ESAB Precision PLASMARC® Cutting and High Speed Marking System with Integrated Flow Control Installation manual

F-15-652

November, 2003

Installation, Operation and Maintenance Manual for the

Precision PLASMARC



Cutting and High Speed Marking SYSTEM with Integrated Flow Control

411 s. Ebenezer Road

Florence, SC 29501-0545

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

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

Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold by 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 F15-652

Rev A indicates new IFC Schematic, installation instructions (p13-14) and fluid schematic mod.

December: Updated Torch solenoid wiring, updated parts section

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, 2001

Printed in U.S.A.

Precision Plasma Integrated Flow Control - CE Table of Contents

Page

Section 1 Safety

1.1 Introduction ........................................................................................

1

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

1

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

2

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

3

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

4

1.6 Operating A Plasma Cutting Machine ..................................................

4-9

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

9

1.8 Safety References ...............................................................................

10

Section 2 Description

2.1 General...............................................................................................

1

2.2 Scope.................................................................................................

1

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

1

2.4 Technical Specifications

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

2

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

3

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

3

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

3

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

3

2.4.5 PT-24 Torch ...............................................................................

4

Section 3 Installation

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 Interconnecting Lines ..........................................................................

5-10

3.8 Precision Plasmarc Component Interconnecting Diagram ....................

7

3.9 Torch Mounting...................................................................................

11

3.10 Torch Coolant ....................................................................................

12

3.11 Inspection Of Gas And Coolant Lines..................................................

12

3.12 Using the 5 Solenoid Torch Manifold..................................................

13

3.13 Adapting to use a 4 Solenoid Torch Manifold .....................................

14 i


Page

Section 4 Operation

4.1 Power Supply Controls

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

1

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

1

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

2

4.1.4 Meters........................................................................................

2

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

2

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

4.2.1 Introduction ................................................................................

3

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

3

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

4

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

5

4.2.5 Dross .........................................................................................

6-7

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

8

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction ................................................................................

9

4.3.2 Aluminum ...................................................................................

9

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

10

4.3.4 Stainless Steel ............................................................................

11

4.4 Process Data

4.4.1 Introduction ................................................................................

13

4.4.2 Process Data Settings.................................................................

14-55

Aluminum ............................................................................

14-21

Carbon Steel........................................................................

22-31

Stainless Steel .....................................................................

32-55

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

56

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

56

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

58

4.4.3.3 Stainless Steel Kerf Values O

2

/N

2

/O

2

...................................

61

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4

................................

62

4.4.3.5 Stainless Steel Kerf Values N

2

/N

2

/CH

4

.................................

63

4.4.3.6 Stainless Steel Kerf Values N

2

/N

2

........................................

64

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

66

Plasma Marking Data ..........................................................

68 ii


Page

Section 5 Maintenance

5.1 General...............................................................................................

1

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

1

5.3 PT-24 Torch Description .....................................................................

2-4

5.4 IFC 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 ..................................................................

10-11

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

12

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

13

Section 6 Troubleshooting

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

1

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

1

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

2

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

2

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 IFC Fluid Schematic ............................................................................

5

IFC Manifold Valve Identification...................................................

5

6.4 IFC Electrical Schematic......................................................................

6-7

6.5 Precision Plasma Power Source Electrical Schematic...........................

8-9

6.6 Precision Plasma Power Source Wiring Diagram (includes CE Version) 10-14

6.7 Power Module Schematic – CE Version ...............................................

15

6.8 Precision Plasma Power Module Wiring Diagram – CE Version .............

16-17

6.9 Torch Manifold ....................................................................................

18 iii


Page

Section 7 Replacement Parts

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 IFC .....................................................................................................

26-27

7.7 IFC Manifold .......................................................................................

28-29

7.8 PT-24 Torch Assembly IFC Series with Marking..................................

30-31

7.9 Torch Manifold with marking ...............................................................

32-33

7.10 Interface Cables and Hoses ..............................................................

34-35

Customer/Technical Information Back Manual Cover iv

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.

Precision Plasma with Integrated Flow Control -

1-1

SECTION 1

1.2 Safety Notations And Symbols

!

!

!

DANGER

WARNING

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.

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

!

WARNING

!

WARNING

SAFETY

Machine starts automatically.

This equipment moves in various directions and speeds.

·

Moving machinery can crush.

·

Only qualified personnel should operate or service equipment.

·

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

·

Keep gear racks and rails clear of debris or obstructions, such as tools or clothing.

·

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

·

Post appropriate WARNING signs at every work cell entrance.

·

Follow lockout procedure before servicing.

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

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

·

Read entire procedure before operating or performing any system maintenance.

·

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

·

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

·

Read all safety publications made available by your company.


1-3

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.

Poor Performance Will Result When

Cutting Above Water.

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

Cutting above water may result in:

· reduced consumable life

· degradation of cut quality

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

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


1-9

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

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.

1-12


SECTION 1

International

Accident Prevention

SAFETY

VBG 1 General Provisions

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working methods

VBG 48 Shot Blasting Works

VBG 61

VBG 62

Gases

Oxygen

VBG 87 Operating liquid jet cutting machines

VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE Regulations

VDE 0100 Erection of power installations with normal voltages up to 1000 volts

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users guide (DIN EN 60825)

VDE 0837-

50

Specification for laser guards

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-206 Acetylene cylinder battery systems

TRG Technical Rules for Pressure gases

TRG 100 General regulations for pressure gases

TRG 101 Pressure gases

TRG 102 Technical gas mixtures

TRG 104 Pressure gases; alterative use of compressed gas tanks


1-13

SECTION 1 SAFETY

DIN Standards

DIN 2310

Part 1

DIN 2310

Part 2

DIN 2310

Part 4

DIN 2310

Part 5

DIN 4844

Part 1

Thermal cutting; terminology and nomenclature

Thermal cutting; determination of quality of cut faces

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

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

Safety markings (DIN EN 7287)

DIN EN ISO Harmonized Standards

DIN EN

292/1 and 2

Safety of machinery

DIN EN 559 Hoses for welding, cutting and allied processes

DIN EN 560 Hose connections and hose couplings for equipment for welding, cutting and allied processes

DIN EN 561 Gas welding equipment hose couplings

DIN EN

626-1

DIN EN

848-1

DIN EN

1829

DIN EN

9013

DIN EN

12584

DIN EN

12626

DIN EN

28206

DIN EN

31252

DIN EN

31553

DIN EN

60204-1

DIN EN

60825

Safety of machines, reduction of risks to health

Single spindle vertical milling machines

High pressure water jet machines

Thermal cutting, oxygen cutting, process principles, dimensional tolerances

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

Laser processing machines

Acceptance testing for oxygen cutting machines

Laser Equipment

Laser and laser related equipment

Electrical equipment of machines

Radiation safety of laser products

VDI Guidelines

DIN EN 999 Arrangement of protection devices

VDI 2906 Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting

VDI 2084 Room air; Technical systems for welding workshops

1-14


SECTION 2 DESCRIPTION

2.1 General The PT-24 Precision Plasmarc Integrated Flow

Control System provides programmable gas switching and pressure control. The IFC is the next generation electronic flow control combining junction and flow control box components for:

a reduced combined footprint,

fewer parts,

improved reliability,

and improved high speed marking option.

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

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

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

2.3 Package Options Available

Precision Plasmarc® Integrated Flow Control package options available through your ESAB dealer

Precision Plasmarc® Power Source (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

Integrated Flow Control Box P/N 0558002069

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)

P/N 0558002337

P/N 0558002338

P/N 0558002339

P/N 22428

Power Bundle (one required)

Control Lead, CNC to Power Supply (one required)

25 ft. (7.6 m)

40 ft. (12.2 m)

60 ft. (18 m)

80 ft. (24.4 m)

100 ft. (30 m)

10 ft. (3 m)

20 ft. (6.1 m)

30 ft. (9 m)

P/N 21905

P/N 22504

P/N 21906

P/N 22505

P/N 21907

P/N 0560987422

P/N 0560987423

P/N 0560987424

60 ft. (18 m)

100 ft. (30 m)

P/N 0560987425

P/N 0560987426

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

NOTES:

•

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

•

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

•

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


2-1

SECTION 2

2.4 Precision Plasma Technical Specifications

2.4.1 System

DESCRIPTION

Input Voltage

Input Current

Power Factor

Output Current Range

Output Load Voltage

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

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

0.95

15-100 amps dc

120 V dc

Duty Cycle 100%

Open Circuit Voltage

42" (1067mm)

Power Supply

CONTROL

CURRENT

RECISION PLASMARC

POWER

22" (559mm)

WEIGHT = 560 lbs. (254 kg)

315 V dc

44" (1118mm)

PT-24 Torch and Torch Bundle

20 " (50.8 mm)

Integrated Flow Control

7.5 " (19.0 mm)

14.5 " (36.8 mm)

WEIGHT = 59 lbs. (130 kg)

2-2


SECTION 2

2.4.2 Plasma Gas Technical Specifications

DESCRIPTION

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

2.4.3 Start Gas Technical Specifications

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

Flow

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

150 psig (10.4 bar) N

2

, O

2

, Air

60 cfh (28 l/min) max

(varies with application)

Minimum Purity Required N

2

, O

2

, CH

4

- 99.995% Air –Clean, Dry

2.4.5 Cut Gas Technical Specifications

Type N

2

, O

2

, Air

Pressure

Flow

150 psig (10.4 bar) N

2

, O

2

60 cfh (28 l/min) max

(varies with application)

, Air

Minimum Purity Required 99.995% N

2

, 99.8% O

2 and Air


2-3

SECTION 2

2.4.5 Pt-24 Torch Technical Specifications

Type

Rating

Dimensions

DESCRIPTION

Water-Cooled, Dual Gas

100 amps @ 100 % duty cycle

See Package Options (2.3)

2-4


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

Flow Control (gas flowing).

·

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

·

Primary Input Cable.

·

25 micron gas filters (P/N 56998133) are required on the supply side for the IFC 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 .

Precision Plasma with Integrated Flow Control -

3-1

3-2

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


SECTION 3

Ground Connection

TB2

200

230

380

415

460

575

TB1

200

230

380

415

460

575

200

230

380

415

460

575

200

230

380

415

460

575

K1

Factory Wired for 575 volts

!

CAUTION

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.

Input Power Cable

(Customer supplied)

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

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.

Main

Contactor

7 Position

Terminal Block

Auto

Transformer

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

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

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

Input Power Jumper Connection

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

Factory wired for 575 V .

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

TB2

3-3



3.5 Alternate Connection Locations For IFC

I/O Strain Relief

Alternate

I/O

Torch

There are two locations for the I/O 24v input and for the torch. This provides flexibility while mounting the box to a machine.

NOTE:

When changing over to an alternate connection location, be sure to replace hole covers to keep the box sealed.

Plug unused I/O strain relief holes to seal box.

Alternate torch

3.6 IFC Basic Component Identification And Connection Points (Cover Removed)

Process Gas

Connections

Pilot Arc

Connection

Torch Power

Connection

Power/Pilot Arc Strain Relief

Proportional Valves

Solenoid Valves

Process ASIOB

Voltage

Selector

Switch

Torch Bundle

Strain Relief

Torch Solenoid Connection (not seen)

Torch Cooling Water Return/Pilot Arc Cable

Cooling Water to Torch/Power Cable

3-4


Process Control I/O

Strain Relief

SECTION 3

3.7 Interconnecting Lines

Torch Bundle

INSTALLATION

Cooling water return/Pilot arc cable

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

Gas lines

Cooling water to torch

Cables /Hoses enter here

Solenoid

Cable

2. Connect lines in torch bundle IFC Box. Lines and connections are labeled and/or color coded.

Connections, top to bottom:

Shield 2 =black

Shield 1 = orange

Plasma 2 = yellow

Plasma 1 = blue

Argon = red


3-5

SECTION 3

Power supply and IFC connections

INSTALLATION

Power Supply Bundle

Coolant IN

Coolant Out

Pilot Arc

Connection

3. Connect power and coolant lines in Power

Supply Bundle from power source to IFC box.

Power bundle consists of #6 and # 7 coolant lines (with 5/8-18 L.H. fittings), power cable (#3

AWG) and yellow pilot arc cable (#16 AWG).

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

Power Supply

Negative

Connection

Power Supply

Strain Relief

IFC Voltage

Selector

Switch

Voltage Selector Switch is preset for IFC input voltage of 115 V / 60 Hz applications. An alternate setting accommodates 230 V / 50 Hz IFC input voltage.

3-6



3.8

Precision Plasmarc® Component Interconnecting Diagram

8

9

10

11

20

7

6

12

5

3

4

13

14

15

17

16

2

18

1

19

CH

4

N

2

O

2

1 wall disconnect (cust. sup.)

2 primary power cable

3 precision plasma power source

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

Ar Air

11 height control ASIOB enclosure

12 integrated flow control box

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

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


3-7

SECTION 3

!

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

4. Purge gas lines between supply and the IFC 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.

3-8



Gas connections and

I/O Strain Relief

1/4 NPT

25 micron Gas Filter

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

25 µ Filters

CH

4

H-35 N

2

O

2

Ar Air

CAUTION

Proportional And Check Valves Are

Sensitive To Dirt And Debris.

Thoroughly purge the gas delivery system with

N

2

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

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


3-9

SECTION 3

Pilot Arc

Work

Torch

INSTALLATION

Remove Access Cover

P

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

Power Source

7 Amp 500

VAC Fuse

Rating

Label

Serial

Tag

Flow Control

Lead

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

Coolant In from IFC (return from torch)

Coolant Out to IFC (deliver to torch)

8. Connect coolant lines of the power bundle to power supply and IFC

3-10


SECTION 3

3.9 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


3-11

SECTION 3

3.10 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.

3.11 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

3-12



3.12 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 IFC is shipped configured to use the 5 solenoid torch manifold.

NOTICE Marking with the PT-24 torch and the IFC 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.

3.13 Converting Integrated Flow Control Manifold to Accommodate a 4 Solenoid Torch

Manifold

4

3

2

1

The Integrated Flow Control manifold is setup to accommodate a 5 solenoid torch. Some modification is required to permit marking with the

IFC and a 4 solenoid torch.

Ar

Flow Control Manifold

1 Argon inlet connection

2 Argon Solenoid

3 Marking Conversion Access 1/8 NPT

4 Air / Argon manifold outlet


3-13


B

Procedure to modify IFC 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 IFC 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

3-14


SECTION 4 OPERATION

4.1 Power Supply Controls

4.1.1 Main Power Switch

EMERGENCY

STOP

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.


4-1


4.1.3 Fault Indicator Lights

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

·

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

·

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

4-2



4.1.5 Current Control Switch

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.


4-3


4.2 Cut Quality

4.2.1 Introduction

NOTICE

Causes affecting cut quality are interdependent.

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

§

4.2.2 Cut Angle, negative or positive

§

4.2.3 Cut not flat, rounded or undercut

§

4.2.4 Surface roughness

§ 4.2.5 Dross

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

·

Make small incremental adjustments when making corrections.

·

Adjust Arc Voltage in 5 volt increments, up or down as required.

·

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

Before attempting ANY corrections, check cutting

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

Data.

4-4



4.2.2 Cut Angle

Part

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

Drop 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).

4-5



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

Top Edge Undercut

·

Standoff low (Arc Voltage)

4-6

Drop Part



4.2.4 Surface Finish

Process Induced Roughness

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

·

Incorrect Shield Gas mixture (See Process Data)

Top View

·


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


4-7


4.2.5 Dross

Cut Face

Lag

Lines

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

4-8



Side View

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


4-9


4.2.6 Dimensional Accuracy

Generally using the slowest possible speed

(within approved levels) will optimize part accuracy. Select consumables to allow a lower arc voltage and slower cutting speed.

NOTICE Recommended cutting speed and arc voltage will give optimal cutting performance in most cases.

Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings.

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

4-10



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 .062" to .625" (1,6 mm to 15,9 mm)

Cut Qualities:

· Smooth cut face

· Virtually no dross

Plasma Gas: Nitrogen

Shield Gas: Nitrogen/Methane

Discussion:

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


4-11


NOTICE

Refer to Cutting Process Data in the PT24

Manual for recommended flow/pressure settings.

4.3.3 Carbon Steel

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

Cut Qualities:

·

Smooth cut face

· Virtually no dross

Plasma Gas: Oxygen

Shield Gas: Oxygen/Nitrogen

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.

4-12



NOTICE

Refer to Cutting Process Data in the PT24

Manual for recommended flow/pressure settings.

4.3.4 Stainless Steel


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.


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


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.


4-13


NOTICE

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

Stainless Steel


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.


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.


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.

4-14



4.4 Process Data


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

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

· cutting aluminum, carbon and stainless steel

· arc voltage (standoff)

· cutting speed

· current (amperes)

· gas flow rates for all plasma/shield gas combinations

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

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


4-15


4.4.2 IFC PT-24 Process Data

Material: Aluminum

Initial Amperes: 15

Final Amperes: 30

Plasma Gas: Nitrogen (N

2

) @ 150 psi / 10.4 bar

Shield Gas: Nitrogen (N

2

) @ 150 psi / 10.4 bar

® Shield Mix Gas: Methane (CH

4

) @ 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

4-16



Process Data

Precision Plasma Integrated Flow Control

15 Initial / 30 Final Amperes

Aluminum

Shield Gas 1

N

2

Shield Gas 2

CH

4

Material Thickness

Plasma Gas

N

2

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. .100 .100 .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54 2,54 2,54

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

In. .125 .130 .135 .165 .220 .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.

4-17







2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar

® Shield Mix Gas:

Methane (CH

4

) @ 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

!


4-18



Process Data


28 Initial – 55 Final Amperes

Aluminum

Shield Gas 1

N

2

Shield Gas 2

CH

4


Plasma Gas

N

2

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. 100 100 100 100 mm 2,54 2,54 2,54 2,54

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

In. .09 0.9 .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.


4-19






2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Methane (CH

4

) @ 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 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-20



Process Data



Aluminum

Shield Gas 1

N

2

Shield Gas 2

CH

4


Plasma Gas

N

2

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. .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54

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

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

IPM 80 65 66 30

MM/MIN 3032 1651 1397 762

Notes:



4-21






2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Methane (CH

4

) @ 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 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-22



Process Data



Aluminum

Shield Gas 1

N

2

Shield Gas 2

CH

4


Plasma Gas

N

2

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. .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54

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

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

IPM 95 80 65 50

MM/MIN 2413 2032 1778 1270

Notes:



4-23


Material: Carbon Steel



Plasma Gas: Oxygen (O

2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Oxygen (O

2

) @ 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

!


4-24



Process Data



Carbon Steel

Shield Gas 1

N

2

Shield Gas 2

O

2


Plasma Gas

O

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.)





Shield Gas





Initial Height

Pierce Height

Cutting Height

71.3

/4.9

83.2

/5.7

12.9

/0.8

2.0

/0.1

2.2

/0.1

71.3

/4.9

83.2

/5.7

12.9

/0.8

2.0

/0.1

2.2

/0.1

71.3

/4.9

83.2

/5.7

12.9

/0.8

2.0

/0.1

2.4

/0.2

71.3

/4.9

83.2

/5.7

12.9

/0.8

2.4

/0.2

3.0

/0.2

71.3

/4.9

83.2

/5.7

12.9

/0.8

2.0

/0.1

2.2

/0.1

71.3

/4.9

83.2

/5.7

12.9

/0.8

2.4

/0.2

3.0

/0.2

103 105 115 118 116 117

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

In. mm 1,52 1,52 1,52 1,52 2,92 2,92

In. .108 .118 .140 .144 .126 .126 mm 2,74 2,74 3,56 3,66 3,20 3,20

IPM 100 85 80 60 50 36

MM/MIN 2540 2159 2032 1524 1270 914

Notes:


4-25







2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Oxygen (O

2

) @ 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

!


4-26



Process Data



Carbon Steel

Shield Gas 1

N

2

Shield Gas 2

O

2


Plasma Gas

O

2

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. .04 .04 .04 .04 0.4 mm 1,02 1,02 1,02 1,02 1,02

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

In. .103 .113 .118 .118 .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:


4-27







2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Oxygen (O

2

) @ 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

!


4-28



Process Data



Carbon Steel

Shield Gas 1

N

2

Shield Gas 2

O

2


Plasma Gas

O

2

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





Shield Gas





Initial Height

Pierce Height

Cutting Height

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

108 111 114 121 124

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

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

In. .145 .155 .145 .205 .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:


4-29







2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Oxygen (O

2

) @ 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

!


4-30



Process Data



Carbon Steel

Shield Gas 1

N

2

Shield Gas 2

O

2


Plasma Gas

O

2

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





Shield Gas psi/bar psi/bar



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 2- Cut - psi/bar

Arc Voltage (standoff)

Initial Height

Pierce Height

Cutting Height

108 110 114 113 135 140

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

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

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

IPM 110 95 70 60 30 25

MM/MIN 2794 2413 1778 1524 762 635

Notes:


4-31







2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Oxygen (O

2

) @ 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

!


4-32



Process Data



Carbon Steel

Shield Gas 1

N

2

Shield Gas 2

O

2


Plasma Gas

O

2

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





Shield Gas





Initial Height

Pierce Height

Cutting Height

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

115 120 132 137 142

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

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

In. .175 .190 .280 .290 .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:


4-33



Material: Stainless Steel




2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Oxygen (O

2

) @ 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

!


4-34



Process Data



Stainless Steel

Shield Gas 1

N

2

Shield Gas 2

O

2


Plasma Gas

O

2

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. .06 .06 .06 .06 .06 mm 1,52 1,52 1,52 1,52 1,52

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

In. .105 .120 .107 .109 .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:


4-35






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

!


4-36



Process Data 25 Intial / 50 Final Amperes

Precision Plasma Integrated Flow Control Stainless Steel

Plasma Gas Shield Gas 1 Shield Gas 2

Air Air


In.

0.125 0.187 0.250 0.375 mm 3,2 4,7 6,4 9,5

Timers






Shield Gas





Initial Height

Pierce Height

Cutting Height

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

134 140 145 157

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

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

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

IPM 90 60 40 18

MM/MIN 2286 1524 1016 457

Notes:



4-37









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

!


4-38



Process Data 35 Initial / 70 Final Amperes



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





Shield Gas





Initial Height

Pierce Height

Cutting Height

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

131 152 158 157

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

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

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

IPM 100 50 28 20

MM/MIN 2540 2270 711 609

Notes:



4-39









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

!


4-40






Air Air


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

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

129 135 142 150

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

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

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

IPM 80 60 35 25

MM/MIN 2030 1520 889 635

Notes:



4-41








Methane (CH

4

) @ 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 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-42



Process Data



Stainless Steel

Shield Gas 1

Air

Shield Gas 2

CH

4


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. .100 .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54 2,54

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

In. .115 .170 .210 .230 .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:


4-43









Methane (CH

4

) @ 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 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-44






Air Air CH

4


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. .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54

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

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

IPM 80 60 35 25

MM/MIN 2030 1524 889 635

Notes:



4-45






2

) @ 150 psi / 10.4 bar


2

) @ 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

!


4-46



Process Data


25 Intial / 50 Final Amperes

Stainless Steel

Shield Gas 1

N

2

Shield Gas 2


Plasma Gas

N

2

In.

0.125 0.187 0.250 0.375 mm 3,2 4,7 6,4 9,5

Timers






Shield Gas





Initial Height

Pierce Height

Cutting Height

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

128 135 144 155

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

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

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

IPM 90 60 40 22

MM/MIN 2286 1524 1016 558

Notes:



4-47






2

) @ 150 psi / 10.4 bar


2

) @ 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

!


4-48



Process Data



Stainless Steel

Shield Gas 1

N

2

Shield Gas 2


Plasma Gas

N

2

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

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

132 150 154 159

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

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

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

IPM 75 50 28 24

MM/MIN 1905 1270 711 609

Notes:



4-49






2

) @ 150 psi / 10.4 bar


2

) @ 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

!


4-50



Process Data



Stainless Steel

Shield Gas 1

N

2

Shield Gas 2


Plasma Gas

N

2

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

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

135 145 153 157

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

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

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

IPM 80 60 35 25

MM/MIN 2032 1520 889 635

Notes:



4-51




Final Amperes: 50 -- using 70A nozzle


2

) @ 150 psi / 10.4 bar


Methane (CH

4

) @ 100 psi / 6.9 bar

PT-24 Torch with Integrated Flow Control


2

) @ 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

!


4-52



Process Data


25 Initial / 50 Final Amperes*

Stainless Steel

Shield Gas 1

N

2

Shield Gas 2

CH

4


Plasma Gas

N

2

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

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

In. .100 .100 .130 .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)


4-53






2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Methane (CH

4

) @ 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 21543, "D"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-54



Process Data



Stainless Steel

Shield Gas 1

N

2

Shield Gas 2

CH

4


Plasma Gas

N

2

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. .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54

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

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

IPM 75 50 28 24

MM/MIN 1905 1270 711 609

Notes:



4-55






2

) @ 150 psi / 10.4 bar


2

) @ 150 psi / 10.4 bar


Methane (CH

4

) @ 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 21923, "E"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-56



Process Data



Stainless Steel

Shield Gas 1

N

2

Shield Gas 2

CH

4


Plasma Gas

N

2

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

Arc Voltage (standoff)

Initial Height

Pierce Height

Cutting Height psi/bar psi/bar




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. .100 .100 .100 .100 .100 mm 2,54 2,54 2,54 2,54 2,54

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

In. .138 .165 .190 .252 .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:


4-57


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

1.905

Material Thickness (mm)

2.286

3.175

4.750

6.350

0.140

3.556

0.120

0.100

0.080

0.060

0.040

0.020

0.000

1.270

0.050

0.062

1.270

0.050

1.270

0.050

1.524

0.060

0.075

0.090

0.125

Material Thickness (inches)

1.651

0.065

0.187

3.048

2.210

0.087

2.540

2.032

1.524

1.016

0.508

0.000

0.250

Aluminum N /N /CH 50 Amperes

2 2 4


1.575

3.175

4.775

6.350

1.524

0.060

1.651

0.065

2.032

0.080

2.362

0.093

3.556

3.048

2.540

2.032

1.524

1.016

0.508

0.000

4-56

0.062

0.125

0.188


Precision Plasma with Integrated Flow Control - CE

0.250

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

4-57

0.080

0.060

0.040

0.020

0.000

0.140

0.120

0.100


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

3.048

0.100

0.080

0.060

0.040

0.020

0.000

1.118

0.044

1.473

0.058

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

2.032

1.524

1.016

0.508

0.000

3.556

3.048

2.540

4-58

0.060

0.125



0.250

0.080

0.060

0.040

0.020

0.000

0.140

0.120

0.100


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

2.032

1.524

1.016

0.508

0.000

3.556

3.048

2.540

0.135

0.250

0.375



0.500

4-59


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

1.524

0.040

0.020

0.000

1.016

0.508

0.000

0.375

0.500


0.750

4-60 Precision Plasma with Integrated Flow Control - CE

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

Precision Plasma with Integrated Flow Control - CE 4-61

0.130

0.110

0.090

0.070

0.050

0.190

0.170

0.150


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

3.302

2.794

2.286

1.778

1.270

4.826

4.318

3.810

4-62

0.250

0.375

0.500



0.625

0.130

0.110

0.090

0.070

0.050

0.190

0.170

0.150


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 /N /CH 100 Amperes

2 2 4


6.350

9.525

12.700

15.875

2.540

0.100

2.794

0.110

3.302

0.130

3.810

0.150

3.302

2.794

2.286

1.778

1.270

4.826

4.318

3.810

0.250

0.375

0.500



0.625

4-63

0.080

0.060

0.040

0.020

0.000

0.140

0.120

0.100

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

2.032

1.524

1.016

0.508

0.000

3.556

3.048

2.540

4-64

0.187

0.250

0.375



0.500

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


0.080

0.060

0.040

0.020

0.000

0.140

0.120

0.100


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

2.032

1.524

1.016

0.508

0.000

3.556

3.048

2.540

4-66

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



Plasma Marking With Precision

Plasma And Integrated Flow Control

Material: Carbon and Stainless Steel

Amperes: 10

Plasma Gas: Argon, Ar @ 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 21536 (3 holes)

!

Nozzle

P/N 21541, "B"


P/N 22007


P/N 22010



(Ref. P/N 996528)


P/N 22531

!


4-68


SECTION 4

Plasma Marking

OPERATION

Process Data

10 Amperes


Plasma Gas

Carbon and Stainless Steel

Shield Gas 1

Ar Air


Timers

0


Plasma Start Gas 1- psi 83.2/5.6 bar

Plasma Cut Gas 1- psi 83.2/5.6 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

Travel Speed

IPM 200

MM/MIN 5080

Notes:


4-69






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

!


4-70


SECTION 4

Plasma Marking

OPERATION

Process Data

15 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar


Initial Height .040" / 1 mm

Pierce Height .040" / 1 mm

Cutting Height .040" / 1 mm

Travel Speed

IPM 300

MM/MIN 7620

Notes:


4-71






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

!


4-72


SECTION 4

Plasma Marking

OPERATION

Process Data

10 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





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

Travel Speed

IPM 100

MM/MIN 2540

Notes:


4-73






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

!


4-74


SECTION 4

Plasma Marking

OPERATION

Process Data

15 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 200

MM/MIN 5080

Notes:


4-75






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

!


4-76


SECTION 4

Plasma Marking

OPERATION

Process Data

15 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 300

MM/MIN 7620

Notes:


4-77






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

!


4-78


SECTION 4

Plasma Marking

OPERATION

Process Data

10 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 100

MM/MIN 2540

Notes:


4-79






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

!


4-80


SECTION 4

Plasma Marking

OPERATION

Process Data

20 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 200

MM/MIN 5080

Notes:


4-81






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

!


4-82


SECTION 4

Plasma Marking

OPERATION

Process Data

30 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 500

MM/MIN 12700

Notes:


4-83






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

!


4-84


SECTION 4

Plasma Marking

OPERATION

Process Data

10 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 100

MM/MIN 2540

Notes:


4-85






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

!


4-86


SECTION 4

Plasma Marking

OPERATION

Process Data

30 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 300

MM/MIN 7620

Notes:


4-87






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

!


4-88


SECTION 4

Plasma Marking

OPERATION

Process Data

30 Amperes


Plasma Gas


Shield Gas 1

Ar Air


Timers

0





Shield Gas

SG1- Cut - psi 132/9.0 bar





Travel Speed

IPM 500

MM/MIN 12700

Notes:


4-89


SECTION 4

This page intentionally left blank.

OPERATION

4-90


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.


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


SECTION 5 MAINTENANCE

Check Valve

IFC Fluid Schematic

2 Way Solenoid Valve

SHIELD GAS 2 OUT

PROP. VALVE

4

PS4

PS

Proportional Valve

Pressure Switch

PLASMA GAS 2 OUT

V

E

N

T

PROP. VALVE

2

PS2

PS

·

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.

SHIELD GAS 1 OUT PLASMA GAS 1 OUT

OPTIONAL ARGON

DIRECT OUT

WITH REMOVABLE PLUG

INSTALLED

V

E

N

T

PROP. VALVE

3

V

E

N

T

PS3

PS

N

2

P

U

O

E

R

G

R

IF

IC

E

PROP. VALVE

1

PS1

PS

V

E

N

T

T

O

R

C

H

C

O

N

N

E

C

T

IO

N

O

T

A

R

C

C

O

P

IL

N

N

E

C

T

IO

N

M

ET

H

A

N

E

H

-3

5

N

2-

3

O

2-

2

O

2-

1

N

2-

1

A

IR

-1

A

IR

-2

N

2

-2

A

R

G

O

N

M

E

T

H

A

N

E

IN

H

-3

5

IN

O

X

Y

G

E

N

IN

A

IR

I

N

N

IT

R

O

G

E

N

IN

A

R

G

O

N

IN

L

IN

G

R

IN

C

O

O

W

A

T

E

C

O

O

A

T

W

L

IN

G

E

R

O

U

T


5-3

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

5-4


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.

5-5


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.

5-6



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.

5-7


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.

5-8



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.


5-9


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).

5-10


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


5-11


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.

5-12


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 IFC 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 IFC.

5-13


SECTION 5

5.8 Proportional Valve Removal

MAINTENANCE

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

1. Access the outside bottom of the unit by unbolting the IFC box from the machine.

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

5-14


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.

Precision Plasma with Integrated Flow Control -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 continuous pilot arc

Position torch more carefully or start on adjacent scrap material.

Work Flipping The nozzle may be damaged if the torch hits a flipped up part.

Catching on Pierce Spatter Increase standoff or start with longer lead-in

Pierce not complete before starting Increase initial delay time.

6-2 Precision Plasma with Integrated Flow Control -CE

SECTION 6

6.2.2 Poor Cut Quality

TROUBLESHOOTING

See Cut Quality In Section 4

6.2.3 No Pilot Arc

Bad (shorted) Pilot Arc Cable Replace Cable

Contaminated Electrode Clean or replace electrode

6.2.4 No Arc Transfer

Insufficient spark gap setting in plumbing box.

Set spark gap to 0.040”

Pilot Arc Contactor (PAC) malfunctioning

Replace contactor

6.2.5 No Preflow

Cutting current setting too low.

Raise cutting current (see Process Data)

Torch too high above workpiece

Lower torch standoff (see Process Data)

Work lead not connect to cutting table

Ensure work lead is firmly connected to workpiece or cutting table

N

2

or O

2

check valve in torch body may be stuck open

See maintenance section for check valve repair.

Emergency stop signal open Check for continuity between TB3-18 and TB3-19

Shorted, closed or jumpered out

Cooling Water Flow Switch

Check cooling water LED on front panel. Should be lit if switch is open

No Cooling Water 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


SECTION 6

6.2.7 Nozzle Life Extremely Short

TROUBLESHOOTING

Pilot Arc H/L switch in wrong position

Refer to Process Data

Nozzle arcing inside bore Gas quality below purity specification

Start gas flow too low Check Process Data cutting parameters

6.2.8 Short Electrode Life

Insufficient cooling Check pump for 150 psi output pressure

Start gas quality Gas quality below purity specification

Cut gas quality Gas quality below purity specification

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

Precision Plasma with Integrated Flow Control -CE

SECTION 6 TROUBLESHOOTING

6.3 IFC Fluid Schematic and Manifold Valve Identification

Air

Schematic Legend

1 ARGON

AIR 2 AIR 1

Ar Check Valve

2

O2 Proportional Valve

O2-2

N2-2

O2-1

N2-1

3

N2-3

N2 Pressure Switch 50 psi rising

H-35

4

H-35 METHANE

CH4

Solenoid Valve

SHIELD GAS 2 OUT PLASMA GAS 2 OUT SHIELD GAS 1 OUT PLASMA GAS 1 OUT

OPTIONAL ARGON

DIRECT OUT

WITH REMOVABLE

PLUG INSTALLED

PROP. VALVE

4

PS4

PS

V

E

N

T

PROP. VALVE

2

PS2

PS

V

E

N

T

PROP. VALVE

3

PS3

PS

V

E

N

T

PROP. VALVE

1

N

2

P

U

R

G

E

O

R

IF

IC

E

PS1

PS

V

E

N

T

PLUG

INSTALLED

T

O

R

C

H

C

O

N

N

E

C

T

IO

N

P

IL

O

T

A

R

C

C

O

N

N

E

C

T

IO

N

M

ET

H

A

N

E

H

-3

5

N

2-

3

O

2-

2

O

2-

1

N

2-

1

A

IR

-1

A

IR

-2

N

2-

2

A

R

G

O

N

M

E

T

H

A

N

E

I

N

H

-3

5

IN

O

X

Y

G

E

N

IN

A

IR

I

N

N

IT

R

O

G

E

N

IN

A

R

G

O

N

I

N

C

O

O

L

W

A

IN

G

R

I

N

T

E

IN

G

C

O

O

L

W

A

T

E

R

O

U

T


SECTION 6

6.4 IFC Electrical Schematic

TROUBLESHOOTING

Part 1

Next Page

P3

1

SIO

SION

GNDE

VCCE

2

GROUND 5

3

4

FUSE

1 AMP

115 VAC

OPERATION

0.5 AMP

230 VAC

OPERATION

+ 24 VDC

P2

ANALOG GROUND 3

24 VDC GROUND 2

1

P1

115/230 VAC PWR.

4

115/230 VAC PWR.

3

115 VAC FROM P/S

2

115 VAC FROM P/S 1

POWER SUPPLY (-)

PILOT ARC IN

1

1A

1B

1

2B

2A

2

SW1

3

2

4

PRIMARY

VOLTAGE

SELECTOR SW1

SHOWN IN

230 VOLT

POSITION

5

6

7

8

RED

WHITE

GREEN

BLACK

SHIELD

BLACK #18

BLUE #18

ESAB ASIOB SYSTEM

X35-1 SIO

X35-2 SION

X35-3 GNDE

X35-4 VCCE

X35-5

X6-1

GROUND

+15 VDC

BLACK

PS1 (PLASMA 1)

RED

PS2 (PLASMA 2) RED

X6-2 P/S #1

PS3 (SHIELD 1)

BLACK

RED

PS4 (SHIELD 2) RED

X32-2

X6-3

X7-1

P/S #2

+15 VDC

X7-2 P/S #3

X7-3 P/S#4

X8-2 UNUSED INPUT

X8-3 UNUSED INPUT

X3-3

24 VAC

X3-2

X32-2

X33-2

X34-2

X33-2

X34-2

X35-2

X32-1

X33-1

X34-1

X35-2

X32-1

X33-1

X34-1

X35-1 X35-1

X31-3

X31-2

X30-3

X30-2

X1-2 GND

X1-1 +24 VDC

OUTPUT CARD #1

X3A X4A

1

2

3

1

2

3

X1A 1 2 3

X1B

1 2 3

X2A

X2B

1 2

1 2

3

3

X3B 1 2 3

X4B 1 2 3

X5A

X5B

1 2 3

1 2 3

NOTE 3

X1A

1 2 3

X1B

X2A

1 2

1 2

3

3

X2B 1 2 3

X3A

X3B

1 2

1 2

3

3

X4A 1 2 3

X4B 1 2 3

X5A

X5B

1 2 3

1 2 3

NOTE 3

P5

6

7

4

5

2

3

1 PLASMA 2

PLASMA 1

SHIELD 1

SHIELD 2

COMMON

8

9 ARGON

METHANE

H-32

NITROGEN 1

NITROGEN 2

NITROGEN 3

AIR 1

AIR 2

OXYGEN 1

OXYGEN 2

ARGON

Next Page

BLACK #18

BLUE #18

STEP UP

TRANSFORMER

115 VAC

INPUT

AC

LINE

FILTER

A

B

SPARK GAP

0.040

X1

C1, C2 2500 pF

X2 X3

REACTOR

X1

X2

FILTER

PCB

REACTOR

X3

NOTES:

1. ALL ASIOB OUTPUT CARD X1A THRU X4B PIN 1 ARE INTERNALLY JUMPERED

TO X3-3.

2. ALL ASIOB OUTPUT CARD X1A THRU X4B PINS 2 AND 3 ARE N.O. RELAY CONTACT.

3. X5A AND X5B ON OUTPUT CARD IS NEUTRAL BUSS. BUSS IS INTERNALLY

CONNECTED TO X3-2.

TORCH (-)

PILOT ARC TO

TORCH


SECTION 6

6.4 Part 2 IFC Electrical Schematic

Previous page

P4

PLASMA GAS 1

PRESSURE

PLASMA GAS 2

PRESSURE

SHIELD GAS 1

PRESSURE

SHIELD GAS 2

PRESSURE

4

5

6

7

8

1

2

3

P4-1

P4-2

P4-3

P4-4

P4-5

P4-6

P4-7

P4-8

LCD Meter

Output For

Troubleshooting

TROUBLESHOOTING

Previous

Page

BLACK #18

BLUE #18

X32-1

X32-2

P4-1

P4-2

X33-1

X33-2

P4-3

P4-4

X34-1

X34-2

P4-5

P4-6

X35-1

X35-2

P4-7

P4-8

Proportional Valves

PLASMA GAS 1 9-BAR

PROPORTIONAL VALVE V1

1 +24 VDC

2 GND

RED

BLACK

PAIR

3 +PRESSURE SET GREEN

BLACK

PAIR

4 -PRESSURE SET

6

-4-20MA LOOP

+4-20MA LOOP

BLACK

PAIR

WHITE

CABLE COLOR CODING FOR ALL

PROPORTIONAL VALVES

PLASMA GAS 2 9-BAR


1 +24 VDC

2 GND

3 +PRESSURE SET

4 -PRESSURE SET

-4-20MA LOOP

6 +4-20MA LOOP

SHIELD GAS 1 9-BAR


1 +24 VDC

2 GND

3 +PRESSURE SET

4 -PRESSURE SET

-4-20MA LOOP

6 +4-20MA LOOP

SHIELD GAS 2 6-BAR


1 +24 VDC

2 GND

3 +PRESSURE SET

4 -PRESSURE SET

-4-20MA LOOP

6 +4-20MA LOOP



6.5 Precision Plasma Power Source Electrical Schematic Part 1

1

2

ZD3

180VAC

P2 J2

TB2

7

575V

6

460V

5

415V

4

380V

3

230V

2

200V

1

3

4

H7

H6

H5

H4

H3

H2

H1

T3

2 6

FNT

PNL

ON/OFF

1 5

S1

A

K4

5 3

B

6 4

1 4

M2

COOLANT

PUMP

H7

H6

H5

H4

X5

X8

X7

X4

X3

X13

X12

X11

X16

X15

X14

X6

H3

H2

H1

T1

X10

X9

X2

X1

3

4

5

1

2

6

7

8

9

10

11

12

13

14

15

16

J4 P4

2 1

FS1

(COOLING

WATER)

ZD1,180V

2

1

M1

120VAC

A

K1

B

ØC

L3 T3

MOV2

610V

575V

18

460V

17

415V

16

380V

15

230V

14

200V

13

1

MOV3

5

610V

ØB L2 T2

575V

12

460V

11

415V

10

380V

9

230V

8

200V

7

MOV1

CB1

3A

6

ØA

L1 T1

610V

Line Load

575V

6

460V

5

415V

4

380V

3

230V

2

200V

1

TB1

J3

4

3

2

1

6

5

P3

8

7 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

2

12VAC

120VAC

P2-5

P2-4

P2-2

P2-1

P3-1

P3-2

P1-3

P1-2

CH7 T2

CH8

CH6

CH5

CH4

CH3

CH2

CH1

BH7

BH8

BH6

BH5

BH4

BH3

BH2

BH1

AH7

AH8

AH6

AH5

AH4

AH3

AH2

AH1

AM1

AMMETER

PCB

TRIM POT

1

LED1

LED2

PCB1

ISOLATION AMPLIFIER AND

FAULT SIGNAL PCB

LED4

LED5

38103

LED7

VOLTMETER

INPUTS

P7-1

P7-3

LED8

LED3

6

LED6

V1

VOLTMETER

MOD1

1

2

6

7

10

5

P1 J1

7

9

1

2

START

5

6

3

8

FAULT

ARC ON

POWER MODULE #1

Next Page

J2

NOT USED ON

PRECISION PLASMA CONSOLE

P1

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

TB2-2

TB2-1

BR1-A

BR1-B

BR1-C

LED9

CURRENT

ANALOG

VOLTAGE

P4-1

P4-2

P4-7

P4-8

P1-12

P1-11

P1-18

P5-1

P5-2

P1-17

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

29a

28a

27a

26a

25a

24a

8a

7a

6a

5a

4a

3a

2a

1a

18a

17a

16a

15a

14a

13a

12a

11a

10a

9a

23a

22a

21a

20a

19a

T2-AH2

T2-BH2

T2-CH2

A

B

C

A

B

C

BR1-A

BR1-B

BR1-C

For CE units only


SECTION 6

Part 2

29b

28b

27b

26b

25b

24a

TB4-1

TB4-2

TROUBLESHOOTING

Component Legend

1

3

4

T1

TB2

TB4

J3

P3

J4

P4

M2

PCB1

CB2

K4

ZD1

M1

CB1

FS1

ZD3

Transformer control, plasma interface

Terminal strip

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

V1

S1

K1

Voltmeter

Switch on/off

Contactor 70A @600V

5

6

TB1 Terminal brd

MOV1,2,3 Mov 610V

T2 Auto transformer

J2

R2

ZD2

K2,3

Receptacle 19 pos

Potentiometer 10K

Zener diode 180v

Contactor 120VAC pilot arc and Hi/Low

C1,2 Capacitor 20µf 400V

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

R10

S3

Resistor 3.1 ohm 300w

Switch spst

PCB2

MOD1

P/C brd start-up

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

23b

22b

21b

15b

14b

13b

12b

11b

10b

9b

20b

19b

18b

17b

16b

ZD2

A

180VAC

B

K2

L1 T1

L2 T2

L3 T3

120VAC

RELAY

C2

20uf

400V

R11

10K

8W

R3

4.99K

FRONT PNL LOCAL

CURRENT SETTING POT

R2

10K

MIN MAX

R4

4.99K

1

2

3

8b

7b

6b

5b

4b

3b

2b

1b

3

1 2 3 4 5 6 7 8 9 10

P3

1

2

6

5

4

FRONT PNL

CURRENT

SETTING

LOCAL/REMOTE

DPDT

S3

P4

MOD1

Power

Module #1

4

3

6

5

2

1

10

9

8

7

24

VDC

TB6-5

R6

39K

2W

R5

39K

2W

TB6-4

TB6-2

1

1A

F3 2

SH1-2

SH1-1

TB3-1

TB3

16

17

18

19

20

21

22

23

24

13

14

15

9

10

11

12

5

6

7

8

1

2

3

4

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

U

V

J

C

H

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

ZD4

180VAC

L1

H2

H1

C1

20uf

400V

R14

R15

R12

10K

OHM

8W

D1

20

OHM

50W

R13

10K

OHM

8W

20

OHM

50W

A

K3

B

L1 T1

L2 T2

L3 T3

R1

R7

20

OHM

300W PILOT ARC

HI / LOW

CONTACTOR

P1-2

START

UP P1-1

20 OHM

300W

R8

R9

20 OHM

300W

20 OHM

300W

P1-3

PCB2

38039

PA

P1-6


CNC

R10

3.1

OHM

300W

6-9


6.6 Precision Plasma Power Source Wiring Diagram - CE

Part 1

Note: PLC1 (connection) refers to an area located on an enclosure that housed the former Programmable Logic

Controller. This plasma power supply is CNC (cutting machine) controlled and does not use a PLC.

P1

1

2

3

4

5

6

7

8

9

P4-14(BRN)

P4-13(RED)

PCB1 P1-6(BLK)

PCB1 P1-5(BLK)

10

11 PCB1 P1-12(BLK)

12 PCB1 P1-11(BLK)

13 MOD1 P1-5 (BLK)

14 MOD1 P1-6 (RED)

15 MOD1 P1-2 (BLU)

16 MOD1 P1-1 (VIO)

17 PCB1 P1-18(BLK)

18 PCB1 P1-17(BLK)

P2

1 P4-10(VIO)

8

9

6

7

4

5

2

3

P4-9(VIO)

P4-8(ORN)

P4-7(ORN)

P3-3(GRY)

P3-4(RED)

10 P3-5(GRY)

11 P4-4(BRN)

12 P4-3(BRN)

13 P4-2(BLU)

14 P4-1(BLU)

15 P3-1(YEL)

16 P3-2(YEL)

PCB1

1

P3

P4-11(GRY)

2

3

4

5

6

7

8

9

P4-12(BLU)

10

11

12

13

14

15

MOD1 P1-3(ORN)

MOD1 P1-4(WHT)

16

17

18

PCB-TB P1-6(YEL)

MOD1 P1-7(BLU)

P4

1

2

3

4

5

6

PLC1 P1-1 (BRN)

PLC1 P1-2 (GRY)

MOD1 P3-1(RED)

MOD1 P3-2(YEL)

7

8

9

PLC1 P1-3 (YEL)

PLC1 P1-8 (ORN)

10

11 MOD1 P3-7(RED)

12

13

14

15

MOD1 P3-8(BLK)

MOD1 P3-9(VIO)

MOD1 P3-10(YEL)

MOD1 P3-3(BLU)

16

17

18

MOD1 P3-4(ORN)

1

2

P5

PLC1 P1-5 (BLK)

PLC1 P1-6 (VIO)

P7

1 P2-5(BLK)

2

3 TB6-5(RED)

P9

1 MOD1 P1-14(RED)

2

3 MOD1 P1-15(BLK)

P10

1 S3-5(VIO)

2

3

4

5

S3-2(RED)

P3-7(BLK)

P3-6(WHT)

P3-8(WHT)

R2

S3- 4 BLU

S3 -1- BRN

MOD1 P1 - 9 ORN

S3-1 (BRN)

2

1 3

MOD1 P1-9 (ORN)

S3-4 (BLU)

VIEW OF R2

PCB1 P10-1(VIO)

TB6-8(GRY)

MOD1 P1-7(BLU)

R2-3(BLU)

R2-2(BRN)

4 5 6

1 2 3

PCB1 P10-2(RED)

TB6-7(ORN)

S3

R2

1

2

3

SEE

VIEW

OF R2

1 P1 18

4

1

P9

16

4

P5

1

PCB4

3

1

P7

P2

1

18

P3

5

P10

1 18

P4

1

1

K1-L2 (BLU)

F4-1 (YEL)

S1

L1

H2

H1

S2-5 (BLK)

K2-L3(BLU)

*

M1-GND (GRN)

GND1

H

I

J

K

L

M

N

A

B

C

D

E

F

G

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)

TB3-3 (ORN)

TB3-12 (VIO)

TB3-22 (WHT)

TB3-11 (RED)

TB3-2 (GRY)

TB3-1 (BRN)

6-10

J2

*

12

F4

12

CB2 CB1

NC

RED

*

BLK *

FS1 C

NO

ORN *

J4-14(BRN)

J4-13(RED)


1

M1 GND

2

CB1-1 (WHT)

*

MOD1 TB2-1(BLK)

*


Wiring Diagram – Precision Plasma Power Source -CE

Part 2



BR1-A

BR1-B

LINE LOAD

A A T2-AH2

B B T2-BH2

BR1-C C C T2-CH2

Detail for CE units only

T1

TOP

ZD3

A

K4

2

4

6

1

3

5

B

K4

MOD1

T1

SEE

DETAIL

M2

SEE DETAIL

BR1

A

MOV

T2-AH2

T2-BH2

T2-CH2

MOD1 BR1-A

T3

J4-11(GRY)

SEE T3

DETAIL

MOD1 BR1-B

MOD1 BR1-C

AH2

BH2

CH2

13

14

15

16

17

18

7

8

5

6

3

4

1

2

9

10

11

12

TB2

SEE

DETAIL

K1

L1 L2

ZD1

A

T1 T2

TB1

MOV1

MOV3

L3

B

T3

MOV2

BLK

BLK

BLK

J4-12(BLU)

T2

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

2

3

4

5

6

7

BLK

GRN

M2

3

6

1

2

4

SPLICE

MOD1 TB2-1(RED)

WHT (INTERNAL)

RED (INTERNAL)

CB2-2 (WHT)

BRN (INTERNAL)

SPLICE

TB2-4 (YEL)

TB2-5 (BRN)

TB2-6 (ORN)

TB2-7 (VIO)

H4 H1

H5

H6

H7

T3

H2

H3

S1-6 (RED)

T1-H1 (RED)

TB2-2 (BLK)

TB2-3 (GRY)

T1-H3 (GRY)



Wiring Diagram – Precision Plasma Power Source -CE

Part 3



MOD1

TB2

CB1-2(GRY)

M1-1(BLK)

S1-6(RED)

M2-1 SPLICE (RED)

2

1

MOD1

P4

3

4

5

1

2

6

7

8

9

TB3-11(RED)

TB3-12(VIO)

F3-1(RED)

TB3-18(VIO)

10 TB3-19(YEL)

1

2

3

4

5

6

7

8

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)

9

10

11

12

13

6

7

8

14

15

16

1

2

3

4

5

J4

T1-X8(BLU)

T1-X7(BLU)

T1-X4(BRN)

T1-X3(BRN)

T1-X10(ORN)

T1-X9(ORN)

T1-X2(VIO)

T1-X1VIO)

K1-A(GRY)

K1-B(BLU)

FS1-NO(RED)

FS1-C(BRN)

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

1

J4

16

REAR VIEW

WITH REAR PANEL

REMOVED

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

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)



Wiring Diagram – Precision Plasma Power Source - CE

Part 4



TB5

MOD1 SH1-2(BLK)

PA

WORK

PCB2-PA(YEL)

K2-T1 (YEL)

PLC1 J2-5(RED)

PCB2 P1-1 (RED)

PCB2 P1-6 (BLK)

PCB2

MOD1 TB3-1(BLK)

TORCH

VIEW F-F

TB5-PA(YEL)

PCB2 - P1

P1-1

P1-2

P1-3

P1-6

TB5-WORK(RED)

TB3-13(ORN)

TB3-14(BRN)

TB5-TORCH(BLK)

VIEW E-E

1

2

J1

TB3-1 (BRN)

TB3-2 (GRY)

3

4

5

6

TB3-15 (VIO)

Not Used

TB3-5 (BLK)

TB3-6 (VIO)

7 TB3-20 (BLU)

8

9

10

TB3-16 (BLK))

TB3-21 (GRY)

Not Used

PLC1 MODULE

1

2

J2

TB3-24 (RED)

TB4-2 (WHT)

Not Used 3

4 J1-C(ORN)

7

8

9

5

6

TB5-WORK(RED)

TB4-1 (BLK)

TB4-2 (WHT)

Not Used

Not Used

10 TB3-23 (BLK)

11 Not Used

12 Not Used

13 Not Used

14 Not Used

15 Not Used

16 Not Used

E

BLU

BLU

2

2 2

2

2

R1

0

1

1

R

9

BLU

BLU

1

R

8

1

BLU

R

7

1

R

1

TB5

F

PCB2

F

E

3 A

2 L

1 B

3

T 2

1

J

1

TB

4

J2

PLC1 P2-6 (BLK)

TB3-22 (WHT)

1 2

TB4

PLC1 J2-7 (WHT)

K3-B(WHT)

GND

PLC1 J2-2 (WHT)

T

2



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.

1

2

3

4

5

6

7

P3

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)

8

9

10

11

PCB1 P4-14(YEL)

12

13

14 PCB1 P9-1 (RED)

15 PCB1 P9-3 (BLK)

16

3

4

5

6

7

8

1

2

NOT USED

1

2

3

4

5

P1

PCB1 P4-3 (RED)

PCB1 P4-4 (YEL)

PCB1 P4-15 (BLU)

PCB1 P4-16 (ORN)

TB6-6 (BRN)

13

14

15

16

6

7

TB6-8 (GRY)

PCB1 P4-11 (RED)

PCB1 P4-12 (BLK) 8

9 PCB1 P4-13 (VIO)

10 PCB1 P4-14 (YEL)

11

12

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)

1

2

3

4

5

6

7

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)

P4-2 (BLU)

PCB1 P5-1 (BLK)

PCB1 P5-2 (VIO)

P4-15 (RED)

PCB1 P4-8 (ORN)

P4-16 (BRN)

5

6

7

8

9

3

4

PCB1 P7-1(BLK)

P4-5 (BLK)

P4-6 (WHT)

14

15

16

10 K2-B(RED)

11

12

13

P1

8

MOD1

WHT

T1 T2 T3

K2

ZD2

P1

1

1

P2

16

1

TB6

PLC MOD

WHT

16

1 2 3 4 5 6 7 8

SEE DETAIL

P3

1

K2-L3 (BLU)

10

C1

1

2

1

2

C2

SH1

K2-T1(YEL)

K2-T3(WHT)

1

TB6-2(RED)

TB5-TORCH(BLK)

R15-2 (RED)

P3

1

1

P4

D1

R14-1 (GRY)

1

8

TB3

8

P2

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)

3

4

1

2

5

P4

PCB1 P2-14 (BLU)

PCB1 P2-13 (BLU)

PCB1 P2-12 (BRN)

PCB1 P2-11 (BRN)

PCB1 P2-6 (BLK)

6

7

8

9

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

16

PCB1 P1-7 (RED)

PCB1 P1-9 (BRN)



6.7 Power Module Schematic - CE Version



6.8 Power Module Wiring Diagram – CE Version

PAGE 1


SECTION 6

Power Module Wiring – CE Version

PAGE 2

TROUBLESHOOTING


SECTION 6

6.9 Torch Manifold

TROUBLESHOOTING

Wire

Numbers

3

6

1

4

5

9

7

2

Plasma 2

Plasma 1

Shield 2

Shield 1

Shield 1 & Shield 2 Common

Plasma 1 & Plasma 2 Common

Argon Common

Argon


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 Welding and Cutting Products

ATTN: Customer Service Department

PO Box 100545 Ebenezer Road

Florence, SC USA 29501-0545

Phone (843) 664-4405

(800) ESAB-123 (372-3123)

ESAB Cutting Systems - Canada

6010 Tomken Road

Mississauga, Ontario, Canada L5T 1X9

Phone (905) 670-0220

Fax (905) 670-4879

ESAB Cutting Systems 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

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.

Precision Plasma with Integrated Flow Control

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

4

5

6

2

3

995227

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

10

8

9

See

"TEE"

Detail

Page 7-12

7-4


SECTION 7

Item

Number

1

2

3

4

5

6

7

8

9

10

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

9

10

11

12

13

4

5

2

3

6

7

8

952209

97W63

23610197

950874

952137

32202GY

58V75

954599

950829

950937

13730763

954565


Description Symbol

(Elec-Ay)

Door Access Rear

J2

CB2

F4

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

8

9

3

2

10

7-8

12

13

11


14

1

SECTION 7

Item

Number

1

Part Number

35920GY

14

15

16

17

10

11

12

13

18

8

9

6

7

2

3

4

5

37355GY

952012

35682

952179

952013

71200732

952095

951061

38103

950487

9639533

38103

950096

952053

952034

952030

952032

952205

37345GY

673458

951209

17300020

17300931



(Elec-Ay)

Base, Precision Plasma

T2

AM1,VM1

PCB1

TB4

PCB1

PCB1 P9,7

PCB1 P10

PCB1 P1,3,4

PCB1 P2

PCB1 P5

K2,K3

PCB2

R1,7,8,9

R10

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

5

1

6

10 7

11

13

7

2

12

1

14


15

13

14

15

16

9

10

11

12

4

5

2

3

6

7

8

SECTION 7

Item

Number

1

Part Number

952026

673502

672002GY

2062334

36417GY

951215

951347

13735308

0558002158

33550

37805

32203GY

182W82

10Z30

950179

37359

37360



(Elec-Ay)

TB2 Terminal Block

T3

MOD1

MOD1(CE)

K1

M1

M2

K4

Contactor 3 Pole 75A

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


7-11

SECTION 7

8 6


15 5

9

7 1

10

11 2

12

2

3

10 3

12

4

13

14

15

7-12

44" Long

“TEE” Detail

16 X5


SECTION 7

Item

Number

1

Part Number

36538

13

14

15

16

9

10

11

12

4

5

2

3

6

7

8

950001

21124

36539

90858009

36418

36423

90858007

90858009

10Z30

182W82

58V75

952182

952181

952179

994471



(Elec-Ay)

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

9

2

3

7-14

7

1

8


SECTION 7

Item

Number

1

Part Number

13735961

4

5

2

3

6

7

8

9

10

950823

950167

995103

35919

2017483

92W57

639533

35930GY

2234891



(Elec-Ay)

Heat Exchanger

TB3

TB5

F3

MOD1 P4

Bushing, Snap

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

9

10

11

12

13

4

5

2

3

6

7

8

2234521

2234519

2234519

2214521

635686

647065

38193

17750020

36527GY

951161

673458

2234521

2234877

2234891

2234518

2234520

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



(Elec-Ay)

Bushing, Snap

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



(Elec-Ay)

Base Power Module

PCB1 P1, 5

PCB1 P2, 6

L1

L1

Bracket, PCB KYDEX

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

4

5

2

3

6

7

8

9

10

SECTION 7

Item

Number

1

Part Number

2234877

951182

950487

950823

35700

17280215

35680

35681

952160

952612



(Elec-Ay)

J3,4 Block Terminal 10 Position

R2

L2

T3

FN5

FN1

M1

TB2

L1

Fan, Axial

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

2

6

1

7

7-22


SECTION 7

Item

Number

1

Part Number

2234518

4

5

2

3

6

7

38047

2234519

35917GY

951981

2234877

674156



(Elec-Ay)

J2 Block Terminal, 8 Position

SH1

J1

J3, 4

TB3

Shunt, Feedback

Block Terminal, 16 Position

Baffle Heatsink

Heatsink

Block Terminal, 10 Position

Adaptor


7-23

18

19

20

19

15

16

17


14

10

13

12

11

CE units only

10

28

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

2

12

13

14

15

16

17

18

19

7

8

9

10

11

5

6

3

4

24

25

26

27

20

21

22

23

28

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



(Elec-Ay)

T1

BR1

SCR1

Q1,2

R4,5

R1

C6,7

C4,5

Q1,2

R6,7,8,9

D1,2

C8,9

T2

TS1,2

C1

C3

FN2,3

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


7-25


7.6 Precision Plasma Flow Control Unit Replacement Parts

1

6

5

4

3

7-26

2


4

5

2

3

6

SECTION 7

Item

Number

1

Part Number

See Detail

37401

674969

56996230

2237927

2237924



(Elec-Ay)

IFC Manifold Assembly

Electrode, Spark Gap, .188” Dia.w/SolderLug

PCB Special Function Filter

ASIOB Relay Output Card

ASIOB Analog Output Card

ASIOB Control System Motherboard


7-27


7.7 IFC Flow Control Manifold Assembly - Detail

1

10

9

8

2

5

4

6

3

4

6

PS1

7

PS2

Bottom View-

Manifold

PS4

PS3

7-28

PS3 Black

PS4 Black

PS3 Red

PS4 Red

1

3 2

X7

X6

1

2

4 3

PS2 Red

PS1 Red

PS1 Black

PS2 Black


SECTION 7

Item

Number

1

2

3

Part Number Quantity

0558002074

952921

10Z30

1

10

1


Description

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

6

7

8

4

5

9

10

74S76

3389

3390

952920

0558002070

0558002071

0558002254

2

4

1

1

2

2

1

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


7-29


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

20

18

14

13

6

4

3

11

12

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

19

2

15

.284" HEX for Electrode

7-30

21

22

23

1

3/8 - 24

L.H. (Ref)

5/8 - 18

L.H. (Ref)

.189" HEX for Cooling Water Tube


Not

Shown

17 Silcone Lubricant

24 Krytox AntiSeize

25 Torch Start -Up Kit

26 Torch Spare Parts Kit

26

23

24

25

18

19

20

21

22

10

11

12

13

7

8

9

14

15

17

SECTION 7

Item

Number

1

2

3

4

5

6

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, 22101

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)


7-31

SECTION 7

7.9 Torch Ar Gas Manifold PT24 IFC


7-32

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 Description

(Elec-Ay)

Flange

2 Way Solenoid Valves

O-Ring


7-33

SECTION 7

7.10 PT-24 IFC Interface Cables


11

10

8

9

7

6

5

4

3

1

2

7-34

CH

4

N

2

O

2

Ar Air


SECTION 7

Item

Number

1

2

3

4

5

Part Number

Reference

Reference

Reference

Reference

Reference

21905

22504

21906

22505

21907

0560987423

0560987424

0560987425

0560987426


Description

Gas Supply Lines

Main Power Cable

120 VAC/24 VDC Cable

Process ASIOB Cable

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

25 ft. Power Bundle





20 ft. Power supply I/O cable




11

Notes:

0558002511

0558002512

0558002502

0558002503

0558002504

21761

22424

0558002505

21762

22425

0558002509

0558002506

0558002507

0558002508

Reference

12 ft. Torch Bundle (5 Hose)

20 ft. Torch Bundle (5 Hose)

Note: Torch Bundle includes items below

4.5 ft. (2.13 m) Gas Tube Assembly (5 hoses)

12 ft. (5.7 m) Gas Tube Assembly (5 hoses)

20 ft. (9.4 m) Gas Tube Assembly (5 hoses)

4.5 ft. (2.13 m) Power Cable

12 ft. (5.7 m) Power Cable

20 ft. (9.4 m) Power Cable

4.5 ft. (2.13 m) Pilot Arc Cable

12 ft. (5.7 m) Pilot Arc Cable

20 ft. (9.4 m) Pilot Arc Cable

4.5 ft. (2.13 m) Solenoid Cable

12 ft. (5.7 m) Solenoid Cable

20 ft. (9.4 m) Solenoid Cable

Height Control I/O Cable


7-35

SECTION 7

7-36



See back of Title Page for revision list.

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

ESAB Precision PLASMARC® Cutting and High Speed Marking System with Integrated Flow Control Installation manual

Installation, Operation and Maintenance Manual for the

Precision PLASMARC

Cutting and High Speed Marking SYSTEM with Integrated Flow Control

©

WARNING

§

WARNING

§

Power Supply

Integrated Flow Control

3.2 Equipment Required

CAUTION

Torch Mounting Options.

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