]
0.53”
[13.5mm]
2.50”
[63.5mm]
4.47”
[113.5mm] x6 M8x1.25 - 6H
THRU HOLES
5.00”
[127.0mm]
Recommended Mounting Bracket/Nut Plate
Hoses and Cables
Cable / Hose
Description
Description
CAN Bus Cable
Available
Lengths m ( ft. )
1m (3.3’)
2m (6.5’)
3m (10’)
4m (13’)
5m (16’)
6m (19’)
7m (23’)
8m (26’)
9m (30’)
10m (33’)
11m (36’)
12m (39’)
13m (43’)
14m (46’)
15m (49’)
20m (66’)
25m (82')
36m (118')
30m (100')
40m (131')
45m (150')
50m (164')
55m (180')
60m (200')
ESAB
Part Number
0558008464
0558008465
0558008466
0558008467
0558008468
0558008469
0558008470
0558008471
0558008472
0558008473
0558008474
0558008475
0558008476
0558008477
0558008478
0558008479
0558008809
0558008480
0558008481
0558008482
0558008483
0558008484
0558008485
0558008486
55
56
Cable / Hose
Description
Power Supply Enable
Cable / Hose
Description
VDR Cable
Description
Available
Lengths m ( ft. )
5m (16’)
10m (33’)
15m (49’)
20m (66')
25m (82')
Available
Lengths m ( ft. )
0.5m (1.7’)
1.5m (5’)
3m (10’)
4m (13’)
5m (16’)
6m (19’)
6.1m (20')
7m (23’)
8m (26’)
9m (30’)
10m (33’)
15m (49’)
20m (66’)
25m (82')
ESAB
Part Number
0558008329
0558008330
0558008331
0558008807
0558008808
ESAB
Part Number
0560947067
0560947075
0560947076
0560947068
0560947077
0560947069
0560946782
0560947070
0560947071
0560947072
0560947078
0560947073
0560947074
0560946758
Description
Cable / Hose
Description
Pilot Arc Cable
Torch
Description
PT-36 m3 CAN
Plasma Torch
Cable / Hose
Description
PS & CC Control Cable
Cable, Control (14PX-14S), Family
0558011630
ESAB
Part Number
0558008310
0558008311
0558008312
0558008313
0558008314
0558008315
0558008316
0558008317
ESAB
Part Number
0558008301
0558008302
0558008303
0558008308
0558008304
0558008305
0558008306
0558008307
ESAB
Part Number
0558011840
0558011631
0558011632
0558011633
0558011634
0558011635
0558011636
0558011637
0558011963
0558011638
0558011964
0558011639
0558011965
0558011640
Available
Lengths m ( ft. )
2.9m (9.5’)
7.6m (25’)
10m (33’)
15m (50’)
20m (66’)
23m (75’)
25m (82’)
30m (100’)
35m (115’)
40m (131’)
45m (150’)
50m (164’)
55m (180’)
60m (200’)
Available
Lengths m ( ft. )
1.4m (4.5’)
1.8m (6’)
3.6m (12’)
4.3m (14’)
4.6m (15’)
5.2m (17’)
6.1m (20’)
7.6m (25’)
Available
Lengths m ( ft. )
1.4m (4.5’)
1.8m (6’)
3.6m (12’)
4.6m (15’)
5.2m (17’)
6.1m (20’)
7.6m (25’)
4.5m (14.5’)
57
NOTE:
This cable is only used with a ICH to connect the second Interface Box.
For multiple CAN hubs on
ESAB cutting machines use cable 0558008824.
Description
Cable / Hose
Description
CAN Bus Crossover Cable
115 / 230 VAC Input Power Cable
Combined Gas Control
Power Cable
Available
Lengths m ( ft. )
0.5m (1.7’)
5m (16’)
10m (33’)
15m (49')
20m (66’)
25m (82')
1.5m (5’)
3m (10’)
4m (13’)
5m (16’)
6m (19’)
7m (23’)
8m (26’)
9m (30’)
10m (33’)
12.8m (42')
15m (49’)
20m (66’)
ESAB
Part Number
0558008524
0558008261
0558008262
0558008810
0558008811
0558008812
0560947079
0560947080
0560947061
0560947081
0560947062
0560947063
0560947064
0560947065
0560947082
0560946780
0560947066
0560947083
58
Description
PT-36 Mechanized Plasmarc Cutting Torch p/n 0558008300
The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the field. Only the torch frontend has replaceable parts.
The purpose of this section is to provide the operator with all the information required to install and service the PT-36 Mechanized Plasmarc Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package.
Specifications
Type: Water cooled, Dual gas, mechanized plasmarc cutting torch
Current Rating: 1000 Amps @ 100% duty cycle
Mounting Diameter: 2 “(50.8 mm)
Length of Torch without leads: 16.7 “(42 cm)
IEC 60974-7 Voltage Rating: 500 volts peak
Striking Voltage (maximum value of HI-FREQUENCY voltage): 8000 VAC
Minimum Coolant Flowrate: 1.3 GPM (5.9 L/min)
Minimum Coolant Pressure at Inlet: 175 psig (12.1 bar)
Maximum Coolant Pressure at Inlet: 200 psig (13.8 bar)
Minimum Acceptable Rating of Coolant Recirculator: 16,830 BTU/HR (4.9 kW) at High Coolant Temperature - Ambient
= 45 ° F (25 ° C) and 1.6 USGPM (6 L/min)
Maximum Safe Gas Pressures at Inlets to Torch: 125 psig (8.6 bar)
Safety Interlocks: This torch is intended for use with ESAB plasmarc cutting systems and controls employing a water flow switch on the coolant return line from the torch. Removal of the nozzle retaining cup to service the torch breaks the coolant return path.
59
Description
7.54"
(191.5 mm)
2.00"
(50.8 mm)
6.17"
(156.7 mm)
9.13"
(231.9 mm)
10.50" (266.7 mm)
Length of Sleeve
Package Options Available
PT-36 package options available through your ESAB dealer. See Replacement Parts section for component part numbers.
Optional Accessories
Bubble Muffler - When used in conjunction with a water pump recirculating water from the table and by using compressed air, this device creates a bubble of air which enables a PT-36 Plasmarc Cutting Torch to be used underwater with less sacrifice of cut quality. This system also permits operation above water as the flow of water through the muffler reduces fume, noise, and arc U.V. Radiation.
(for installation/operation instructions see manual 0558006722).............................. 37439
Air Curtain - This device when supplied with compressed air is used to improve the performance of the PT-36 Plasmarc Cutting Torch when cutting underwater. The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone, even though the torch has been submerged to reduce noise, fume, and arc radiation. To be used in underwater applications only.
(for installation/operation instructions see manual 0558006404) .............................37440
60
Description
Speedloader assembly, handheld ...............................................................0558006164
NOTE:
Cannot be used with vent hole nozzles.
Speedloader assembly, 5 fixtures ................................................................0558006165
PT-36 Torch Consumable Kits
PT-36 Repair & Accessories Kit ...................................................................................0558005221
Part Number
0558003804
0004485648
0558002533
0558001625
0558002534
0558002530
0558005457
0558003924
0004485671
0004470045
0004470030
0004470031
0004470115
0004470046
0558003858
0004470044
0004470049
0558007105
0558003918
0004470869
Quantity Description
2
6
1
2
1
5
10
2
1
1
2
1
1
3
1
1
2
2
1
10
Torch Body PT-36 w/O-rings
O-ring 1.614 ID x .070
Baffle, 4 Hole x .032
Baffle, 8 Hole x .047
Baffle, 4 x .032 Reverse
Baffle, 8 x .047 Reverse
Baffle, 4 Hole x .022
Electrode Holder PT-36 w/O-ring
O-ring .364 ID x .070
Nozzle Retaining Cup, Standard
Shield Gas Diffuser, Low Current
Shield Gas Diffuser, Standard
Shield Gas Diffuser, Reverse
Shield Retainer, Standard
Contact Ring w/screw
Screw, Contact Ring
Hex Key Wrench .109"
Nut Driver 7/16" (Electrode tool)
Electrode Holder Tool PT-36
Silicon Grease DC-111 5.3oz
61
62
Description
PT-36 Start-Up Kits ..............................................................................................................................
0558010625
600 AMP
5
5
5
5
5
1
5
5
5
1
5
1
5
5
5
5
5
5
5
0558010624
450 AMP
5
5
-
5
5
1
5
5
-
1
5
1
5
5
5
-
5
5
5
0558010623
360 AMP
5
-
-
5
5
-
5
-
-
-
5
1
5
5
5
-
5
5
5
0558010622
200 AMP
5
-
-
5
-
-
5
-
-
-
5
1
5
5
5
-
5
5
-
Part No
0558009400
0558003914
0558003928
0558009406
0558009411
0558006018
0558006020
0558006030
0558006028
0558006041
0558009550
0558009425
0558006141
0558006166
0558009551
0558006199
0558009548
181W89
950561
Description
ELECTRODE MICRO PT-36
ELECTRODE O2 ULTRALIFE, Standard PT-36
ELECTRODE N2/H35, Standard PT-36
NOZZLE 0.6mm (.024") MICRO PT-36
NOZZLE 1.1mm (.043") MICRO PT-36
NOZZLE 1.8mm (.070") PT-36
NOZZLE 2.0mm (.080") PT-36
NOZZLE 3.0mm (.120") PT-36
NOZZLE 2.8mm (.109") Divergent (O2) PT-36
NOZZLE 4.1mm (.161") PT-36
NOZZLE RETAINING CUP HD PT-36
SHIELD 2.5mm (.099") MICRO PT-36
SHIELD 4.1mm (.160") PT-36
SHIELD 6.6mm (.259") PT-36
SHIELD 5.1mm (.200") HD PT-36
SHIELD 9.9mm (.390") PT-36
SHIELD RETAINER HD PT-36
O-RING 1.114 ID x .070 CR
TOOL BOX
PT-36 H35 Heavy Plate Start-up Kit ............................................................................0558005225
Part Number
0558003963
0558003965
0558003964
0558005689
0558003967
0558002532
0558006688
0558003918
0558003962
0558008737
Quantity Description
5
1
2
5
1
2
2
2
5
5
Electrode, Tungsten 3/16"D
Nozzle H35 .198" Divergent
Collet 3/16"D Electrode
Electrode/Collet Holder PT-36
Collet Body
Baffle, 32 Hole x .023
Shield High Current
Electrode Holder Tool PT-36
Tungsten Electrode Tool
Nozzle Retaining Cup Assy High Current
Description
Recommended Regulators
Liquid Cylinder Service:
O
N
2
2
: R-76-150-540LC ................................................................................................................P/N 19777
: R-76-150-580LC ................................................................................................................P/N 19977
High Pressure Cylinder Service:
O
2
: R-77-150-540 .........................................................................................................P/N 0558010676
Ar & N
2
H
2
& CH
: R-77-150-580 .................................................................................................P/N 0558010682
4
: R-77-150-350 ............................................................................................P/N 0558010680
Industrial Air : R-77-150-590 ...................................................................................P/N 0558010684
Station/Pipeline Service:
O
2
: R-76-150-024 .........................................................................................................P/N 0558010654
Ar & N
2
Air, H
2
: R-76-150-034 .................................................................................................P/N 0558010658
, & CH
4
: R-6703 .............................................................................................................P/N 22236
Replacement Parts
NOTE:
Additional Parts lists, Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm
(11” x 17”) paper are included inside the back cover of this manual.
63
64
Description
Installation
66
InstallatIon
InstallatIon
Check upon receipt
1. Verify all the system components on your order have been received.
2. Inspect the system components for any physical damage that may have occurred during shipping. If there is evidence of damage, please contact your supplier with the model number and serial number from the nameplate.
Before Installation
WARNING
All installation and service of the electrical and plumbing systems must conform to national and local electrical and plumbing codes.
Installation should be performed only by qualified, licensed personnel. Consult your local authorities for any regulation issues.
Locate the major components to the right position prior to making electrical, gas, and interface connections.
Refer to the system interconnection diagrams for major components placement. Ground all major components to earth at one point. To prevent leaks, make sure to tighten all gas and water connections with specific torque.
Grounding
Introduction
Machine grounding is an important part of the installation process, which can be greatly simplified if prepared in advance. The most difficult part of the grounding process is designing and installing a low impedance Earth ground rod. However, the better the Earth ground rod, the less chance there is of having electromagnetic interference problems after the installation is complete.
Most national electric codes address grounding for the purpose of fire prevention and short circuit protection; they do not address equipment protection and electromagnetic interference noise reduction. Therefore, this manual presents more stringent requirements for machine grounding.
WARNING
Electric Shock Hazard.
Improper grounding can cause severe injury or death. Improper grounding can damage machine electrical components. Machine must be properly grounded before putting it into service. The cutting table must be connected to machine earth grounding rod.
67
68
A common symbol used to identify a chassis ground on drawings.
A common symbol used to identify an earth ground on drawings.
InstallatIon
Grounding Overview
There are three parts to a ground system;
•
Component or "chassis" ground
•
Earth ground
•
Protective Earth ground
Component grounding connects all pieces to a single component, like the machine chassis, which is then connected to a common point known as the star point. This provides a path for electromagnetic interference (EMI) from the enclosure to ground.
An earth ground provides a electromagnetic interference (EMI) to return to its source.
A protective earth (PE) ground provides a safe path for fault current. Without a properly grounded system, an unintended path through people or sensitive equipment may be found, resulting in serious injury, death, and/or premature equipment failure.
This section focuses on machines with a plasma cutting system. Machines with plasma cutting capability are particularly prone to electromagnetic interference problems and often utilize dangerous voltages and currents. All machines must have electrical components grounded and attached to an earth ground, regardless of process type (shape cutting, marking, or other material preparation).
A common symbol used to identify a protective earth (PE) ground.
InstallatIon
Basic Layout
The electrical ground layout is similar for both large and small machines. The chassis ground , plasma
6 7 table. This common connection is referred to as a star point (see illustration below). One cable connects
5
1
9
8
3 output of the plasma power supply . Specification of cable sizes is discussed later in this manual. Some country standards or directives require a separate ground rod for the plasma power supply. Consult your machine schematics for more information.
8
Note: The three phase electrical input an electrical ground.
2 to the plasma power supply must include
This illustration demonstrates multiple ground cables fastened with a single bolt to create a star
8 cutting table will vary.
69
InstallatIon
Elements of a Ground System
The ground system consists of five main components:
• plasma current return path
• plasma system safety ground
• utility power electrical ground
• cutting machine chassis ground
• rail system safety ground.
Ensure provisions are made during the installation for each of these elements for creating a complete ground system.
Plasma Current Return Path
The return path ground cable is the most important element of the ground system. It completes the path for the plasma current. Solid, low impedance, well maintained electrical connections are a necessity.
The plasma cutting current is generated by the plasma power supply . A welding cable carries this current
5
4
2 3 torch. The current then arcs to the work piece on the cutting table. The current path must be closed so that the current can easily return to its source. This is done by connecting the cutting table to the positive (+) connection on the plasma power supply. If the return path ground cable is not connected, the plasma system will not work. There will be no way for the arc to establish between the torch and the work piece. If the cable is connected, but the connections have a very high resistance, it will limit the current of the arc, and cause dangerous voltage levels between system components.
1
2
3
4
5
70
InstallatIon
The only way to ensure that all components are at the same voltage level (same potential), and thus eliminate the possibility of being shocked, is to ensure that all interconnections are making good electrical contact.
Good electrical contact requires that connections are made with bare metal to metal contact, the connections are very tight, and are protected from rust and corrosion. Use a grinder or wire wheel to clean all paint, rust, and dirt from the surface when connecting cable lugs to any metal surface. Use an electrical joint compound between cable lugs and metal surfaces to prevent future rust and corrosion. Use the largest size bolts, nuts, and washers possible, and tighten fully. Use lock washers to ensure that connections stay tight.
Plasma System Safety Ground
The plasma system safety ground (or ground rod ) serves several important purposes. It provides:
•
Frame voltage for personnel safety by ensuring that there are no potential differences between system components and building components.
•
A stable signal reference for all digital and analog electrical signals on the cutting machine.
•
Helps control electromagnetic Interference (or
EMI).
•
Provides a discharge path for short circuits and high voltage spikes, such as those caused by lightening strikes.
71
InstallatIon
There are many misconceptions about the ground rod, and the role it plays in reducing electromagnetic interference. In theory, the ground rod is present to eliminate possible potential differences between equipment and building structures. However many people believe that the ground rod allows all radio
1 rod will eliminate radio frequency noise problems.
Misconception about Earth ground rods.
1
72
InstallatIon
In reality the ground rod is providing a low impedance path by which noise currents may return to their
2
1
Earth ground rod reality.
2
1
73
74
InstallatIon
Rail System Safety Ground
The rail system safety ground makes sure that the entire rail is at ground potential, eliminating any possible shock hazard, and providing backup for the machine chassis ground in case of a plasma current short circuit. All four corners of the rail system should be connected to the cutting table.
InstallatIon
Earth Ground Rod
The best way to make sure that your Earth ground connection is optimized is to enlist the services of a professional. There are a number of engineering firms which specializes in designing and installing Earth grounding systems. However, if this option cannot be used, then there are several things which can be done to ensure that your Earth ground connection is good:
Ground Rod
The ground rod itself can be optimized in two ways: length and diameter. The longer the grounding rod, the better the connection. The same is true for diameter: the larger the diameter, the better the connection.
However, if the soil resistance is very low, then a ground rod longer than 3m [10 feet] does not make a significant difference.
Since soil resistivity is rarely as good as it could be, a standard grounding rod should be
25mm [1 inch] in diameter and 6m [20 feet] long.
Soil Resistivity
Soil resistivity can be changed in two ways: by altering the mineral content, the moisture content, or both.
The ideal solution to poor soil resistivity is to excavate the immediate area and backfill with conditioned soil additives. In extremely dry areas, the moisture content can be improved by installing a drip system which continually moisturizes the soil surrounding the ground rod. A crude way of affecting soil moisture and content is to use salt water, or rock salt to condition the surrounding soil.
75
InstallatIon
Utility Power Electrical Ground
The utility power electrical ground must accompany all 3 phase and single phase power feeds. This electrical ground provides the proper reference for all incoming power. Failure to provide this ground is a violation of most electrical codes, and a serious safety hazard.
Depending on the 3 phase power arrangement (either a “Delta” or a “Y”), the line to ground voltage may be equal to, or less than the line to line voltage. A problem exists any time the line to ground voltage exceeds any individual line to line voltage (difference in potential). Contact your local utility company if you are not sure that your 3 phase power has a proper electrical ground. Make sure that your electrical contractor properly installs the electrical ground wire with all 3 phase and single phase power feeds.
The electrical ground must be connected to the appropriate terminal inside of the plasma power supply. Size wire according to local electrical codes.
2
1
3
1
2
3
Utility Power Electrical Ground
3 Phase Electrical Supply
Plasma Power Supply
76
InstallatIon
Multiple Ground Rods
There are a number of reasons why multiple ground rods should not be used. While installing multiple rods may improve a safety ground or lightening ground, it offers no advantage for electromagnetic interference reduction, and can cause more problems than it is worth.
The problem with multiple ground rods is that each rod uses an “interfacing Electromagnetic Interference
1
2
Multiple ground points can also create undetectable
“sneak” pathways for radio frequency noise currents, actually causing more interference! Instead of considering multiple ground rods, take steps to make the single ground rod as good a ground connection as possible.
1.1
l l
1 2
2.5 l
Multiple ground rods should be avoided if possible.
However, if all other avenues have been explored to lessen your systems’ electronic interferences, multiple ground rods are an option.
Such a system should be installed by a professional and the distance between the rods should exceed
2.5 times the length of the rods.
77
78
InstallatIon
Machine Grounding Schematic
1
2
3
8
10
9
5
6
7
8
9
3
4
1
2
10
Main Control Enclosure
Component Enclosures
Main Star Ground
Rails
Cutting Table
System Star Ground (on Table)
Earth Ground Rod
Plasma Power Supply
Plasma Power Supply Ground (required by EU
Standards)
Electrical System Ground
(+)
4
5
6
7
•
All electrical enclosures bolted to the machine chassis
•
Machine chassis grounded to star point on cutting table.
•
Rails grounded to cutting table
•
Plasma ground connected to star point on cutting table
•
Earth ground rod connected to star point on cutting table.
•
A separate ground rod is required for the plasma power supply by some regulations and directives. Check with local regulations to determine if this additional ground rod is required.
InstallatIon
Placement of Power Supply
WARNING
Failure to follow instructions could lead to death, injury or damaged property. Follow these instructions to prevent injury or property damage. You must comply with local, state and national electrical and safety codes.
•
A minimum of 1 meter (3 ft.) clearance on front and back for cooling air flow.
Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection.
•
Locate the power supply relatively close to a properly fused electrical power supply.
Keep area beneath power supply clear for cooling air flow.
•
Environment should be relatively free of dust, fumes and excessive heat. These factors will affect cooling efficiency.
Input Power Connection
WARNING
Electric shock can kill! Provide maximum protection against electrical shock. Before any connections are made inside the machine, open the line wall disconnect switch to turn power off.
Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.
Input Conductors
•
Customer needs to supply the input conductors, which may consist either of heavy rubber covered copper conductors (three power and one ground) or run in solid or flexible conduit.
•
Size of input conductors is dependent on the current. Please refer to the specific power supply manual for the size on input conductors.
79
InstallatIon
Input Connection Procedure
Primary Terminals
Power Input Cable Access
Opening (Rear Panel)
Chassis Ground
1. Remove small rear panel of the plasma unit.
2. Thread cables through the access opening in the rear panel.
3. Secure cables with strain relief at the access opening.
4. Connect the ground lead to the stud on the chassis.
5. Connect the power leads to the primary terminals.
6. Connect the input conductors to the line (wall) disconnect.
7. Before applying power, replace the rear cover panel.
WARNING
Electric shock can kill! Dangerous voltage and current may be present any time working around a plasma power source with covers removed:
•
DISCONNECT POWER SOURCE AT THE LINE (WALL) DISCONNECT.
•
HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSITIVE
AND NEGATIVE) WITH A VOLTMETER.
80
InstallatIon
Output Connection Procedure
1. Open access panel on the lower front of the power source by removing four M6 screws.
2. Thread output cables through the openings at the bottom of the power source immediately behind the front panel.
3. Connect cables to designated terminals mounted inside the power source using UL listed pressure wire connectors.
4. Close front access panel.
Front Access
Panel Opened
Front Access
Panel Closed
Remove four M6 screws to open
Access Panel
To ease connections, thread cables/hoses through these
3 access holes
The plasma unit does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch. Optionally, an input power disconnect box (ESAB p/n 0558011541) can be used.
81
InstallatIon
Interface Cables/Connections
CAN Connector
This is the CAN communication bus connector. The cable from this connector is tied to the CNC/process controller.
J1 (RAS)
This is a connector for interfacing with Remote Arc Starter (RAS) unit. The cable from this connector carries signals such as: Mark
Mode and Hi-Frequency ON.
Interface Cable Connectors Panel (bottom side of front panel)
Analog
Interface
CAN
J1 (RAS)
82
InstallatIon
Placement of RAS Box
Connections on the RAS Box
1. Remove or unlock the cover screws and lift the box cover off to expose internal components.
WARNING
The cover is grounded to the Remote Arc Starter Box internally with a short ground wire. Remove cover carefully to avoid damage to the wire or loosening of the ground wire.
2. Power cables pass through the strain relief fittings. To make the power supply connection to the RAS box, you must first open the unit: remove or unlock the cover screws and lift the box cover off to expose internal components.
Pilot Arc Cable enters through strain relief fitting to Voltage Divider (VDR)
Coolant IN to Power Supply Enable to Power Supply
Coolant OUT
Strain Relief Fittings
Power Source Cables enter through strain relief fittings
83
Buss Bar / Block
InstallatIon
Nomex Insulation
Connection for Pilot Arc Cable
Locking Screw
3. Strip back the insulation of the 4/0 (95 mm 2 ) cable, approximately 38 mm.
4. Insert the 4/0 (95 mm 2 ) cable in the buss bar/block hole until copper extends to the edge of the buss bar / block.
5. Tighten the locking screw(s) down on the cable.
Amperage
Up to 200 amps
Amperage
Up to 400 amps
Up to 800 amps
Up to 1000 amps
Required # of 1/0 Cables
1
Required # of 4/0 Cables
1
2
3
NOTICE
Careful attention while stripping the insulation of the 4/0 (95 mm
2
) cable will make installation in the buss clamp easier. Do not spread or flare the copper conductors.
Note:
Chassis must be connected to the machine ground.
84
InstallatIon
Standard VDR Cable VDR Cable (with free end)
6. If a non-ESAB lifter is to be used with a system the supplied VDR cable will only have a connector on one end. The other end of the cable will have no connector. The end with the supplied connector is to be connected to the RAS box to its corresponding socket which is labeled “Voltage Divider.”
The free end of the VDR cable will be connected to the lifter. Although this is a three conductor cable, only two of the wires are used, BRN (VDR - ) and BLU (WORK). The black wire is a spare and is to be terminated and capped inside of the lifter. The corresponding pin at the RAS box comes terminated from the factory. The RAS box is not to be modified.
It is imperative that the BLUE wire be connected to ground. The BROWN wire is the VDR(-) output.
Customer
Supplied
Lifter
VDR (Voltage Divider Cable)
Ground in Lifter is required for reference
85
InstallatIon
Torch Connections
Torch hook-up requires the connection of power cables / coolant hoses, pilot arc cable and chassis ground. On the PT-36 torch, the coolant hoses from the RAS box to the torch also carry electrode power.
The pilot arc cable is connected inside the arc starter box. The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.
Power Cable /
Coolant Connections
Pilot Arc Connection
Ground
Stud
Pilot
Arc Cable
Chassis
Ground
Wire
Power Cable /
Coolant
PG Hose
SG Hose
86
InstallatIon
Connection of Torch to Plasma System
DANGER
Electric Shock Can Kill!
• Disconnect primary power source before making any adjust ments.
• Disconnect primary source before doing maintenance on system components.
• Do not touch front-end torch parts (nozzle, retaining cup, etc.) without turning primary power off.
Ground Stud
Ground cable
Power cables
Pilot Arc cable
Connection to the Remote Arc Starter Box
The PT-36 has two water cooled power cables which must be connected to the negative output from the power supply. The right handed 7/16-20 fitting is on the cable supplying coolant to the torch. The left handed 7/16-20 fitting is on the cable returning coolant from the torch. Both of these cables have a green/yellow wire to be connected to the ground stud shown above.
The pilot arc cable is connected to the arc starter box (see Installation section). The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.
87
InstallatIon
Mounting Torch to Machine
DANGER
CLAMPING ON TORCH BODY MAY CAUSE DANGEROUS CURRENT
TO FLOW THROUGH MACHINE CHASSIS.
Mount torch on insulated sleeve here
DO NOT mount on steel torch body here
•
Do not mount on stainless steel torch body.
•
Torch body is electrically insulated, however high frequency start current may arc through to find a ground.
•
Clamping near torch body may result in arcing between body and machine.
•
When this arcing occurs, torch body may require non-warranty replacement.
•
Damage to machine components may result.
•
Clamp only on insulated torch sleeve (directly above label) not less than 1.25" (31.75mm) from the torch end of the sleeve.
Placement of ICH
The ICH should be located close to the operator for easy access.
Connect required CAN cables between ICH and other CAN nodes, such as EPP-202/362 Power Source, B4 lifter, if applicable. CAN connection is always made from left to right, if one node is removed from CAN bus, all nodes on the right need to be shifted to left. After connecting all CAN nodes, a terminator is required. Leave all unused
CAN ports open.
Connect DB37 cable to port “CNC” on ICH. The other side of DB37, is connected to the customer’s CNC via a male DB37 connector. An optional breakout board may be used. A DB37 to free end cable is also available.
Connect power from ICH to PDB and B4 lifter, if applicable. Make sure the power switch on ICH is off.
Connect power to ICH box.
88
InstallatIon
Placement of CGC
The CGC regulates the plasma gas and shield gas. For optimum performance, it should always be placed close to torch. According to the material being cut, the customer needs to select and connect the correct inlet gases. Inline filters are embedded into the inlet fittings. Please make sure all inlet gases meet the pressure and flow requirements.
Connect 24V AC/DC power from PDB, then connect CAN cable to ICH.
Plasma
Shield
Air Curtain
Gas
Argon
O2/H35/F5
N2/Air
N2/Air
Air
Gas &
Pressure
Air (85psi / 5.9bar)
Process
Nitrogen
(125psi / 8.6bar)
Oxygen
(125psi / 8.6bar)
Pressure
125 psi (8.6 bar), 200 SCFH (5.7 SCMH)
125 psi (8.6 bar) for O2, 75 psi (5.2 bar) for H35/F5, 255 SCFH (7.2 SCMH)
125 psi (8.6 bar), 255 SCFH (7.2 SCMH)
125 psi (8.6 bar), 353 SCFH (10.0 SCMH)
80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)
Maximum Gas Flow Rates - CFH (CMH)
With PT-36 Torch
269
(7.6)
385
(10.9)
66
(1.9)
Gas Purity
Clean, Dry, Oil Free
Filtered to 25 microns
99.99%, Filtered to 25 microns
99.5%, Filtered to 25 microns
Placement of PDB
The PDB should be placed on the deck as it is used for supplying power to the CGC.
89
InstallatIon
Individual Component Connections
Part numbers and lengths for the cables shown below are provided on the following page.
PDB front ICH back
A
B
CGC front
C
PDB back
“A” - Power cable from ICH to PDB (115/230V)
Part Number Length Part Number Length
0560947962 1m (3.3’) 0560947088 5m (16’)
0560946776
0560947964
0560947087
2m (6.4’)
3m (10’)
4m (13’)
0560947089
0560947090
6m (19’)
7m (23’)
90
“C” - Power cable PDB to CGC (24 VAC/DC)
Part Number Length Part Number Length
0560947079 1.5m (5’) 0560947064 8m (26’)
0560947080
0560947061
0560947081
0560947062
0560947063
3m (10’)
4m (13’)
5m (16’)
6m (19’)
7m (23’)
0560947065
0560947082
0560946780
0560947066
0560947083
9m (30’)
10m (33’)
12.8m (42')
15m (49’)
20m (66’)
“B” - CAN cable from ICH to CGC
Part Number Length Part Number Length
0558008464 1m (3.3’) 0558008473 10m (33’)
0558008465
0558008466
0558008467
0558008468
0558008469
0558008470
0558008471
0558008472
2m (6.5’)
3m (10’)
4m (13’)
5m (16’)
6m (19’)
7m (23’)
8m (26’)
9m (30’)
0558008474
0558008475
0558008476
0558008477
0558008478
0558008479
0558008809
0558008480
11m (36’)
12m (39’)
13m (43’)
14m (46’)
15m (49’)
20m (66’)
25m (82')
36m (118')
InstallatIon
ACC Component Connections
A
Compressed Air
Part Number
0560947067
0560947075
0560947076
0560947068
0560947077
0560947069
0560946782
Part Number
0558004841
0558004842
0558004843
0558004844
0558004845
0558006865
0558008502
“A” - Cable from ACC to PDB
Length Part Number
0.5m (1.7’)
1.5m (5’)
0560947070
0560947071
3m (10’)
4m (13’)
5m (16’)
6m (19’)
6.1m (20')
0560947072
0560947078
0560947073
0560947074
0560946758
“B” - Air Curtain hose from ACC to CGC
Length Part Number
1.4m (4.75’)
1.8m (6’)
3.7m (12’)
4.6m (15.25’)
5.3m (17.25’)
6.1m (20’)
7.0m (23’)
0558004846
0558008503
0558008504
0558008505
0558008506
0558008507
B
Length
7m (23’)
8m (26’)
9m (30’)
10m (33’)
15m (49’)
20m (66’)
25m (82')
Length
7.6m (25’)
8.0m (26.25’)
9.1m (30’)
10.1m (33')
11.0m (36.25’)
11.9m (39.5’)
91
InstallatIon
Component Placement Example
5
6 alternative mounting location
8
6
7
2
1
4
3
92
3
4
5
6
7
8
1
2
Components
CNC
Interface Control Hub (ICH)
PT-36 Torch
B4 Lift
Combined Gas Control (CGC)
Remote Arc Starter Box (RAS)
Power Supply
Power Distribution Box (PDB)
InstallatIon
DANGER
Hydrogen explosion hazard! Read the following before attempting to cut with a water table.
A hazard exists whenever a water table is used for plasma arc cutting. Severe explosions have resulted from the accumulation of hydrogen beneath the plate being cut. Thousands of dollars in property damage has been caused by these explosions. Personal injury or death could result from such an explosion. The best available information indicates that three possible sources of hydrogen exists in water tables:
1. Molten Metal Reaction
Most of the hydrogen is liberated by a fast reaction of molten metal from the kerf in the water to form metallic oxides. This reaction explains why reactive metals with greater affinity for oxygen, such as aluminum and magnesium, release greater volumes of hydrogen during the cut than does iron or steel. Most of this hydrogen will come to the surface immediately, but some will cling to small metallic particles. These particles will settle to the bottom of the water table and the hydrogen will gradually bubble to the surface.
2. Slow Chemical Reaction
Hydrogen may also result from the slower chemical reactions of cold metal particles with the water, dissimilar metals, or chemicals in the water. The hydrogen gradually bubbles to the surface.
3. Plasma Gas
Hydrogen may come from the plasma gas. At currents over 750 amps, H-35 is used as cut gas. This gas is 35% hydrogen by volume and a total of about 125 cfh of hydrogen will be released.
Regardless of the source, the hydrogen gas can collect in pockets formed by the plate being cut and slats on the table, or pockets from warped plate. There can also be accumulation of hydrogen under the slag tray or even in the air reservoir, if these are part of the table design. The hydrogen, in the presence of oxygen or air, can then be ignited by the plasma arc or a spark from any source.
4. Follow these practices to reduce hydrogen generation and accumulation:
A. Clean the slag (especially fine particles) from the bottom of the table frequently. Refill the table with clean water.
B. Do not leave plates on the table overnight or a weekend.
C. If a water table has been unused for several hours, vibrate it in some way before the first plate is laid in position.
This will allow accumulated hydrogen in the refuse to break loose and dissipate before it is confined by a plate on the table. This might be accomplished by laying the first plate onto the table with a slight jolt, then raising the plate to permit hydrogen to escape before it is finally set down for cutting.
D. If cutting above water, install fans to circulate air between the plate and the water surface.
E. If cutting underwater, agitate the water under the plate to prevent accumulation of hydrogen. This can be done by aerating the water using compressed air.
F. If possible, change the level of the water between cuts to dissipate accumulated hydrogen.
G. Maintain pH level of the water near 7 (neutral). This reduces the rate of chemical reaction between water and metals.
93
InstallatIon
WARNING
Possible explosion hazard from plasma cutting aluminum-lithium alloys!
Aluminum-Lithium (Al-Li) alloys are used in the aerospace industry because of 10% weight savings over conventional aluminum alloys. It has been reported that molten Al-Li alloys can cause explosions when they come into contact with water. Therefore, plasma cutting of these alloys should not be attempted in the presence of water. These alloys should only be dry cut on a dry table. Alcoa has determined that "dry" cutting on a dry table is safe and gives good cutting results.
DO NOT dry cut over water. DO NOT water injection cut.
The following are some of the Al-Li alloys currently available:
Alithlite (Alcoa)
Alithally (Alcoa)
2090 Alloy (Alcoa)
X8090A (Alcoa)
X8092 (Alcoa)
X8192 (Alcoa)
Navalite (U. S. Navy)
Lockalite (Lockheed)
Kalite (Kaiser)
8091 (Alcan)
For additional details and information on the safe use from the hazards associated with these alloys, contact your aluminum supplier.
WARNING
Oil And Grease Can Burn Violently!
• Never use oil or grease on this torch.
• Handle torch clean hands only on clean surface.
• Use silicone lubricant only where directed.
• Oil and grease are easily ignited and burn violently in the presence of oxygen under pressure.
WARNING
Hydrogen explosion hazard.
Do Not Cut Underwater With H-35! Dangerous buildup of hydrogen gas is possible in the water table.
Hydrogen gas is extremely explosive. Reduce the water level to 4 inches minimum below the workpiece.
Vibrate plate, stir air and water frequently to prevent hydrogen gas buildup.
94
Spark hazard.
WARNING
Heat, spatter, and sparks cause fire and burns.
• Do not cut near combustible material.
• Do not cut containers that have held combustibles.
• Do not have on your person any combustibles (e.g. butane lighter).
• Pilot arc can cause burns. Keep torch nozzle away from yourself and others when activating plasma process.
• Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and hat.
• Wear flame-retardant clothing that covers all exposed areas.
• Wear cuffless trousers to prevent entry of sparks and slag.
InstallatIon
Preparing to Cut
•
Select an appropriate condition from the Cut Data manual (SDP File) and install recommended torch front-end parts (nozzle, electrode, etc.) See Cut Data manual to identify parts and settings.
•
Position torch over material at desired start location.
•
See Power Source Manual for proper settings.
•
See Description and Installation sections for gas control and startup procedures.
Mirror Cutting
When mirror cutting, a reverse swirl gas baffle and reverse diffuser are required. These reverse parts will “spin” the gas in the opposite direction, reversing the “good” side of the cut.
Reverse 4 x .032 Baffle
Reverse 8 x .047 Baffle
P/N 0558002534
P/N 0558002530
Reverse Diffuser P/N 0004470115
Cut Quality
Causes affecting cut quality are interdependent. Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to different undesirable cutting results. To begin select the most prominent condition:
•
Cut Angle, negative or positive
•
Cut Flatness
•
Surface Finish
•
Dross
•
Dimensional Accuracy
Usually the recommended cutting parameters will give optimal cut quality, occasionally conditions may vary enough that slight adjustments will be required. If so:
•
Make small incremental adjustments when making corrections.
•
Adjust Arc Voltage in 5 volt increments, up or down as required.
•
Adjust cutting speed 5% or less as required until conditions improve.
95
InstallatIon
CAUTION
Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in
Cut Data manual.
Cut Angle
Negative Cut Angle
Top dimension is greater than the bottom.
•
Misaligned torch
•
Bent or warped material
•
Worn or damaged consumables
•
Standoff low (arc voltage)
•
Cutting speed slow (machine travel rate)
Part
Part
Positive Cut Angle
Top dimension is less than the bottom dimension.
•
Misaligned torch
•
Bent or warped material
•
Worn or damaged consumables
•
High standoff High (arc voltage)
•
Cutting speed fast
•
Current high or low. (See Cut Data manual for recommended current level for specific nozzles).
Drop
Part
Drop Part
96
InstallatIon
Cut Flatness
Top And Bottom Rounded. Condition usually occurs when material is .25" thick (6.4mm) or less.
•
High current for given material thickness.
(See Cut Data manual for proper settings).
Drop Part
Top Edge Undercut
•
Standoff low (Arc Voltage).
Drop Part
97
InstallatIon
Surface Finish
Process Induced Roughness
Cut face is consistently rough. May or may not be confined to one axis.
•
Incorrect Shield Gas mixture (See Cut Data manual).
•
Worn or damaged consumables.
Machine Induced Roughness
Can be difficult to distinguish from Process Induced
Roughness. Often confined to only one axis. Roughness is inconsistent.
•
Dirty rails, wheels and/or drive rack/pinion.
•
Carriage wheel adjustment.
Top View
Cut Face
Process
Induced
Roughness or
Machine
Induced
Roughness
Dross
Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Cut Data manual.
High Speed Dross
Material weld or rollover on bottom surface along kerf. Difficult to remove. May require grinding or chipping. “S” shaped lag lines.
•
Standoff high (arc voltage).
•
Cutting speed fast.
Lag Lines
Cut Face
Rollover
Side View
Lag Lines
Cut Face
Slow Speed Dross
Forms as globules on bottom along kerf. Removes easily.
•
Cutting speed slow.
Globules
Side View
98
CAUTION
InstallatIon
Recommended cutting speed and arc voltage will give optimal cutting performance in most cases. Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings.
Top Dross
Appears as splatter on top of material. Usually removes easily.
•
Cutting speed fast
•
Standoff high (arc voltage)
Intermittent Dross
Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross.
•
Possible worn consumables
Other Factors Affecting Dross;
•
Material temperature
•
Heavy mill scale or rust
•
High carbon alloys
Side View
Splatter
Cut Face
CAUTION
Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in the Cut Data manual.
Dimensional Accuracy
Generally using the slowest possible speed (within approved levels) will optimize part accuracy. Select consumables to allow a lower arc voltage and slower cutting speed.
NOTICE
Recommended cutting speed and arc voltage will give optimal cutting performance.
Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings. Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in the Cut Data manual.
99
Torch Flow Passages
InstallatIon
Water OUT & Power
Pilot Arc
Water IN (L.H.)
Plasma Gas IN
Shield Gas IN
100
Operation
operation
Interface Control Hub
The ICH (Interface Control Hub) is used to interface the ESAB m3 Process Control with the customer CNC using
RS232/RS422/RS485 and digital I/O.
Operation of the m3 IGC system can be made via the ICH (Interface Control Hub) in the following modes.
1. Remote mode without serial communications. (Default)
2. Remote mode with serial communications.
3. Local mode - diagnostics only.
The following pages describe how to operate the ICH.
103
operation
1 2 3 4
ICH front view
5
8 9 10 11 12
16
15
GND
Note:
Chassis must be connected to the machine ground.
104
ICH back view
13
14
7
6
operation
ICH Operation
ICH Connectors
11
12
13
14
15
16
9
10
7
8
Item Number
1
2
3
4
5
6
Item Description
Plasma Start
Gas Test
Local/Remote
Station Select
In Local mode, this switch will start the plasma process. If the Gas Test switch is set to on, then the process will go into TEST Mode. In TEST Mode the power supply faults, errors, and warnings are ignored while at the same time the steps for starting the power supply and turning HF on are skipped.
In Local mode, this switch will start the plasma gas and shield gas at their start values. If the plasma start switch is turned on after this one, the plasma process will start in TEST mode.
This switch will change the ICH system from being remotely controlled, via the serial communications and digital inputs from the CNC, to locally controlled via the switches on the Interface Control Hub.
This switch is a momentary switch which will change the station of which the information on the screen is displaying. If the system is in local mode, then the station selected will change to only the station displayed.
Screen Select
Encoder Wheel with Push Button
Power Switch
Input Power
This switch will allow the user to select different screens.
This only has an effect in local mode under normal operation, when communication is set to none, and in the set up mode. This wheel will allow you to change the parameter the cursor is currently on. The button will also allow you to see a more detailed error message when on the error log screen.
To work the wheel for editing a parameter, push the wheel, move the wheel to change the value, and then press the wheel again to lock in the value.
This switch will turn on the Interface Control Hub.
Customer supplied input power to ICH. See specifications for power requirements.
AHC Power
Gas Power
RS232
ASIOB1
Power connection for an ESAB lift (B4 or A6).
Power connection to the Power Distribution Box (PDB), which provides 24 VAC/
DC to the Combined Gas Control (CGC).
RS232 protocol for remote control if needed.
ASIOB1 protocol for retrofitting older ESAB systems.
CNC
AUX Control
DB37 connector to interface to customer I/O. This also has the RS422/485 connections.
DB25 connector for auxiliary options such as Air Curtain.
CAN Vision 5x Not used.
Fuses Replace fuses with same type and size.
105
operation
Display Screens
Startup Screen
On powerup the ICH screen displays the following information for 3 seconds:
Software version
Editing a Parameter on the Display
Only available when communication is set to none or Local/Remote switch is set to Local.
1. Use the encoder wheel to scroll to the parameter.
2. Push the wheel.
3. Turn the wheel to edit the value.
4. Push the wheel again to lock the value.
Gas Selection Screen
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
Current Output (Amp)
12
13
14
8
9
6
7
10
11
4
5
2
3
GS
Gas Select Table
Plasma Shield
Start Cut Start Cut
1 N2 O2 N2 N2
Air O2 Air
N2 N2 N2
N2 H35 Air
N2 H35 N2
Ar
Ar
Ar
Ar
Air
N2
Air Air Air
N2 O2 Air
N2 N2 Air
Ar O2 N2
Air
N2
Air
Air
Air
N2
Air
N2
Air
N2
Ar
Ar
O2
Ar
Air
H2O
Air
H2O
N2 N2 H2O H2O
106
Timers Screen
operation
Timers
Current Ramp Up Time (seconds)
Piercing Time (seconds)
Second Ramp for Thick Plate (seconds)
Current Ramp Down Time (seconds)
Time to delay gas off from the time plasma start is removed. (seconds)
Time to raise torch when cutting is complete (Height Control option required) (seconds)
Height Control Screen (Height Control option required)
Height Settings
Initial/Ignition Height (mm)
Piercing Height (mm)
Cutting Height (mm)
Plate Thickness (mm)
Arc Voltage (volts)
Encoder Height (mm)
Arc Voltage Output (volts)
107
CNC Input Screen
CNC Output Screen
operation
Inputs
Plasma Start
Corner
Block AHC
Plasma Test
Mark Mode
Stat 1 ON
Stat 2 ON
Stat 1 UP**
Stat 1 Down**
Stat 2 UP**
Stat 2 Down**
CNC’s Direct
Input
0
0
0
0**
0**
0
0
0
0
0**
0**
ACT
(selection program is currently running)
0
0
0
0**
0**
0
0
0
0
0**
0**
**only present when the Height Control option is present
Outputs
Defined by motion signal
System has faulted
Arc was lost during cut/mark
System is not ready to cut/mark
Station 1 is on Upper Limit Switch
Station 2 is on Upper Limit Switch
Motion Signal options:
Arc On Motion Enable only goes high when arc is on. Normally used when no torch lifter is supplied with plasma system.
Motion - Motion Enable only goes high when motion is allowed. Normally used when a torch lifter is supplied with plasma system.
Simple - Motion Enable goes high after the pierce time and low after plasma start is removed or there is a fault.
108
operation
Setup Descriptions
Setup - The “setup screen” on the Interface Control Hub is accessed by having “Plasma Start” set to “ON” and “Remote/
Local” set to “LOCAL” when powering up the box. It is exited by turning the power off and then back on. Make sure to reset the switches back to the original state for parameter display. The encoder wheel with pushbutton, is used to select an item and change the values or to select a sub-menu.
An example shown here, is for setting up a Plasma
System configured for the following:
1. m3 Integrated Gas Control System
2. EPP-360 Plasma Power Supply
3. Supplied with ESAB Lifter
4. No Water Injection option
Long Preflow Timer (seconds)
Short Preflow Timer (seconds)
Gas purge before Intial Height sensing (seconds)
Power Supply type
ESAB lifter installed
ESAB Water Injection Module installed
Motion Enable Signal meaning
Gas Control type
Gas Test timeout (seconds)
Error Log
Communication Options
Station 1 Lift Options
Station 2 Lift Options
Save Constants
Reload Constants
If the ESAB lifter has not been supplied with the system, the ICH setup screen for the above configuration would be as shown below:
Long Preflow Timer (seconds)
Short Preflow Timer (seconds)
Gas purge before Intial Height sensing (seconds)
Power Supply type
ESAB lifter installed
ESAB Water Injection Module installed
Motion Enable Signal meaning
Gas Control type
Gas Test timeout (seconds)
Error Log
Communication Options
Save Constants
Reload Constants
109
operation
Described below are the various options to be modified before setting up the plasma system for operation:
Long Preflow
Short Preflow
Power Supply
ESAB Lifter
The long preflow is the time, in milliseconds, the system will wait for the gases to flow before starting the power supply. This time is only used for each start until there is a successful start (after power-up) or when the gas being used is not compatible with the previous gas being used.
The short preflow is the time, in milliseconds, the system will wait for the gases to flow before starting the power supply. This time is only used for when it can be asserted that the last gas used and the current gas are compatible.
The power supply option is where the power supply attached to the system is specified. The EPP-201, EPP-360, EPP-450 and the
EPP-601 are the available choices.
The ESAB Lifter option is set to “YES” if an ESAB lifter was purchased for use with this system.
ESAB Injection
Motion Signal
Gas Control
The ESAB Injection option specifies that the ESAB water injection module was purchased for use with this system.
Arc On - Motion Enable only goes high when arc is on. Normally used when no torch lifter is supplied with plasma system.
Motion - Motion Enable only goes high when motion is allowed. Normally used when a torch lifter is supplied with plasma system.
This option specifies which type of Gas Control is to be used. The options are: (1) Water - Water Injection is the only shield available, (2) CGC - Combined Gas Control in use, (3) Full - The fully automatic gas control system is in use.
Gas Timeout This specifies the maximum time, in seconds, which gases will be allow to flow during a gas test before they are automatically shut off.
Error Log The error log stores up to 13 errors at a time reported by the ICH in the order they are detected. These errors are only cleared by selecting “CLEAR”. Select the error, by pushing the pushbutton part of the encoder wheel, to see more details about the error.
Communication The communication section is used to change the serial communications between the ICH and the CNC.
Protocol - There are four options: None, RS-232, RS-422, and RS-485 ASIOB. Serial communications is disabled when none is selected. The RS-422 protocol uses four wire while the RS-485 uses two wire. ASIOB is only used for interfacing to older ESAB
CNCs.
Baud Rate - The baud rate must be set to the same rate as the CNC’s serial communication transfer rate. Available options are:
300, 1200, 2400, 9600, 19200.
Parity - The parity needs to match the CNC’s serial communication parity. Available options are: None, Even, and Odd.
Stop Bits - The stop bits needs to match the CNC’s serial communication stop bits. Available options are: 1 or 2.
Communication Options
Communication Options
Protocol
Baud Rate
Parity
Stop Bits
Previous Screen
110
operation
Station Options
The following are the options listed under station 1 and station 2:
Lift Type
Arc Volt Cut
Arc Volt Mark
ULS to Table
The lifter type specifies which lift is being used. Available options are: A6 or B4.
The arc voltage calibration used when in CUTTING mode. Using a calibrated voltmeter, measure the voltage from the bus bar in the Remote Arc Starter Box to ground, while the process is active in cut mode. If that is higher than the arc voltage requested, then raise this number. If it is lower, then low this number.
The arc voltage calibration used when in marking mode. Using a calibrated voltmeter, measure the voltage from the bus bar in the Remote Arc Starter Box to ground, while the process is active in MARK mode. If that is higher than the arc voltage requested, then raise this number. If it is lower, then lower this number. The result should be around half of the “Arc Volt Cut” option.
The distance from the torch tip, when on the upper limit switch, to the top of the table slats. This is in micrometers.
Fast Speed
Slow Speed
This is the speed at which the lifter will move when not in the slowdown zone, when using height control, or when moving up.
The slowdown zone is the plate thickness, plus 25 millimeter, above the table slats.
This is the speed at which the lifter will move when in the slowdown zone or using height control. The slowdown zone is the plate thickness, plus 25 millimeter, above the table slats.
Station 1 Lift Options
Lift Type
Arc Voltage for Cutting
Arc Voltage for Marking
Upper Limit Switch to Table (µm)
Fast Speed (Relative speed 0-500)
Slow Speed (Relative speed 0-500)
Previous Screen
Station 2 Lift Options
Lift Type
Arc Voltage for Cutting
Arc Voltage for Marking
Upper Limit Switch to Table (µm)
Fast Speed (Relative speed 0-500)
Slow Speed (Relative speed 0-500)
Previous Screen
111
operation
Once the setup is complete, make sure to save the constants by selecting the “Save Constants” tab. The following screen will be displayed for a couple of seconds to confirm that your changes have been taken.
Save Complete
If you do not want to keep the changes you have made and would like to revert back to the last saved settings then select the “Reload Constants” tab. The following screen will be displayed for a couple of seconds to confirm that your changes have been taken.
Load Complete
112
operation
Digital I/O
Digital Inputs
Digital inputs are to be only turned on with 24 VDC. Any other voltage may damage the board or cause unpredictable results. The best method is to send the 24 VDC from the DB37 connector back on the input, via a relay or opto-isolator chip.
Signal Name
Corner
Description
Informs the ICH to reduce the current to the corner current and block height control (if enabled)
Block AHC
Plasma Test
Plasma Start
Mark
Block height control
Prevents the ICH from sending the start signal to the high frequency unit and power supply during a plasma start. Power supply faults are ignored.
Start the plasma process
Switch to marking mode and use the last loaded marking data
Station 1 Up Move the station 1 lifter up (if installed)
Station 1 Down Move the station 1 lifter down (if installed)
Station 2 Up Move the station 2 lifter up (if installed)
Station 2 Down Move the station 2 lifter down (if installed)
Station 2 On
Station 1 On
Turn on station 2.
Turn on station 1.
Digital Outputs
Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement.
Signal Name
Motion Enable/Arc On
System Fault
Arc Lost
Not Ready
Station 1 ULS
Station 2 ULS
Description
This signal is high when the arc is on or the process is off, when motion signal is set to Motion in the setup screen. This signal is high when the arc is on, when motion signal is set to Arc On in the setup screen.
The ICH has detected a problem which required the process to stop. Send message 003 or check the error log to get the exact set of errors. These are reset with a 000 command, but will remain in the error log.
The arc was lost during a cut/mark operation. This is reset on the next plasma start.
The ICH is not ready to start the process. Possible causes: no Station selected, not in Remote Mode, Plasma Start was high on boot up and is still high, Gas settings missing, Start Current missing, Cut Current missing, Timers missing,
Height Control settings missing (if a lifter is installed).
Station 1 is on the upper limit switch.
Station 2 is on the upper limit switch.
113
operation
Modes of Operation:
Remote Interface without Serial Communication
This mode describes the instance when the CNC controls everything except parameter selection via the digital inputs and outputs. To operate in this mode, go to the setup screen and change the “Protocol” to “None” under “Communications” .
•
The process parameters need to be modified on the ICH screen every time the CNC needs to change the cutting or marking parameters. The ICH system supports a cutting parameter set and a marking parameter set. The last used set will be available upon restarting the ICH. This requires starting the process at least once with the set.
•
The cutting parameters and marking parameters can be loaded into different tables in the ICH. After all the parameters are loaded, switching can be done by pressing the push button on the parameter line in the
Gas Selection screen.
•
Gas Test - The gas test function is designed to allow diagnostics of the gas control system. The gas test feature can be enabled by turning on the “Plasma Test” digital input and issuing a “Plasma Start” . The gases flowing in each test and the pressure/flow at which they are set to, is based on the currently loaded parameters on the ICH display.
•
The ICH system has two possible sequences it can be running. One with the lifter height controlled by the
ICH system and another with the lifter height controlled by the CNC.
Described below are examples for cutting a part from the CNC. The parameters from the cut data manual used for the setup below are detailed on the following page.
Material Type
Material Thickness
Cut Quality
Current
Start Gas
Cut Gas
Shield Gas
Carbon Steel
12 mm
Production
200 Amps
N2
O2
Air
114
90 115
operation
Operation sequence with ESAB supplied plasma lifter:
1. Setup the part program that needs to be cut from the CNC.
2. Go to the ICH screen for “ C:Cutting Parameters” and setup the parameters according to the cut data manual:
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table under DISPLAY SCREENS section)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
Current Output (Amp)
3. Next, go to the ICH screen for Timers and setup the timer values according to the cut data manual:
Timers
Current Ramp Up Time (seconds)
Piercing Time (seconds)
Second Ramp for Thick Plate (seconds)
Current Ramp Down Time (seconds)
Time to delay gas off from the time plasma start is removed. (seconds)
Time to raise torch when cutting is complete (Height Control option required) (seconds)
116
operation
4. Next, go to the ICH screen for Height Settings and setup the height parameters according to the cut data manual:
Height Settings
Initial/Ignition Height (mm)
Piercing Height (mm)
Cutting Height (mm)
Plate Thickness (mm)
Arc Voltage (volts)
Encoder Height (mm)
Arc Voltage Output (volts)
5. Once all of the setups have been completed on the ICH, refer to the cut data manual for the Speed and Kerf inputs to be made on the CNC part program.
6. Execute the program from the CNC and send a “Plasma Start” signal to the ICH.
7. The following happens while the CNC waits for motion enable.
a. The ICH starts the purge before initial height sensing.
b. The torch comes down, does the initial height sensing and finishes the preflow.
c. The ICH starts the power supply.
d. The ICH waits for the arc to transfer and the main current to start, turning the high frequency generator off once the arc has transferred. If the motion signal constant is set to “Arc On” , this is when the
“Motion Enable” signal is returned to the CNC.
e. The gas switches from start to cut values and gas.
f. The ICH ramps the current up to the desired cutting/marking current.
g. The ICH raises to the piercing height.
h. The ICH waits a time, from the parameters, for the current to pierce the plate.
i. The ICH lowers down to the cutting height. If the motion signal constant is set to “Motion” , this is when the “Motion Enable” signal is returned to the CNC.
8. Start moving the machine in the shape desired, turning the corner signal on when not going at full speed for the parameters sent.
9. Remove the “Plasma Start” signal to the ICH at the end of cut.
10. The following happens while the CNC waits for “Motion Enable” to be removed and come back (if the motion signal constant is set to “Motion” ).
a. is removed, if the motion signal constant is set to b. The current ramps down.
“Motion” .
c. The power supply is turned off and, after a time specified in the parameters, the gas stop flowing.
If the motion signal constant is set to “Arc On” , this is when the “Motion Enable” signal is removed.
d. The lift raises for an amount of time specified in the process parameters.
e. If the motion signal constant is set to “Motion” , then this is when “Motion Enable” is returned.
117
operation
Operation sequence with customer supplied plasma lifter:
1. Setup the part program that needs to be cut from the CNC.
2. Go to the ICH screen for “C:Cutting Parameters” and setup the parameters according to the cut data manual:
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table under DISPLAY SCREENS section)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
Current Output (Amp)
3. Next go to the ICH screen for Timers and setup the timer values according to the cut data manual:
Timers
Current Ramp Up Time (seconds)
Piercing Time (seconds)
Second Ramp for Thick Plate (seconds)
Current Ramp Down Time (seconds)
Time to delay gas off from the time plasma start is removed. (seconds)
Time to raise torch when cutting is complete (Height Control option required) (seconds)
118
Gas Selection (see table under DISPLAY SCREENS section)
Plasma Start (Bar) operation
4. Once all of the setups have been completed on the ICH, refer to the cut data manual for the Speed and Kerf inputs to be made on the CNC part program.
5. Also, setup the height parameters according to the cut data manual from the CNC.
6. Execute the program from the CNC.
7. The torch, controlled from the CNC, comes down and begins ignition height sensing. Block AHC and Corner can be set to start the purge and preflow. Send plasma start to start.
8. Send a “Plasma Start” signal to the ICH after the torch is at ignition height.
9. The following happens while the CNC waits for “Motion Enable” .
a. The ICH starts the purge.
b. The ICH starts the power supply.
c. The ICH waits for the arc to transfer and the main current to start, turning the high frequency generator off once the arc has transferred. If motion signal constant is set to “Arc On” , then “Motion
Enable” is sent back.
d. The gas switches from start to cut values and gas.
e. The ICH ramps the current up to the desired cutting/marking current. At this time, the torch needs to be raised to piercing height.
f. The ICH waits a fixed time for the current to pierce the plate. If motion signal constant is set to
“Motion” , then “Motion Enable” is sent back.
10. Start moving the machine in the shape desired, turning the corner signal on when not going the full speed for the parameters sent.
11. Remove the “Plasma Start” signal to the ICH at the end of cut.
12. The following happens while the CNC waits for “Motion Enable” to be removed and come back (if the motion signal constant is set to “Motion” ).
a. “Motion Enable” is removed, if the motion signal constant is set to “Motion” .
b. The current ramps down.
c. The power supply is turned off and, after a time specified in the parameters, the gas stop flowing.
If the motion signal constant is set to “Arc On” , this is when the “Motion Enable” signal is removed.
d. If the motion signal constant is set to “Motion” , then this is when “Motion Enable” is returned.
Remote Interface with Serial Communication
This mode of operation is used if the customer needs to have plasma parameter selection controlled from the
CNC. There are two ways this can be achieved:
1. ESAB Serial Communication Interface - ESCI.
ESCI is a an easy to use software with a graphical interface for downloading the necessary parameters to the
ICH for the best cut quality. All the operator needs to know is the material type, thickness of the material, cut amperage and type of plasma gas. More details about the software and the system requirements are described in the appendix.
2. Serial protocol controlled by customer CNC.
Detailed information on the protocol is described in the appendix.
119
operation
Local Interface - Diagnostics Only
The local interface is used to test the plasma system for diagnostic purposes. This allows limited use of the system (i.e. only one station at a time) and is normally used for troubleshooting. This will disable the CNC’s ability to control the system, but will still allow the CNC to get the status (including the gas pressures and flows) and errors.
Upon switching to local mode for the first time, since the last reboot, the parameters loaded are for 200 amp
Carbon Steel Air Production cutting.
120
ESAB Welding and Cutting Products
118
Version 4.0 released on 15Mar11
operation
Note:
The actual operation of cutting should not be performed while in this mode as the CNC is not in control of the process.
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
Current Output (Amp)
Operation sequence:
1. To enable the local interface, the “Local/Remote” switch needs to be in the “Local” position.
2. Set up the parameters for the process as needed from the cut data manual.
3. If plasma is to be turned on, then set the “Plasma Start” to “ON” and the gas test switch to the “OFF” position.
4. If the plasma lifter is supplied from ESAB, then the lifter will perform an initial height sense operation.
5. The following happens after the torch is at ignition height: a. The ICH starts the purge.
b. The ICH starts the power supply.
c. The ICH waits for the arc to transfer and the main current to start, turning the high frequency generator off once the arc has transferred. If motion signal constant is set to “Arc On” , then “Motion Enable” is sent back.
d. The gas switches from start to cut values and gas.
e. The ICH ramps the current up to the desired cutting/marking current.
f. The ICH waits a fixed time for the current to pierce the plate.
6. If is turned on before “Plasma Start” is on, then all the above steps are repeated except that a signal to the power supply is not sent from the ICH.
121
Timing Sequence
operation
122
operation
Interface Wiring Descriptions
Interface Wiring
DB37 Connector
This cable should be a twisted pair cable with an overall shield attached to the shell on both ends of the cable.
It has a DB37 male connector on each end.
Wire No.
1
30
31
32
33
26
27
28
29
34
35
36
37
FG
22
23
24
25
18
19
20
21
14
15
16
17
10
11
12
13
8
9
6
7
4
5
2
3
Signal Name
RS422 RX-
GND
Digital Input 5
RS422 RX+
RS422/485 TX+
GND
Digital Output 1 (+)
Digital Output 2 (+)
Digital Output 3 (+)
Digital Output 4 (+)
Digital Output 5 (+)
Digital Output 6 (+)
Digital Output 7 (+)
Digital Output 8 (+)
Digital Input 6
Digital Input 7
Digital Input 8
Digital Input 9
Digital Input 11
GND
24VDC
Field Ground
RS422/485 TX-
RS422/485 GND
Digital Output 1 (-)
Digital Output 2 (-)
Digital Output 3 (-)
Digital Output 4 (-)
Digital Output 5 (-)
Digital Output 6 (-)
Digital Output 7 (-)
Digital Output 8 (-)
Digital Input 1
Digital Input 2
Digital Input 3
Digital Input 4
Digital Input 10
24VDC
Function
Serial receive negative
Serial transmit negative
Communication Ground
Motion Enable Emitter
System Fault Emitter
Arc Lost Emitter
Not Ready Emitter
Station 1 ULS Emitter
Station 2 ULS Emitter
Spare Output Emitter
Spare Output Emitter
Corner
Block AHC
Plasma Test
Cycle Start
Station 2 On
24 VDC Power
Ground
Mark
Serial receive positive
Serial transmit positive
Ground
Motion Enable Collector
System Fault Collector
Arc Lost Collector
Not Ready Collector
Station 1 ULS Collector
Station 2 ULS Collector
Spare Output Collector
Spare Output Collector
Station 1 Up (If installed)
Station 1 Down (If installed)
Station 2 Up (If installed)
Station 2 Down (If installed)
Station 1 On
Ground
24 VDC Power
Cable Shield Ground (Connected via the connector shell)
123
operation
DB37 Connector
The customer has 3 options available for wiring to the DB37 connector shown below:
Connection assemblies for ICH and CNC interface.
Option 1:
ESAB provided DB37 cable (Male-Male) and terminal block assembly for connection to CNC.
DB37 Cable
ICH Box
Example DB37 Breakout boards:
Manufacturer
Sea Level
Winford
Advantech *
Part Number
TB02-KT
BRK37F series
ADAM-3937
DB37 Terminal
Block Assembly
*ESAB recommended part available as ESAB part number 0558009990.
Option 2:
ESAB provided DB37 cable (Male-Male) and customer provided DB37 (Female) connector. Customer builds their own DB37 Interface for connection to CNC.
DB37 Cable
To Customer provided
DB37 Interface
ICH Box
Part Number
0558010071
0558010072
0558010073
0558010074
0558010075
Length
2 M
3 M
4 M
5 M
6 M
DB37 Cable
Part Number
0558010076
0558010077
0558010078
0558010079
0558010080
Length
7 M
10 M
15 M
20 M
25 M
Option 3:
ESAB provided DB37 cable (Male-open end). Customer builds their own Interface for connection to CNC. P/N 0558010157 5 meter length.
DB37 Cable
To Customer provided
Interface
124
operation
125
RS422 Cable Wiring: operation
Customer supplied cable - must be shielded, twisted pair (STP) cable with shield bonded to ground.
RS422 Adaptor
1 TXD +
2 TXD -
3 RXD +
4 RXD -
5 GND
Example serial converters:
Manufacturer
B & B Electronics
Part Number
485DRCI
B & B Electronics
Comm Front
4WSSD9OTB
CVT-485-422-4
Axeon * STS-1915SI
*ESAB recommended part available as ESAB part number
0558009988.
ICH via DB37
21 TXD +
2 TXD -
20 RXD +
1 RXD -
3 GND
DB25 Connector- Air Curtain Option
The DB25 connector is used to connect ICH to the Power Distribution Box (PDB). This cable should be a shielded, twisted pair cable that has a DB25 male connector on one end and a DB25 female connector on the other end.
The DB25 connector is used with the Air Curtain option.
Wire No.
Signal Name
1
2
Analog Input 1
Analog Input 2
8
9
6
7
10
3
4
5
11
12
13
Spare
Spare
Function
Analog Output 1
Analog Output 2
Spare
Spare
CNC Analog Common CNC Analog COM
Analog Input 3
Analog Input 4
Analog Output 3
Analog Output 4
Input 1
Spare
Spare
Spare
Spare
Spare
Input 2
Input 3
Input 4
Spare
Spare
Spare
Wire No.
Signal Name
14
Function
Station 1 Air Curtain(-) Station 1 Air Curtain
18
19
20
15
16
17
21
22
23
24
25
Station 2 Air Curtain(-) Station 2 Air Curtain
Spare 3
Spare 4
Spare output emitter
Spare output emitter
Spare 5 Spare output emitter
Station 1 Air Curtain (+) Station 1 Air Curtain
Station 2 Air Curtain (+) Station 2 Air Curtain
Spare 3
Spare 4
Spare 5
24VDC
CHASSIS GND
Spare output collector
Spare output collector
Spare output collector
Power
Ground
126
operation
DB9 Connector
This is a standard DB9 RS232 cable. This communication port is not recommended for production use.
Function
7
8
9
5
6
3
4
Wire No.
Signal Name
1
2
NC
RS232 RX
RS232 TX
NC
NC
GND
No Connect
Receive
Transmit
No Connect
No Connect
Ground
RS232 RTS Ready To Send
RS232 CTS Clear To Send
NC No Connect
Power Connector
Wire No.
Signal Name
1
2
3
Line 1
Line 2
NC
4 GND
Digital Output Wiring Examples
Function
Line 1 of 230 VAC or Line of 115 VAC (No Height Control)
Line 2 of 230VAC or Neutral of 115 VAC (No Height Control)
No Connect
Ground
Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement. There are two good methods for doing this. There is a small voltage drop across the opto-isolator in the Interface Control Hub, so it is recommended that a voltage of at least 12 VDC be used in order to protect against noise generated by the plasma system’s starting circuit.
24V
Method 1: Using the 24 VDC to drive a digital input circuit on the
CNC’s input.
DO+ 1
R1 R2
DO- 1 5V
10K
R3
2.74K
1M
Method 2: Using the 24 VDC to drive a relay coil and using the contact on the coil however the CNC needs it.
24V
DO+ 1
DO- 1
R1
10K
R3
2.74K
R2
1M
5V
DO+ 1
DO- 1
24V
A coil B
External CNC
Serial
Digital I/O
127
DO+ 1
DO- 1
A coil B
24V
External CNC
Serial
Digital I/O
External Power
230V/3A w/ Height Control
Water Injection
120V/3A w/o Height Control
Water Injection
Optional
Standard
ICH
(Interface
Control Hub)
CGC
RAS BOX or
External Power
230V/3A w/ Height Control
120V/3A w/o Height Control
B4 Lift
Optional
SGB
Standard
PGB
Water
Injection
ICH
(Interface
Control Hub)
CGC
RAS BOX or
CAN PS
B4 Lift
SGB
PGB
Water
Injection
128 operation
Maintenance/Troubleshooting
130
Maintenance/troubleshooting
Maintenance/troubleshooting
ICH Maintenance/Troubleshooting
Communication Problems
502 Error message
Problem
Unable to send and receive messages
Resolution
Make sure the CNC’s RX - is on pin 2, TX – is on pin 1, RX + is on pin 21, and TX + is on pin 20 of the DB37 connector. Also make sure the constant for the communication protocol is set properly. Communication ground should be connected to pin 3.
The command is not allowed in this state.
Digital Input Problems
Problem
The wrong input on the screen is changing when the CNC turns on an input to the ICH
No input on the screen is changing when the
CNC turns on an input to the ICH
Resolution
Make sure the inputs are wired to the proper input on the ICH.
Make sure the CNC is only sending the 24 VDC from DB37 connector back to the ICH as the input when turning the input on.
Digital Output Problems
Problem
The ICH shows the output turning on but there is no voltage on the output’s emitter side.
Gas Problems
Problem
The CNC turns on a gas test and no gas comes out of the torch.
Resolution
Check for voltage on the collector side. If there is a DC voltage there greater than 10 volts, then call service.
Resolution
Make sure the plasma gas box and shield gas box have power (green
LED on the same side as the cable connections is lit).
Power Supply Problems
Problem
Power supply will not start.
Resolution
Make sure power is supplied.
Check for an error code on the power supply display.
Check for plasma test signal being low.
Check for E-stop signal not connected to RAS Box.
131
Maintenance/troubleshooting
Error Messages on the ICH Display
Error Log Screen
Last received error always shown at top.
Clear all errors on screen.
This screen can be accessed by using “Switch Screen” on the ICH and displays a log of the last 13 errors received by the ICH. By moving the cursor to the error and pressing the hand wheel, more details of the error are displayed.
Error Screen
Station number
Type of Error
Error ID
Error details
This screen can be accessed by scrolling down to the
“fault” text and pressing the hand wheel or through the error log screen.
132
Error Screen
Maintenance/troubleshooting
Station number
Type of error
Power supply error code
Error details
Error Screen
Station number
Type of Error
Number of starts since ICH boot up
Error ID
Command value for error
Actual value when error occurred
Error details
133
134
Maintenance/troubleshooting
Module Errors
ID
3
9
B
11
12
1A
1B
1C
1D
31
34
53
23
2B
2C
2D
2E
2F
30
1E
1F
22
54
59
5A
Problem Solution
The CRC was wrong on the module.
The checksum of the station constants do not match the station constants.
The watchdog telegram has not been received in 400 ms.
The module is reporting a checksum error.
The module has caries out a reset.
The watchdog counter has been exceeded.
The output driver has a short circuit.
The wrong or no expansion board is installed.
There was a checksum error during the transfer of the station constants.
The CAN send buffer overflowed.
The CAN receive buffer overflowed.
The output of the digital output does not match the command.
The checksum of the calibration data is wrong.
The Junma amplifier is reporting an alarm.
There is a checksum error in the calibration data.
The output signal status on the relay output are varying.
The heat sink is over heating.
There is no input voltage for the motor.
The checksum of the local PLC on the module is wrong.
The output cable to the motor is shorted.
There is a problem with the encoder cable.
The checksum of the local PLC on the module is wrong.
The output signal status on the relay output are varying.
There was a checksum error during the transfer of the station constants.
The module has preformed a reset.
This error will normally correct itself. If it continues, replace the module/board.
This error will normally correct itself. If it continues, replace the module/board.
1. Check the CAN cable connection between the module and the ICH.
2. Make sure there is a terminating resistor plug at the end of the CAN bus chain or the last module is plugged into port 7.
3. Make sure the CAN modules are plugged in, starting at port 1 and not skipping a port.
4. Check that the module has power.
5. Replace the module.
This error will normally correct itself. If it continues, replace the module/board.
1. Check if the unit has a stable power supply.
2. Check if the module is properly grounded.
3. Replace the module.
1. Check if the unit has a stable power supply.
2. Check if the module is properly grounded.
3. Replace the module.
1. Check the driver output for a short circuit in the wiring.
2. Replace the module.
Replace the module.
This error will normally correct itself. If it continues, replace the module/board.
Please report these errors to service with the steps you took to produce them.
1. Check the driver output for a short circuit in the wiring.
2. Replace the module.
Replace the module.
Check the Junma's LEDs for more details on the error.
Replace the module.
1. Check the driver output for a short circuit in the wiring.
2. Replace the module.
Please report these errors to service with the steps you took to produce them.
Replace the module.
Please report these errors to service with the steps you took to produce them.
Replace the module.
1. Check the driver output for a short circuit in the wiring.
2. Replace the module.
This error will normally correct itself. If it continues, replace the module/board.
1. Check if the unit has a stable power supply.
2. Check if the module is properly grounded.
3. Replace the module.
Maintenance/troubleshooting
5B
5C
5D
5E
5F
Module Errors
ID Problem
The wrong position sensor is in use.
There is no servo amplifier.
The limit switch has been reached.
There is an over current in the servo amplifier.
The watchdog counter has been exceeded.
C8
C9
CA
CB
CC
FD
FE
FF
Solution
Please report these errors to service with the steps you took to produce them.
The commanded value is too high.
The input pressure on plasma gas 1 is above 145 PSI
(10 BAR).
The input pressure on plasma gas 1 is below 51 PSI
(3.5 BAR).
The input pressure on plasma gas 2 is above 145 PSI
(10 BAR).
The input pressure on plasma gas 2 is below 51 PSI
(3.5 BAR).
There was an unkown error from the CAN port in the
ICH.
The module has preformed a reset.
The module's telegram counters did not match the
ICH's telegram counter
1. Check if the unit has a stable power supply.
2. Check if the module is properly grounded.
3. Replace the module.
1. Check that the command does not exceed the input pressure/flow abilities of the module.
1. Check that the input pressures to the Shield Gas Control are below
145 PSI (10 BAR).
2. Replace the Plasma Gas Control.
1. Check that the input pressures to the Shield Gas Control are above 51
PSI (3.5 BAR).
2. Check that the line between the Shield Gas Control and Plasma Gas
Control, labeled PG1, is not clogged or leaking.
3. Check the pressure on PG1. If it is below 51 PSI (3.5 BAR), then replace the Shield Gas Control.
4. Replace the Plasma Gas Control.
1. Check that the input pressures to the Shield Gas Control are below
145 PSI (10 BAR).
2. Replace the Plasma Gas Control.
1. Check that the input pressures to the Shield Gas Control are above 51
PSI (3.5 BAR).
2. Check that the line between the Shield Gas Control and Plasma Gas
Control, labeled PG2, is not clogged or leaking.
3. Check the pressure on PG2. If it is below 51 PSI (3.5 BAR), then replace the Shield Gas Control.
4. Replace the Plasma Gas Control.
Please report these errors to service with the steps you took to produce them.
1. Check if the unit has a stable power supply.
2. Check if the module is properly grounded.
3. Replace the module.
1. Check the CAN cable connection between the module and the ICH.
2. Make sure there is a terminating resistor plug at the end of the CAN bus chain or the last module is plugged into port 7.
3. Make sure the CAN modules are plugged in, starting at port 1 and not skipping a port.
4. Check that the module has stable power.
5. If this is happening often, replace the module.
135
136
Maintenance/troubleshooting
Process Errors
ID
1
2
3
4
5
6
9
A
D
E
F
10
11
12
13
Problem Solution
The input pressure on plasma gas is above 145 PSI (10
BAR).
The input pressure on plasma gas is below 51 PSI (3.5
BAR).
The input pressure on shield gas is above 145 PSI (10
BAR).
The input pressure on shield gas is below 51 PSI (3.5
BAR).
The output pressure of the plasma gas is more than 7
PSI (0.5 BAR) above the command.
The output pressure of the plasma gas is more than 7
PSI (0.5 BAR) below the command.
The shield gas flow is more than 35 CFH (1 CMH) above the command.
The shield gas flow is more than 35 CFH (1 CMH) below the command.
The arc voltage is more than 300 Volts above the command.
The arc voltage is more than 300 Volts below the command.
The current output is more than 50 Amps above the command.
The current output is more than 50 Amps below the command.
The torch has crashed into the work piece.
The arc went out before the plasma start went low.
The initial height sensing failed to complete in 10 seconds.
1. Check that the input pressures to the Combined Gas Control are below 145 PSI (10 BAR).
2. Replace the Combined Gas Control.
1. Check that the input pressures to the combined Gas Control are above 51 PSI (3.5 BAR).
2. Replace the Combined Gas Control.
1. Check that the input pressures to the Combined Gas Control are below 145 PSI (10 BAR).
2. Replace the Combined Gas Control.
1. Check that the input pressures to the Combined Gas Control are above 51 PSI (3.5 BAR).
2. Replace the Combined Gas Control.
1. Check for a clogged line between the Combined Gas Control and the torch.
2. Check for clogged/damaged consumables.
3. Replace the Combined Gas Control.
1. Check for a leaking line between the Combined Gas Control and the torch.
2. Check for the correct consumables are properly installed.
3. Replace the Combined Gas Control.
1. Check for a leaking line between the Combined Gas Control and the torch.
2. Check for the correct consumables are properly installed.
3. Replace the Combined Gas Control.
1. Check for a clogged line between the Combined Gas Control and the torch.
2. Check for clogged/damaged consumables.
3. Replace the Combined Gas Control.
1. Check for a short in the VDR cable.
2. Check for good grounding on the lifter control box.
3. Replace the MCU in the lifter control box.
1. Check for a short in the VDR cable.
2. Check for good grounding on the lifter control box.
3. Replace the MCU in the lifter control box.
1. Check the feedback voltage from the power supply is the expected value.
2. Check the command voltage to the power supply is the expected value.
1. Check the feedback voltage from the power supply is the expected value.
2. Check the command voltage to the power supply is the expected value.
1. Make sure the stand-off voltage, if using arc voltage height control mode, is correct for the thickness being cut/marked.
2. Make sure the CNC speed is correct for the thickness being cut/ marked.
3. Make sure the plate is level, if using encoder height control mode.
1. Make sure the part being cut/marked fits on the work piece.
2. If this was during a hole cutting, make sure to turn off the plasma start signal before doing overburn.
1. Make sure the work piece is below the torch.
2. Make sure the work piece is properly grounded.
3. Make sure the torch tip is free of debris.
Maintenance/troubleshooting
Process Errors
ID
16
17
18
19
1A
1B
1C
1D
Problem Solution
The Combined Gas Control (CGC) failed to respond properly to the ICH's watchdog command.
The Water Injection Control (WIC) failed to respond properly to the ICH's watchdog command.
The lifter failed to respond properly to the ICH's watchdog command.
1. Check the CAN cable connection between the Combined Gas Control and the ICH.
2. Make sure the switch in the CAN power supply is set to ""CLOSED"" and the CAN power supply is the last module on the CAN bus.
3. Make sure the CAN modules are plugged in, starting at port 1 and not skipping a port.
4. Check that the Combined Gas Control has power. If it does not, check the power cable for a short. If no short is present, check the Power
Distribution Box's fuse and input power.
5. Replace the Combined Gas Control.
1. Check the CAN cable connection between the Water Injection Control and the ICH.
2. Make sure the switch in the CAN power supply is set to ""CLOSED"" and the CAN power supply is the last module on the CAN bus.
3. Make sure the CAN modules are plugged in, starting at port 1 and not skipping a port.
4. Check that the Water Injection Control has power. If it does not, check the Water Injection Control's fuse and input power.
5. Replace the Water Injection Control's PCUA.
1. Check the CAN cable connection between the lifter and the ICH.
2. Make sure the switch in the CAN power supply is set to ""CLOSED"" and the CAN power supply is the last module on the CAN bus.
3. Make sure the CAN modules are plugged in, starting at port 1 and not skipping a port.
4. Check that the lifter has power. If it does not, check the power cable for a short.
5. Replace the lifter's MCU.
The coolant flow is below 1 GPM (3.78 LPM).
The power supply is reporting a fault.
The CAN Power Supply failed to respond properly to the ICH's watchdog command.
1. Check the coolant level in the coolant tank.
2. Check for a clog in the filter.
3. Check for a clog in the flow sensor.
4. Check for a kink in the coolant lines.
5. Check for power to the flow sensor.
Check the CAN power supply documentation for more details.
1. Check the CAN cable connection between the CAN Power Supply and the ICH.
2. Make sure the switch in the CAN power supply is set to ""CLOSED"" and the CAN power supply is the last module on the CAN bus.
3. Make sure the CAN modules are plugged in, starting at port 1 and not skipping a port.
5. Replace the CAN Power Supply's control board.
The torch failed to start within 2 seconds of preflow finishing.
1. Make sure the torch is the recommended distance from the work piece.
2. Increase the pilot arc current, up to 10 amps.
3. Check that the HF is coming out of the torch. If not, check the HF relay in the RAS.
The lower limit switch, on the lifter, has been tripped.
1. Check for a short in the lower limit switch wiring.
2. Make sure the cutting does not require the lifter to move beyond its limits.
137
138
Maintenance/troubleshooting
23
24
25
26
27
28
Process Errors
ID
1E
1F
20
21
22
29
2C
2D
2E
2F
30
31
32
Problem Solution
The ICH has reset because of a trap error.
The ICH has reset because of an OP code error.
The ICH has reset because the reset pin on the processor was shorted.
The ICH has reset because of a software command.
The ICH has reset because of the hardware watchdog timed out.
Please report these errors to service with the steps you took to produce them.
The ICH has reset because of a brown out.
The ICH has reset because of a power on reset.
The serial port has reported a parity error.
The serial port has reported a framing error.
The cut water output pressure is more than 200 PSI (14
BAR), while the pump is on.
1. Check for cable grounding issues.
2. If using RS-232, try using a fiber optic converter and short (< 6") cables to the ICH and the computer.
The serial port has reported a receive buffer overrun.
Slow the communication speed of the ICH and computer.
The serial port has reported an unknown error.
1. Check for cable grounding issues.
2. If using RS-232, try using a fiber optic converter and short (< 6") cables to the ICH and the computer.
The LCD has reset.
1. Check the grounding of the ICH enclosure.
2. Replace the ICH's main board.
1. Check the output pressure of the regulator inside the Water Injection
Control.
2. Check the voltage feedback from the pressure sensor. If it is ok, replace the Water Injection Control's PCUA.
3. Replace the pressure sensor.
The cut water output pressure is less than 44 PSI (3
BAR), while the pump is on.
The CAN port has reported a receive buffer overrun.
The CAN port has reported an invalid message on the bus.
The CAN port has reported that the bus was corrupted.
There was an ASIOB bus error.
The initial height sensors are shorted.
1. Check the fuses for the pump.
2. Check that the contactor for the pump is not destroyed.
3. Check the output signal to the contactor from the PCUA is coming on.
4. Check that the pump motor is coming on.
5. Make sure the pump head is moving water and not bypassing 100%.
6. Replace the pressure sensor.
1. Make sure all CAN cables are connected securely.
2. Make sure all modules are properly grounded.
3. Make sure there is a terminating resistor plug at the end of the CAN bus chain or the last module is plugged into port 7.
4. Make sure all the dip switches on the top of the ICH are toggled towards the display.
5. Make sure there are no CAN cables being coiled or run with the power leads or torch leads.
1. Make sure the 5V from the CNC's ASIOB connection is not connected to the main board in the ICH.
2. Make sure all the dip switches on the ICH's main baord are toggled towards the display.
3. Make sure the ASIOB cable is securely connected to the ICH.
1. Check for debris on the shield of the torch.
2. If using the omni crash protection, check that the sensor is properly adjusted.
Maintenance/troubleshooting
33
34
35
36
37
38
39
3A
Process Errors
ID Problem Solution
An unkown error has occurred.
The ICH has rebooted because of a request to switch to the bootloader.
The ICH has rebooted because an unexpected interrupt was fired.
The ICH has rebooted because of an addressing issue.
The ICH has rebooted because of an oscillator failure.
The ICH has rebooted because of a stack overflow or underflow.
The ICH has rebooted because of a math error.
The ICH has rebooted for an unkown reason.
Please report these errors to service with the steps you took to produce them.
139
Maintenance/troubleshooting
Torch Front End Disassembly
Wear on torch parts is a normal occurrence to plasma cutting. Starting a plasma arc is an erosive process to both the electrode and nozzle. Regularly scheduled inspection and replacement of PT-36 parts must take place to maintain cut quality and consistent part size.
DANGER
HOT TORCH WILL BURN SKIN!
ALLOW TORCH TO COOL BEFORE SERVICING.
1. Remove the Shield Cup Retainer.
NOTE:
If the shield cup retainer is difficult to remove, try to screw the nozzle retaining cup tighter to relieve pressure on the shield cup retainer.
2. Inspect mating metal surface of shield cup and shield cup retainer for nicks or dirt that might prevent these two parts from forming a metal to metal seal. Look for pitting or signs of arcing inside the shield cup. Look for melting of the shield tip. Replace if damaged.
3. Inspect diffuser for debris and clean as necessary. Wear on the top notches does occur, effecting gas volume.
Replace this part every other shield replacement. Heat from cutting many small parts in a concentrated area or when cutting material greater than 0.75" (19.1mm) may require more frequent replacement.
CAUTION
Incorrect assembly of the diffuser in the shield will prevent the torch from working properly. Diffuser notches must be mounted away from the shield as illustrated.
Shield Cup
Diffuser
Nozzle Retaining Cup
Shield Cup Retainer
140
Nozzle
Electrode
Torch Body
Maintenance/troubleshooting
4. Unscrew nozzle retainer and pull nozzle straight out of torch body. Inspect insulator portion of the nozzle retainer for cracks or chipping. Replace if damaged.
Inspect nozzle for:
• melting or excessive current transfer.
• gouges from internal arcing.
• nicks or deep scratches on the O-ring seating surfaces .
•
O-ring cuts, nicks, or wear.
•
Remove hafnium particles (from the nozzle) with steel wool.
Replace if any damage is found.
NOTE:
Discoloration of internal surfaces and small black starting marks are normal and do not effect cutting performance.
If the holder was tightened sufficiently, the electrode may unscrew without being attached to the electrode holder. When installing the electrode, use only sufficient force to adequately secure the electrode.
5. Remove electrode using electrode removal tool.
6. Disassemble electrode from electrode holder. Insert flats on the holder into a 5/16" wrench. Using the electrode tool, rotate electrode counter-clockwise to remove. Replace electrode if center insert is pitted more than 0.09" (3/32").
Torch Body
Electrode Removal Tool
Electrode
Replace electrode if center insert is pitted more than 0.09" (3/32")
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Maintenance/troubleshooting
7. Remove electrode holder from torch body. Hex on the end of the electrode holder removal tool will engage in a hex in the holder.
Removal
Tool
Gas Baffle
Electrode Holder Assembly
Electrode
NOTE:
The electrode holder is manufactured in two pieces. Do not disassemble. If the holder is damaged, replace the electrode holder assembly.
8. Disassemble electrode holder and gas baffle. Carefully remove O-ring from electrode holder and slide baffle from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not attempt to clear holes. Replace baffle if damaged.
NOTE:
Check all O-rings for nicks or other damage that might prevent O-ring from forming a gas/water tight seal.
Gas Baffle
O-ring
Electrode Holder Assembly
NOTE:
Discoloration of these surfaces with use is normal. It is caused by galvanic corrosion.
142
Maintenance/troubleshooting
Torch Front End Assembly
CAUTION
Over-tightened parts will be difficult to disassemble and may damage torch. Do not over tighten parts during reassembly. Threaded parts are designed to work properly when hand-tightened, approximately 40 to 60 inch/pounds.
•
Reverse order of disassembly.
•
Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates easy future assembly and disassembly for service.
•
Installing the electrode requires only moderate tightening. If the electrode holder is made tighter than the electrode, it is possible to change worn electrodes without removing the electrode holder.
•
Turn on the coolant circulator and purge the gases through the torch.
NOTE:
When assembling, place the nozzle inside the nozzle retaining cup and thread the nozzle retaining cup/nozzle combination on the torch body. This will help align the nozzle with the assembly.
The shield cup and shield cup retainer should be installed only after installing the nozzle retaining cup and nozzle. Otherwise the parts will not seat properly and leaks may occur.
Diffuser
Shield
Cup
Shield Cup Retainer
Nozzle
Nozzle Retaining
Cup
Electrode
Torch body
143
Maintenance/troubleshooting
Torch Front End Assembly using the Speedloader
Use of a speedloader, p/n 0558006164, will ease assembly of the torch front end parts. step 1. To use the speedloader, first insert the nozzle into the nozzle retaining cup.
Nozzle
Nozzle Retaining Cup step 2. Screw the speedloader into the nozzle retaining cup to secure the nozzle.
step 3. Secure retaining nut on nozzle with preassembly tool, p/n 0558005917 included with the speedloader.
step 4. Remove the speedloader. It is very important to remove the speedloader to ensure proper seating of the remaining parts.
step 5. Insert the diffuser into the shield cup.
Retaining nut p/n 0558005916
Shield Cup
Diffuser
Shield cup retainer step 6. Insert the nozzle retaining cup assembly into the shield cup retainer.
Nozzle retaining cup assembly
Shield cup retainer assembly step 7. Screw shield cup retainer assembly onto nozzle retaining cup assembly.
144
Preassembly tool
Maintenance/troubleshooting
Torch Front End Disassembly (for Production Thick Plate)
DANGER
HOT TORCH WILL BURN SKIN!
ALLOW TORCH TO COOL BEFORE SERVICING.
1. Remove the Shield Cup Retainer.
NOTE:
If the shield cup retainer is difficult to remove, try to screw the nozzle retaining cup tighter to relieve pressure on the shield cup retainer.
2. Inspect mating metal surface of shield cup and shield cup retainer for nicks or dirt that might prevent these two parts from forming a metal to metal seal. Look for pitting or signs of arcing inside the shield cup. Look for melting of the shield tip. Replace if damaged.
3. Inspect diffuser for debris and clean as necessary. Wear on the top notches does occur, effecting gas volume.
Replace this part every other shield replacement. Heat from cutting many small parts in a concentrated area or when cutting material greater than 0.75" (19.1mm) may require more frequent replacement.
CAUTION
Incorrect assembly of the diffuser in the shield will prevent the torch from working properly. Diffuser notches must be mounted away from the shield as illustrated.
Diffuser
Torch Body
Nozzle
Nozzle Retaining Cup
Shield Cup
Shield Cup Retainer
145
Maintenance/troubleshooting
4. Unscrew nozzle retainer and pull nozzle straight out of torch body. Inspect insulator portion of the nozzle retainer for cracks or chipping. Replace if damaged.
Inspect nozzle for:
• melting or excessive current transfer.
• gouges from internal arcing.
• nicks or deep scratches on the
O-ring seating surfaces.
•
O-ring cuts, nicks, or wear.
•
Remove tungsten particles (from the nozzle) with steel wool.
Torch Body
Nozzle Retaining Cup
Replace if any damage is found.
Nozzle
NOTE:
Discoloration of internal surfaces and small black starting marks are normal and do not effect cutting performance.
If the holder was tightened sufficiently, the electrode may unscrew without being attached to the electrode holder. When installing the electrode, use only sufficient force to adequately secure the electrode.
5. Remove electrode using electrode removal tool.
6. Disassemble electrode from electrode holder. Insert flats on the holder into a 5/16" wrench. Using the electrode tool, rotate electrode counter-clockwise to remove. Replace electrode if center is pitted more than
0.06" (1/16") or if the flat has become irregular in shape or is worn to a larger diameter.
Torch Body
Note:
The electrode has two usable ends.
When one end is worn, flip electrode to other end for continued use.
Electrode
Electrode Removal Tool
Collet
Collet Body
Electrode, Tungsten
146
Maintenance/troubleshooting
7. Remove electrode holder from torch body. Hex on the end of the electrode holder removal tool will engage in a hex in the holder.
Torch Body
Electrode Holder
Removal Tool
8. Disassemble electrode holder and gas baffle. Carefully remove O-ring from electrode holder and slide baffle from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not attempt to clear holes. Replace baffle if damaged.
NOTE:
Check all O-rings for nicks or other damage that might prevent O-ring from forming a gas/water tight seal.
Electrode Holder
Gas Baffle
O-ring (located underneath baffle)
Pull Gas Baffle back to remove and access o-ring
147
Maintenance/troubleshooting
Torch Front End Assembly (for Production Thick Plate)
CAUTION
Over tightened parts will be difficult to disassemble and may damage torch. Do not over tighten parts during reassembly. Threaded parts are designed to work properly when hand tightened, approximately 40 to 60 inch/pounds.
•
Reverse order of disassembly.
•
Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates easy future assembly and disassembly for service.
•
Installing the electrode requires only moderate tightening.
Torch Body
1. Replace electrode holder in torch body. Hex on the end of the electrode holder removal tool will engage in a hex in the holder.
Collet
Collet Body
Electrode, Tungsten
2. To replace the electrode, assemble collet, collet body and electrode. Insert electrode assembly into the electrode removal tool and ensure electrode makes contact with bottom of tool hole (electrode will fall into place).
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Maintenance/troubleshooting
3. Screw electrode assembly in a clockwise direction to torch body. Electrode will tighten in the correct position when collet closes.
Nozzle Retaining Cup
Torch Body
Nozzle
NOTE:
When assembling, place the nozzle inside the nozzle retaining cup and thread the retainer/ nozzle combination on the torch body. This will help align the nozzle with the assembly. The shield cup and shield cup retainer should be installed only after installing the nozzle retaining cup and nozzle. Otherwise the parts will not seat properly and leaks may occur.
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Maintenance/troubleshooting
Torch Body Maintenance
•
Inspect O-rings daily and replace if damaged or worn.
•
Apply a thin coat of silicone grease to O-rings before assembling torch. This facilitates easy future assembly and disassembly for service.
•
O-ring (1.61" (41mm) I.D. x .07" (1.8mm) BUNA-70A) p/n 996528.
WARNING
Electric Shock Can Kill!
Before performing torch maintenance:
•
Turn power switch of the power source console to the OFF position
•
Disconnect primary input power.
•
Keep electrical contract ring contact points free of grease and dirt.
•
Inspect ring when changing nozzle.
•
Clean with cotton swab dipped in isopropyl alcohol.
Contact Ring Points
O-Ring locations
Contact Ring
Contact Ring Screw
Contact Ring Points
150
Maintenance/troubleshooting
Torch Body Removal and Replacement
Electric Shock Can Kill!
WARNING
Before performing torch maintenance:
•
Turn power switch of the power source console to the OFF position .
•
Disconnect primary input power.
1. Loosen the worm gear hose clamp so that the torch sleeving can be freed and pulled back up the cable bundle. Approximately 7 inches should be far enough. Unscrew the torch sleeve and slide it back until the pilot arc connection is exposed.
Handle
Torch Body
2. Disconnect the power cables which are threaded onto the shorter stems at the back of the torch. Note that one of these connections is left-handed. Unscrew the gas hoses from the torch head assembly by using a
7/16" (11.1mm) and a 1/2" (12.7mm) wrench. Removal of the gas hoses is easier if the power cables are removed first.
1/2" power cable connections
1/2" shield gas connection
7/16" plasma gas connection
151
Maintenance/troubleshooting
3. Unwrap the electrical tape at the back of the gray plastic insulator over the pilot arc connection. Slide the insulator back and undo the knife connectors.
Electrical Tape
(shown removed)
Wire splice
Pilot Arc Cable
Knife-splice connection
4. To install the new torch head assembly - Connect the pilot arc cable and the main power cable by reversing the steps taken to disconnect them. Be sure the gas and water fittings are tight enough to prevent leaks, but do not use any kind of sealant on them. If the knife connection seems loose, tighten the connection by pressing on the parts with needle-nosed pliers after they are assembled. Secure the gray pilot arc insulator with 10 turns of electrical tape.
5. Slide the handle forward and thread it firmly onto the torch body.
New Torch Head Assembly
152
Maintenance/troubleshooting
Reduced Consumable Life
1. Cutting Up Skeletons
Cutting skeletons (discarded material left after all pieces have been removed from a plate). Their removal from the table can adversely affect electrode life by:
•
Causing the torch to run off the work.
•
Greatly increasing the start frequency. This is mainly a problem for O
2
cutting and can be alleviated by choosing a path with a minimum number of starts.
•
Increasing likelihood that the plate will spring up against the nozzle causing a double arc. This can be mitigated by careful operator attention and by increasing standoff and reducing cutting speeds.
If possible, use an OXWELD torch for skeleton cutting or operate the PT-36 at a high standoff.
2. Height Control Problems
•
Torch crashing is usually caused by a change in arc voltage when an automatic height control is used. The voltage change is usually the result of plate falling away from the arc. Disabling the height control and extinguishing the arc earlier when finishing the cut on a falling plate can effectively eliminate these problems.
•
Torch crashing can also occur at the start if travel delay is excessive. This is more likely to occur with thin material. Reduce delay or disable the height control.
•
Torch crashing can also be caused by a faulty height control.
3. Piercing Standoff Too Low
4. Starting on edges with
continuous pilot arc
5. Work Flipping
Increase pierce standoff
Position torch more carefully or start on adjacent scrap material.
The nozzle may be damaged if the torch hits a flipped up part.
6. Catching on Pierce Spatter
7. Pierce not complete before
starting
8. Coolant flow rate low,
Plasma gas flow rate high,
Current set too high
9. Coolant leaks in torch
Increase standoff or start with longer lead-in.
Increase initial delay time.
Correct settings
Repair leaks
153
Maintenance/troubleshooting
Checking for Coolant Leaks
Coolant leaks can originate from seals on the electrode, electrode holder, nozzle, and torch body. Leaks could also originate from a crack in the insulating material of the torch or nozzle retaining cup or from a power cable.
To check for leaks from any source remove the shield cup, clean off the torch, purge it, and place it over a clean dry plate. With the gases off, run the water cooler for several minutes and watch for leaks. Turn on the plasma gas and watch for any mist from the nozzle exit. If there isn’t any, turn off the plasma gas, turn on the shield gas, and watch for any mist from the shield gas passages in the nozzle retaining cup.
If a leak appears to be coming from the nozzle orifice, remove and inspect the o-rings on the nozzle, electrode, and electrode holder. Check the sealing surfaces on the electrode holder and stainless steel torch liner.
If you suspect that a leak is coming from the electrode itself, you can install a 100 to 200 amp 2-piece nozzle base without a nozzle tip. After purging, run the water cooler with the gas off and observe the end of the electrode. If water is seen to collect there, make sure it is not running down the side of the electrode from a leak at an o-ring seal.
WARNING
If it is necessary to supply power to the power source to run the water cooler, it is possible to have high voltages at the torch with no arc present. Never touch the torch with the power source energized.
154
Appendix
156 appendix
appendix
ESAB Serial Communication Interface
Introduction
ESAB Serial Communication Interface (ESCI) is the software developed for operating the Interface Control
Hub (ICH) remotely. This software is developed on the .NET Framework which will communicate with the ICH through a serial interface.
For customers who have RS232, instead of RS422, an RS232 to RS422 converter may be used to communicate via RS422 with the ICH.
System Requirements
There are certain requirements that need to be met in order to install and operate the ESAB Serial
Communication Interface on your system.
Minimum Requirements:
1. CPU: 1.2GHz P4
2. Memory: 256MB
3. Operating System: Windows XP SP2
4. Hard disk: 30MB + Log Space
5. Serial Communication Port (RS232 or RS422)
6. Display: 800x600
7. Keyboard or Touch screen
8. Windows Installer 3.1 (Included in Redistro Folder)
9. .Net Framework 2.0 (Included in Redistro Folder)
Recommended Requirements:
1. CPU: 2GHz P4
2. Memory: 512MB
3. Operating System: Windows XP SP3
4. Hard disk: 30MB + Log Space
5. Serial Communication Port (RS232 or RS422)
6. Display: 800x600
7. Keyboard or Touch screen
8. Windows Installer 3.1 (Included in Redistro Folder)
9. .Net Framework 2.0 (Included in Redistro Folder)
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appendix
Installation
Installation of the ESCI software is straight forward. Insert the media containing the ESCI setup file into the system on which you want to install ESCI and run the setup.exe file. Then follow the instructions on screen.
When installation is complete, run the configurator to setup the software for first use.
Figure 1: Communication Configurations
Figure 2: System Options
Figure 3: GRP File Generator
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appendix
The communication settings (shown in Figure 1), i.e., Port, Speed, Parity and Stop Bit, must match the ICH settings.
The different log levels (shown in Figure 2) available are:
None - Do not record any information.
Errors only - Record the communication errors.
Errors and warnings only - Record communication errors and warnings.
Errors, warnings and information - Record communication errors, warnings, and information about the parameter database etc.
Everything (debug) - Record all the information. This is not recommended unless there are serious problems and the customer wants to debug it.
The GRP generator (shown in Figure 3) allows for the recreation of the GRP file, based on the power supply and a WIC being present. Select the power supply installed, if there is a WIC present, and then click generate. When the file is created, a message will be displayed.
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appendix
Operation
This section shows how to operate the ESCI software with ICH for remote operation. Launch the ESCI software on your system, the ESAB logo, as shown in Figure 7, is displayed which states ESCI is loading parameters database.
Figure 7: ESCI Loading Screen
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appendix
Once the ESCI has finished loading the parameter database, the user graphical interface screen, as shown in
Figure 8 for m3 Gen2 and Figure 9 for IGC, will be displayed depending on the mode of operation.
Figure 8: m3 Gen2 Parameter Screen with one station turned on
161
appendix
Figure 8 is with one station turned on. As stations are turned on, the tab for the station(s) will appear like they are in Figure 9 and 10.
162
Figure 9: IGC Parameter Screen with all stations on
appendix
Figure 10: m3 Gen2 with all stations turned on
Throughout the application, this document will assume there is a mouse or touch screen attached to the computer/CNC running the software. If only a keyboard is attached, the tab key can be used to move between buttons and dropdown lists, the arrow keys can be used to change the dropdown lists, and the spacebar key can be used to “click” the buttons.
From all the tabs, it is possible to view the consumables, edit the parameters, freeze the gauges, clear errors, get version information, minimize the application, get the information needing to be loaded on the CNC, and download parameters to the ICH. To view the consumables needed for the currently selected parameters, click the SHOW CONSUMABLES button, Figure 11 will then be displayed. To get rid of the consumables screen click it or press any key. To download the parameters to the ICH, click on the DOWNLOAD button. Once the download is started, a progress bar (Figure 12) will appear and when complete, the progress bar will disappear and a message box (Figure 13) stating that the download is complete will appear for a few seconds. The speed, kerf, and arc voltage (if height control is not controlled by the ICH) will have the values, needing to be set on the CNC, displayed in the bottom right area of the screen.
163
appendix
164
Figure 11: Consumable Pictures
Figure 12: Parameter Download Status Bar
Figure 13: Parameter Download Complete
appendix
The freeze gauges on error option allows the gauges to be frozen in the state they were last in when an error occurs. The station error list will display the error reported by the ICH, which can be cleared by clicking the
CLEAR button. This will also unfreeze the gauges. To get greater detailed information about the error, click on the error.
The version information will display the version of the ICH and the application’s version. The power supply type will also be displayed in the same area.
The GAS TEST buttons on the parameter screen will allow for testing each gas output for the currently downloaded parameters, which is displayed on the gauges to the left. The blue arrow is the start value and the red arrow is the cut/mark value.
The HEIGHT CONTROL TEST button will only show up if the ICH controls the lifter. This button will cause the height control to find the initial height for cutting/marking.
The AIR CURTAIN button will enable/disable the air curtain output. The CLEAR TIMERS/COUNTERS button will reset the number of starts and the arc on time, which are displayed on the station’s tab.
The EDIT PARAMETERS button will display the screen in Figure 14 (m3 Gen 2) or Figure 15 (IGC). This is where all the parameter editing occurs. On this screen all the parameters can be changed. When saving the parameters a parameter group must be specified and can not be the “Standard” group. The “Standard” group is reserved for the parameters from ESAB. The RELOAD button will reload the parameters on the screen back to what they were originally.
Figure 14: m3 Gen2 parameter edit screen
165
appendix
Figure 15: IGC parameter edit screen
The station’s tab is where the feedback from the ICH is displayed, as shown in Figure 16 (m3 Gen2) and Figure
17 (IGC). The red area on the gauges is the area where an error will occur. The yellow area is the area where the performance of the plasma system will be degraded, but still work without producing an error. The green area is the ideal area to be in. Below the needle in each gauge, there is the digital value being read back from the ICH. The yellow and red areas on the gauges measuring the output pressures and flow will only appear when the process is active. This is indicated when the process step is not 0. The process step displays the step number the ICH is currently in. The step 0 is the idle step, where gas and height control tests can be done. The coolant level warning text will only appear when there is a low coolant level detected in the coolant circulator, it is recommended to check for coolant leaks and refill the coolant circulator when this occurs. The warning will not stop the plasma system from functioning. But the coolant flow error is more likely to occur during a cut/mark operation, which can damage the part being made by the plasma system when it shuts down.
166
appendix
Figure 16: m3 Gen2 station tab
167
appendix
168
Figure 17: IGC station tab
appendix
Demo Server
This section shows how to operate the Demo Server. The demo server software will simulate an ICH via an
Ethernet connection. The protocol used on the Ethernet connection is the same as the one used on the serial connection. Launch the Demo Server on your system and when it is loaded, the screen in Figure 18 will be displayed.
Figure 18: Demo Server Main Screen
From here the system type, power supply, lifter, and WIC options can be selected. Once these options are setup to simulate the ICH system desired, the ESCI software can be launched. This can be done by clicking the
LAUNCH ESCI button or by running the ESCI software via other means. The recommended method is via the
LAUNCH ESCI button on the demo server. Once the ESCI software is launched, via the launch ESCI button, the
LAUNCH ESCI button will change to Quit ESCI. This button can be used to quit the ESCI software at any time.
The three buttons above the LAUNCH ESCI button simulate the digital inputs from the CNC to the ICH. The
PLASMA START button will start the process and lock out the MARK MODE button. The MARK MODE button will put the simulator into Marking mode. The CORNER button will switch the simulator between corner current and cut/mark current. The STATION ON buttons will toggle the station on/off, simulating the station on digital input from the CNC to the ICH.
The step is the current process step being simulated. The warning code, fault code and extended fault code are the raw codes sent back to the ESCI software. The meaning of the code is explained in the serial protocol section of the manual. By clicking the EDIT FAULT AND WARNING CODE button, they can be edited by the name of the fault/warning. This can be seen in Figure 19. By clicking on the ADD button, Figure 20 will appear where the fault codes can be added. The CLEAR ALL FAULTS button will clear all of the faults.
169
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170
Figure 19: Demo Server Error Screen
Figure 20: Demo Server Error Selection Screen
appendix
ICH Serial Communication Protocol
The serial communication with the ICH can be achieved by RS-232, RS-422, or RS-485. This is selectable via the constant editor mode. Each command and response from the Interface Control Hub has a two character checksum on the end. The checksum can be calculated with the following formula:
Checksum = Hex (Truncate ((ASCII (Character1) + ASCII (Character2) + … + ASCII (CharacterN)), 8 bits))
Where Character1 through CharacterN are the characters of the command/response and data to be sent with the command/response. Truncate is a function that drops all bits higher than the number of bits specified. Hex converts the number into its hexadecimal representation in a string.
Note:
During the starting of the plasma process a high frequency generator will become active for about one second. This will cause communication checksum errors on messages sent and received for up to three seconds. The ICH will automatically resume normal communication after this time.
Commands
000: Hello command
This will also reset all errors.
Command:
000<Checksum>
Response:
000ESAB
001: Version request
Command:
001<Checksum>
Response:
001<Power Supply Version> <ICH Version><Checksum>
Power Supply Version is 4 characters long and in hexadecimal format. ICH Version is 4 characters long and in hexadecimal format. The first two characters are the major and the second two characters are the minor (e.g. Major.Minor)
002: Get station status
Command:
002<Checksum>
Response:
002<Station 1 Status> <Station 2 Status><Checksum>
Station 1 Status and Station 2 Status are 4 characters of hexadecimal, each in the following format:
Bit 11-15:
Bit 10:
Bit 9:
Bit 8:
Bit 0-7:
Spare
Coolant Level OK
Mark Mode
Station Selected
Process Step
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003: Get station errors
Command:
003<Checksum>
Response:
003<Station 1 Errors> <Station 2 Errors><Checksum>
Station 1 Errors and Station 2 Errors are 8 characters of hexadecimal each in the following format:
Bit 15:
Bit 14:
Bit 13:
Bit 12:
Bit 11:
Bit 10:
Bit 9:
Bit 8:
Bit 7:
Bit 6:
Bit 5:
Bit 4:
Bit 3:
Bit 2:
Bit 1:
Bit 0:
Bit 31:
Bit 30:
Bit 29:
Bit 28:
Bit 27:
Bit 26:
Bit 25:
Bit 24:
Bit 23:
Bit 22:
Bit 21:
Bit 20:
Bit 19:
Bit 18:
Bit 17:
Bit 16:
Extended Errors exist
Lower Limit Switch
Spare
Spare
Spare
Power Supply Fault
Crash
Coolant Flow OK
Current too low
Current too high
Arc Voltage too low
Arc Voltage too high
Shield Gas 2 Flow too low
Shield Gas 2 Flow too high
Shield Gas 1 Flow too low
Shield Gas 1 Flow too high
Plasma Gas 2 Flow too low
Plasma Gas 2 Flow too high
Plasma Gas output pressure too low
Plasma Gas output pressure too high
Plasma Gas 2 input pressure too low
Plasma Gas 2 input pressure too high
Plasma Gas 1 input pressure too low
Plasma Gas 1 input pressure too high
Water Injection Module Missing
Power Supply Missing
Plasma Gas Box Missing
Shield Gas Box Missing
Lifter Missing
Arc Lost
Ignition Timeout
IHS Timeout
004: Remote Mode
Command:
004<Checksum>
Response:
0040<Checksum> if in local mode and 0041<Checksum> if in remote mode
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005: Get extended errors (only available on version 1.7 or later)
Command:
005<Checksum>
Response:
005<Station 1 Errors> <Station 2 Errors><Checksum>
Station 1 Errors and Station 2 Errors are 8 characters of hexadecimal each in the following format:
Bit 16-31:
Bit 15:
Bit 14:
Bit 13:
Bit 12:
Bit 11:
Bit 10:
Bit 9:
Bit 8:
Bit 7:
Bit 6:
Bit 5:
Bit 4:
Bit 3:
Bit 2:
Bit 1:
Bit 0:
Spare
Lower limits switch
Current feedback, inside RAS, too low
Current feedback, inside RAS, too high
WIC Error
WIC Watchdog
RAS Error
RAS Watchdog
CGC Error
CGC Watchdog
PGC Error
PGC Watchdog
SGC Error
SGC Watchdog
Sensor short on lifter
Lifter Error
Lifter Watchdog
006: Parameter Loading Mark/Cut
Command:
0061<Checksum> for mark parameters are being loaded and 0060<Checksum> for parameters.
Response:
0061<Checksum> at all times.
007: Air Curtain enable/disable
Command:
0071<Checksum> for enabled and 0070<Checksum> for disabled.
Response:
0070<Checksum> if action not allowed and 0071<Checksum> if the action was allowed.
173
appendix
008: Retrieve Options
Command:
008<Checksum>
Response: 008<Lifter><Water Injection><Gas Control><Checksum>
Each is 1 byte long. There is a ICH controlled lifter if Lifter is “1”, otherwise there is no height control from the Interface Control Hub. There is a water injection module attached if Water Injection is “1”, otherwise there is no water injection module.
The Gas Control determines which type of control there is.
“0” - Water Injection only.
“1” - Combined Gas Control is used.
“2” - Full Gas Control is used.
028: Read current
Command:
028<Checksum>
Response:
028<Station 1 Current> <Station 2 Current><Checksum>
Station 1 Current and Station 2 Current are both 4 characters long and in the unit amperes.
058: Set currents
Command:
058<Start Current> <Cut Current> <End Current> <Pilot Arc Current><Checksum>
All the currents are in amperes and 4 characters long.
Response:
0581<Checksum> if allowed and 0580<Checksum> if not
060: Shield Cut Gas Test Begin
Command:
060<Checksum>
Response:
0600<Checksum> if not allowed and 0601<Checksum> if allowed
061: Shield Cut Gas Test End
Command:
061<Checksum>
Response:
0611<Checksum>
062: Shield Start Gas Test Begin
Command:
062<Checksum>
Response:
0620<Checksum> if not allowed and 0621<Checksum> if allowed
174
appendix
063: Shield Start Gas Test End
Command:
063<Checksum>
Response:
0631<Checksum>
064: Start Gas Test Begin
Command:
064<Checksum>
Response:
0640<Checksum> if not allowed and 0641<Checksum> if allowed
065: Start Gas Test End
Command:
065<Checksum>
Response:
0651<Checksum>
066: Cut Gas Test Begin
Command:
066<Checksum>
Response:
0660<Checksum> if not allowed and 0661<Checksum> if allowed
067: Cut Gas Test End
Command:
067<Checksum>
Response:
0671<Checksum>
069: IHS Test
Command:
069<On/Off><checksum>
On is 1 and Off is 0.
Response:
0691<Checksum> if allowed and 0690<Checksum> if not allowed
070: Set Corner Current
Command:
070<Corner
The corner current is in amperes and is 4 characters long
Response:
0701<Checksum> if allowed and 0700<Checksum> if not allowed
175
appendix
078: Gas Pressure/Flow loading
Command:
078<PG1 Start> <PG1 Cut> <PG2 Start> <PG2 Cut> <SG1 Start> <SG1 Cut> <SG2 Start> <SG2
Cut><Checksum>
Plasma gases (PG) are in millibar (mBar) and 5 characters long, while shield gases (SG) are in 1000 times cubic meter per hour (1000 * CMH) or milliliters per minute (mLM) and 5 characters long.
Response:
0781<Checksum> if allowed and 0780<Checksum> if not allowed
087: Set height settings
Command:
087<Initial Height> <Cutting Height> <Pierce Height> <Arc Voltage> <Thickness><Checksum>
Initial Height, Cutting Height, Pierce Height, and Arc Voltage are in micrometers and 5 characters long.
Thickness is in micrometers and is 6 characters long.
Response:
0871<Checksum> if allowed and 0870<Checksum> if not allowed.
094: Gas pressure/flow readings from sensors
Command:
094<Checksum>
Response:
094<Station 1 SG1 Flow> <Station 1 SG2 Flow> <Station 1 PG Output Pressure> <Station 1 PG2
Flow> <Station 1 PG1 Input Pressure> <Station 1 PG2 Input Pressure> <Station 1 SG Output
Pressure> <Station 2 SG1 Flow> <Station 2 SG2 Flow> <Station 2 PG Output Pressure> <Station
2 PG2 Flow> <Station 2 PG1 Input Pressure> <Station 2 PG2 Input Pressure> <Station 2 SG Out
Pressure><Checksum>
All the readings are 5 characters each. Pressures are in millibar (mBar) and flows are in 1000 times cubic meter per hour (1000 * CMH). If water injection is in use than SG1 and SG2 flow are the water injection flow in milliliter per minute (mLM) and SG Output Pressure is the water injection pressure.
095: Load timers
Command:
095<Current Ramp Up> <Current Ramp Down> <Gas Off Delay> <Preflow> <Raise When
Complete>
All timers are in milliseconds and 5 characters long.
Response:
0951<Checksum>
096: Gas select
Command:
096<Gas
Gas Select is 2 Characters long.
Response:
0961<Checksum> if allowed and 0960<Checksum> if not allowed
176
appendix
097: Load thick plate timer
Command:
The timer is in milliseconds and 5 characters long.
Response:
0971<Checksum>
099: Read current gas pressure/flow parameters
Command:
099<Checksum>
Response:
099<PG1 Cut> <PG1 Start> <PG2 Cut> <PG2 Start> <SG1 Cut> <SG1 Start> <SG2 Cut> <SG2
Start><Checksum>
Plasma gases (PG) are in millibar (mBar) and 5 characters long, while shield gases (SG) are in 1000 * cubic meter per hour (1000 * CMH) or milliliters per minute (mLM) and 5 characters long.
098 & 122: Read gas select
Command:
098<Checksum>
122<Checksum>
Response:
Select><Checksum>
122<Gas
Gas Select is 2 Characters long.
124: Reset Timers/Counters
Command:
124<Checksum>
Response:
1241<Checksum> all the time
125: Read Timers/Counters
Command:
125<Checksum>
Response:
125<Station 1 Timer> <Station 1 Counter> <Station 2 Timer> <Station 2 Counter><Checksum>
Timers are in the format “hh:mm:ss” and counters are 4 characters long hexadecimal numbers. The counter represents the number of times the torch has been fired since the last reset and the timer is how long the process was running since the last reset.
177
appendix
ICH Communication Errors
There are three possible communication errors:
500: Bad Checksum
The message was received but the checksum was incorrect. Wait one second and then retry. Another
500 will be transmitted after the one second is up.
501: Unknown Command
The command was received but the received command was not a recognized command.
502: Communication Not Allowed
Communication is not allowed because the Local/Remote toggle switch is set to local.
Toggle the Local/Remote switch to remote, and try again.
ICH Login Sequence
The login sequence should be in the following order:
1.
2.
3.
4.
5.
6.
7.
Hello (000)
Version (001)
Get status (002)
Get errors (003)
Get Timers/Counters (125)
Check remote mode status (004)
Retrieve options (008)
Example:
Send
00090
00191
00292
00393
12598
00494
00898
Receive
000ESAB m3-CAN OEM4B
0010168 010041
0020000 000032
00300000000 00000000B3
12500:00:00 0000 00:00:00 0000A0
0041C5
00800129
178
appendix
ICH Communication Error Messages
Error
IHS Timeout
Ignition Timeout
Arc Lost
Lifter Missing
Shield Gas Box
Missing
Plasma Gas Box
Missing
Power Supply
Missing
Water Injection
Module Missing
Plasma Gas 1 input pressure too high
Plasma Gas 1 input pressure too low
Plasma Gas 2 input pressure too high
Plasma Gas 2 input pressure too low
Resolution
Check that there is a plate below the torch and within the stroke of the lifter.
Check the ICH display to see if the station is selected.
Check the lift amplifier in the lift box for a fault.
Call service if none of the above work.
Check that the power supply is turned on.
Check that the torch is within the specified distance to the plate.
Check that the pilot arc cable is attached, in the Remote Arc Starter box, to the pilot arc connection point and on the other end to the power supply’s pilot arc connection point.
Check that the electrode cables are connected to the block in the Remote Arc Starter box.
Check that the work cables are connected to the work piece, normally via a slat.
Check that the machine did not stall over a small hole or try to cut across a large hole (or off the edge of the plate).
Check that the input power to the power supply did not drop out.
Check that the lifter has the CAN cable connected and there are no empty plugs between the lifter’s CAN plug and CAN 1 on the Interface Control Hub.
If this setup has no lifter, then edit the constant, via the constant editing mode, to disable the lifter functions.
Call service if there seems to be no cabling issues.
Check for 230/115 VAC on the power plug of the Shield Gas Box.
Check that the Shield Gas Box has the CAN cable connected and there are no empty plugs between the Shield
Gas Box’s CAN plug and CAN 1 on the Interface Control Hub.
Call service if there seems to be no cabling issues.
Check for 24 VDC and 24 VAC on the power plug of the Plasma Gas Box.
Check that the Plasma Gas Box has the CAN cable connected and there are no empty plugs between the Plasma
Gas Box’s CAN plug and CAN 1 on the Interface Control Hub.
Call service if there seems to be no cabling issues.
Check that the Remote Arc Starter has the CAN cable connected and there are no empty plugs between the
Remote Arc Starter’s CAN plug and CAN 1 on the Interface Control Hub.
Call service if there seems to be no cabling issues.
Check that the Water Injection Box has the CAN cable connected and there are no empty plugs between the
Water Injection Box’s CAN plug and CAN 1 on the Interface Control Hub.
If this setup has no water injection box, then edit the constant, via the constant editing mode, to disable the water injection functions.
Call service if there seems to be no cabling issues.
Check the input gas regulator to insure the input pressure to the system is below 10 Bar (145 PSI).
If the input pressure has been verified to be below 10 Bar (145 PSI), then call service.
Check the input gas regulator to insure the input pressure to the system is above 4 Bar (60 PSI).
Check for a clogged inline filter.
Check for a gas leak or pinched hose between the regulator and the Plasma Gas Box.
If the input pressure has been verified to be above 4 Bar (60 PSI), then call service.
Check the input gas regulator to insure the input pressure to the system is below 10 Bar (145 PSI).
If the input pressure has been verified to be below 10 Bar (145 PSI), then call service.
Check the input gas regulator to insure the input pressure to the system is above 4 Bar (60 PSI).
Check for a clogged inline filter.
Check for a gas leak or pinched hose between the regulator and the Plasma Gas Box.
If the input pressure has been verified to be above 4 Bar (60 PSI), then call service.
179
appendix
Error
Plasma Gas output pressure too high
Plasma Gas output pressure too low
Plasma Gas 2 Flow too high
Plasma Gas 2 Flow too low
Shield Gas 1 Flow too high
Shield Gas 1 Flow too low
Shield Gas 2 Flow too high
Shield Gas 2 Flow too low
Arc Voltage too high
Arc Voltage too low
Current too high
Current too low
Coolant Flow OK
Crash
Resolution
Check for a pinched hose between the Plasma Gas Box and the torch.
Check consumables for correctness and damage.
Call Service.
Check for a leak in the hose between the Plasma Gas Box and the torch.
Check consumables for correctness and damage/wear.
Check input pressure to be at least 1 Bar (14.5 PSI) above command output pressure.
Call Service.
Check consumables for correctness and/or damage/wear.
Check for correct gas on the input lines to the plasma gas box and shield gas box.
Check for a leak in the hose between the Plasma Gas Box and the torch.
Call Service.
Check consumables for correctness and/or damage/wear.
Check for correct gas on the input lines to the plasma gas box and shield gas box.
Check for a pinched hose between the Plasma Gas Box and the torch.
Call Service.
Check consumables for correctness and/or damage/wear.
Check for correct gas on the input lines to the shield gas box.
Check for a leak in the hose between the Shield Gas Box and the torch.
Call Service.
Check consumables for correctness and/or damage/wear.
Check for correct gas on the input lines to the shield gas box.
Check for a pinched hose between the Shield Gas Box and the torch.
Call Service.
Check consumables for correctness and/or damage/wear.
Check for correct gas on the input lines to the shield gas box.
Check for a leak in the hose between the Shield Gas Box and the torch.
Call Service.
Check consumables for correctness and/or damage/wear.
Check for correct gas on the input lines to the shield gas box.
Check for a pinched hose between the Shield Gas Box and the torch.
Call Service.
Check that the torch did not just go over a hole in the plate.
Adjust the arc voltage calibration for errors between read voltage and actual voltage.
Check for a wavy plate.
Call Service.
Check for a damaged or missing VDR cable.
Adjust the arc voltage calibration for errors between read voltage and actual voltage.
Check for a wavy plate.
Call Service.
Check commanded current on the display on the power supply matches the desired current.
Call Service.
Check commanded current on the display on the power supply matches the desired current.
Call Service.
Check coolant level in the reservoir in the coolant circulator.
Call Service.
Check for damage to the torch consumables; replace damaged consumables with new ones.
Remove the obstacle(s) from the path of the torch.
Power Supply
Fault
Check the fault on the display panel of the power supply and follow instructions in the power supply’s manual.
180
appendix
Error
Lifter Watchdog
Lifter Error
Plasma Gas Control Watchdog
Plasma Gas Control Error
Combined Gas
Control Watchdog
Combined Gas
Control Error
Remote Arc
Starter Watchdog
Remote Arc
Starter Error
Water Injection
Control Watchdog
Water Injection
Control Error
Sensor short on
Lifter
Current Feedback, inside RAS, too high
Current Feedback, inside RAS, too low
Lower Limit
Switch
Resolution
The Lifter’s control module has watchdogged.
Check the CAN cables for damage.
Make sure the terminating resistor is installed, if not, all 7 parts are in use.
Make sure the switch on the ICH is set to have the 120 Ohm resistor installed on the CANbus.
The Lifter’s control module has reported an error.
Check the ICH Error Log for exact error.
The Plasma Gas Control’s control module has watchdogged.
Check the CAN cables for damage.
Make sure the terminating resistor is installed, if not, all 7 parts are in use.
Make sure the switch on the ICH is set to have the 120 Ohm resistor installed on the CANbus.
The Plasma Gas Control’s control module has reported an error.
Check the ICH Error Log for exact error.
The Combined Gas Control’s control module has watchdogged.
Check the CAN cables for damage.
Make sure the terminating resistor is installed, if not, all 7 parts are in use.
Make sure the switch on the ICH is set to have the 120 Ohm resistor installed on the CANbus.
The Combined Gas Control’s control module has reported an error.
Check the ICH Error Log for exact error.
The Remote Arc Starter’s control module has watchdogged.
Check the CAN cables for damage.
Make sure the terminating resistor is installed, if not, all 7 parts are in use.
Make sure the switch on the ICH is set to have the 120 Ohm resistor installed on the CANbus.
The Remote Arc Starter’s control module has reported an error.
Check the ICH Error Log for exact error.
The Water Injection Control’s control module has watchdogged.
Check the CAN cables for damage.
Make sure the terminating resistor is installed, if not, all 7 parts are in use.
Make sure the switch on the ICH is set to have the 120 Ohm resistor installed on the CANbus.
The Water Injection Control’s control module has reported an error.
Check the ICH Error Log for exact error.
The Lifter has a sensor short.
Check the crash sensor for proper operation and adjust as needed.
The current feedback, inside the RAS box, is too high.
Check the 24 pin cable to the power supply for a short.
Verify the command to the power supply is greater than 10 volts.
The current feedback, inside the RAS box, is too low.
Check the 24 pin cable to the power supply for a short.
The lower limit switch was tripped on the lifter.
Shield Gas Control
Watchdog
Shield Gas Control
Error
The Shield Gas Control’s control module has watchdogged.
Check the CAN cables for damage.
Make sure the terminating resistor is installed, if not, all 7 parts are in use.
Make sure the switch on the ICH is set to have the 120 Ohm resistor installed on the CANbus.
The Shield Gas Control’s control module has reported an error.
Check the ICH Error Log for exact error.
181
appendix
ICH Parameter Loading
The sequence for loading a whole parameter set.
1. Parameter type (006)
2. Gas select (096)
3. Gas pressure and flows (078)
4. Current (058)
5. Corner current (070)
6. Timers (095)
7. Heights (087) (if lifter exists)
The sequence for loading a single parameter is to send the parameter type command (006) and then the command for the parameter to be updated (with all the fields populated with the updated values). One marking and one cutting parameter set is the maximum the ICH will store. The parameters are only stored until the next power cycle of the Interface Control Hub.
Example :
The following example is for loading the parameters to mark and cut a 6 mm (~0.250”) plate with 200 Amps and only air for the gas when cutting.
Send
0060C6
Receive
0061C7
0960807 0961D0
07800000 00000 02000 03030 04270 04270 00000 0000021 0781D0
0580100 0200 0100 002003
070020059
09500600 00600 00350 00000 01000 00100F4
08704000 03200 10000 00143 00600017
0581CE
0701C8
0951CF
0871D0
0061C7
0960605
0061C7
0961D0
07802760 02760 00000 00000 02000 02000 00000 0000021 0781D0
0580012 0014 0014 00200C 0581CE
070001058
09500100 00100 00350 00000 01000 00000E9
08704000 04100 04000 00070 0250001A
0701C8
0951CF
0871D0
182
Replacement Parts
184
Replacement paRts
Replacement paRts
General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.
Ordering
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.
NOTE:
Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm
(11” x 17”) paper are included inside the back cover of this manual.
Items listed in the assembly drawing Bill of Materials (included in the back of this publication) that do not have a part number shown are not available from ESAB as a replaceable item and cannot be ordered. Descriptions are shown for reference only. Please use local retail hardware outlets as a source for these items.
185
PT-36
Mechanized Plasmarc Cutting Torch for Production Thick Plate
Replacement paRts
Use:
PT-36 H35 Heavy Plate Start-up Kit .................................
0558005225
Item No.
7
8
5
6
9
10
3
4
1
2
Part Number Description
0558003963
0558003965
0558003964
0558005689
0558003967
0558002532
0558006688
0558003918
0558003962
0558008737
Electrode, Tungsten 0.19" (4.8mm)D
Nozzle H35 .198" (5.0mm) Divergent
Collet 0.19" (4.8mm)D Electrode
Electrode/Collet Holder PT-36
Collet Body
Baffle, 32 Hole x .023" (0.6mm)
Shield High Current
Electrode Holder Tool PT-36
Tungsten Electrode Tool
NOZZLE RETAINING CUP HIGH CURRENT PT-36
8
7
10
9
6
4
3
2
488158
1
181W89
5
NOTE:
These are the only items that are different for Production Thick Plate. Refer to the Cut Data manual
(0558008434/0558008435) for complete setup and parameters.
NOTE:
P/N 0558003965 is supplied with (2) p/n
181W89 installed & (1) p/n 488158 loose in the box. When using the high current nozzle retaining cup and high current shield, as recommended, remove and discard the o-ring nearest the orifice and install p/n
488158 on the step originally intended for the diffuser.
186
Replacement paRts
* bill of materials listed on 11 x 17 fold-out pages (0558008300)
9
21
6
3
O-rings supplied with
Torch Body,
P/N 996528
17
O-ring supplied with
Electrode Holder assembly, P/N 86W99
11
O-ring supplied with
Electrode
16
O-rings, p/n 181W89 supplied with Nozzle
10
19
18
33
8
15
NOTE:
Items 8, 15, 18 & 33 are supplied in a bag with the torch.
187
188
Replacement paRts
REVISION HISTORY
1. Originally released -xxxx
2. revision 06/2014 - removed RAS handle.
C.
B.
D.
A.
E.
F.
G.
H.
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Order Entry Product Availability
Hours: 8:00 AM to 7:00 PM EST
Pricing Order Information Returns
ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers Technical Applications Specifications
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 8:00 AM to 5:00 PM EST
Equipment Recommendations
Hours: 7:30 AM to 4:00 PM EST
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status
Hours: 7:30 AM to 3:30 PM EST
WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123
TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 4:00 PM EST
Hours: 7:30 AM to 4:00 PM EST
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com
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