ESAB IEFC-S PT-24 Precision Plasmarc System Installation manual

F-15-754

Dec, 2010

Installation, Operation and Maintenance Manual for the

IEFC-S

PT-24 Precision Plasmarc System

With Integrated Flow Control (Separable)

Gas Bundle

Flow Console

Ignition Console

Torch

Power Console

Cutting Systems

411 South Ebenezer Road

Florence, South Carolina, U.S.A

.

The equipment described in this manual is potentially hazardous. Use caution when installing, operating and maintaining this equipment.

Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting

Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold be ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB’s responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total customer satisfaction. We constantly look for ways to improve our products, service and documentation. As a result, we make enhancements and/or design changes as required. ESAB makes every possible effort to ensure our documentation is current. We cannot guarantee that each piece of documentation received by our customers reflects the latest design enhancements.

Therefore, the information contained in this document is subject to change without notice.

This manual is ESAB Part Number F15754

This manual is for the convenience and use of the cutting machine purchaser. It is not a contract or other obligation on the part of ESAB Cutting

Systems.

©

ESAB Cutting Systems, 2002

Printed in U.S.A.

Precision Plasma IEFC-S - CE Table of Contents

Section 1 Safety Page 1--(_)

1.1 Introduction ........................................................................................ 1

1.2 Safety Notations And Symbols ............................................................ 2

1.3 General Safety Information .................................................................. 3

1.4 Installation Precautions........................................................................ 4

1.5 Electrical Grounding ............................................................................ 5

1.6 Operating A Plasma Cutting Machine .................................................. 6-10

1.7 Service Precautions............................................................................. 11

1.8 Safety References ............................................................................... 12-17

Section 2 Description Page 2--(_)

2.1 General............................................................................................... 1

2.2 Scope................................................................................................. 1

2.3 Package Options Available .................................................................. 2

2.4 Technical Specifications

2.4.1 Precision Plasma System ........................................................... 3

2.4.2 Plasma Gas ............................................................................... 4

2.4.3 Start Gas ................................................................................... 4

2.4.4 Secondary Gas .......................................................................... 4

2.4.5 Cut Gas ..................................................................................... 4

2.4.6 PT-24 Torch ............................................................................... 4 i


Section 3 Installation Page 3--(_)

3.1 General .............................................................................................. 1

3.2 Equipment Required ........................................................................... 1

3.3 Location ............................................................................................. 1

3.4 Primary Electrical Input Connections ................................................... 2-3

3.5 Alternate Connection Locations for IFC ............................................... 4

3.6 IFC Basic Component Identification..................................................... 4

3.7 Ignition Console Basic Components and Connection Points ................ 5

3.8 Interconnecting Lines.......................................................................... 6

3.9 Joining Ignition and Gas Consoles....................................................... 7

3.10 Connection Separated Gas and Ignition Consoles ............................. 8

3.11 Power Console Connections............................................................. 9

3.12 Voltage Selector Switch .................................................................... 9

3.13 Separated Gas and Ignition Console Interconnection Diagram ........... 10-11

3.14 Combined Gas and Ignition Console Interconnection Diagram ........... 12-13

3.15 Input to Gas Console ........................................................................ 14-15

3.16 Input to Power Console .................................................................... 16

3.17 Torch Mounting ................................................................................ 17

3.18 Torch Coolant................................................................................... 18

3.19 Inspection Of Gas And Coolant Lines ................................................. 18

3.20 Using the 5 Solenoid Torch Manifold ................................................. 19

3.21 Converting IEFC-S Gas Console Manifold to Accommodate a 4

Solenoid Torch Manifold....................................................................

19-20 ii


Section 4 Operation

4.1 Power Supply Controls

Page 4--(_)

4.1.1 Main Power Switch ..................................................................... 1

4.1.2 Pilot Arc Switch........................................................................... 1

4.1.3 Fault Indicator Lights ................................................................... 2

4.1.4 Meters ........................................................................................ 2

4.1.5 Current Control Switch ................................................................ 2

4.2 Cut Quality..........................................................................................

4.2.1 Introduction................................................................................. 3

4.2.2 Cut Angle.................................................................................... 4

4.2.3 Cut Flatness................................................................................ 5

4.2.4 Surface Finish ............................................................................. 6

4.2.5 Dross.......................................................................................... 7-8

4.2.6 Dimensional Accuracy ................................................................. 9

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction................................................................................. 10

4.3.2 Aluminum.................................................................................... 10

4.3.3 Carbon Steel............................................................................... 11

4.3.4 Stainless Steel............................................................................. 12-13

4.4 Process Data

4.4.1 Introduction................................................................................. 15

4.4.2 Process Data Settings ................................................................. 16-61

Aluminum............................................................................. 16-23

Carbon Steel ........................................................................ 24-33

Stainless Steel...................................................................... 34-61

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness ..... 62

4.4.3.1 Aluminum Kerf Values.......................................................... 62

4.4.3.2 Carbon Steel Kerf Values..................................................... 64

4.4.3.3 Stainless Steel Kerf Values O

2

/N

2

/O

2

.................................... 67

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4

................................. 68

4.4.3.5 Stainless Steel Kerf Values N

2

/N

2

/CH

4

.................................. 69

4.4.3.6 Stainless Steel Kerf Values N

2

/N

2

......................................... 70

4.4.3.7 Stainless Steel Kerf Values Air/Air........................................ 72

Plasma Marking Data........................................................... 74 iii


Section 5 Maintenance Page 5--(_)

5.1 General .............................................................................................. 1

5.2 Inspection and Cleaning...................................................................... 1

5.3 PT-24 Torch Description..................................................................... 2-4

5.4 IEFC-S Fluid Schematic ...................................................................... 3

5.4 Torch Maintenance............................................................................. 5-6

5.5 PT-24 Consumable Disassembly and Inspection ................................. 7-10

5.6 PT-24 Torch Re-Assembly.................................................................. 11-12

5.7 Flow Control....................................................................................... 13

5.8 Proportional Valve Removal................................................................. 14

Section 6 Troubleshooting Page 6--(_)

6.1 General Safety.................................................................................... 1

6.2 Troubleshooting Guide........................................................................ 2

6.2.1 Reduced Consumable Life .......................................................... 2

6.2.2 Poor Cut Quality ......................................................................... 3

6.2.3 No Pilot Arc ................................................................................ 3

6.2.4 No Arc Transfer .......................................................................... 3

6.2.5 No Preflow.................................................................................. 3

6.2.6 Torch Fails to Fire ....................................................................... 3

6.2.7 Nozzle Life Extremely Short......................................................... 4

6.2.8 Short Electrode Life .................................................................... 4

6.2.9 Short Electrode AND Nozzle Life ................................................. 4

6.3 IEFC-S Fluid Schematic ...................................................................... 5

IEFC-S Manifold Valve Identification............................................. 5

6.4 IEFC-S Electrical Schematic................................................................ 6-7

6.5 Ignition Console Electrical Schematic .................................................. 8

6.6 Ignition Console Fluid Schematic......................................................... 8

6.7 Precision Plasma Power Source Electrical Schematic .......................... 10-11

6.8 Precision Plasma Power Source Wiring Diagram (includes CE Version) 12-16

6.7 Power Module Schematic – CE Version............................................... 18-19

6.8 Precision Plasma Power Module Wiring Diagram – CE Version ............ 20-21

6.9 Torch Manifold.................................................................................... 22 iv


Section 7 Replacement Parts Page 7--(_)

7.1 General............................................................................................... 1

7.2 Ordering ............................................................................................. 1

7.3 Plasmarc Power Source – Exterior Components .................................. 2-7

7.4 Plasmarc Power Source – Internal Components .................................. 8-17

7.5 Power Source Module......................................................................... 18-25

7.6 IEFC-S Gas Console ........................................................................... 26-27

7.7 IEFC-S Gas Manifold........................................................................... 28-29

7.8 IEFC-S Ignition Console...................................................................... 30-31

7.9 PT-24 Torch Assembly IFC Series ...................................................... 32-33

7.10 Torch Manifold 5 solenoid ................................................................. 34-35

7.11 Interface Cables and Hoses............................................................... 36-37

Customer/Technical Information Back Manual Cover v


This page intentionally left blank. vi

SECTION 1

1.1 Introduction

SAFETY

The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool.

ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness.

Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be accomplished. Failure to observe certain precautions could result in serious personnel injury or severe equipment damage. The following precautions are general guidelines applicable when working with cutting machines. More explicit precautions pertaining to the basic machine and accessories are found in the instruction literature. For a wide scope of safety information on the field of cutting and welding apparatus, obtain and read the publications listed in the Recommended References.

PT-24 Precision Plasma System IEFC-S -

1-1

SECTION 1

1.2 Safety Notations And Symbols

!

!

DANGER

SAFETY

The following words and symbols are used throughout this manual. They indicate different levels of required safety involvement.

ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used with other symbols and information.

Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury or loss of life.

!

WARNING

Used to call attention to potential hazards that could result in personal injury or loss of life.

!

CAUTION

CAUTION

NOTICE

Used to call attention to hazards that could result in minor personal injury or equipment damage.

Used to call attention to minor hazards to equipment.

Used to call attention to important installation, operation or maintenance information not directly related to safety hazards.

1-2


SECTION 1

1.3 General Safety Information

NOTICE

!

WARNING

SAFETY

Some subjects listed are not related specifically to the type of equipment covered in this manual.

However, the safety principles still apply. They are offered as a reminder that this equipment or related apparatus should be operated with alertness and understanding. Safety of operators, technicians, maintenance workers and observers should not be taken for granted.

Machinery may start automatically.

Equipment positioning mechanized plasma torches moves in various directions and speeds.

· Moving machinery can crush.

· Only qualified personnel should operate or service this power source.

· Keep all personnel, materials, and equipment not involved in production process clear of entire system area.

· Fence off entire work cell to prevent personnel from passing through area or standing in the working envelope of the equipment.

· Post appropriate WARNING signs at every work cell entrance.

· Follow lockout procedure before servicing any equipment.

!

WARNING

Failure to follow operating instructions could result in death or serious injury.

Read and understand this operator’s manual before using machine.

· Read entire procedure before operating or performing any system maintenance.

· Special attention must be given to all hazard warnings that provide essential information regarding personnel safety and/or possible equipment damage.

· All safety precautions relevant to electrical equipment and process operations must be strictly observed by all having system responsibility or access.

· Read all safety publications made available by your company.

1-3


SECTION 1

!

WARNING

SAFETY

Failure to follow safety warning label instructions could result in death or serious injury.

Read and understand all safety warning labels on machine.

Refer to operator’s manual for additional safety information.

1.4 Installation Precautions

!

WARNING Improperly Installed Equipment Can Cause

Injury Or Death.

Follow these guidelines while installing machine:

· Do not connect a cylinder directly to machine inlet.

An appropriate cylinder regulator must be installed on a fuel gas cylinder to reduce pressure to a reasonable inlet supply pressure. Machine regulator is then used to obtain pressure required by torches.

· Contact your ESAB representative before installation. He can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure maximum security.

· Never attempt any machine modifications or apparatus additions without first consulting a qualified ESAB representative.

· Observe machine clearance requirements for proper operation and personnel safety.

· Always have qualified personnel perform installation, troubleshooting and maintenance of this equipment.

· Provide a wall mounted disconnect switch with proper fuse sizes close to the power supply.

1-4


SECTION 1

1.5 Electrical Grounding

!

WARNING

SAFETY

Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s

Installation section for detailed grounding instructions.

Electric shock hazard.

Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into service.

!

WARNING

Improper Grounding Can Damage

Machine And Electrical Components.

· Machine must be properly grounded before put into service.

·

Cutting table must be properly grounded to a good

Earth ground rod.


1-5

SECTION 1 SAFETY

1.6 Operating A Plasma Cutting Machine

!

!

WARNING

WARNING

Flying debris and loud noise hazards.

· Hot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying debris generated during operation.

· Chipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses.

· Noise from plasma arc can damage hearing. Wear correct ear protection when cutting above water.

Burn hazard.

Hot metal can burn.

· Do not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with water.

· Do not touch plasma torch immediately after cutting. Allow torch time to cool.

1-6


SECTION 1

!

WARNING

SAFETY

Hazardous voltages. Electric shock can kill.

· Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

· Always turn power off to plasma power supplies before touching or servicing plasma torch.

· Always turn power off to plasma power supplies before servicing any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when machine is connected to power source.

· Wear insulating gloves, shoes and clothing to insulate yourself from workpiece and electrical ground.

· Keep gloves, shoes, clothing, work area, and equipment dry.

· Replace worn or damaged cables.

!

WARNING

Fume hazard.

Fumes and gases generated by the plasma cutting process can be hazardous to your health.

· Do NOT breathe fumes.

· Do not operate plasma torch without fume removal system operating properly.

· Use additional ventilation to remove fumes if necessary.

· Use approved respirator if ventilation is not adequate.

· Provide positive mechanical ventilation when cutting galvanized steel, stainless steel, copper, zinc, beryllium, or cadmium. Do not breathe these fumes.

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


1-7

SECTION 1

!

WARNING

!

WARNING

SAFETY

Radiation hazard.

Arc rays can injure eyes and burn skin.

· Wear correct eye and body protection.

· Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended lens shades for plasma cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

· Replace glasses/goggles when lenses are pitted or broken

· Warn others in area not to look directly at the arc unless wearing appropriate safety glasses.

· Prepare cutting area to reduce reflection and transmission of ultraviolet light.

§ Paint walls and other surfaces with dark colors to reduce reflections.

§

Install protective screens or curtains to reduce ultraviolet transmission.

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and violently release gas.

· Avoid rough handling of cylinders.

· Keep cylinder valves closed when not in use.

· Maintain hoses and fittings in good condition.

· Always secure cylinders in an upright position by chain or strap to a suitable stable object not part of an electrical circuit.

· Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.

· Use approved pressure reducing regulator for the specific gas.

· Refer to CGA Standard P-1, “Precautions for Safe

Handling of Compressed Gases in Cylinders”, available from Compressed Gas Association.

1-8


SECTION 1

!

WARNING

CAUTION

SAFETY

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

· Do not cut near combustible material.

· Do not have on your person any combustibles (e.g. butane lighter).

· Pilot arc can cause burns. Keep torch nozzle away from yourself and others when activating plasma process.

· Wear correct eye and body protection.

· Wear gauntlet gloves, safety shoes and hat.

· Wear flame-retardant clothing covering all exposed areas.

· Wear cuff-less trousers to prevent entry of sparks and slag.

· Have fire extinguishing equipment available for use.

Do Not Use this Torch Under Water.

The PT-24 is designed to be a dry cutting process.

Cutting under water may result in:

· reduced consumable life

· degradation of cut quality

· possible damaged torch

Cutting under water may result in poor cutting performance. Water vapor created when hot material or sparks contact liquid may cause arcing inside torch.

When cutting on a water table, reduce the water level to provide maximum clearance between water and material.


1-9

SECTION 1

!

WARNING

!

WARNING

SAFETY

Explosion hazard.

· Certain molten aluminum-lithium (Al-Li) alloys can cause explosions when plasma cut OVER water.

§ These alloys should only be dry cut on a dry table.

§ DO NOT dry cut over water.

§

Contact your aluminum supplier for additional safety information regarding hazards associated with these alloys .

· Do not cut in atmospheres containing explosive dust or vapors.

· Do not carry any combustibles on your person

(e.g. butane lighter)

· Do not cut containers that have held combustibles.

Pinch hazard.

Moving vertical slides can crush or pinch.

Keep hands clear of torch and slide during operation.

1-10


SECTION 1

1.7 Service Precautions

!

WARNING

!

CAUTION

CAUTION

SAFETY

Hazardous voltages. Electric shock can kill.

· Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.

· Always turn power off to plasma power supplies before touching or servicing plasma torch.

· Always turn power off to plasma power supplies before removing covers or panels to service any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when machine is connected to power source.

· Keep gloves, shoes, clothing, work area, and equipment dry.

· Inspect power and ground leads cables for wear or cracking. Replace worn or damaged cables. Do not use if damaged.

· Never bypass safety interlocks.

· Follow lock-out procedures.

Establish and adhere to preventive maintenance. A composite program can be established from recommended schedules.

Avoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage could occur to equipment or machine.

Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage.

Power off before using test probes to prevent accidental shorting of components.

All circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all guards and covers replaced before power is turned on.


1-11

SECTION 1

1.8 Safety References

Domestic

1-12

SAFETY

The following nationally recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are not related specifically to this type of industrial cutting apparatus, the principles of safety apply equally.

·

“Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035.

ESAB Cutting

Systems.

·

“Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529.

ESAB Cutting Systems.

·

“Safety in Welding and Cutting” - ANSI Z 49.1

, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

·

“Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94

, American Welding Society.

·

“Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

·

“Recommended Practices for Arc Cutting” - AWS C5.2

, American

Welding Society.

·

“Safe Practices” - AWS SP

, American Welding Society.

·

“Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B

, National Fire Protection Association, 60

Batterymarch Street, Boston, Massachusetts, 02110.

·

“Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51

, National Fire

Protection Association.

·

“Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499

. ESAB Cutting

Systems. Obtainable through your ESAB representative or local distributor.

·

"Design and Installation of Oxygen Piping Systems," Form 5110

.

ESAB Cutting Systems.

· “

Precautions for Safe Handling of Compressed Gases in

Cylinders

”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with gaseous materials is also available from the Compressed Gas

Association, Inc., 500 Fifth Ave., New York, NY 10036.



International

Accident Prevention

VBG- Unfallverhütungsvorshriften

General Provisions

VBG 1

Allgemeine Unfallverhütungsvorshriften

VBG 4

VBG 15

VBG 48

VBG 61

Electrical Equipment and operating Equipment

Elektrische Anlagen

Welding, Cutting and related working methods

Schweißen un Schneiden un verwandte Verfahren

Shot Blasting Works

Strahlarbeiten

Gases

Gase

VBG 62

Oxygen

Sauerstoff

Operating liquid jet cutting machines

VBG 87

VBG 93

VBG 121

Arbeiten mit Flüssigkeitsstrahlem

Laser beams, accident prevention and Electrotechnology

Laserstrahlung, Unfallverhütungs-vorschriften für

Feinmechnik und Elektrotechnik

Noise

Lärm


1-13

SECTION 1

VDE Regulations

VDE - Vorschriften

VDE 0100

SAFETY

Erection of power installations with normal voltages up to

1000 volts

Bestimmungen für das Errichten von Stakstromanlagen mit Nennspannungen bis 1000 Volt

Electrical equipment of industrial machines

VDE0113

VDE 0837

Elektrishe Ausrüstung von Industriemaschinen

Radiation safety of laser products; users guide (DIN EN

60825)

Strahlungssicherheit von Lasereinrichtungen und

Benutzungsrichtlinen (DIN EN 60825)

Specification for laser guards

VDE 0837-

50

Anforderung an Lasershcutzwänden

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager

Acetylene lines

TRAC-204

Azetylenleitungen

TRAC-206

Acetylene cylinder battery systems

Azetylenflaschenbatterieanlagen

TRAC-207

TRG Technical Rules for Pressure gases

TRG – Technische Regein für Druckgase

TRG 100

Safety devices

Sicherheitseinrichtungen

General regulations for pressure gases

Allgemeine Bestimmungen für Druckgase

TRG 101

Pressure gases

Druckgase

TRG 102

TRG 104

Technical gas mixtures

Technishe Gasgemische

Pressure gases; alterative use of compressed gas tanks

Druckgase, wahlweise Verwendung von

Druckgasbehältem

1-14



TRGS – Technische Richtlinien für Gefahrstoffe

TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe

TRGS-402

Ermittlung u. Beurteilung der Konzentration gefährlicher

Stoffe in der Luft im Arbeitsbereich

TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)

DIN Standards

DIN-Normen

TA

DIN 2310

Part 1

Teil 1

DIN 2310

Part 2

Teil 2

DIN 2310

Part 4

Teil 4

DIN 2310

Part 5

Teil 5

DIN 2310

Part 6

Teil 6

DIN 4844

Part 1

Teil 1

TA-Luft un TA-Lärm (BLm SchV)

Thermal cutting; terminology and nomenclature

Thermsiches Schneiden, Allgemeine Begriffe und

Bennungen

Thermal cutting; determination of quality of cut faces

Thermsiches Schneiden, Ermittein der Güte von

Schnittflächen

Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances

Thermsiches Schneiden, Plasmaschneiden,

Verfahrensgrundlagen, Güte, Maßtoleranzen

Thermal cutting; laser beam cutting of metallic materials; process principles

Laserstrahlschneiden von metallischen Werkstoffen,


Thermal cutting; Classification, processes

Einführung, Verfahren

Safety markings (DIN EN 7287)

Sicherheitskennzeichen (Siehe EN 7287)


1-15

SECTION 1

DIN EN ISO Harmonized Standards

DIN EN ISO-Harmonisierte Normen

DIN EN

292/1 and 2

SAFETY

Safety of machinery

Sicherheit von Maschinen, Geräten und Anlagen

Hoses for welding, cutting and allied processes

DIN EN 559

Schläuche für Schweißen, Schneiden und verwandte

Verfahren

Hose connections and hose couplings for equipment for welding, cutting and allied processes

DIN EN 560 Schlauchanschlüsse und Schlauchverbindungen für

Geräte zum Schweißen, Schneiden und verwandte

Verfahren

DIN EN 561

Gas welding equipment hose couplings

Gasschweißgeräte, Kupplungen

DIN EN

626-1

DIN EN

848-1

DIN EN

1829

DIN EN

9013

DIN EN

12584

DIN EN

12626

Safety of machines, reduction of risks to health

Sichereit von Maschinen, Reduzierung des

Gesundheitsrisikos

Single spindle vertical milling machines

Fräsmaschine für einseitige Bearbeitung mit drehendem

Werkzeug

High pressure water jet machines

Hochdruckwasserstrahlschneidmaschine

Thermal cutting, oxygen cutting, process principles, dimensional tolerances

Thermisches Schneiden, Autogenes Brennschneiden,


Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma

Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und

Plasmaschnitten

Laser processing machines

Laserbearbeitungsmaschinen

DIN EN

28206

DIN EN

31252

Acceptance testing for oxygen cutting machines

Abnahmeprüfung für Brennschneidmaschinen

Laser Equipment

Lasergeräte

1-16



DIN EN

31553

DIN EN

60204-1

Laser and laser related equipment

Laser und Laseranlagen

Electrical equipment of machines

Elekrische Ausrüstung von Maschinen

DIN EN

60825

Radiation safety of laser products

Strahlensicherheit von Laseranlagen

VDI Guidelines

Arrangement of protection devices

DIN EN 999

Anordnung von Schutzeinrichtungen

Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting

VDI 2906 Schnittflächenqualität beim Schneiden von Werkstücken aus Metall, Abrasiv- Wasserstrahischneiden und

Plasmastrahischneiden

Room air; Technical systems for welding workshops

VDI 2084

Raumluft techn. Anlagen für Schweißwerkstätten


1-17

SECTION 1

This page intentionally left blank.

SAFETY

1-18


SECTION 2

2.1 General

DESCRI

2.2 Scope

PTION

The PT-24 Precision Plasmarc IEFC-S System provides programmable gas switching and pressure control. The IEFC-S is the third generation electronic flow control for the ESAB 100A precision plasma system. Advantages over the original electronic flow control are:

• reduced combined footprint over the original design

• fewer parts

• improved reliability

• improved high speed switch-over marking option

While using the same highly reliable integrated design and components, the gas and ignition consoles have been separated to two enclosures.

The gas and ignition consoles can be bolted as a combined unit or separated to allow the ignition console to be placed closer to the torch. This new design allows maximum component locating flexibility.

The gas pressure and switching is controlled through the cutting machine CNC eliminating the need for other programmable controls.

The purpose of this manual is to provide the operator with all the information required to install and operate the Precision Plasmarc System.

Technical reference material is also provided to assist in troubleshooting the cutting package.

PT-24 Precision Plasma with IEFC-S Consoles

2-1

SECTION 2 DESCRI

2.3 Package Options Available

Precision Plasmarc® IEFCS package options available through your ESAB dealer

PTION

Precision Plasmarc® Power Console (200/230/380/415/460/575) 3-phase 50/60 Hz

(required) CNC Controllable/Without PLC CE Version (covered in this manual) P/N 0558002263

Split IEFC Control System (reference)

Consists of: Gas console, Ignition console & Interconnection bundle

P/N 0558003639

Gas Console P/N 0558003641

Ignition Console

PT-24 Torch with high speed marking

4.5 ft. (1.4 m)

12 ft. (3.7 m)

20 ft. (6.1 m)

12 ft. (3.7 m)

25 ft. (7.6 m)

P/N 0558003640

P/N 0558002337

P/N 0558002338

P/N 0558002339

P/N 22428

P/N 21905

Power Bundle (one required)

Interconnection Bundle

40 ft. (12.2 m)

60 ft. (18 m)

80 ft. (24.4 m)

100 ft. (30 m)

10 ft. (3 m)

20 ft. (6 m)

30 ft. (9 m)

10 ft. (3 m)

P/N 22504

P/N 21906

P/N 22505

P/N 21907

P/N 0558003642

P/N 0558003643

P/N 0558003644

P/N 0560987422

Control Lead, CNC to Power Supply (one required)

20 ft. (6.1 m)

30 ft. (9 m)

60 ft. (18 m)

100 ft. (30 m)

P/N 0560987423

P/N 0560987424

P/N 0560987425

P/N 0560987426

Torch Coolant (one gallon (3.8 liters) containers. four gallons (15 liters) required) P/N 156F05

•

•

•

NOTES:

•

Interconnection Bundle is only required if Gas Console and Ignition Console are separated. See

Interconnection Diagram in section 3.

Control lead from the power source to customer CNC is supplied based on customer order.

Gas supply, hoses, work lead and input primary cable are all supplied by the customer.

See Process Data Sheets for a list of torch consumable parts.

2-2



2.4 Precision Plasma Technical Specifications

2.4.1 System

Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz

Input Current

Power Factor

Output Current Range

65/60/50/40/30/25 amps per phase

0.95

15-100 amps dc

Output Load Voltage

Duty Cycle

Open Circuit Voltage

200mm

559mm

369mm


215 Vdc

100%

315 V dc

1067mm

191mm

PTION

1118mm

Power Console

PT-24 Torch with

Manifold

369mm

Gas Console

289mm

191mm


2-3


2.4.2 Plasma Gas Technical Specifications

PTION

Type O

2

, N

2

, Ar, Air

Pressure 150 psig (10.4 bars) O

2

, N

2

, Air: 85 psig (5.9 bars) Ar

Flow

Purity Required*

Recommended Liquid Cylinder Service

Regulators

Recommended Cylinder 2-Stage

Regulators

100 cfh (47 l/min) max. (varies with application)

O

2

-99.8 to 99.995% N

2

, Ar-99.995%

Air-clean, dry and oil free

Oxygen: R-76-150-540LC (P/N 19777)

Inert gas: R-76-150-580LC (P/N 19977)

Oxygen: R-77-150-540 (P/N 998337

Hydrogen/Methane:R-77-150-350 (P/N 998342)

Nitrogen: R-77-150-580 (P/N 998344)

Industrial Air: R-77150=590 (P/N 998348)

Recommended Heavy –Duty Hi-flow

Station or Pipeline Regulators

Recommended High-capacity Station or Pipeline Regulators

Oxygen: R-76-150-024 (P/N 19151)

R-6703 (P/N 22236)

Gas Filter Required

2.4.3 Start Gas Technical Specifications

25 micron w/bowl guard (P/N 56998133)

Type N

2

, Ar, Air

Pressure

Flow

150 psig (10.4 bars) N

2

, Air: 85 psig (5.9 bars) Ar

60 cfh (28 l/min) max (varies with application)

Minimum Purity Required N2, Ar - 99.995% Air –Clean, Dry

2.4.4 Secondary Gas Technical Specifications

Type N

2

, O

2

, Methane, Air

Pressure

100 psig (6.6 bar) H-35, Methane;

150 psig (10.4 bar) N

2

, O

2

, Air

Flow 60 cfh (28 l/min) max (varies with application)

Minimum Purity Required

2.4.5 Cut Gas Technical Specifications

N

2

, O

2

, CH

4

- 99.995% Air –Clean, Dry

Type N

2

, O

2

, Air

Pressure

Flow

150 psig (10.4 bar) N

2

, O

2

, Air

60 cfh (28 l/min) max (varies with application)

Minimum Purity Required

2.4.6 Pt-24 Torch Technical Specifications

Type

99.995% N

2

, 99.8% O

2 and Air- clean and dry

Rating

Dimensions

Water-Cooled, Dual Gas

100 amps @ 100 % duty cycle

See Package Options (2.3)

2-4


3-1

SECTION 3

3.1 General

NOTICE

3.2 Equipment Required

3.3 Location

!

CAUTION

INSTALLATION

Proper installation can contribute materially to the satisfactory and trouble-free operation of the

Precision Plasmarc® System. It is suggested that each step in this section be studied and carefully followed.

·

Gas Supply and Hoses. Gas supply may be from a bulk source or from a bank of manifold cylinders and regulated to supply 150 psig (10.4 bar) to the gas console (gas flowing).

·

Work Lead. No. 4 AWG cable is recommended for connecting workpiece to power source.

·

Primary Input Cable.

·

25 micron gas filters (P/N 56998133) are required on the supply side for the IEFC-S to function properly.

·

Ventilation is necessary to provide proper cooling of the power supply.

·

Minimize dirt, dust and exposure to external heat sources.

·

Allow a minimum of two feet clearance around the power supply for free air movement.

Restricting Air Flow Will Cause Over-Heating

Restricting intake air with any type of filter on or around the power supply will cause over-heating and void the warranty .


SECTION 3 INSTALLATION

3.4 Primary Electrical Input Connections

!

DANGER

Electric Shock Can Kill!

Provide maximum protection against electrical shock.

Before any connections are made inside the machine, open the line (wall) disconnect switch and unplug the power cord.

!

WARNING

Input Power Configuration

Machine must be properly configured for your input power.

The machine is shipped from the factory configured for 575 V, 60 Hz input.

Do NOT connect a power source of any other voltage unless machine is reconfigured. Damage to the machine will occur.

Input Power Connection At Wall

A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel.

Connect the input power cable of the power source directly to the disconnect switch or a proper plug and receptacle may be purchased from a local electrical supplier. (See table on the next page for recommended input conductors and fuses )

Recommended Sizes For Input Conductors And Line Fuses

Input requirements

Volts Phase Amps

Input & ground conductor, cu/awg/mm

2

Fuse ratings / phase, amps

3-2


3-3

SECTION 3

Ground

Connection

TB2

200

230

380

415

460

575

TB1

230

380

415

460

575

200

230

380

415

460

575

200

230

380

415

460

575

200

K1

!

INSTALLATION

The following procedure explains the proper installation steps for connecting primary electrical power to the power source.

1. Remove right side panel.

2. Ensure input power cable is disconnected from all electrical sources.

3. Route input power cable through the strain relief located at the rear panel.

Input Power

Cable

4. Pull input power cable through the strain relief to allow cable wires sufficient length to connect to the main contactor. Tighten strain relief to ensure input power cable is secured.

5. Connect input power cable ground wire to the ground lug provided on the base of the power source.

Main

Contactor 6. Connect three power leads of the input power cable to the terminals located atop the main contactor. Secure the leads by tightening each screw.

7 position

Termainal Block

Auto Transformer

7. Connect jumper power cables from the bottom of the main contactor to the proper input voltage marked on the auto transformer. The unit is factory set for 575 V as shown to the left.

Factory Wired for 575 Volts

CAUTION

Input Power Jumper Connection

Ensure each input power jumper cable is connected to the correct input voltage on auto transformer.

Factory wired for 575 V .

8. Connect jumper wire to the proper input voltage connector located on the 7-position terminal block.

TB2



3.5 Alternate Connection Locations For IEFC-S Gas Console

There are two locations for the torch strain relief in the ignition console. This provides flexibility while mounting the box to a machine.

NOTE:

When changing over to an alternate connection location, plug unused I/O strain relief holes to seal box.

Torch Strain Relief Alternate Location for

Torch Strain Relief

3.6 Gas Console Basic Component Identification And Connection Points (Cover Removed)

ASIOB Connection Process ASIOB

P-1 115/230V In

24VAC In

P-2 Desired Current

Value (not shown)

Voltage Selector

Switch

Gas Supply In

Solenoids

Gas Supply In

Manifold

3-4


P-5 Connection

Gas Output (not shown)

Proportional Valves

3-5


3.7 Ignition Console Basic Components and Connections Points

Alternate Torch

Bundle Strain

Relief Location

Cooling Water to

Torch/Arc Current

Pilot Arc Strain Relief

Torch Bundle Strain

Relief

Chassis Ground

Cooling water from

Torch/Pilot Arc

H.F. 120V Input

Spark Gap Adjustment

Torch Power Strain

Relief

Cooling Water

To/From Power

Console Fittings

(not shown)


SECTION 3

3.8 Interconnecting Lines

1 2

3 4

INSTALLATION

Torch Bundle

All interconnecting service lines supplied are labeled or color coded on each end with corresponding labels/colors marked on the cabinets.

1

2

COOLING WATER TO TORCH/ARC

CURRENT CABLE

COOLING WATER FREOM TORCH/ PILOT

ARC CABLE

3 TORCH BUNDLE GAS LINES

4 P-2 SOLENOID CONTROL CABLE

1 2

1. Connect lines in torch bundle to ignition console. Lines and connections are labeled and/or color coded.

4

3

Joined Gas and Ignition

Consoles

Interconnect Bundle

(connecting Gas and

Ignition Consoles when not joined.)

View of inside ignition console will be the same if the gas and ignition consoles are combined or separated.

The interface plate of the interconnect bundle is configured identically to the gas/signal output of the gas console.

3-6



3.9 Joining Ignition and Gas Consoles to Form One Unit

Remove black button head filler screws from mating faces of the consoles. Some of these screws are captured with hex nuts from the inside of the gas console.

Remove top covers. These are held on with ¼ turn quick release fasteners.

Remove these screws from mating faces.

The gas console output connections (and P5) are designed to fit into cutouts in the ignition console allowing the two faces to mate flush.

Use filler screws previously removed to fasten consoles together. Most screw positions, screws will pass through a clearance hole in the gas console to be threaded into a pressed cap nut in the ignitions console. There may be a few exceptions.

3-7

View of joined consoles from inside ignition console



3.10 Connecting Separated Gas and Ignition Consoles

An interconnect bundle is required to connect separated consoles

Gas console connections. Hoses/cables and fixed fittings are labeled.

Ignition Console Interface Bundle

Faceplate

Fasten faceplate to the ignition console using 4 screws provided.

3-8

View inside Ignition console with face plate attached.


3-9

SECTION 3

3.11 Power Console Connections

INSTALLATION

Power Supply Bundle

2. Connect power and coolant lines in Power

Supply Bundle from power console to ignition console. Power bundle consists of #6 and # 7 coolant lines (with 5/8-18 L.H. fittings), power cable (#3 AWG) and yellow pilot arc cable (#16

AWG). Coolant lines are stamped with a 6 or 7 on the fitting to assist in identification.

Input Power Strain

Relief

3.12 Voltage Selector Switch

Cooling Water In/Out

Voltage

Selector

Switch

Voltage selector switch inside the gas console is preset for IEFC-S input voltage of 115 V / 60 Hz applications. An alternate setting accommodates

230 V / 50 Hz IEFC-S input voltage.



3.13 Precision Plasmarc® Separated Gas and Ignition Console Component

Interconnecting Diagram

8

11

9

10

20

7

6

12

5

21

22

4

3

13

14

15

3-10

16

17

2

18

19

CH

4

N

2

O

2

Ar Air


1

SECTION 3

1 wall disconnect (cust. sup.)

INSTALLATION

2 primary power cable

3 precision plasma power console

4 power bundle

5 power supply I/O cable

6 earth ground

7 work cable (+)

8 torch and height control

9 height control I/O cable

10 torch bundle

11 height control ASIOB enclosure

12 ignition console

13 height control ASIOB cable*(see note)

14 process ASIOB cable

15 120 vac/24vdc cable

16 CNC

17 process gas lines

18 25 micron filters

19 process gas supply (cust. sup.)

20 cutting table

21 Interconnecting Console Bundle

22 Gas Console

Note: #13 height control ASIOB cable comes from a junction with #14 process ASIOB cable inside the IEFC-S.

3-11



3.14

Precision Plasmarc® Combined Gas and Ignition Console Component

Interconnecting Diagram

8

11

9

10

20

7

6

12

5

13 22

4

3

14

15

3-12

16

17

2

18

19

CH

4

N

2

O

2

Ar Air


1

SECTION 3

1 wall disconnect (cust. sup.)

INSTALLATION

2 primary power cable

3 precision plasma power console

4 power bundle

5 power supply I/O cable

6 earth ground

7 work cable (+)

8 torch and height control

9 height control I/O cable

10 torch bundle

11 height control ASIOB enclosure

12 ignition console

13 height control ASIOB cable*(see note)

14 process ASIOB cable

15 120 vac/24vdc cable

16 CNC

17 process gas lines

18 25 micron filters

19 process gas supply (cust. sup.)

20 cutting table

21 interconnecting Console Bundle (not shown -- not required when consoles are combined)

22 Gas Console

Note: #13 height control ASIOB cable comes from a junction with #14 process ASIOB cable inside the IEFC-S.

3-13


SECTION 3

3.15 Input To Gas Console

!

CAUTION

INSTALLATION

Gas Line Contamination Will

Damage Proportional Valves And

Check Valves

Purge Gas Lines

Before connecting gas delivery lines to the

Integrated Flow Control, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your flow control .

!

CAUTION

1. Purge gas lines between supply and the IEFC-

S before connecting. Proportional and check valves are very sensitive to dust and other foreign particles.

Unfiltered Gases Will Damage Flow

Control System.

Unfiltered cut and shield gases will clog or damage small orifices and gas seals.

25µ filters are required for all cut and shield gases including nitrogen, oxygen, argon, methane, and air.


3-14


Gas Console Input

1/4 NPT

25 micron gas filter

2. Connect gas delivery lines to integrated flow control. Install 25 micron gas filters in all delivery lines between gas source and gas console.

3-15

25 micron filters

CH

4

H-35 N

2

O

2

Ar Air


SECTION 3

3.16 Input to Power Console

CAUTION

INSTALLATION

Proportional And Check Valves Are

Sensitive To Dirt And Debris.

Thoroughly purge the gas delivery system with

N

2

before connecting to the gas console. Hose manufacturing often leaves a fine dust inside.

This dust may cause proportional valves to prematurely fail. Check valves may become clogged.

Pilot Arc

Work

Torch

P

Remove cover

1. Remove panel from rear of console and attach the pilot-arc, torch and work lead.

Input Strain Relief

7 Amp 500VAC

Fuse

Rating

Lable

Serial

Tag

Lead

Cooling Water In From Ignition Console

Cooling Water Out

3-16

2. Connect power supply I/O cable between the console and the CNC.


SECTION 3

3.17 Torch Mounting

CAUTION

1.812

"

(46mm)

Diameter Collar

INSTALLATION

Do Not Cover Vent Hole.

When mounting, do not to cover the small vent hole in the side of the sleeve. This hole allows coolant to drain from inside the sleeve should a leak occur in a service line.

2.0

"

(51mm)

Diameter Sleeve

Torch Mounting Options.

Vent Hole

·

The torch is normally mounted by the 2.0 inch diameter (51mm) sleeve. Do not cover vent hole.

·

For custom alternative mounting, the torch can be mounted by the 1.812" (46 mm) dia collar shown.

This insulated collar and its shoulder are machined relative to the nozzle retainer thread on the torch body.

Use only specified mounting surfaces

3-17


SECTION 3

3.18 Torch Coolant

Coolant

Fill Cap

INSTALLATION

CONTROL

CURRENT

RECISION PL

ASMARC

POWER

·

Remove coolant fill cap at front of console and fill coolant tank with 4 gallons (15 liters) of plasma coolant, P/N 156F05 (one gallon).

·

Do not fill above maximum level

·

Reinstall Cap.

!

CAUTION

Commercial Antifreeze Will Cause

Torch To Malfunction

Use Special Torch Coolant! P/N156F05

Due to high electrical conductivity, DO NOT use tap water or commercial antifreeze for torch cooling. A specially formulated torch coolant is

REQUIRED. This coolant also protects for freezing to –34° C.

Operating the unit without coolant will cause permanent damage to the coolant pump.

3.19 Inspection of Gas and Coolant Lines

To complete installation, it is necessary to inspect field assembled connections for leaks.

·

Gas lines, use a standard soap solution.

Pressurize the system from the control (SDP file)

·

Coolant- check connections for signs of moisture at connections

3-18



3.20 Using a 5 Solenoid Torch Manifold

The 5 solenoid torch manifold allows 1 second conversion from cutting to marking and back to cutting compared to 7 to 10 second switching delay.

The IEFC-S is shipped configured to use the 5 solenoid torch manifold.

NOTICE Marking with the PT-24 torch and the IEFC-

S does not utilize a proportional valve to regulate Argon pressure. An external regulator for the argon supply must be set to 85 PSI (5,6 bar). See marking process data for more information.

3.21 Converting IEFC-S Gas Console Manifold to Accommodate a 4 Solenoid Torch

Manifold

4

3

2

1

The gas console manifold is setup to accommodate a 5 solenoid torch. Some modification is required to permit marking with the IEFC-S and a 4 solenoid torch.

Ar

3-19

Gas Console Manifold

1 Argon inlet connection

2 Argon Solenoid

3 Marking Conversion Access 1/8 NPT

4 Air / Argon manifold outlet



B

Procedure to modify IEFC manifold for 4 solenoid torch manifold.

View A-A

To plasma gas outlet

From plasma gas inlet

B

A

Remove access plug

From View B-B argon solenoid to expose port plug

A. Locate and remove access plug (1/8 NPT) next to the argon flow control solenoid as shown.

B. Remove port plug (1/16 NPT) from bottom of access hole.

C. Replace access plug.

Note: If necessary, use a oxygen safe commercially available pipe sealant. DO NOT USE Teflon Tape.

Pieces of tape may break free resulting in poor cut quality or torch failure. A

Remove 1/16

NPT plug to open Ar port

Cross Section Views of Argon Marking

Port

Gas Out (5 th

Solenoid)

Schematic for Marking with IEFC and 4 Solenoid torch manifold.

Proportional

Valve 1

Pressure

Switch 1

Vent

Removable

Plug shown removed

With the plug installed and a 5 solenoid torch,

Argon gas goes directly to the 5 th solenoid (Argon).

Argon is diverted across and out the plasma gas line with the plug removed and a 4 solenoid torch.

The line to the fifth torch solenoid is capped with a one way quick release fitting (acts similar to a check valve)

Air -2

To Air-1

To N

2

-1 and

N

2

-3

Air In

N

2

-2

N

2

In

Argon In

3-20


SECTION 4

4.1 Power Supply Controls

4.1.1 Main Power Switch

EMERGENCY

STOP

OPERATION

Main Power Switch

Controls the input power to the fan, water cooler and the PC Board. Amber indicator light to the left of the switch.

4.1.2 Pilot Arc Switch

Pilot Arc Switch

Previously a manual setting, This switch has been eliminated from the CNC controllable power console.

Now handled by the machine CNC control to select

HIGH or LOW start pilot arc, depending on cutting conditions. See Process Data for more information on which conditions high and low start are used.

PT-24 Precision Plasma System IEFC-S 4-1

SECTION 4

4.1.3 Fault Indicator Lights

OPERATION

Fault Indicator Lights

·

Coolant flow will show low coolant flow. When unit is turned on, the light will briefly show a fault and then go out.

·

P/S Fault Indicator – fault in plasma control PCB in the inverter power source. Power source will shut down.

·

Over-Under Voltage fault Indicator -- indicate input voltage is above or below the tolerances of the

PCU console. Will latch until power is recycled by main power switch.

·

Emergency Stop fault indicator -- shows CNC

Interlock condition. Power Source will not work.

4.1.4 Meters

4.1.5 Current Control Switch

4-2

·

Cutting Current Meter (A) -- Displays actual cutting current in amperes.

·

Cutting Voltage Meter (V) -- Displays actual cutting voltage.

Control Remote/Panel Switch

·

Panel Position – Output current is set by the output current dial

· Remote Position – output current is set by the

CNC (or remote pot) with an analog dc signal

0-10 Vdc = 0-100 Adc

·

Current Adjust – used to manually adjust current in panel mode. View Amp meter for values.

PT-24 Precision Plasma System IEFC-S

SECTION 4

4.2 Cut Quality

4.2.1 Introduction

NOTICE

4.2.2 Cut Angle

Part

OPERATION

Causes affecting cut quality are interdependent.

Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to different undesirable cutting results. To begin select the most prominent condition:

§

4.2.2 Cut Angle, negative or positive

§

4.2.3 Cut not flat, rounded or undercut

§

4.2.4 Surface roughness

§ 4.2.5 Dross

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

·

Make small incremental adjustments when making corrections.

·

Adjust Arc Voltage in 1 volt increments, up or down as required.

·

Adjust cutting speed 5% or less as required until conditions improve.

Before attempting ANY corrections, check cutting

variables with the factory recommended settings/consumable part numbers listed in Process

Data.

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)

Drop Part


SECTION 4

Drop

OPERATION

Part

Part

Positive Cut Angle

Top dimension is less than the bottom dimension.

·

Misaligned torch

·

Bent or warped material

·


·

High standoff High (arc voltage)

·

Cutting speed fast

·

Current high or low. (See Process Data for recommended current level for specific nozzles).

4.2.3 Cut Flatness

Top And Bottom Rounded

Condition usually occurs when material is .25” thick

(6,4mm) or less.

·

High current for given material thickness (See

Process Data for proper settings).

Drop Part

4-4 PT-24 Precision Plasma System IEFC-S

SECTION 4 OPERATION

Top Edge Undercut

·

Standoff low (Arc Voltage)

Drop Part

4.2.4 Surface Finish

Top View

Process Induced Roughness

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

·

Incorrect Shield Gas mixture (See Process Data)

·


Cut Face or

Process

Induced

Roughness

Machine

Induced

Roughness

M achine 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. (Refer to Maintenance Section in machine operation manual).

·

Carriage wheel adjustment


SECTION 4

4.2.5 Dross

Lag

Lines

Cut Face

OPERATION

Dross is a by-product of the cutting process.

It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to

Process Data.

Rollover

High Speed Dross

Material weld or rollover on bottom surface along kerf.

Difficult to remove. May require grinding or chipping.

“S” shaped lag lines.

·

Standoff high (arc voltage)

·

Cutting speed fast

Side View

Lag

Lines

Cut Face

Globules

Slow Speed Dross

Forms as globules on bottom along kerf. Removes easily.

·

Cutting speed slow

Side View


SECTION 4

Side View

OPERATION

Splatter

Cut Face

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

·

Contanminated gas source


SECTION 4

4.2.6 Dimensional Accuracy

NOTICE

NOTICE

OPERATION

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.

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.

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



4.3 Influence of Gas Options on Cut Quality


All gases are not suitable for all situations. Certain gases assist in cutting specific materials and thickness. The following explains why certain gases are selected and their influence on the finished part.

Other influences such as arc voltage and gas flow/pressure are covered in the Process Data.

NOTICE

4.3.2 Aluminum

Refer to Cutting Process Data in this section for recommended flow/pressure settings.

Material

Thickness:

All thickness’ between 0.062" to .625" (1,6 mm to 15,9 mm)

Cut Qualities:

·

Smooth cut face

·

Virtually no dross

Plasma Gas: Nitrogen

Shield Gas: Nitrogen/Methane

Discussion:

Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1 part methane ratio is desired. Incorrect ratio results in heavy dross.


SECTION 4

NOTICE

4.3.3 Carbon Steel

OPERATION

Refer to Cutting Process Data in the PT24

Manual for recommended flow/pressure settings.

Material

Thickness:

26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm)

Cut Qualities:

·

Smooth cut face

·

Virtually no dross

Plasma Gas: Oxygen

Shield Gas: Oxygen/Nitrogen

Discussion:

Shield gas is normally nitrogen. A small amount of oxygen combined with nitrogen can effectively improve dross formation on thin material of 26 GA to 10

GA carbon steel. Also. an oxygen only shield may provide acceptable results on thinner materials.

Material

Thickness:

.125" to .75" (3,2 mm to 19,1 mm)

Cut Qualities:

·

Smooth cut face

·

Virtually no dross

Plasma Gas: Oxygen

Shield Gas: Nitrogen

Discussion:

Cutting carbon steel with oxygen results in an exothermic reaction. This chemical reaction causes the carbon in the material to burn similar to when oxyfuel cutting. This plus the electrical energy uses lower amperage levels without sacrificing cut speed.


SECTION 4

NOTICE

4.3.4 Stainless Steel

OPERATION

Refer to Cutting Process Data in the PT24

Manual for recommended flow/pressure settings.

Material

Thickness:

22 GA (.028") to 16 GA (0.062") (0,7 mm to 1,6 mm)

Cut Qualities:

·

Positive cut angle

·

Excellent dross performance

·

Shiny cut surface.



Discussion:

Because of high cut speeds. a positive cut face angle is expected. Use a 70amp nozzle at 50 amps to allow more gas to exit the nozzle.

Material

Thickness:

26 GA (.018") to 16 GA (0.062") (0,5 mm to 1,6 mm)

Cut Qualities:

·

Dark cut face

·

Virtually dross free

·

Improved cut squareness

Plasma Gas: Oxygen

Shield Gas: Oxygen/Nitrogen

Discussion:

Low amperage cutting/slower speeds produce squarer cuts in thin materials.

The oxygen allows for a lower arc voltage, improving cut squareness. The “B” nozzle is used at 30 amps

Material

Thickness:

.125" to .625" (3,2 mm to 15,9 mm)

Cut Qualities:

·

Cut edge dark

· good dross performance

·

Good cut angle

Plasma Gas: Air

Shield Gas: Air

Discussion:

When they are the same, the shield and plasma gases combine. This combination has the effect of increasing the cut gas flow/pressure. This increased flow/pressure directly influences cut squareness.


SECTION 4

NOTICE

Stainless Steel

OPERATION

Refer to Cutting Process Data for recommended flow/pressure settings.

Material

Thickness:

.125" to .625" (3,2 mm to 15,9 mm)

Cut Qualities:

·

Matted cut edge appearance

·

Light gray color

·

Much smoother finish

·

Possible slight increase in cut angle

Plasma Gas: Air

Shield Gas: Air/Methane

Discussion:

Too much methane in the shield gas mixture can result in more dross formation.

4:1 ratio air to methane is recommended. Because methane is a fuel gas, possible slight increase in cut angles could be experienced.

Material

.125" to .625" (3,2 mm to 15,9 mm)

Thickness:

Cut Qualities:

·

Dark cut face similar to air

·

Excellent dross performance

·

Good cut angle


Shield Gas: Nitrogen

Discussion:

Shield and plasma gases combine, the volume/pressure of shield gas can negatively affect cut squareness. Higher shield volume produces a negative cut angle. A lower volume, produces a positive angle.

Material

.187" to .625" (4,7 mm to 15,9 mm)

Thickness:

Cut Qualities:

·

Shiny cut face

·

Lip formation at the bottom

·

Dross formation can be extensive and difficult to remove



Discussion:

Because methane is a fuel gas, flow/pressure rates can affect the cut angle.

High flow/pressure results in a negative cut angle, low flow/pressure results in a positive cut angle. Nitrogen to methane ratio is 10 to 14 parts N2/ 1 part CH4.

The lip formed on the cut face bottom is severe, making Nitrogen/Methane shield gas combination unsuitable for some finished part applications.


SECTION 4

4.4 Process Data


OPERATION

The following information is a result of many hours of testing and is a general guide for setting up and cutting with a PT-24 Precision Plasmarc® System.

In most cases these settings will provide a quality cut. The data contains values for:

· cutting aluminum, carbon and stainless steel

· arc voltage (standoff)

· cutting speed

· current (amperes)

· gas flow rates for all plasma/shield gas combinations

This same data is contained in SDP files. (See your control manual for more information on SDP files.)

Also included is information on consumable part numbers for current being used.


SECTION 4

4.4.2 IFC PT-24 Process Data

OPERATION

Material: Aluminum

Initial Amperes: 15

Final Amperes: 30

Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar

Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar

® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar

PT-24 Torch with Integrated Flow Control

Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21536 (3 holes)

!

Nozzle

P/N 21541, "B"

Nozzle Retainer/Diffuser

P/N 22007

Shield Cup Insulator

P/N 22010

Insulator Shield Retainer w/O-Ring P/N 21712

O-Ring - Shield Retainer ,

(Ref. P/N 996528)

Cup shield w/Retainer

P/N 22531

!

Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage



Process Data 15 Initial / 30 Final Amperes

Precision Plasma Integrated Flow Control Aluminum

Plasma Gas Shield Gas 1 Shield Gas 2

N2 N2 CH4

Material Thickness

In.

0,062 0,075 0,09 0,125 0,187 0,250 mm 1,6 1,9 2,3 3,2 4,7 6,4

Timers

Pierce Delay (sec.) 0 0 0 0 0 0

Initial to Final Current (sec.) 0,2 0,2 0,2 0,2 0,2 0,2

Setup Parameters

Plasma Start Gas 1-

Plasma Cut Gas 1-

Shield Gas

Arc Voltage (standoff) psi/bar psi/bar

1-Start - psi/bar

1- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

93,1

/6,3

132,0

/9,0

42,9

/2,9

16,5

/1,3

12,3

/0,8

93,1

/6,3

132,0

/9,0

42,9

/2,9

16,5

/1,3

12,3

/0,8

93,1

/6,3

132,0

/9,0

42,9

/2,9

16,5

/1,3

12,3

/0,8

93,1

/6,3

132,0

/9,0

42,9

/2,9

16,5

/1,3

12,3

/0,8

93,1

/6,3

132,0

/9,0

42,9

/2,9

16,5

/1,3

12,3

/0,8

93,1

/6,3

132,0

/9,0

42,9

/2,9

16,5

/1,3

12,3

/0,8

150 152 153 165 180 189

In. 0,100 0,100 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54 2,54 2,54

In. 0,150 0,150 0,150 0,160 0,220 0,250 mm 6,35 6,35 6,35 4,04 5,59 6,35

In. 0,125 0,130 0,135 0,165 0,220 0,250 mm 3,18 3,30 3,43 4,19 5,59 6,35

IPM 150 135 105 78 45 40

MM/MIN 3810 3429 2667 1981 1143 1016

Notes:

Pilot Arc –LOW,








® Shield Mix Gas:

Methane, CH4 @ 100 PSI / 6,9 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!




Process Data 28 Initial – 55 Final Amperes



N2 N2 CH4


In.

0,062 0,125 0,125 0,250 mm 1,6 3,2 4,7 6,4

Timers

Pierce Delay (sec.) 0 0 0 0

Initial to Final Current (sec.) 0,2 0,2 0,2 0,2




Shield Gas





Initial Height

Pierce Height

Cutting Height

64

/4,4

100,3

/6,8

42,9

/2,9

16

/1,1

12,3

/0,8

64

/4,4

100,3

/6,8

42,9

/2,9

16

/1,1

12,3

/0,8

64

/4,4

100,3

/6,8

42,9

/2,9

16

/1,1

12,3

/0,8

64

/4,4

112,3

/7,6

42,9

/2,9

16

/1,1

12,3

/0,8

136 139 152 168

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,09 0,09 0,180 mm 2,29 2,29 4,57 3,81

In. 0,09 0,09 0,180 mm 2,29 2,29 4,57 5,72

IPM 170 130 78 46

MM/MIN 4318 3302 1981 1168

Notes:

Pilot Arc –HIGH,











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010


O-Ring - Shield Retainer

(Ref. P/N 996528)


P/N 22531

!







N2 N2 CH4


In.

0,187 0,250 0,375 0,500 mm 4,7 6,4 9,5 12,7

Timers

Pierce Delay (sec.) 0 0 0,1





Shield Gas





Initial Height

Pierce Height

Cutting Height

76,6

/5,2

68,6

/4,7

43,8

/3,0

15,4

/1,0

11,7

/0,8

76,6

/5,2

108,5

/7

43,8

/3,0

15,4

/1,0

11,7

/0,8

76,6

/5,2

108,5

/7

43,8

/3,0

15,4

/1,0

11,7

/0,8

76,6

/5,2

108,5

/7

43,8

/3,0

15,4

/1,0

11,7

/0,8

150 157 168 182

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,190 0,150 0,240 0,260 mm 4,83 3,81 6,10 6,60

In. 0,190 0,225 0,240 0,260 mm 4,83 5,72 6,10 6,60

IPM 80 65 66 30

MM/MIN 3032 1651 1397 762

Notes:












Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







N2 N2 CH4


In.

0,250 0,375 0,500 0,625 mm 6,4 9,5 12,7

Timers






Shield Gas





Initial Height

Pierce Height

Cutting Height

76,4

/5,2

95,6

/6,5

61,5

/4,2

27,3

/1,9

17,9

/1,2

76,4

/5,2

95,6

/6,5

61,5

/4,2

27,3

/1,9

17,9

/1,2

76,4

/5,2

95,6

/6,5

61,5

/4,2

27,3

/1,9

17,9

/1,2

76,4

/5,2

95,6

/6,5

61,5

/4,2

27,3

/1,9

17,9

/1,2

155 160 166 174

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,190 0,225 0,260 0,285 mm 4,83 5,72 6,60 7,24

In. 0,190 0,225 0,260 0,285 mm 4,83 5,72 6,60 7,24

IPM 95 80 65 50

MM/MIN 2413 2032 1778 1270

Notes:




Material: Carbon Steel



Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar



Oxygen, O2 @ 150 PSI / 10.4 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21852 (2 holes)

!

Nozzle

P/N 21540, "A"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!




Process Data

Precision Plasma Integrated Flow Control

16 Initial / 16 Final Amperes

Carbon Steel

Plasma Gas

O2 N2 O2

Shield Gas 1 Shield Gas 2


In.

20Ga 18Ga 16Ga 14Ga 12Ga 10Ga mm

0,9 1,2 1,6 2,0 2,7 3,4

Timers

Pierce Delay (sec.)

0 0 0 0,1 0,5 0,5

Initial to Final Current (sec.)

0,2 0,2 0,2 0,2 0,2 0,2




Shield Gas psi/bar psi/bar




71,3

/4,9

83,2

/5,7

12.9

/0.89

4.1

/0.28

2.2

/0.15

71,3

/4,9

83,2

/5,7

12.9

/0.89

4.1

/0.28

2.2

/0.15

71,3

/4,9

83,2

/5,7

12.9

/0.89

4.1

/0.28

2.4

/0.27

71,3

/4,9

83,2

/5,7

12.9

/0.89

4.1

/0.28

3.0

/0.21

71,3

/4,9

83,2

/5,7

12.9

/0.89

3.1

/0.21

2.2

/0.15

71,3

/4,9

83,2

/5,7

12.9

/0.89

3.5

/0.24

2.3

/0.16

Arc Voltage (standoff) 108 110 120 123 121 123

In.

0,04 0,04 0,04 0,04 0,04 0,04

1,02 1,02 1,02 1,02 1,02 1,02

In.

0,06 0,06 0,06 0,06 0,115 Pierce Height mm

Cutting Height mm

0,115

1,52 1,52 1,52 1,52 2,92 2,92

0,108 0,118 0,140 0,144 0,126 0,126

2,74 2,74 3,56 3,66 3,20 3,20

Travel Speed

IPM

95 80 75 55 50 33

MM/MIN

2413 2032 1905 1397 1270 838

Notes:



4-23








Oxygen, O2 @ 150 PSI / 10.4 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21536 (3 holes)

!

Nozzle

P/N 21541, "B"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!





Precision Plasma Integrated Flow Control Carbon Steel


O2 N2 O2


In.

14Ga 0,125 0,135 0,187 0,250 mm 1,9 3,2 3,4 4,7 6,4

Timers

Pierce Delay (sec.) 0 0 0 0 0,2

Initial to Final Current (sec.) 0,2 0,2 0,2 0,2 0,2




Shield Gas





Initial Height

Pierce Height

Cutting Height

86,9

/5,9

102,9

/7,0

46,5

/3,2

86,9

/5,9

102,9

/7,0

46,5

/3,2

86,9

/5,9

102,9

/7,0

46,5

/3,2

86,9

/5,9

102,9

/7,0

46,5

/3,2

86,9

/5,9

102,9

/7,0

46,5

/3,2

0 0 0 0 0

2,5

/0,2

2,5

/0,2

2,5

/0,2

2,5

/0,2

2,5

/0,2

113 119 120 122 124

In. 0,04 0,04 0,04 0,04 0,04 mm 1,02 1,02 1,02 1,02 1,02

In. 0,103 0,113 0,118 0,118 0,130 mm 2,62 2,87 3,00 3,00 3,30

In. 0,103 0,113 0,118 0,118 0,130 mm 2,62 2,87 3,00 3,00 3,30

IPM 80 55 52 40 30

MM/MIN 3032 1397 1320 1016 762

Notes:










Oxygen, O2 @ 150 PSI / 10.4 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







O2 N2 O2


In.

0,125 0,135 0,187 0,250 0,375 mm 3,2 3,4 4,7 6,4 9,5

Timers

Pierce Delay (sec.) 0 0,3 0,3 0,3 0,4








73,8

/5,0

86,2

/5,9

48,1

/3,3

11,2

/0,8

73,8

/5,0

86,2

/5,9

48,1

/3,3

11,2

/0,8

73,8

/5,0

86,2

/5,9

48,1

/3,3

11,2

/0,8

73,8

/5,0

86,2

/5,9

48,1

/3,3

11,2

/0,8

73,8

/5,0

86,2

/5,9

48,1

/3,3

11,2

/0,8

0 0 0 0 0 2- Cut - psi/bar

Arc Voltage (standoff)

Initial Height

Pierce Height

Cutting Height

108 111 114 121 124

In. 0,100 0,100 0,100 0,100 0,100 mm 25,4 25,4 25,4 25,4 25,4

In. 0,145 0,155 0,145 0,205 0,164 mm 3,68 3,94 3,68 5,21 2,41

In. 0,145 0,155 0,145 0,205 0,164 mm 3,68 3,94 3,68 5,21 2,41

IPM 60 50 45 35 20

MM/MIN 1524 1270 1143 889 508

Notes:










Oxygen, O2 @ 150 PSI / 10.4 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







O2 N2 O2


In.

0,187 0,250 0,312 0,375 0,500 0,625 mm 4,7 6,4 7,9 9,5 12,7

Timers

Pierce Delay (sec.) 0,3 0,3 0,3 0,4 0,5 0,5

Initial to Final Current (sec.) 0,2 0,2 0,2 0,2 0,2 0,2




Shield Gas





Initial Height

Pierce Height

Cutting Height

66,7

/4,5

81,6

/5,6

49,1

/3,3

20,6

/1,4

66,7

/4,5

81,6

/5,6

49,1

/3,3

28,4

/1,9

66,7

/4,5

81,6

/5,6

49,1

/3,3

20,6

/1,4

66,7

/4,5

81,6

/5,6

49,1

/3,3

28,4

/1,9

66,7

/4,5

81,6

/5,6

49,1

/3,3

13,5

/0,9

66,7

/4,5

81,6

/5,6

49,1

/3,3

135,

/0,9

0 0 0 0 0 0

108 110 114 113 135 140

In. 0,100 0,100 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54 2,54 2,54

In. 0,140 0,140 0,165 0,160 0,275 0,315 mm 3,56 3,56 4,19 40,06 6,99 8,00

In. 0,140 0,140 0,165 0,160 0,275 0,315 mm 3,56 3,56 4,19 40,06 6,99 8,00

IPM 110 95 70 60 30 25

MM/MIN 2794 2413 1778 1524 762 635

Notes:










Oxygen, O2 @ 150 PSI / 10.4 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







O2 N2 N2


In.

0,312 0,375 0,500 0,625 0,750 mm 7,9 9,5 12,9 19,1

Timers

Pierce Delay (sec.) 0,3 0,3 0,4 0,5 0,5








77,5

/5,2

89,5

/6,1

60,5

/4,1

26,3

/1,8

77,5

/5,2

89,5

/6,1

60,5

/4,1

26,3

/1,8

77,5

/5,2

89,5

/6,1

60,5

/4,1

26,3

/1,8

77,5

/5,2

89,5

/6,1

60,5

/4,1

26,3

/1,8

77,5

/5,2

89,5

/6,1

60,5

/4,1

26,3

/1,8

0 0 0 0 0 2- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

115 120 132 137 142

In. 0,100 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54 2,54

In. 0,175 0,190 0,280 0,290 0,320 mm 4,45 4,83 7,11 7,37 8,13

In. 0,175 0,190 0,280 0,290 0,320 mm 4,45 4,83 7,11 7,37 8,13

IPM 90 80 50 30 25

MM/MIN 2290 2030 1270 760 630

Notes:




Material: Stainless Steel






Oxygen, O2 @ 150 PSI / 10.4 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21536 (3 holes)

!

Nozzle

P/N 21541, "B"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!





Precision Plasma Integrated Flow Control Stainless Steel


O2 N2 O2


In.

26Ga 24Ga 22Ga 18Ga 16Ga mm 0,4 0,6 0,7 1,2 1,6

Timers

Pierce Delay (sec.) 0 0 0 0 0





Shield Gas





Initial Height

Pierce Height

Cutting Height

99,8

/6,8

116,8

/7,9

32,7

/2,2

10,3

/0,7

7,1

/0,5

99,8

/6,8

116,8

/7,9

32,7

/2,2

10,3

/0,7

7,1

/0,5

99,8

/6,8

116,8

/7,9

32,7

/2,2

10,3

/0,7

7,1

/0,5

99,8

/6,8

116,8

/7,9

32,7

/2,2

10,3

/0,7

7,1

/0,5

99,8

/6,8

116,8

/7,9

32,7

/2,2

10,3

/0,7

7,1

/0,5

105 105 107 109 111

In. 0,06 0,06 0,06 0,06 0,06 mm 1,52 1,52 1,52 1,52 1,52

In. 0,105 0,120 0,107 0,109 0,111 mm 2,67 3,05 2,72 2,77 2,82

In. 0,105 0,120 0,107 0,109 0,111 mm 2,67 3,05 2,72 2,77 2,82

IPM 250 200 190 140 100

MM/MIN 6350 5080 4826 3556 2540

Notes:







Plasma Gas: Air @ 150 PSI / 10.4 Bar

Shield Gas: Air @ 150 PSI / 10.4 Bar



Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!




Process Data 25 Intial / 50 Final Amperes



Air Air


In.

0,125 0,187 0,250 0,375 mm 3,2 4,7 6,4 9,5

Timers










77

/5,2

125,7

/8,5

44,5

/3,0

31,9

/2,2

77

/5,2

125,7

/8,5

44,5

/3,0

31,9

/2,2

77

/5,2

125,7

/8,5

44,5

/3,0

31,9

/2,2

77

/5,2

125,7

/8,5

44,5

/3,0

31,9

/2,2

0 0 0 0


Initial Height

Pierce Height

Cutting Height

134 140 145 157

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,145 0,165 0,160 0,220 mm 3,68 4,19 40,06 5,59

In. 0,145 0,165 0,160 0,220 mm 3,68 4,19 40,06 5,59

IPM 90 60 40 18

MM/MIN 2286 1524 1016 457

Notes:











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







Air Air


In.

0,187 0,250 0,375 0,500 mm 4,7 6,4 9,5 12,7

Timers

Pierce Delay (sec.) 0,3 0,4 0,5 0,6








79,1

/5,4

105,5

/7,2

62,6

/4,3

38,3

/2,6

79,1

/5,4

105,5

/7,2

62,6

/4,3

38,3

/2,6

79,1

/5,4

105,5

/7,2

62,6

/4,3

38,3

/2,6

79,1

/5,4

105,5

/7,2

62,6

/4,3

38,3

/2,6

0 0 0 0 2- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

131 152 158 157

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,150 0,240 0,280 0,280 mm 3,81 6,10 7,11 7,11

In. 0,150 0,240 0,280 0,280 mm 3,81 6,10 7,11 7,11

IPM 100 50 28 20

MM/MIN 2540 2270 711 609

Notes:











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







Air Air


In.

0,250 0,375 0,500 0,625 mm 6,4 9,5 12,7

Timers









79,1

/5,4

69,3

/4,7

62

/4,2

37,8

/2,6

79,1

/5,4

69,3

/4,7

62

/4,2

37,8

/2,6

79,1

/5,4

69,3

/4,7

62

/4,2

37,8

/2,6

79,1

/5,4

69,3

/4,7

62

/4,2

37,8

/2,6

0 0 0 0 2- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

129 135 142 150

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,220 0,265 0,295 0,325 mm 5,59 6,73 7,49 8,26

In. 0,220 0,265 0,295 0,325 mm 5,59 6,73 7,49 8,26

IPM 80 60 35 25

MM/MIN 2030 1520 889 635

Notes:












Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!




Process Data


35 Initial / 70 Final Amperes

Stainless Steel

Shield Gas 1

Air

Shield Gas 2

CH4


Plasma Gas

Air

In.

0,125 0,187 0,250 0,375 0,500 mm 3,2 4,7 6,4 9,5 12,7

Timers

Pierce Delay (sec.) 0,2 0,3 0,4 0,5 0,6





Shield Gas





Initial Height

Pierce Height

Cutting Height

80,5

/5,5

111,1

/7,6

61,5

/4,2

40,3

/2,7

26,7

/1,8

80,5

/5,5

111,1

/7,6

61,5

/4,2

40,3

/2,7

26,7

/1,8

80,5

/5,5

111,1

/7,6

61,5

/4,2

40,3

/2,7

26,7

/1,8

80,5

/5,5

111,1

/7,6

61,5

/4,2

40,3

/2,7

26,7

/1,8

80,5

/5,5

111,1

/7,6

61,5

/4,2

40,3

/2,7

26,7

/1,8

131 146 154 166 175

In. 0,100 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54 2,54

In. 0,115 0,170 0,210 0,230 0,275 mm 2,92 4,32 5,33 5,84 6,99

In. 0,115 0,170 0,210 0,230 0,275 mm 2,92 4,32 5,33 5,84 6,99

IPM 120 80 50 30 24

MM/MIN 3048 2032 1270 762 609

Notes:












Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







Air Air CH4


In.

0,250 0,375 0,500 0,625 mm 6,4 9,5 12,7

Timers






Shield Gas





Initial Height

Pierce Height

Cutting Height

78,6

/5,3

96

/6,5

62

/4,2

40,8

/2,7

28,2

/1,9

78,6

/5,3

96

/6,5

62

/4,2

40,8

/2,7

28,2

/1,9

78,6

/5,3

96

/6,5

62

/4,2

40,8

/2,7

28,2

/1,9

78,6

/5,3

96

/6,5

62

/4,2

40,8

/2,7

28,2

/1,9

140 150 159 170

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,175 0,210 0,225 0,250 mm 4,54 5,33 5,72 6,35

In. 0,175 0,210 0,225 0,250 mm 4,54 5,33 5,72 6,35

IPM 80 60 35 25

MM/MIN 2030 1524 889 635

Notes:











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!




Process Data


25 Intial / 50 Final Amperes

Stainless Steel

Shield Gas 1

N2

Shield Gas 2


Plasma Gas

N2

In.

0,125 0,187 0,250 0,375 mm 3,2 4,7 6,4 9,5

Timers









78,5

/5,3

116,4

/7,9

42,4

/2,9

27,3

/1,9

78,5

/5,3

116,4

/7,9

42,4

/2,9

27,3

/1,9

78,5

/5,3

116,4

/7,9

42,4

/2,9

27,3

/1,9

78,5

/5,3

116,4

/7,9

42,4

/2,9

27,3

/1,9

0 0 0 0 2- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

128 135 144 155

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,05 0,09 0,130 mm 1,27 2,29 3,30 4,57

In. 0,05 0,09 0,130 mm 1,27 2,29 3,30 4,57

IPM 90 60 40 22

MM/MIN 2286 1524 1016 558

Notes:











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







N2 N2


In.

0,187 0,250 0,375 0,500 mm 4,7 6,4 9,5 12,7

Timers









81,1

/5,5

107,1

/7,3

61

/4,1

35,1

/2,4

81,1

/5,5

107,1

/7,3

61

/4,1

35,1

/2,4

81,1

/5,5

107,1

/7,3

61

/4,1

35,1

/2,4

81,1

/5,5

107,1

/7,3

61

/4,1

35,1

/2,4

0 0 0 0 2- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

132 150 154 159

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,120 0,190 0,170 0,220 mm 3,05 4,83 4,32 5,59

In. 0,120 0,190 0,170 0,220 mm 3,05 4,83 4,32 5,59

IPM 75 50 28 24

MM/MIN 1905 1270 711 609

Notes:











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







N2 N2


In.

0,250 0,375 0,500 0,625 mm 6,4 9,5 12,7

Timers









79,1

/5,4

93,1

/6,3

61

/4,1

27,9

/1,9

79,1

/5,4

93,1

/6,3

61

/4,1

27,9

/1,9

79,1

/5,4

93,1

/6,3

61

/4,1

27,9

/1,9

79,1

/5,4

93,1

/6,3

61

/4,1

27,9

/1,9

0 0 0 0 2- Cut - psi/bar


Initial Height

Pierce Height

Cutting Height

135 145 153 157

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,180 0,235 0,250 0,272 mm 4,57 5,97 6,35 6,91

In. 0,180 0,235 0,250 0,272 mm 4,57 5,97 6,35 6,91

IPM 80 60 35 25

MM/MIN 2032 1520 889 635

Notes:




Material: Thin Stainless Steel

Initial Amperes: 30A

With special nozzle P/N 21923SS

Final Amperes: 60A





With Special Nozzle for Stainless

Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923SS


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!



SECTION 4

Process Data

OPERATION


30 Amperes Initial

60 Amperes Final

Stainless Steel

Using Special Nozzle P/N 21923SS


Plasma Gas

N2

Shield Gas 1

N2

In.

0,030 0,039 0,059

Shield Gas 2 mm 0,75 1,0 1,5

Timers



0 0 0

0 0 0




Shield Gas


Initial Height psi/bar psi/bar




69

/4,75

73

/5,05

59

/4,05

73

/5,05

69

/4,75

73

/5,05

59

/4,05

73

/5,05

69

/4,75

73

/5,05

59

/4,05

73

/5,05

0 0 0

118 120 119

In. 0,100 0,100 0,100 mm 2,54 2,54 2,54

IPM 362 256 236

MM/MIN 9200 6500 6000

Notes:




Material: Thin Stainless Steel

Initial Amperes: 40A

With special nozzle P/N 21923SS

Final Amperes: 80A





With Special Nozzle for Stainless

Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923SS


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!



SECTION 4

Process Data

OPERATION

40 Amperes Initial

80 Amperes Final

Stainless Steel Precision Plasma Integrated Flow Control

Using Special Nozzle P/N 21923SS


Plasma Gas

N2

In.

0,078 0,118 mm 2,0 3,0

Shield Gas 1

N2

Shield Gas 2

Timers



0 0

0 0




Shield Gas





Initial Height

80

/5,52

79

/5,45

59

/4,05

73

/5,05

80

/5,52

79

/5,45

59

/4,05

73

/5,05

0 0

118 122

In. 0,100 0,100 mm 2,54 2,54

IPM 220 197

MM/MIN 5600 5000

Notes:






Final Amperes: 50 -- using 70A nozzle





PT-24 Torch with Integrated Flow Control

Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!




Process Data 25 Initial / 50 Final Amperes*



N2 N2 CH4


In.

22Ga 20Ga 18Ga 16Ga mm 0,7 0,9 1,2 1,6

Timers






Shield Gas





Initial Height

Pierce Height

Cutting Height

78,5

/5,3

93,1

/6,3

25,1

/1,7

27,3

/1,9

25,8

/1,7

78,5

/5,3

93,1

/6,3

25,1

/1,7

27,3

/1,9

25,8

/1,7

78,5

/5,3

93,1

/6,3

25,1

/1,7

27,3

/1,9

25,8

/1,7

78,5

/5,3

93,1

/6,3

25,1

/1,7

27,3

/1,9

25,8

/1,7

130 130 130 130

In. 0,06 0,06 0,06 0,100 mm 1,52 1,52 1,52 2,54

In. 0,100 0,100 0,130 0,100 mm 2,54 2,54 3,30 2,54

In. 0,100 0,100 0,130 0,100 mm 2,54 2,54 3,30 2,54

IPM 550 475 350 225

MM/MIN 13970 12065 8890 5081

Notes:


*50 Amp cutting using 70 Amp Nozzle (P/N 21543)











Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







N2 N2 CH4


In.

0,187 0,250 0,375 0,500 mm 4,7 6,4 9,5 12,7

Timers






Shield Gas





Initial Height

Pierce Height

Cutting Height

79,6

/5,4

93,6

/6,4

60,5

/4,1

37,6

/2,6

20,7

/1,4

79,6

/5,4

93,6

/6,4

60,5

/4,1

37,6

/2,6

20,7

/1,4

79,6

/5,4

93,6

/6,4

60,5

/4,1

37,6

/2,6

20,7

/1,4

79,6

/5,4

93,6

/6,4

60,5

/4,1

37,6

/2,6

20,7

/1,4

136 150 159 162

In. 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54

In. 0,154 0,225 0,240 0,232 mm 3,91 5,72 6,10 5,89

In. 0,154 0,225 0,240 0,232 mm 3,91 5,72 6,10 5,89

IPM 75 50 28 24

MM/MIN 1905 1270 711 609

Notes:












Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21692 (4 holes)

!

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!







N2 N2 CH4


In.

0,250 0,312 0,375 0,500 0,625 mm 6,4 7,9 9,5 12,7

Timers

Pierce Delay (sec.) 0,3 0,3 0,4 0,5 0,6





Shield Gas





Initial Height

Pierce Height

Cutting Height

79,6

/5,4

97,2

/6,6

60,5

/4,1

39,7

/2,7

22,7

/1,5

79,6

/5,4

97,2

/6,6

60,5

/4,1

39,7

/2,7

22,7

/1,5

79,6

/5,4

97,2

/6,6

60,5

/4,1

39,7

/2,7

22,7

/1,5

79,6

/5,4

97,2

/6,6

60,5

/4,1

39,7

/2,7

22,7

/1,5

79,6

/5,4

97,2

/6,6

60,5

/4,1

39,7

/2,7

22,7

/1,5

138 140 150 162 170

In. 0,100 0,100 0,100 0,100 0,100 mm 2,54 2,54 2,54 2,54 2,54

In. 0,138 0,165 0,190 0,252 0,290 mm 3,51 4,19 4,83 6,40 7,37

In. 0,138 0,165 0,190 0,252 0,290 mm 3,51 4,19 4,83 6,40 7,37

IPM 80 70 60 35 25

MM/MIN 2032 1778 1524 889 635

Notes:



0.140

0.120

0.100

0.080

0.060

0.040

0.020

0.000


4.4.3.1 Aluminum Kerf Values N

2

/N

2

/CH

4

1.575

Aluminum N

2

/N

2

/CH

4

30 Amperes

Material Thickness (mm)

1.905

2.286

3.175

4.750

6.350

0.140

3.556

4-60

0.120

0.100

0.080

0.060

0.040

0.020

0.000

1.270

0.050

0.062

0.075

0.090

0.125

Material Thickness (inches)

0.187

Aluminum N

2

/N

2

/CH

4

50 Amperes


1.575

3.175

4.775

6.350

0.250

1.524

0.060

0.062

1.270

0.050

1.270

0.050

1.651

0.065

1.524

0.060

2.032

0.080

1.651

0.065

0.125

0.188



3.048

2.210

0.087

2.540

2.032

1.524

1.016

0.508

0.000

2.362

0.093

0.250

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

0.190

0.170

0.150

0.130

0.110

0.090

0.070

0.050


4.750

Aluminum N

2

/N

2

/CH

4

70 Amperes


6.350

9.525

12.700

0.190

4.826

0.170

0.150

0.130

0.110

0.090

0.070

0.050

2.540

0.100

2.845

0.112

2.540

0.100

3.048

0.120

4.318

3.810

3.302

2.794

2.286

1.778

1.270

0.187

0.250

0.375


0.500

6.350

Aluminum N

2

/N

2

/CH

4

100 Amperes


9.525

12.700

15.875

2.540

0.100

2.667

0.105

2.921

0.115

3.302

0.130

4.826

4.318

3.810

3.302

2.794

2.286

1.778

1.270

0.250

0.375

0.500



0.625

4-61

0.140

0.120

0.100

0.080

0.060

0.040

0.020

0.000


4.4.3.2 Carbon Steel Kerf Values O

2

/N

2

/O

2

Carbon Steel O

2

/N

2

/O

2

16 Amperes


1.219

3.404

0.140

3.556

0.120

0.100

0.080

0.060

0.040

0.020

0.000

1.118

0.044

1.473

0.058

3.048

2.540

2.032

1.524

1.016

0.508

0.000

0.048

0.134


Carbon Steel O

2

/N

2

/O

2

35 Amperes


1.524

3.175

6.350

1.168

0.046

1.321

0.052

1.499

0.059

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

4-62

0.060

0.125



0.250

0.140

0.120

0.100

0.080

0.060

0.040

0.020

0.000


Carbon Steel O

2

/N

2

/O

2

45 Amperes


3.175

6.350

9.525

0.140

0.120

0.100

0.080

0.060

0.040

0.020

0.000

1.626

0.064

1.930

0.076

2.413

0.095

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

0.125

0.250


0.375

Carbon Steel O

2

/N

2

/O

2

70 Amperes


3.429

6.350

9.525

12.700

1.575

0.062

1.778

0.070

2.032

0.080

2.540

0.100

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

0.135

0.250

0.375



0.500

4-63


Carbon Steel O

2

/N

2

/O

2

100 Amperes


9.525

12.700

19.050

0.140

3.556

0.120

3.048

0.120

3.048

0.100

2.337

0.092

2.540

0.100

2.540

0.080

2.032

0.060

0.040

0.020

0.000

1.524

1.016

0.508

0.000

0.375

0.500


0.750

4-64


0.100

0.080

0.060

0.040

0.020

0.000


4.4.3.3 Stainless Steel Kerf Values O

2

/N

2

/O

2

0.457

Stainless Steel O

2

/N

2

/O

2

30 Amperes


0.584

0.726

1.207

1.588

0.140

3.556

0.120

3.048

0.889

0.035

0.889

0.035

0.889

0.035

0.889

0.035

1.143

0.045

2.540

2.032

1.524

1.016

0.508

0.000

26GA 24GA 22GA


18GA 16GA


4-65

0.190

0.170

0.150

0.130

0.110

0.090

0.070

0.050


4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4

Stainless Steel Air/Air/CH

4

70 Amperes


3.175

4.775

6.350

9.525

12.700

0.140

3.556

0.120

2.921

0.115

3.048

0.100

0.080

1.778

0.070

2.032

0.080

2.286

0.090

2.540

0.100

2.540

2.032

0.060

1.524

0.040

0.020

0.000

1.016

0.508

0.000

0.125

0.188

0.250


0.375

0.500

Stainless Steel Air/Air/CH


4

100 Amperes

6.350

9.525

12.700

15.875

2.286

0.090

2.540

0.100

3.048

0.120

3.556

0.140

4.826

4.318

3.810

3.302

2.794

2.286

1.778

1.270

4-66

0.250

0.375

0.500



0.625

0.190

0.170

0.150

0.130

0.110

0.090

0.070

0.050


4.4.3.5 Stainless Steel Kerf Values N

2

/N

2

/CH

4

Stainless Steel N

2

/N

2

/CH

4

70 Amperes


4.750

6.350

9.525

12.700

0.140

3.556

0.120

0.100

2.413

0.095

2.667

0.105

2.921

0.115

3.048

2.540

0.080

2.032

0.080

2.032

0.060

1.524

0.040

0.020

0.000

1.016

0.508

0.000

0.187

0.250

0.375


0.500

Stainless Steel N

2

/N

2

/CH

4

100 Amperes


6.350

9.525

12.700

15.875

2.540

0.100

2.794

0.110

3.302

0.130

3.810

0.150

4.826

4.318

3.810

3.302

2.794

2.286

1.778

1.270

0.250

0.375

0.500



0.625

4-67

0.140

0.120

0.100

0.080

0.060

0.040

0.020

0.000

0.100

0.080

0.060

0.040

0.020

0.000


4.4.3.6 Stainless Steel Kerf Values N

2

/N

2

3.175

Stainless Steel N

2

/N

2

50 Amperes


4.750

6.350

9.525

0.140

3.556

0.120

3.048

1.524

0.060

1.651

0.065

1.778

0.070

2.032

0.080

2.540

2.032

1.524

1.016

0.508

0.000

0.125

0.187

0.250


0.375

4.750

Stainless Steel N

2

/N

2

70 Amperes


6.350

9.525

12.700

1.778

0.070

2.286

0.090

2.286

0.090

2.540

0.100

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

4-68

0.187

0.250

0.375



0.500

0.190

0.170

0.150

0.130

0.110

0.090

0.070

0.050

0.150

0.130

0.110

0.090

0.070

0.050


6.350

Stainless Steel N

2

/N

2

100 Amperes


9.525

12.700

15.875

0.190

4.826

0.170

4.318

2.540

0.100

2.794

0.110

3.048

0.120

3.556

0.140

3.810

3.302

2.794

2.286

1.778

1.270

0.250

0.375

0.500


0.625

With 21923SS nozzle

0.762

1.016

Stainless Steel N2/N2 60/80A

Material Thickness (mm)

1.499

2.007

3.00

2.743

0.108

2.997

0.118

3.251

0.128

3.759

0.148

3.86

0.15

4.826

4.318

3.810

3.302

2.794

2.286

1.778

1.270

0.030

0.040

0.059

Material Thickness (inches)

0.079

0.12


4-69

0.140

0.120

0.100

0.080

0.060

0.040

0.020

0.000


4.4.3.7 Stainless Steel Kerf Values Air/Air

3.175

Stainless Steel Air/Air 50 Amperes


4.750

6.350

9.525

0.140

3.556

0.120

3.048

0.100

0.080

0.060

1.524

0.060

1.651

0.065

2.032

0.080

2.413

0.095

2.540

2.032

1.524

0.040

0.020

1.016

0.508

0.000

0.000

0.125

0.187

0.250


0.375

4.750



6.350

9.525

12.700

1.905

0.075

2.794

0.110

2.921

0.115

2.921

0.115

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

4-70

0.187

0.250

0.375



0.500


6.350



9.525

12.700

15.875

0.190

4.826

0.170

0.150

0.130

0.110

0.090

0.070

0.050

2.921

0.115

3.302

0.130

3.556

0.140

4.064

0.160

4.318

3.810

3.302

2.794

2.286

1.778

1.270

0.250

0.375

0.500


0.625


4-71


RECISION

LASMARC

PT-24

Plasma Marking

With Precision Plasma And IEFC-S

Material: Carbon and Stainless Steel

Amperes: 10

Plasma Gas (4 Solenoid) : Argon, Ar @ 83.2 PSI / 5,6 Bar

Plasma Gas (5 Solenoid) : Argon, Ar @ 85 PSI / 5,9 Bar


Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

!

Swirl Baffle

P/N 21536 (3 holes)

!

Nozzle

P/N 21541, "B"


P/N 22007


P/N 22010


O-Ring - Shield Retainer .

(Ref. P/N 996528)


P/N 22531

4-72

Precision Plasma with IEFC-S -

SECTION 4

Plasma Marking

Process Data

Precision Plasma IEFC-S

OPERATION

10 Amperes

Plasma Gas

Carbon and Stainless Steel

Shield Gas 1

Ar Air


Timers

0

Setup Parameters 4 Solenoid

Assembly

5 Solenoid

Assembly

Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar

Plasma Cut Gas 1- psi 83.2/5.6 bar 85/5,87 bar

SG1-Start -psi 132/9.0 bar

Shield Gas

SG1- Cut - psi 132/9.0 bar

Arc Voltage (standoff) 77

Initial Height .040" / 1 mm

Pierce Height .040" / 1 mm

Cutting Height .040" / 1 mm

132/9,1 bar

132/9,1 bar

Travel Speed

IPM 200

MM/MIN 5080

Notes:

· Pilot Arc –LOW.

· The IEFC-S manifold does not include a proportional valve for argon marking gas. This gas is externally regulated.

4-73



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 15




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21536 (3 holes)

Nozzle

P/N 21541, "B"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-74


SECTION 4

Plasma Marking

Process Data


OPERATION

15 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar


Initial Height .040" / 1 mm

Pierce Height .040" / 1 mm

Cutting Height .040" / 1 mm

132/9,1 bar

132/9,1 bar

Travel Speed

IPM 300

MM/MIN 7620

Notes:



4-75



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 10




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-76


SECTION 4

Plasma Marking

Process Data


OPERATION

10 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar


Initial Height 0.100" / 2.54 mm

Pierce Height 0.100" / 2.54 mm

Cutting Height 0.100" / 2.54 mm

132/9,1 bar

132/9,1 bar

Travel Speed

IPM 100

MM/MIN 2540

Notes:



4-77



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 15




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-78


SECTION 4

Plasma Marking

Process Data


OPERATION

15 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 200

MM/MIN 5080

Notes:



4-79



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 15




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21542, "C"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-80


SECTION 4

Plasma Marking

Process Data


OPERATION

15 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 300

MM/MIN 7620

Notes:



4-81



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 10




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-82


SECTION 4

Plasma Marking

Process Data


OPERATION

10 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 100

MM/MIN 2540

Notes:



4-83



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 20




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-84


SECTION 4

Plasma Marking

Process Data


OPERATION

20 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 200

MM/MIN 5080

Notes:



4-85



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 30




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-86


SECTION 4

Plasma Marking

Process Data


OPERATION

30 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 500

MM/MIN 12700

Notes:



4-87



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 10




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-88


SECTION 4

Plasma Marking

Process Data


OPERATION

10 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 100

MM/MIN 2540

Notes:



4-89



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 30




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-90


SECTION 4

Plasma Marking

Process Data


OPERATION

30 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 300

MM/MIN 7620

Notes:



4-91



RECISION

LASMARC

PT-24

Plasma Marking



Amperes: 30




Torch Body

P/N 21758

Water Baffle

P/N 21725

O-Ring

P/N 638797

O-Ring

P/N 86W62

O-Ring

P/N 950714

O-Ring

P/N 98W18

Electrode

P/N 21539

Swirl Baffle

P/N 21692 (4 holes)

Nozzle

P/N 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

4-92


SECTION 4

Plasma Marking

Process Data


OPERATION

30 Amperes

Plasma Gas


Shield Gas 1

Ar Air


Timers

0


Assembly

5 Solenoid

Assembly




Shield Gas

SG1- Cut - psi 132/9.0 bar





132/9,1 bar

132/9,1 bar

Travel Speed

IPM 500

MM/MIN 12700

Notes:



4-93


SECTION 4


OPERATION

4-94


SECTION 5

5.1 General

!

WARNING

Maintenance

If this equipment does not operate properly, stop work immediately and investigate the cause. Qualified personnel must perform maintenance work. Do NOT permit untrained persons to inspect, clean or repair equipment. Use only recommended replacement parts.


Before attempting any inspection or repair inside any of the components of the Precision Plasma, open wall disconnect or wall circuit breaker.

5.2 Inspection And Cleaning

Frequent inspection and cleaning of the Precision

Plasmarc® System is recommended for safety and proper operation. Consider the following during inspection and cleaning:

·

Check work cable to workpiece connection.

·

Check safety earth ground at workpiece and at power source chassis.

·

Check heat shield on torch. Replace if damaged.

·

Check torch electrode and cutting nozzle for wear daily.

Location of pump filter

·

Ensure cable and hoses are not damaged or kinked.

·

Ensure all plugs, fittings, and ground connections are tight.

·

Check screen filter in coolant pump located inside

Power Source periodically and flush as required.

PT-24 Precision Plasmarc System IEFC-S 5-1

SECTION 5

!

WARNING

Maintenance

Flying Debris Hazard.

Flying Debris Can Seriously Injure Eyes

Wear protective eyewear whenever cleaning with compressed air.

CAUTION

Avoid Potential Equipment Damage

Water and/or oil can accumulate in compressed air lines. Be sure to direct the first air blast away from equipment to avoid damaging the junction box or flow control box.

·

With all input power disconnected and with proper eye and face protection, blow out the inside of the power source, flow control, and junction box using low-pressure, clean/dry compressed air.

·

Occasionally, bleed all water from the filter below the air filter-regulator.

5.3 PT-24 Torch Description

1.812" (46 mm)

Diameter Collar

2.0" (51 mm)

Diameter Sleeve

Vent Hole

·

Mounting. The torch can be mounted by the 2

"

(51 mm) dia. sleeve or by the 1.812

"

(46 mm) dia machined surface shown. This insulated surface and its shoulder are machined relative to the nozzle retainer thread on the torch body. They are held concentric to the cutting nozzle within a total indicator reading of 0.010

"

(0.25 mm) or the nozzle bore is within 0.005

"

(0.13mm) of any point on the

1.812

"

dia. When mounting, do not to cover the small vent hole in the side of the sleeve. This hole prevents coolant from building inside the sleeve if a leak occurs.

5-2 PT-24 Precision Plasmarc System IEFC-S

SECTION 5

Check Valve

Proportional Valve

Pressure Switch

2 Way Solenoid Valve

Maintenance

IEFC-S Gas Console Fluid Schematic

·

Plasma Cut and Start Gas. These gases enter the torch through connections that house check valves within the torch body. The valves acting in conjunction with solenoid valves control the back and forth switching of start and cut gases.

ARGON IN NITROGEN IN

AIR IN

ARG0N

N2 2

AIR 2

OXYGEN IN

AIR 1

N2 PURGE

ORIFICE

N2 1

02 1

H-35 IN METHANE IN

O2 2 N2 3

H-35

METHANE

REMOVABLE PLUG

(SHOWN INSTALLED)

PS5

VENT

PS1

PROP. VALVE 1

VENT

PS3

PROP. VALVE 3

VENT

PS2

PROP. VALVE 2

VENT

PS4

PROP. VALVE 4

ARGON OUT

PLASMA GAS 1 OUT

SHIELD GAS 1 OUT

PLASMA GAS 2 OUT SHIELD GAS 2 OUT


SECTION 5

Coolant Out via

Pilot Arc Cable

Maintenance

Coolant In via

Power Cable

Crossover

Tube

·

Shield Gas. Shield preflow, cut shield and postflow enter the torch through one connection.

These gases pass through:

§ the torch body,

§ the shield gas diffuser,

§ out the orifice in the shield cap surrounding the plasma jet.

·

Power and Pilot Arc Lines. Coolant IN to the torch is through the power cable (-). Coolant OUT from the torch is through the pilot arc (+) line.

Water Cooling.

1. Coolant enters the torch through the power cable

(-),

2. circulates through the torch body and the electrode,

3. crosses over to the nozzle (+) section of the torch body through nonconductive crossover tubes,

4. travels back through the body and circulates between the nozzle retainer and the nozzle,

5. back through the torch body to the junction box via the pilot arc cable.

Electrode Body

Pilot Arc Body

Water Baffle

Nozzle Retainer

Swirl Baffle

Electrode

Nozzle


SECTION 5

5.4 Torch Maintenance

!

WARNING

O-ring

P/N 950714

O-ring

P/N 86W62

O-ring

P/N 638797

Maintenance

Electric Shock Can Kill

Before performing torch maintenance:

·

Turn power switch on the console to the OFF position.

·

Disconnect primary input power.

Torch Body O-Rings

·

Each day before starting operation, check O-rings on the torch body. Replace if damaged or worn.

·

Apply a thin coat of silicone grease to O-rings before assembling to torch. Do not use Krytox.

·

The O-ring, P/N 638797, inside the torch body that seals the nozzle is especially critical.

§

Damage or wear is not readily apparent because of its location,

§

We recommend replacing this O-ring on a daily basis.

§

Be careful not to scratch or damage the torch surface.

§

A wooden toothpick works well for removing Orings.

§

The O-ring can be replaced without removing the water baffle P/N 21725; however if the baffle is removed, always use a 3/16" (5 mm) hex wrench or nut driver.

Vent Hole

Torch Sleeve Vent

·

Water leaks, moisture or coolant dripping from the sleeve vent hole indicates service line damage.

·

If service lines must be replaced, always use two wrenches to avoid twisting the metal tubes.


SECTION 5

Sleeve

P/N 22568

CAUTION

Check Valve Body P/N 21739

Ball P/N 21740

Spring P/N 21741

Maintenance

Torch Sleeve

·

The torch sleeve P/N 22568 is threaded onto the torch body.

·

If the sleeve is too tight for hand removal, use a large adjustable wrench on the body flats or lightly tighten these flats in a vise. With the body secured, using two hands on the sleeve may break it free. If not, use a strap wrench.

Before replacing sleeve, always check service line connections for leaks.

Damaged Or Incorrect Torch Check Valve

Parts Will Affect Cutting Performance.

·

Do not damaged the check valve seat, ball and spring when handling.

·

Do not substitute any other spring or ball. If they are lost, dropped, or damaged, they must be replaced with factory replacement parts.

·

Using non-authorized or damaged torch check valve parts will affect set pressures and cause poor starting and piercing.

CAUTION

Improperly Seated Fittings Will Cause Leaks

And Poor Performance.

·

Keep threads and seat surfaces clean when reassembling check valves.

·

If dirt or foreign matter contaminates check valves, disassemble, clean or replace.


SECTION 5 Maintenance

5.5 PT-24 Consumable Disassembly And Inspection

!

WARNING

Hot Torch Will Burn!

·

Allow torch to cool before servicing.

·

Torch is water cooled, but may be hot immediately after use.

!

!

WARNING

WARNING


·

Turn power switch on the console OFF.

·

Disconnect primary input power.

·

If the nozzle retainer/diffuser is difficult to remove, the console may be on.

Pressurized Coolant Increase Shock And

Sight Hazard!

·

Cooling Water Is Under Pressure When

Console Is On!

·

Wear appropriate safety equipment.

·

Cooling water is pressurized to 115 PSI

·

(7.8 bar) when console is turned on.

·

Disassembly of torch front end while console is turned of may result in cooling water splashing. This will increase electric shock hazard. Splashing coolant water may cause possible eye hazards. If coolant gets eyes seek first aid immediately and consult coolant safety data sheet.


SECTION 5

PT-24 Front End

Maintenance

NOTE:

If the console is on, the pump will be running and coolant pressure behind the retainer will prevent it from turning freely. Check the console before attempting to remove the nut. Notice that a small amount of coolant is lost each time consumables are removed. This is normal and the coolant will eventually have to be replaced. Check coolant before each operation.

Shield Cup

Insulator

Insulator Shield

Retainer

Cup Shield w/Retainer

1. Unscrew the cup shield/retainer. Inspect around orifice for damage. Replace orifice edge if nicked or damaged. A distorted orifice will not produce straight cuts.

2. Unscrew and remove insulator shield

3. The shield cup insulator is sandwiched between the cup and the nozzle retainer/diffuser. It may remain attached to nozzle retainer because of the very close fit between these members.



Nozzle

Nozzle

Retainer

No damage to the contact area.

4. Unscrew the nozzle retainer/diffuser. Inspect for damage, especially where the retainer contacts the nozzle. The surface between the retainer and nozzle create a metal to metal seal for the coolant.

Any damage to this sealing surface will cause a leak resulting in poor cutting. Replace as necessary, but do not attempt to repair. Check small gas passages for blockages. Clear blockages with an air blast.

Nozzle

Electrode and Nozzle Tool P/N 21765

5. Use the tool provided to remove the nozzle. Place the slot around the nozzle groove and pull it free.



Nozzle

Removal Slot

.189" HEX for Cooling Water Tube

.284" HEX for Electrode

Electrode

Swirl Baffle

Nozzle

6. Remove the swirl baffle from the nozzle. If the baffle remains in the torch, it will come free when removing the electrode. Check the small gas passages of the swirl baffle for blockage and clear blockages with an air stream. If blockages cannot be cleared, replace baffle. Do NOT insert anything in these holes when trying to clear them. Distorting these holes will impair cutting performance.

7. Use the electrode and nozzle tool provided to unscrew the electrode. (P/N 21765).


SECTION 5

5.6 PT-24 Torch Tip Re-assembly

Maintenance

1. Electrode

Apply a thin film of silicone grease to the O-ring, just enough to produce a shiny surface. Thread electrode in place and tighten snugly with tool provided. DO

NOT OVER TIGHTEN.

Nozzle Retainer

Nozzle

Small Amount of Krytox

2. Nozzle & Swirl Baffle

Place swirl baffle into nozzle with the grooved end of the baffle going inside nozzle.

When properly assembled, the small spherical tip of nozzle makes a metal to metal coolant seal with the nozzle retainer. Apply a small amount of Krytox (antiseizing compound) on the small diameter of the nozzle retainer as shown. This grease prevents possible galling/seizing between the nozzle and retainer. It also facilitates a watertight seal. Do not put Krytox on nozzle.

3. Nozzle Retainer/Diffuser

Thread the nozzle retainer onto torch and hand tighten.

Water Seal



Shield Cup

Insulator

Nozzle Retainer

4. Shield Cup Insulator

Push the shield cup insulator on the nozzle retainer.

This component is a press fit and may remain assembled when the assembly was taken apart.

NOTICE

CAUTION

5. Insulator Shield Retainer

Apply a thin coat of silicone grease to the O-ring and thread insulator shield retainer on to Shield Cup.

Hand tighten.

Do Not Attach Insulator To The Torch Body

First.

Threading Insulator on to torch body first will not allow shield gases to flow properly. Thread insulator onto the Shield Cup first and then attach both pieces onto the torch body.

6. Shield Cup And Retainer

Screw this assembly (Insulator/Shield Cup and

Retainer) onto the torch and hand tighten.

O-Ring Inspection & Lubrication

·

Inspect O-rings often for nicks and wear. Worn or damaged O-rings will affect starting and cut quality.

·

Applying a thin coat of silicone grease to the torch tip O-rings during service assembly will facilitate future disassembly.

·

Do not use Krytox on O-rings. Krytox is an antiseize lubricant and will dissipate over time, making disassembly difficult.


SECTION 5

5.7 Flow Control

NOTICE

Chamber Vent

Maintenance

Nitrogen Is Vented Inside Integrated

Flow Control Box.

A small amount of nitrogen gas is vented internally to provide cooling, safety, and a slight positive pressure.

To prevent continuous building of pressure, the flow control chamber is externally vented.

!

CAUTION

Expansion Plugs

!

CAUTION

Do Not Remove Integrated Flow

Control Expansion Plugs

Expansion plugs are a necessary safety feature. In the unlikely event of a rapid expansion of gases inside the flow control, these holes will provide a predictable vent area.

Removing these plugs will allow dust and dirt to enter the flow control.

Do not use these holes for cable or hose entry. Use proper entry points.

Dirt And Dust Inside IEFC-S May

Damage Precision Components

Seal all undersized cables and unused holes in strain reliefs with foam tape

(weather stripping) to prevent unwanted dust entry inside the IEFC consoles.


SECTION 5

5.8 Proportional Valve Removal

Maintenance

Proportional Valves can be removed if replacement is required, without disassembling the manifold from gas console.

1. Access the outside bottom of the unit by unbolting the IEFC-S gas console from the machine.

2. Remove the hole plugs to expose cap screws holding the valves.


SECTION 6

6.1 General Safety

!

WARNING

!

!

WARNING

CAUTION

TROUBLESHOOTING


Externally disconnect all primary power to the machine before servicing.

Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside the power source.

High Voltages Can Be Stored In

Capacitors.

Even when power is disconnected or unit is de-energized, capacitors can store high voltages. Assure power supply capacitors are grounded prior to performing maintenance.

Gas Line Contamination Will

Damage Proportional Valves

Purge Gas Lines

Before connecting gas delivery lines to the

Integrated Flow Control, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your flow control.

PT-24 Precision Plasma System IEFC-S -CE

6-1

SECTION 6

6.2 Troubleshooting Guide

6.2.1 Reduced Consumable Life

TROUBLESHOOTING

Cutting Up Skeletons Cutting skeletons (discarded material left after all pieces have been removed from a plate) to facilitate their removal from the table can adversely affect electrode life by:

•

Causing the torch to run off the work.

•

Continuous Pilot Arc edge starts

•

Greatly increasing the frequency of starts. This is mainly a problem for O

2

cutting and can be alleviated by choosing a path with a minimum number of starts.

•

Increase likelihood that the plate will spring up against the nozzle causing a double arc. This can be mitigated by careful operator attention and by increasing standoff and reducing cutting speeds.

If possible, use a gas torch for skeleton cutting.

Height Control Problems •

Torch diving is usually caused by a change in arc voltage when an automatic height control is in use. Usually the voltage change is the result of plate falling away from the arc. These problems can effectively be eliminated by disabling the height control and extinguishing the arc earlier when finishing the cut on a falling plate.

•

Diving can also be caused by a faulty height control.

Piercing Standoff Too Low

Increase pierce standoff

Starting on edges with Position torch more carefully or start on adjacent continuous pilot arc scrap material.

The nozzle may be damaged if the torch hits a

Work Flipping flipped up part.

Catching on Pierce Spatter

Increase standoff or start with longer lead-in

Pierce not complete before starting

Increase initial delay time.

6-2


SECTION 6

6.2.2 Poor Cut Quality

TROUBLESHOOTING

See Cut Quality In Section 4

6.2.3 No Pilot Arc

Bad (open) Pilot Arc Cable

Replace Cable

Contaminated Electrode

Clean or replace electrode

Insufficient spark gap setting in plumbing box.

Set spark gap to 0.040”

Torch negative lead open No open circuit voltage

Replace contactor

6.2.4 No Arc Transfer

Pilot Arc Contactor (PAC) malfunctioning

Cutting current setting too low.

Torch too high

Raise cutting current (see Process Data)

Lower torch standoff (see Process Data) above workpiece

N

2

or O

2

Work lead not

check valve in torch body may be stuck open

Ensure work lead is firmly connected to workpiece connect to cutting table or cutting table

See maintenance section for check valve repair.

6.2.5 No Preflow

Emergency stop signal open

Check for continuity between TB3-18 and TB3-19

No Cooling Water

Check cooling water LED on front panel. Should be

Cooling Water Flow Switch lit if switch is open

Check reservoir. Add coolant until full.

6.2.6 Torch Fails To Fire

Start Gas

Lower start gas flow

Cooling water Flow

Pump pressure too low. Should be 115 psi.

Faulty cooling water flow switch

(CWFS)

Replace CWFS switch

Obstruction in torch limiting cooling water flow

Coolant flow through torch should be greater than

0.375 (3/8) gal/min


6-3

SECTION 6

6.2.7 Nozzle Life Extremely Short

TROUBLESHOOTING

Pilot Arc H/L switch in wrong position

Nozzle arcing inside bore

Refer to Process Data

Gas quality below purity specification

Start gas flow too low

Check Process Data cutting parameters

6.2.8 Short Electrode Life

Insufficient cooling

Check cooling pump for 115 psi output pressure

Start gas quality


Cut gas quality


6.2.9 Short Electrode And Nozzle Life

Water leak on torch front-end Follow torch leak procedure

Front-end of torch leaking

Dis-assemble torch front end down to the electrode

Visually inspect O-rings

Place a thin film of silicone grease on the O-rings before reassembling

Are

O-rings

good?

YES

NO

Visually inspect nozzle to retaining cup metal to metal seat.

Replace O-rings

Replace parts

NO

Is the seat good?

YES

Re-assemble torch

Apply a thin coat of Dupont

Krytox AntiSieze lubricant

73585064 2oz tube

73585065 8oz tube

Turn coolant flow and check for leaks

6-4

Still leaking?

NO

YES

Replace nozzle and/or nozzle retaining cup

Begin cutting


SECTION 6 TROUBLESHOOTING

6.3 Gas Console Fluid Schematic and Manifold Valve Identification

Air

1 ARGON

Schematic Legend

AIR 2 AIR 1

Ar

Check Valve

2

O2

Proportional Valve

N2-3

O2-2

N2-2

O2-1

N2-1

3 N2

Pressure Switch 50 psi rising

H-35

4

H-35 METHANE CH4

Solenoid Valve


6-5

SECTION 6

6.4 IEFC Gas Console Schematic

TROUBLESHOOTING

Part 1

6-6


SECTION 6

6.4 Part 2

IEFC Gas Console Schematic

TROUBLESHOOTING


6-7


6.5 Ignition Console Electrical Schematic

P1-B

120 VAC

P1-A

INPUT

TORCH POWER

AC LINE

FILTER

CORCOM

2VB3

STEP UP

TRANSFORMER

ESAB P/N 8951179

A

B

SPARK GAP

0.040

C1, C2 2500 pF

ESAB P/N

8674969

FILTER

PCB

X1 X2

REACTOR

X1

X3

X2

REACTOR

X3 REACTORS ARE

ESAB P/N 837250

TORCH (-)

PILOT ARC TO

TORCH

6.6 Ignition Console Fluid Schematic

Cooling

Water IN

Cooling

Water OUT


Torch

Connection

Pilot Arc

Connection

6-8


SECTION 6


TROUBLESHOOTING


6-9


6.7 Precision Plasma Power Source Electrical Schematic

Part 1

1

2

6-10

TB2

7

575V

6

460V

5

415V

4

380V

3

230V

2

200V

1

3

4

FNT

PNL

ON/OFF

2

1

H4

H3

H2

H1

H7

T3

H6

H5

ZD3

180VAC

A

5

K4

3

B

1

H7

H6

H5

H4

6 4

X13

X12

X11

X8

X7

X4

X3

X16

X15

X14

X6

X5

H3

H2

H1

T1

X10

X9

X2

X1

6

5

S1

ZD1,180V

4

5

6

7

8

9

10

1

2

3

4

11

12

J4

13

14

15

16

P4

2 1

FS1

(COOLING

WATER)

1

2

M1

ØC

120VAC

A

K1

B

L3 T3

MOV2

610V

575V

18

460V

17

415V

16

380V

15

230V

14

200V

13

5 MOV3

610V

ØB L2 T2

575V

460V

12

11

415V

10

380V

9

230V

8

200V

7

1

MOV1

CB1

3A

2

6

ØA

L1 T1 610V

575V

6

460V

5

415V

4

380V

3

230V

2

200V

1

TB1

J3

3

2

5

4

1

7

6

P3

8

18VAC

18VAC

18VAC

18VAC

24VAC

24VAC

24VAC

P10-5

P10-3

P10-4

P2-10

P2-9

P2-8

P2-16

P2-15

P2-14

P2-13

P2-12

P2-11

12VAC

120VAC

P2-5

P2-4

P2-2

P2-1

P3-1

P3-2

P1-3

P1-2

AH6

AH5

AH4

AH3

AH2

AH1

CH2

CH1

BH7

BH8

BH6

BH5

BH4

BH3

BH2

BH1

AH7

AH8

CH7 T2

CH8

CH6

CH5

CH4

CH3

AM1

AMMETER

LED1

LED2

PCB1

ISOLATION AMPLIFIER AND

FAULT SIGNAL PCB

38103

LED4 LED7

VOLTMETER

INPUTS

P7-1

P7-3

LED5 LED8

LED3

V1

VOLTMETER

PCB

TRIM POT

1 6

LED6 LED9

CURRENT

VOLTAGE

P1-12

P1-11

P1-18

P1-17

P5-1

P5-2

P4-14

P4-13

P4-12

P4-11

P10-1

P10-2

P4-16

P4-15

P4-4

P4-3

P3-18(-)

P3-17(+)

P9-3

P9-1

P1-14

P1-13

P3-13

P3-12

P1-15

P1-16

J2

1 2

NOT USED ON

3 4 5 6 7 8

TB2-2

TB2-1

BR1-A

BR1-B

BR1-C

P4-1

P4-2

P4-7

P4-8

P1

P2 J2

6

7

1

2

10

5

P1

7

9

1

2

J1

START

3

8

FAULT

5

6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MOD1

POWER MODULE #1

ARC ON

TB4-1

1

9

10

11

12

13

14

7

8

Next Page

15

16

17

18

20

21

23

24

25

26

27

28

29

4

5

2

3

6

LINE LOAD

T2-AH2

T2-BH2

T2-CH2

A

B

C

FOR CE UNITS

ONLY

A

B

C

BR1-A

BR1-B

BR1-C


4

5

2

3

6

SECTION 6

Part 2

1

TB4-2

7

8

TROUBLESHOOTING

Component Legend

1 T1 Transformer control, plasma interface

3

TB4

J3

P3

J4

P4

M2

PCB1

CB2

K4

ZD1

M1

CB1

FS1

ZD3

Terminal strip

Recepacle 10 pos

Plug 10 pos

Receptacle 16 pos

Plug 16 pos

Pump motor

P/c brd isolation ampl and fault signal

Circuit breaker 3 amp

Contactor 120vac

Zener diode 180v

Fan motor

Circuit breaker 7A

Flow switch

Zener diode 180v

4

S1

K1

Switch on/off

Contactor 70A @600V

5

6

TB1 Terminal brd

T2

J2

R2

ZD2

K2,3

C1,2

Auto transformer

Receptacle 19 pos

Potentiometer 10K

Zener diode 180v

Contactor 120VAC pilot arc and Hi/Low

Capacitor 20µf 400V

R1,7,8,9 Resistor 20 ohm 300w

R10 Resistor 3.1 ohm 300w

S3

PCB2

Switch spst

P/C brd start-up

MOD1 Power module #1

MOD1,P1 Plug 16 pin

MOD1,P3 Plug 10 pin

MOD1,P4 Plug 10 pin

F3

F4

R11

Fuse 1A

Fuse 15A Fast acting

Res 10K ohm 2w

20

25

26

27

28

29

21

22

24

13

14

15

16

17

18

9

10

11

12

L1

L2

ZD2

A

180VAC

K2

B

L3

120VAC

RELAY

T1

T2

T3

C2 R11

FRONT PNL LOCAL

CURRENT SETTING POT

MIN

1

R2

10K

2

3

MAX

R6

2W

R5

39K

TB6-5

TB6-4

TB6-2

3 1

2

1 2 3 4 5 6 7 8 9 10

P3

MOD1

POWER MODULE #1

6

5

4

3

2

1

10

9

8

7

P4

6 4

FRONT PNL

5 LOCAL/REMOTE

DPDT

S3

24 VDC

SH1-2

SH1-1

TB3-1

1

1A

F3 2

TB3

1

2

5

6

7

8

3

4

12

13

14

15

16

9

10

11

17

18

19

20

21

22

23

24

A.C.

NEUTRAL

J2 (19 POS)

N

M

S

T

START SIGNAL

CNC TO P.S., RELAY CLOSING

PILOT ARC (HI/LOW)

P

G

ARC ON SIGNAL

FROM P.S. TO CNC,

(TRANSISTOR)

L

J

C

H

U

V

E

F

A

B

K

D

R

+10VDC REMOTE CURRENT

SETTING FROM CNC TO P.S.

VOLTAGE DIVIDER, (+)

VOLTAGE DIVIDER, (-)

FAULT

EMERGENCY STOP

FROM CNC TO P.S. (N.C.)

FLOW SWITCH

COOLANT PUMP

PILOT ARC RELAY

120 VOLTS TO CNC I/O

CNC

ZD4

180VAC

L1

C1

20uf

400V

H2

H1

R14

R15

D1

20

OHM

50W

OHM

8W

20

OHM

50W

R12

OHM

8W

A

K3

B

L1 T1

L2

L3

T2

T3

R1

R7

20 OHM

300W

PILOT ARC

HI / LOW

CONTACTOR

P1-2

START

UP P1-1

R9

R8

P1-3

PCB2

38039

PA

P1-6


R10

3.1

OHM

300W

WORK

PILOT

ARC

TORCH

6-11


6.8 Precision Plasma Power Source Wiring Diagram - CE

Part 1

P1

5

6

7

8

9

10

11

12

13

14

1

2

3

4

15

16

17

18

P4-14(BRN)

P4-13(RED)

PCB1 P1-6(BLK)

PCB1 P1-5(BLK)

PCB1 P1-12(BLK)

PCB1 P1-11(BLK)

MOD1 P1-5 (BLK)

MOD1 P1-6 (RED)

MOD1 P1-2 (BLU)

MOD1 P1-1 (VIO)

PCB1 P1-18(BLK)

PCB1 P1-17(BLK)

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

P4-10(VIO)

P4-9(VIO)

P4-8(ORN)

P4-7(ORN)

P3-3(GRY)

P3-4(RED)

P3-5(GRY)

P4-4(BRN)

P4-3(BRN)

P4-2(BLU)

P4-1(BLU)

P3-1(YEL)

P3-2(YEL)

P2

PCB1

P3

5

6

7

8

9

10

11

1

2

3

4

12

13

14

15

16

17

18

P4-11(GRY)

P4-12(BLU)

MOD1 P1-3(ORN)

MOD1 P1-4(WHT)

PCB-TB P1-6(YEL)

MOD1 P1-7(BLU)

11

12

13

14

15

16

17

18

P4

3

4

5

6

1

2

PLC1 P1-1 (BRN)

PLC1 P1-2 (GRY)

MOD1 P3-1(RED)

MOD1 P3-2(YEL)

7

8

9

10

PLC1 P1-3 (YEL)

PLC1 P1-8 (ORN)

MOD1 P3-7(RED)

MOD1 P3-8(BLK)

MOD1 P3-9(VIO)

MOD1 P3-10(YEL)

MOD1 P3-3(BLU)

MOD1 P3-4(ORN)

1

2

P5

PLC1 P1-5 (BLK)

PLC1 P1-6 (VIO)

1

2

3

P7

P2-5(BLK)

TB6-5(RED)

S3-1 (BRN)

2

1 3

S3-4 (BLU)

VIEW OF R2

MOD1 P1-9 (ORN)

MOD1 P1-7(BLU)

R2-3(BLU)

R2-2(BRN)

PCB1 P10-2(RED)

TB6-7(ORN)

4 5 6

1 2 3

PCB1 P10-1(VIO)

TB6-8(GRY)

S3

R2

1

2

3

SEE

VIEW

OF R2

1 P1 18

5

4

P5

1

P10

1

4

P9

1

16

PCB1

P2

1

18

P3 3

1

P7

18

P4

1

1

K1-L2 (BLU)

F4-1 (YEL)

S1

R2

L1

H2

H1

S3- 4 BLU

S3 -1- BRN

MOD1 P1 - 9 ORN

S2-5 (BLK)

K2-L3(BLU)

*

M1-GND (GRN)

GND1

1

2

3

P9

MOD1 P1-14(RED)

MOD1 P1-15(BLK)

1

2

3

4

5

P10

S3-5(VIO)

S3-2(RED)

P3-7(BLK)

P3-6(WHT)

P3-8(WHT)

K

L

M

G

H

J

T

U

V

N

P

R

S

A

B

C

D

E

F

J2

TB3-20 (BLU)

TB3-21 (GRY)

TB3-13 (ORN)

TB3-23 (BLK)

TB3-18 (VIO)

TB3-19 (YEL)

TB3-4 (WHT)

TB3-14 (BRN)

TB3-12 (VIO)

TB3-22 (WHT)

TB3-11 (RED)

TB3-2 (GRY)

TB3-1 (BRN)

TB3-5 (BLK)

TB3-24 (RED)

TB3-3 (ORN)

TB3-4 (WHT)

TB3-15 (VIO

TB3-16 (BLK)

*

12

F4

1

2

CB1

J2

1

M1 GND

2

CB1-1 (WHT)

*

NC

FS1 C

NO

RED

BLK

ORN

*

*

*

J4-14(BRN)

J4-13(RED)

6-12



Wiring Diagram – Precision Plasma Power Source -CE

Part 2

ZD3

A

2

4

6

K4

1

3

5

B

T1

TOP

X7 X8

BR1-A

BR1-B

LINE LOAD

A A

B B

T2-AH2

T2-BH2

BR1-C C C T2-CH2

Detail for CE units only

MOD1

BR1

A

MOV B

MOV C

MOV

T2-AH2

T2-BH2

T2-CH2

K4

T1

SEE

DETAIL

M2

SEE DETAIL

MOD1 BR1-A

T3

SEE T3

DETAIL

MOD1 BR1-B

MOD1 BR1-C

J4-11(GRY)

AH2

BH2

CH2

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

TB2

SEE

DETAIL

K1

L1 L2

ZD1

A

T1 T2

TB1

MOV1

MOV3

BLK

BLK

BLK

L3

B

T3

MOV2

J4-12(BLU)

T2

GRN

M2 3

6

1

2

4

SPLICE

K4-3(RED)

WHT (INTERNAL)

RED (INTERNAL)

K4-4 (WHT)

BRN (INTERNAL)

SPLICE

TB2-4 (YEL)

TB2-5 (BRN)

TB2-6 (ORN)

TB2-7 (VIO)

H4

H5

H6

H7

T3

H1

H2

H3

K4-6 (RED)

S1-6 (RED)

T1-H1 (RED)

TB2-2 (BLK)

TB2-3 (GRY)

T1-H3 (GRY)


F4-2(BLU)

T3-H2(BLK)

T3-H3(GRY)

CB2-1(RED)

T3-H4(YEL)

T3-H5(BRN)

T3-H6(ORN)

T3-H7(VIO)

TB2

1

4

5

6

2

3

7

BLK

6-13


Wiring Diagram – Precision Plasma Power Source -CE

Part 3

MOD1 SH1-2(BLK)

MOD1 TB3-1(BLK)

TB5

PA

WORK

TORCH

PCB2-PA(YEL)

K2-T1 (YEL)

PLC1 J2-5(RED)

PCB2 P1-1 (RED)

PCB2 P1-6 (BLK)

VIEW F-F

TB5-PA(YEL)

PCB2 - P1

P1-1

P1-2

P1-3

P1-6

TB5-WORK(RED)

TB3-14 (BRN)

TB3-13(ORN)

TB5-TORCH(BLK)

PCB2

VIEW E-E

4

5

6

7

8

9

10

1

2

3

J1

TB3-1 (BRN)

TB3-2 (GRY)

TB3-15 (VIO)

Not Used

TB3-5 (BLK)

TB3-6 (VIO)

TB3-20 (BLU)

TB3-16 (BLK))

TB3-21 (GRY)

Not Used

PLC1 MODULE

1

J2

TB3-24 (RED)

2

3

4

5

TB4-2 (WHT)

Not Used

Not Used

TB5-WORK(RED)

6

7

10

11

12

13

14

15

16

8

9

TB4-1 (BLK)

TB4-2 (WHT)

Not Used

Not Used

TB3-23 (BLK)

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

E

R10

1

BLU

BLU

2

2 2

2

2

BLU

BLU

1

R9

1

R8

1

BLU

R7

1

R1

F

TB5

PCB2

F

E

3 A

2 L

1 B

3

T 2

1

K3

J1

J2

TB4

PLC1 P2-6 (BLK)

TB3-22 (WHT)

1 2

TB4

PLC1 J2-7 (WHT)

K3-B(WHT)

GND

PLC1 J2-2 (WHT)

T2

6-14



Wiring Diagram – Precision Plasma Power Source - CE

Part 4

CB1-2(GRY)

M1-1(BLK)

S1-6(RED)

MOD1

TB2

2

1

MOD1

P4

8

9

10

5

6

7

3

4

1

2

TB3-11(RED)

TB3-12(VIO)

F3-1(RED)

TB3-19 (YEL)

TB3-18 (VIO)

5

6

3

4

7

8

1

2

J3

T1-X5(YEL)

T1-X6(YEL)

T1-X14(GRY)

T1-X15(BLK)

T1-X16(GRY)

T1-X11(WHT)

T1-X12(RED)

T1-X13(WHT)

6

7

8

4

5

9

10

11

1

2

3

12

13

14

15

16

J4

T1-X8 (BLU)

T1-X7 (BLU)

T1-X4 (BRN)

T1-X3 (BRN)

K4-A (BLK)

K4-B (WHT)

T1-X10 (ORN)

T1-X9 (ORN)

T1-X2 (VIO)

T1-X1 (VIO)

K1-A (GRY)

K1-B (BLU)

J4-14 (BLK)

J4-13 (BLK)

FS1-2 (RED)

FS1-1 (RED)

SEE DETAIL

TB2

MOD1

MOD1 P4-7 (RED) 1

TB4

F3

2 TB3-15 (RED)

TB3

1

10

P4

PA

WORK

TORCH

8

J3 1

16

1

J4

20

21

22

23

24

14

15

16

17

18

19

9

10

11

12

13

6

7

8

1

2

3

4

5

TB3

PLC J1-1 (BRN)

J2-N (BRN)

PLC1 J1-2 (GRY)

J2-M (GRY)

J2-S (ORN)

K3-A (ORN)

J2-T (WHT)

K3-B (WHT)

J2-P (BLK) & PLC1 J1-5 (BLK)

& TB3-20 (BLK)

J2-G (VIO)

MOD1 P4-5(RED)

J2-L(RED)

MOD1 P4-6(VIO)

J2-J(VIO)

PCB2 P1-2 (ORN)

J2-C (ORN)

PCB2 P1-3 (BRN)

J2-H (BRN)

J2-U (VIO) & PLC1 J1-3 (VIO)

PLC1 J1-8 (BLK) & J2-V (BLK)

F3-2 (RED)

MOD1 P4-10 (VIO)

J2-E (VIO)

MOD1 P4-9 (YEL)

J2-F (YEL)

PLC1 J1-7 (BLU)

J2-A (BLU) & TB3-5 (BLK)

PLC1 J1-9 (GRY)

J2-B(GRY)

TB4-1 (WHT)

J2-K (WHT)

PLC1 J2-10 (BLK)

J2-D(BLK)

PLC1 J2-1 (RED)

J2-R (RED)

REAR VIEW

WITH REAR PANEL

REMOVED


6-15


Wiring Diagram – Precision Plasma Power Source - CE

Part 5

MOD1

P2

Note: PLC1 (connection) or PLC MOD refers to a location that housed the former Programmable

Logic Controller. This plasma power supply is CNC

(cutting machine) controlled and does not use a

PLC.

3

4

5

6

7

1

2

P1

PCB1 P4-3(RED)

PCB1 P4-4(YEL)

PCB1 P4-15(BLU)

PCB1 P4-16(ORN)

PCB1 P1-13 (BLK)

PCB1 P1-14 (RED)

PCB1 P3-18 (BLU)

S3-4 (BLU)

PCB-TP P1-1 (YEL)

R2-3 (ORN)

11

12

13

14

15

16

8

9

10

PCB1 P9-1 (RED)

PCB1 P9-3 (BLK)

3

4

1

2

7

8

5

6

NOT USED

6

7

8

9

10

11

12

13

14

15

16

3

4

5

1

2

P3

PCB1 P4-3 (RED)

PCB1 P4-4 (YEL)

PCB1 P4-15 (BLU)

PCB1 P4-16 (ORN)

TB6-6 (BRN)

TB6-8 (GRY)

PCB1 P4-11 (RED)

PCB1 P4-12 (BLK)

PCB1 P4-13 (VIO)

PCB1 P4-14 (YEL)

1

2

SH1

R10-1 (GRY)

TB5-WORK(BLK)

PCB1 P7-3(RED)

MOD1-TB3-1 (RED)

TB6 1 2 3 4 5 6 7 8

R3

R4

R5

R6

MOD1 P3-6(GRY)

S3-6(GRY)

S3-3(ORN)

MOD1 P3-5(BRN)

6-16

1

4

5

6

7

2

3

8

9

10

PLC1 MODULE

P1

PCB1 P4-1 (BRN)

PCB1 P4-2 (GRY)

PCB1 P4-7 (YEL)

1

2

P2

P4-10 (VIO)

P4-9 (VIO)

K2-A (VIO)

PCB1 P5-1 (BLK)

PCB1 P5-2 (VIO)

P4-15 (RED)

PCB1 P4-8 (ORN)

P4-16 (BRN)

4

3

5

6

7

8

9

PCB1 P7-1(BLK)

P4-5 (BLK)

P4-6 (WHT)

K2-B(RED)

13

14

15

16

10

11

12

P1

8

6 1

PCB-TP

MOD1 WHT

T1 T2 T3

K2

ZD2

P1

1

1

WHT

16

TB6 1 2 3 4 5 6 7 8

P2

1

16

PLC MOD

SEE DETAIL

P3

1

K2-L3 (BLU)

K3-L3 (BLU)

10

C1

TB6-2(RED)

TB5-TORCH(BLK)

R15-2 (RED)

P3

1

1

P4

1

2

1

2

C2

SH1

K2-T1(YEL)

K2-T3(WHT)

1

D1

R14-1 (GRY)

1

TB3

8

P2

8

16

MOD1 TB3-1 (RED) 2

R15

1

2

R14

1

D1(-) GRY

FRONT VIEW

WITH FRONT

PANEL REMOVED


1

2

3

4

5

6

7

8

P3

PCB1 P2-15(YEL)

PCB1 P2-16(YEL)

PCB1 P2-8(GRY)

PCB1 P2-9(RED)

PCB1 P2-10(GRY)

PCB1 P10-4(WHT)

PCB1 P10-3(BLK)

PCB1 P10-5(WHT)

1

2

3

4

P4

PCB1 P2-14 (BLU)

PCB1 P2-13 (BLU)

PCB1 P2-12 (BRN)

PCB1 P2-11 (BRN)

5

6

7

8

9

PCB1 P2-6 (BLK)

PCB1 P2-7 (WHT)

P2-9 (BLK)

PCB1 P2-5 (ORN)

PCB1 P2-4 (ORN)

10

PCB1 P2-2 (VIO)

P2-5 (BLK)

PLC1 P2-2 (VIO)

PCB1 P2-1 (VIO)

PLC1 P2-1 (VIO)

11 PCB1 P3-1 (GRY)

12 PCB1 P3-2 (BLU)

13 PCB1 P1-3 (RED)

14 PCB1 P1-2 (BRN)

15 PCB1 P1-7 (RED)

16 PCB1 P1-9 (BRN)

SECTION 6

Page Intentionally left blank.

TROUBLESHOOTING


6-17


6.9 Power Module Schematic - CE Version

Part 1

J2

1 2 3 4 5 6 7 8

ØA

ØB

ØC

FN1

T1

TB2-2

H3

M1

N2

FN5

N1

TB2-1 H1

A

MOV2 MOV3

275V

275V

B

MOV1

275V

C

X2

X1

X4

X3

X6

X5

X12

X11

X10

X9

X8

X7

12V

P5-3

P1-10

18V

P1-9

P1-6

12V

P5-4

P1-5

P2-14

120V

P2-11

P1-4

20V

P1-3

P2-4

24V

P2-1

+

A ~

B ~

C ~

G

SCR1

25

R1

50W

FN3

(+)

R2

FN2

BR1

-

C1

.22

uf

1KV

C2

1uf

630V

L1

H1 H2

C3

1uf

630V

C4

3300uf

450V

(-)

1.5K

100W

C5

3300uf

450V

PCB1

PLASMA PROCESS

CONTROL BOARD

(+)

PCB2

E2

G2

E2

Q1

E1

G1

C2E1

C6

1uf

600V

C1

(-)

1

2

3

6-18


SECTION 6

Power Module Schematic

Page 2

TROUBLESHOOTING

J1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

C16 C17

.022uf

250VAC

.022uf

250VAC

1 2 3 4 5 6 7 8 9 10

J3

PCB1

PLASMA PROCESS

CONTROL BOARD

1

2

3

PCB3

E2

G2

E2

Q2

E1

G1

C2E1

C1

C7

1uf

600V

C9

C8

40uf

400WVDC

R3

40uf

400WVDC

10K 2W

R4 R5

20

50W

20

50W

C11

.033uf

1KWVDC

X2

CUR

XFMR X1

T2

H1

T3

X1

H2 X2

R6

20OHM

25W

C12

.01uf

630V

C14

.01uf

630V

R8

20OHM

25W

(-)

D1

~

~

D2

(+)

L3

FN4

.047uf

660V

R7

20OHM

25W

C13

.01uf

630V

(-)

(+)

SHUNT

SH1

C15

.01uf

630V

R9

20OHM

25W

L2

OUTPUT INDUCTOR

TB3-1

2

FEEDBACK

1

(-)

(+)

10

9

8

7

6

5

4

3

2

1

J4


6-19


6.10 Power Module Wiring Diagram – CE Version

PAGE 1

6-20


SECTION 6

Power Module Wiring – CE Version

PAGE 2

TROUBLESHOOTING


6-21

SECTION 6

6.11 Torch Manifold

TROUBLESHOOTING

Wire

Numbers

6

5

4

3

2

1

9

7

Plasma 2

Plasma 1

Shield 2

Shield 1

Shield 1 & Shield 2 Common

Plasma 1 & Plasma 2 Common

Argon Common

Argon

6-22


SECTION 7

7.1 General

7.2 Ordering

REPLACEMENT PARTS

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your

ESAB Distributor or from:

ESAB Cutting Systems G

MB

H

Robert-Bosch-Strasse 20

Postfach 1128

D-61184 Karben 1

Phone 011-49-6039-400

Fax 011-49-6039-403-02

http://www.esab.de

ESAB Welding and Cutting Products

ATTN: Customer Service Department

PO Box 100545 Ebenezer Road

Florence, SC USA 29501-0545

Phone (843) 664-4405

(800) ESAB-123 (372-3123)

ESAB Cutting Systems - Canada

6010 Tomken Road

Mississauga, Ontario, Canada L5T 1X9

Phone (905) 670-0220

Fax (905) 670-4879

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the last page of this manual for a list of customer service phone numbers.


7-1

SECTION 7 REPLACEMENT PARTS

7.3 Plasmarc Power Source-Exterior Components

4

3

2

1

5

6

7-2


SECTION 7

Item

Number

1

Part Number

35925YL

2 995227

5

6

3

4

2091514

35924YL

61328087

13734588


Elec. Symbol

Cover-Top

Description

Label Warning-Exposed High Volt

Label Warning

Panel, Side

Screw, HMH ¼-20 X .50 L

Logo ESAB Clear


7-3

SECTION 7

6

5

4


3

2

1

7

9

10

8

See

"TEE"

Detail

Page 7-12

7-4


SECTION 7

Item

Number

1

2

7

8

9

10

3

4

5

6

Part Number

672508

951061

954928

951061

634518

2062018

32286GY

See Below

952182

36346GY

NOTICE


Symbol

(Elec-Ay)

S1

AM1,VM1

AM1,VM1

S2,3

R2

Description

Switch Toggle 2PST 2 Pos 15A

Meter LED 5VDC

Overlay, Control Panel CNC

Meter LED 5VDC

Switch Toggle DPDT 2 Pos 15A

Pot LIN 10.0K 2.00W 0.63L 1 turn

Panel Front

Gauge 200 PSI

Spout Remote Filler w/Cap

BRKT, Remote Filler

Refer to Console Serial Number to determine which gauge to order. Gauges require different hole sizes in front panel and are not interchangeable.

• Console with serial number in PxxJ348xx format require gauge P/N 0558004488

• All others use P/N 598481

P/N 598481 P/N 0558004488


7-5


1

10

11

13

9

12

8

CE

6

2

5

4

3

7

7-6


SECTION 7

Item

Number

1

Part Number

35928GY

952209 2

3 97W63

8

9

10

11

6

7

4

5

12

13

23610197

950874

952137

32202GY

58V75

954599

950829

950937

13730763

954565


Symbol

(Elec-Ay)

Door Access Rear

Description

F4

J2

CB2

CB1

Conn Box Recpt 19 FS SH

3 Strain Relief

Plug Hole .875 Dia. .125 CT Nyl BK

Circuit Breaker 7 AMP

Fuse 7A 500 VAC Fast Acting

Panel Rear

Adaptor B/A-W F ¼ NPTM BKHD

Label Rating Precision Plasma

Circuit Breaker 3 AMP

Strain Relief

Plate, Serial

Label “CE” logo (CE version only)


7-7


7.4 Plasmarc Power Source-Internal Components

15

16

18

17

5

4

7

6

9

8

3

2

10

7-8

12 13

11


14

1

SECTION 7

Item

Number

1

Part Number

35920GY

950487 2

3 9639533

15

16

17

18

11

12

13

14

7

8

9

10

5

6

4

35682

952179

952013

71200732

952095

951061

38103

38103

950096

952053

952034

952030

952032

952205

37345GY

673458

951209

17300020

17300931

37355GY

952012


Symbol

(Elec-Ay)

Description

Base, Precision Plasma

R10

T2

TB4

PCB1

PCB1 P9,7

PCB1 P10

PCB1 P1,3,4

PCB1 P2

PCB1 P5

K2,K3

PCB2

R1,7,8,9

AM1,VM1

PCB1

Term Block 2 pos

Bushing, Snap .88 I.D. X 1.09 MH X .45 L

PCB Isolation AMP

Housing Contact, Crimp 3 pin

Standoff #6-32 X .88 L

Plug 5 Pos

Plug 18 Pos

Plug 16 Pos

Receptacle P/C 4 Pos

Panel, Control

Contactor, 3P 40A 110VAC

Board, PC Startup

Resistor 300W 20ohm 10%

Resistor 300W 3.1 OHM 10%

Bracket, Resistor Pilot Arc

Caster Fixed

XFMR Auto

Tank, Water

Caster Swivel

Adhesive, SIRBR Clr

Spacer, LED

Meter, LED 5VDC

PCB Isolation AMP


7-9

SECTION 7

16


4 3

7-10

8

9

1

17

5

6 10

7

7

13

11

14


15

2

12

1

SECTION 7

Item

Number

1

2

15

16

17

11

12

13

14

7

8

9

10

3

4

5

6

Part Number

952026

673502

672002GY

2062334

36417GY

951215

951347

13735308

0558002158

33550

37805

32203GY

182W82

10Z30

950179

37359

37360

951346


Symbol

(Elec-Ay)

TB2

K1

Description

Terminal Block

Contactor 3 Pole 75A

T3

MOD1

MOD1(CE)

K4

M1

M2

Shroud, Fan

Motor, Fan

Shroud, Fan

Motor, Carb 1/3 Hp

Pump, Carb w/Strainer

Relay Enclose DPDT 120VAC 20A

Kit, Wire Primary

Bracket, Motor

Auto XFMR

Bracket, Auto XFMR

Elbow 90 DEG. ¼ NPT

Adaptor, B/A-W M ¼ NPTM

Tee, Pipe Branch ¼ Brs

Module, Power

Module, Power – CE Version

Pump Motor Fan (8.75)


7-11

SECTION 7

8 6


15 5

9

7-12

7 1

10

11 2 12

2

3

10 3

12

4

13

14

15

44" Long

“TEE” Detail

16 X5


SECTION 7

Item

Number

1

Part Number

36538

950001 2

3 21124

12

13

14

15

16

8

9

10

11

6

7

4

5

36539

90858009

36418

36423

90858007

90858009

10Z30

182W82

58V75

952182

952181

952179

994471


Symbol

(Elec-Ay)

Description

Hose, Assy Pump Outlet- Torch out

FS1 Switch, Flow .25 GPM SPSTB

Valve, Check Assy

Hose, Assy Flowswitch To Core

TBG, Nylobrade 3/8 I.D X .625 O.D.

Hose Assy Tank Bottom- Pump Inlet

Hose Assembly Out to Gauge

Tubing, Braided .625 Dia

TBG, Nylobrade 3/8 I.D X .625 O.D.

Adaptor, B/A-W M ¼ NPTM

Elbow 90 Deg. ¼ NPT

Adaptor, B/A-W F ¼ NPTM BKHD

Spout, Remote Filler w/Cap

Tee, Plastic Pipe

Tank, Water

Clamp, Hose W/D .50 Dia X 1.06 SS


7-13


10 6

5

4

7-14

7

7

9

8


2

3

1

SECTION 7

Item

Number

1

Part Number

13735961

8

9

6

7

4

5

2

3

10

950823

950167

995103

35919

2017483

92W57

639533

35930GY

2234891


Symbol

(Elec-Ay)

Heat Exchanger

Description

Bushing, Snap

TB3

TB5

F3

MOD1 P4

Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W

Terminal Block 24 POS 15A

Board, Terminal Output

Holder, Fuse

Grommet, Rub .63 I.D. X .88 O.D. X .06 W

Bushing, Snap .88 I.D. X 1.09 MH X .45 L

BRKT, Heat Exchanger

Plug, 10 Pos


7-15

SECTION 7

13

9

8

7

10

7-16

11


6

5

4

3

2

1

12


SECTION 7

Item

Number

1

Part Number

950823

17750020 2

3 36527GY

9

10

11

12

13

8

6

7

4

5

951161

673458

2234521

2234877

2234891

2234518

2234520

2234521

2234519

2234519

2214521

635686

647065

38193

R11,12

C1,2

K2,3

P4,MOD1

P1,PLC1 P2

PLC1 J1

MOD1 P3, 4,

PLC1 P1

J3

P3

P1,PLC1 P2

J4, PLC1 J2

J4, PLC1 J2

P1,PLC1 P2

TB6

L1

PCB-TP


Symbol

(Elec-Ay)

Bushing, Snap

Description

Res 20 ohm 50W

Cover, Terminal Board

Cap, Metpoly 20uf 400VDC

Contactor, Pilot Arc 3P 40A

Plug, 16 Pos

Plug, 10 Pos

Receptacle, 10 Pos

Receptacle, 8 Pos

Plug, 8 Pos

Plug, 16 Pos

Receptacle, 16 Pos

Receptacle, 16 Pos

Plug, 16 Pos

Terminal Strip, 8 Pos

Choke Signal #Ch12

Printed Circuit Board Trim Pot


7-17

SECTION 7

7.5 Power Source Power Module


4

3

2

5

6

7

1

7-18


SECTION 7

Item

Number

1

Part Number

35914GY

7

5

6

2

3

4

37102

35918

951339

951340

37101GY

951981

35700

35701


Symbol

(Elec-Ay)

Description

Base Power Module

Bracket, PCB KYDEX

PCB1 P1, 5

PCB1 P2, 6

L1

L1

Wire Kit, Power Module

Plug, Female 12 Position

Plug, Female 14 Position

Deck, Power Module

Heat Sink

Inductor, Power Factor



7-19

SECTION 7

9

CE only

3

4

10

CE only

6


A

2

A

1

5

7-20

7

Section A-A


8

SECTION 7

Item

Number

1

Part Number

2234877

8

9

6

7

4

5

2

3

10

951182

950487

950823

35700

17280215

35680

35681

952160

952612


Symbol

(Elec-Ay)

J3,4

Description

Block Terminal 10 Position

M1 Fan, Axial

L2

T3

FN5

FN1

TB2

L1

R2

Terminal Strip 2 Position

Bushing, Snap


Resistor 1.5K OHM 100W

Inductor Assembly Output

Transformer Assembly, Main

Filter Inductor, Single Phase – CE Version only

Filter EM1 – CE Version only


7-21


3

4

5

6

2

1

7

7-22


SECTION 7

Item

Number

1

Part Number

2234518

6

7

4

5

2

3

38047

2234519

35917GY

951981

2234877

674156


Symbol

(Elec-Ay)

J2

Description

Block Terminal, 8 Position

SH1 Shunt, Feedback

J1

J3, 4

TB3


Baffle Heatsink

Heatsink


Adaptor


7-23

18

19

20

19

15

16

17

SECTION 7

14


10

13

12 11

C

10

2 9 9

8

7

6

5

28 CE units only

4

3

2

1

21

22 21 23 24

21 25

26

27

7-24


SECTION 7

Item

Number

1

11

12

13

14

15

16

17

6

7

8

9

10

3

4

5

2

22

23

24

25

26

27

28

18

19

20

21

29

Part Number

35940

951978

952611

951192

951833

35794

951979

951196

951980

17750020

951194

647345

17250005

951940

951983

35793

950823

35792

35844

951191

951980

35799

35918

639533

17721020

951185

647345

36873

952255

36872

32958

950711

35799

37141

952157

38052


Symbol

(Elec-Ay)

T1

R4,5

R1

C6,7

C4,5

Q1,2

BR1

SCR1

Q1,2

R6,7,8,9

D1,2

C8,9

T2

TS1,2

C1

C3

FN2,3

PCB2,3

Description

Transformer Control

Bridge Diode 3PH 130A

Bridge Diode 3 PH

Pad Thermal Bridge

Pad Termal IGBT 1200V

Busbar Input Bridge

SCR 90A

Pad Thermal SCR Module

IGBT 300A 600V

Resistor 20OHM 50W NI

Pad Thermal Power Resistor 50W

Bushing Snap 1.31 I.D. X 1.5 MH .44 L

Resistor 5OHM 50W

Capacitor 1uf 600VDC

Capacitor 3300 uf

Busbar IGBT (-)/Capacitor

Bushing Snap .687

Busbar IGBT (+)/Capacitor

Nomex Insulator

Pad Thermal IGBT 1200V

IGBT 300A 600V

Wire Kit Module

Busbar Shunt

Bushing Snap .875 I.D. X 1.093 MH

Resistor 20 OHM 25W NI

Module Diode 100A 600V

Bushing Snap 1.31 I.D. X 1.5 MH .44 L

Busbar Capacitor/IGBT

Capacitor Film 40uf 400VDC

Busbar Capacitor

Transformer, Current

Switch Thermal 194 Deg. F.

Wire Kit

Wire Kit

Filter - CE Version only

IGBT Driver


7-25


7.6 IEFC-S Gas Console Replacement Parts

7-26

2

1

VALVE 1

PLASMA 1

3

AIR2 AIR 1

VALVE 2

PLASMA 2

3

ARGON

O2-2 O2-1

VALVE 3

SHIELD 1

3

N2-3 N2-2

VALVE 4

SHIELD 2

3

1 P3 10 1 P4-A 12 1

H-35 METHANE

P4-B 12

N2-1

K2 K2-

3 4 5


SECTION 7

IEFC-S Gas Console P/N 0558003641

Item

Number

Part Number


Symbol

(Elec-Ay)

Description

1 0558002074 IIEFC-S Manifold Assembly without Proportional

Valves

2 2237924

ASIOB Control System Motherboard

0002256475

3

2237927

ASIOB Relay Output Card

4

5

2237927*

ASIOB Analog Output Card “C”

ASIOB Analog Output Card “D”

*Note: Item 5, 1 of 2 Analog Cards, “D”, is a modified ASIOB Analog Output Card


7-27


7.7 IEFC-S Gas Console Manifold Assembly w/o prop. valves - P/N 0558002074

1

10

9

8

2

ARGON

AIR 2 AIR 1

O2-2

O2-1

7 PS1

Bottom View

PS2

11

PS5

PS3

N2-3 N2-2

H-35

N2-1

METHANE

12

P4

A

12

P4

B

1

1

6

6

5

4

3

4

PS4

1

P

3

10


SECTION 7

Item

Number

1

2

3

P a r t N u m b e r

0558002074

952921

10Z30

4

5

6

7

8

9

10

11

74S76

3389

3390

952920

0558002070

0558002071

0558002254

0560943967

Q u a n t i t y

1

1

2

1

10

1

2

1

1

2

4


D e s c r i p t i o n

Manifold Assembly without Proportional Valves

Valve, Solenoid 2-way, Man Mt. O2. S2 24/60 1/8 Or.

Pipe Ftg Brass, Adptr ¼ MNPT X Male 5/8 –11 Hose

Pipe Ftg Brass, Adptr ¼ FNPT X Female 5/8 –11 Hose

Pipe Ftg Brass, Adptr ¼ MNPT X 9/16-18 Male Hose

Pipe Ftg Brass, Adptr ¼ MNPT X 9/16 LH Male Hose

Switch, Pressure, 50PSI Non Adj, N.O. Wire Leads

Valve, Prop., Analog 0-9 Bar 0-10v M.Mt 4-20MA N2

Valve, Prop., Analog 0-9 Bar 0-10v M.Mt 4-20MA O2

Valve, Prop., Analog 0-6 Bar 0-10v M.Mt 4-20MA H2

Switch, Pressure, 75PSI Non Adj, N.O. Wire Leads



7.8 IEFC-S Ignition Console Replacement Parts

X2

X1

2

X3

TORCH

PILOT

ARC

1

A

A

7-30

PLASMA 1 SHIELD 1

ARGON PLASMA 2 SHIELD 2

SECTION A-A


SECTION 7

Item

Number

1

Part Number

674969

2 37401


Symbol

(Elec-Ay)

Description

PCB Special Function Filter

Electrode, Spark Gap w/Solder Lug


7-31


7.9 PT-24 Torch Assembly IFC Series P/N 0558002396

6

4

3

11

12

13

20

7

8

9

10

Shield 1 IN Orange

Shield 1 OUT Orange

Shield 2 IN Black

Plasma 2 IN Yellow

Plasma 2 OUT Yellow

Argon IN Red

Plasma 1 OUT Blue

5

Plasma 1 IN Blue

18

14

19

2

15

.284" HEX for Electrode

7-32

21

22

23

.189" HEX for Cooling Water Tube


1

3/8 - 24

L.H. (Ref)

5/8 - 18

L.H. (Ref)

Not

Shown

17 Silcone Lubricant

24 Krytox AntiSeize

25 Torch Start -Up Kit

26 Torch Spare Parts Kit

25

26

21

22

23

24

13

14

15

17

18

19

20

6

7

8

9

2

3

4

5

10

11

12

SECTION 7

Item

Number

1

Part Number

21758

22568

22381

22380

22382

See Process Data

See Process Data

22007

22010

21712

21539

22531

0558002340

22375

21765

77500101

2234133

996565

0558002510

0558002511

0558002512

21739

21740

21741

73585064

73585065

37609

56996213

21536, 21539

21541, 21542

21543, 21692

21693, 21725

21765, 21923

22007, 22

010

22531, 86W62

638797, 950714


Symbol

(Elec-Ay)

Description

Body & Tube Assembly PT-24 Torch

Sleeve, Torch PT-24

Gas Line Start Blue

Gas Line Cut Yellow

Gas Line Shield Orange/Red

Swirl Baffle (See Process Data)

Nozzle (see Process Data)

Retainer/Diffuser

Insulator Shield Cup

Insulator Shield Retainer

Electrode 250 AMP

Cup Shield w/Retainer

Torch Ar Gas Manifold PT24 IFC

Protector Gortiflex Sensor 7LG

Tool Electrode & Nozzle

LUB Grease DOW DC-111 (NOT Shown)

Clamp, Worm Drive

Clamp, Hose

PT-24 Cable Bundle Assembly 4.5 Ft.

PT-24 Cable Bundle Assembly 12 Ft.

PT-24 Cable Bundle Assembly 17 Ft.

Check Valve Body

Ball

Spring

Dupont Krytox 2 oz tube

Dupont Krytox 8 oz tube

PT-24 Start-up Kit (Quantity of each)

Nozzle “A”(2); Nozzle “B”(2); Nozzle “C”(2); Nozzle

“D”(2); Nozzle “E”(2); Swirl Baffle 15A(1); Swirl Baffle

30A(1); Swirl Baffle 50/70A(1); Lubricant(1); Electrode and Nozzle Tool(1); Shield Insulator Cup(1); O-ring

1.239 x 0.07(1); O-ring 0.614 X 0.07(1), O-ring 1.498

X 0.07(1); Electrode(5)

Torch Spare Parts Kit (Quantity of each)

Swirl Baffle(2), Oxy Electrode(5)

Nozzle “B”(5), Nozzle “C”(5)

Nozzle “D”(5), Swirl Baffle 50/70A(2)

Retainer Shield Cup(1), Water Baffle(1)

Electrode and Nozzle Tool(1), Nozzle “E”(3)

Retainer diffuser Nozzle(1), Shield Insulator Cup(3)

Shield(6), O-ring 1.239 x 0.07(3)

O-ring 0.614 X 0.07(3), O-ring 1.498 X 0.07(3)


7-33

SECTION 7

7.10 Torch Ar Gas Manifold PT24 IFC


7-34

3

2

Plasma 2

Plasma 1

Shield 2

Shield 1

Shield 1 & Shield 2 Common

Plasma 1 & Plasma 2 Common

Argon Common

Argon

1


SECTION 7

Item

Number

1

Part Number

0558001502

2

3

952921

593985


Symbol

(Elec-Ay)

Description

Flange

2 Way Solenoid Valves

O-Ring


7-35

SECTION 7

7.11 PT-24 IFC Interface Cables


11

10

20

9

8

7

12

6

5

4

3

1

2

7-36

CH

4

N

2

O

2

Ar Air


SECTION 7

Item

Number

1

Part Number

Reference

2

3

4

5

Reference

Reference

Reference

Reference

21905

22504

21906

22505

21907

0560987423

0560987424

0560987425

0560987426

REPLACEMENT PARTS

Gas Supply Lines

Main Power Cable

120 VAC/24 VDC Cable

Description

Process ASIOB Cable

Height Control ASIOB Cable (comes from a junction with process ASIOB cable inside the flow control

7,6m (25 ft.) Power Bundle

12,2, (40 ft.) Power Bundle




6,1m (20 ft.) Power supply I/O cable

9,1 (30 ft.) Power supply I/O cable



10

11

0558002510

0558002511

0558002512

0558002502

0558002503

0558002504

21761

22424

0558002505

21762

22425

0558002509

0558002506

0558002507

0558002508

Reference

4.5 ft. Torch Bundle (5 Hose)

12 ft. Torch Bundle (5 Hose)

20 ft. Torch Bundle (5 Hose)

Note: Torch Bundle includes items below

4.5 ft. (1.2 m) Gas Tube Assembly (5 hoses)

12 ft. (3.7 m) Gas Tube Assembly (5 hoses)

20 ft. (6.1 m) Gas Tube Assembly (5 hoses)

4.5 ft. (1.2 m) Power Cable

12 ft. (3.7 m) Power Cable

20 ft. (6.1 m) Power Cable

4.5 ft. (1.2 m) Pilot Arc Cable

12 ft. (3.7 m) Pilot Arc Cable

20 ft. (6.1 m) Pilot Arc Cable

4.5 ft. (1.2 m) Solenoid Cable

12 ft. (3.7 m) Solenoid Cable

20 ft. (6.1 m) Solenoid Cable

Height Control I/O Cable

0558003643

0558003644

6m Remote Interconnecting Bundle

9m Remote Interconnecting Bundle

PT-24 Precision Plasma System IEFC-S 7-37

SECTION 7

Notes:

7-38



revision history

1. Revision of 02/2005 - updated process data page for 16 amps , carbon steel. New data for shield gas, arc voltage, travel speed.

2. Revision of 10/2005 -

Section 2 - Added Split IEFC Control System p/n 0558003639 package reference.

Section 6 - Updated IEFC Gas console schematics at section 6.4.

Section 7 - Changed IEFC-S Gas Console P/N 0558003641, item 3 p/n from: 56996230 to: 0002256475.

Customer // Technical Support

(843) 664-4405

(800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road

Florence, SC 29501-0545 http://www.esab.com

ESAB Cutting Systems – Canada

6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9

Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB Cutting Systems G MB H

Robert-Bosch-Strasse 20

Postfach 1128

D-61184 Karben 1

Phone 011-49-6039-400

Fax 011-49-6039-403-02 http://www.esab.de

Printed in U.S.A

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