Torch Connections. ESAB m3® Plasma Integrated Gas Control (IGC) System - ICH, m3® plasma Integrated Gas Control

InstallatIon

Torch Connections

Torch hook-up requires the connection of power cables / coolant hoses, pilot arc cable and chassis ground. On the PT-36 torch, the coolant hoses from the RAS box to the torch also carry electrode power.

The pilot arc cable is connected inside the arc starter box. The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.

Power Cable /

Coolant Connections

Pilot Arc Connection

Ground

Stud

Pilot

Arc Cable

Chassis

Ground

Wire

Power Cable /

Coolant

PG Hose

SG Hose

86

InstallatIon

Connection of Torch to Plasma System

DANGER

Electric Shock Can Kill!

• Disconnect primary power source before making any adjust ments.

• Disconnect primary source before doing maintenance on system components.

• Do not touch front-end torch parts (nozzle, retaining cup, etc.) without turning primary power off.

Ground Stud

Ground cable

Power cables

Pilot Arc cable

Connection to the Remote Arc Starter Box

The PT-36 has two water cooled power cables which must be connected to the negative output from the power supply. The right handed 7/16-20 fitting is on the cable supplying coolant to the torch. The left handed 7/16-20 fitting is on the cable returning coolant from the torch. Both of these cables have a green/yellow wire to be connected to the ground stud shown above.

The pilot arc cable is connected to the arc starter box (see Installation section). The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.

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InstallatIon

Mounting Torch to Machine

DANGER

CLAMPING ON TORCH BODY MAY CAUSE DANGEROUS CURRENT

TO FLOW THROUGH MACHINE CHASSIS.

Mount torch on insulated sleeve here

DO NOT mount on steel torch body here

•

Do not mount on stainless steel torch body.

•

Torch body is electrically insulated, however high frequency start current may arc through to find a ground.

•

Clamping near torch body may result in arcing between body and machine.

•

When this arcing occurs, torch body may require non-warranty replacement.

•

Damage to machine components may result.

•

Clamp only on insulated torch sleeve (directly above label) not less than 1.25" (31.75mm) from the torch end of the sleeve.

Placement of ICH

The ICH should be located close to the operator for easy access.

Connect required CAN cables between ICH and other CAN nodes, such as EPP-202/362 Power Source, B4 lifter, if applicable. CAN connection is always made from left to right, if one node is removed from CAN bus, all nodes on the right need to be shifted to left. After connecting all CAN nodes, a terminator is required. Leave all unused

CAN ports open.

Connect DB37 cable to port “CNC” on ICH. The other side of DB37, is connected to the customer’s CNC via a male DB37 connector. An optional breakout board may be used. A DB37 to free end cable is also available.

Connect power from ICH to PDB and B4 lifter, if applicable. Make sure the power switch on ICH is off.

Connect power to ICH box.

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InstallatIon

Placement of CGC

The CGC regulates the plasma gas and shield gas. For optimum performance, it should always be placed close to torch. According to the material being cut, the customer needs to select and connect the correct inlet gases. Inline filters are embedded into the inlet fittings. Please make sure all inlet gases meet the pressure and flow requirements.

Connect 24V AC/DC power from PDB, then connect CAN cable to ICH.

Plasma

Shield

Air Curtain

Gas

Argon

O2/H35/F5

N2/Air

N2/Air

Air

Gas &

Pressure

Air (85psi / 5.9bar)

Process

Nitrogen

(125psi / 8.6bar)

Oxygen

(125psi / 8.6bar)

Pressure

125 psi (8.6 bar), 200 SCFH (5.7 SCMH)

125 psi (8.6 bar) for O2, 75 psi (5.2 bar) for H35/F5, 255 SCFH (7.2 SCMH)

125 psi (8.6 bar), 255 SCFH (7.2 SCMH)

125 psi (8.6 bar), 353 SCFH (10.0 SCMH)

80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)

Maximum Gas Flow Rates - CFH (CMH)

With PT-36 Torch

269

(7.6)

385

(10.9)

66

(1.9)

Gas Purity

Clean, Dry, Oil Free

Filtered to 25 microns

99.99%, Filtered to 25 microns

99.5%, Filtered to 25 microns

Placement of PDB

The PDB should be placed on the deck as it is used for supplying power to the CGC.

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InstallatIon

Individual Component Connections

Part numbers and lengths for the cables shown below are provided on the following page.

PDB front ICH back

A

B

CGC front

C

PDB back

“A” - Power cable from ICH to PDB (115/230V)

Part Number Length Part Number Length

0560947962 1m (3.3’) 0560947088 5m (16’)

0560946776

0560947964

0560947087

2m (6.4’)

3m (10’)

4m (13’)

0560947089

0560947090

6m (19’)

7m (23’)

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“C” - Power cable PDB to CGC (24 VAC/DC)

Part Number Length Part Number Length

0560947079 1.5m (5’) 0560947064 8m (26’)

0560947080

0560947061

0560947081

0560947062

0560947063

3m (10’)

4m (13’)

5m (16’)

6m (19’)

7m (23’)

0560947065

0560947082

0560946780

0560947066

0560947083

9m (30’)

10m (33’)

12.8m (42')

15m (49’)

20m (66’)

“B” - CAN cable from ICH to CGC

Part Number Length Part Number Length

0558008464 1m (3.3’) 0558008473 10m (33’)

0558008465

0558008466

0558008467

0558008468

0558008469

0558008470

0558008471

0558008472

2m (6.5’)

3m (10’)

4m (13’)

5m (16’)

6m (19’)

7m (23’)

8m (26’)

9m (30’)

0558008474

0558008475

0558008476

0558008477

0558008478

0558008479

0558008809

0558008480

11m (36’)

12m (39’)

13m (43’)

14m (46’)

15m (49’)

20m (66’)

25m (82')

36m (118')

InstallatIon

ACC Component Connections

A

Compressed Air

Part Number

0560947067

0560947075

0560947076

0560947068

0560947077

0560947069

0560946782

Part Number

0558004841

0558004842

0558004843

0558004844

0558004845

0558006865

0558008502

“A” - Cable from ACC to PDB

Length Part Number

0.5m (1.7’)

1.5m (5’)

0560947070

0560947071

3m (10’)

4m (13’)

5m (16’)

6m (19’)

6.1m (20')

0560947072

0560947078

0560947073

0560947074

0560946758

“B” - Air Curtain hose from ACC to CGC

Length Part Number

1.4m (4.75’)

1.8m (6’)

3.7m (12’)

4.6m (15.25’)

5.3m (17.25’)

6.1m (20’)

7.0m (23’)

0558004846

0558008503

0558008504

0558008505

0558008506

0558008507

B

Length

7m (23’)

8m (26’)

9m (30’)

10m (33’)

15m (49’)

20m (66’)

25m (82')

Length

7.6m (25’)

8.0m (26.25’)

9.1m (30’)

10.1m (33')

11.0m (36.25’)

11.9m (39.5’)

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InstallatIon

Component Placement Example

5

6 alternative mounting location

8

6

7

2

1

4

3

92

3

4

5

6

7

8

1

2

Components

CNC

Interface Control Hub (ICH)

PT-36 Torch

B4 Lift

Combined Gas Control (CGC)

Remote Arc Starter Box (RAS)

Power Supply

Power Distribution Box (PDB)

InstallatIon

DANGER

Hydrogen explosion hazard! Read the following before attempting to cut with a water table.

A hazard exists whenever a water table is used for plasma arc cutting. Severe explosions have resulted from the accumulation of hydrogen beneath the plate being cut. Thousands of dollars in property damage has been caused by these explosions. Personal injury or death could result from such an explosion. The best available information indicates that three possible sources of hydrogen exists in water tables:

1. Molten Metal Reaction

Most of the hydrogen is liberated by a fast reaction of molten metal from the kerf in the water to form metallic oxides. This reaction explains why reactive metals with greater affinity for oxygen, such as aluminum and magnesium, release greater volumes of hydrogen during the cut than does iron or steel. Most of this hydrogen will come to the surface immediately, but some will cling to small metallic particles. These particles will settle to the bottom of the water table and the hydrogen will gradually bubble to the surface.

2. Slow Chemical Reaction

Hydrogen may also result from the slower chemical reactions of cold metal particles with the water, dissimilar metals, or chemicals in the water. The hydrogen gradually bubbles to the surface.

3. Plasma Gas

Hydrogen may come from the plasma gas. At currents over 750 amps, H-35 is used as cut gas. This gas is 35% hydrogen by volume and a total of about 125 cfh of hydrogen will be released.

Regardless of the source, the hydrogen gas can collect in pockets formed by the plate being cut and slats on the table, or pockets from warped plate. There can also be accumulation of hydrogen under the slag tray or even in the air reservoir, if these are part of the table design. The hydrogen, in the presence of oxygen or air, can then be ignited by the plasma arc or a spark from any source.

4. Follow these practices to reduce hydrogen generation and accumulation:

A. Clean the slag (especially fine particles) from the bottom of the table frequently. Refill the table with clean water.

B. Do not leave plates on the table overnight or a weekend.

C. If a water table has been unused for several hours, vibrate it in some way before the first plate is laid in position.

This will allow accumulated hydrogen in the refuse to break loose and dissipate before it is confined by a plate on the table. This might be accomplished by laying the first plate onto the table with a slight jolt, then raising the plate to permit hydrogen to escape before it is finally set down for cutting.

D. If cutting above water, install fans to circulate air between the plate and the water surface.

E. If cutting underwater, agitate the water under the plate to prevent accumulation of hydrogen. This can be done by aerating the water using compressed air.

F. If possible, change the level of the water between cuts to dissipate accumulated hydrogen.

G. Maintain pH level of the water near 7 (neutral). This reduces the rate of chemical reaction between water and metals.

93

InstallatIon

WARNING

Possible explosion hazard from plasma cutting aluminum-lithium alloys!

Aluminum-Lithium (Al-Li) alloys are used in the aerospace industry because of 10% weight savings over conventional aluminum alloys. It has been reported that molten Al-Li alloys can cause explosions when they come into contact with water. Therefore, plasma cutting of these alloys should not be attempted in the presence of water. These alloys should only be dry cut on a dry table. Alcoa has determined that "dry" cutting on a dry table is safe and gives good cutting results.

DO NOT dry cut over water. DO NOT water injection cut.

The following are some of the Al-Li alloys currently available:

Alithlite (Alcoa)

Alithally (Alcoa)

2090 Alloy (Alcoa)

X8090A (Alcoa)

X8092 (Alcoa)

X8192 (Alcoa)

Navalite (U. S. Navy)

Lockalite (Lockheed)

Kalite (Kaiser)

8091 (Alcan)

For additional details and information on the safe use from the hazards associated with these alloys, contact your aluminum supplier.

WARNING

Oil And Grease Can Burn Violently!

• Never use oil or grease on this torch.

• Handle torch clean hands only on clean surface.

• Use silicone lubricant only where directed.

• Oil and grease are easily ignited and burn violently in the presence of oxygen under pressure.

WARNING

Hydrogen explosion hazard.

Do Not Cut Underwater With H-35! Dangerous buildup of hydrogen gas is possible in the water table.

Hydrogen gas is extremely explosive. Reduce the water level to 4 inches minimum below the workpiece.

Vibrate plate, stir air and water frequently to prevent hydrogen gas buildup.

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Spark hazard.

WARNING

Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

• Do not cut containers that have held combustibles.

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

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

• Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.

• Wear flame-retardant clothing that covers all exposed areas.

• Wear cuffless trousers to prevent entry of sparks and slag.

InstallatIon

Preparing to Cut

•

Select an appropriate condition from the Cut Data manual (SDP File) and install recommended torch front-end parts (nozzle, electrode, etc.) See Cut Data manual to identify parts and settings.

•

Position torch over material at desired start location.

•

See Power Source Manual for proper settings.

•

See Description and Installation sections for gas control and startup procedures.

Mirror Cutting

When mirror cutting, a reverse swirl gas baffle and reverse diffuser are required. These reverse parts will “spin” the gas in the opposite direction, reversing the “good” side of the cut.

Reverse 4 x .032 Baffle

Reverse 8 x .047 Baffle

P/N 0558002534

P/N 0558002530

Reverse Diffuser P/N 0004470115

Cut Quality

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

•

Cut Angle, negative or positive

•

Cut Flatness

•

Surface Finish

•

Dross

•

Dimensional Accuracy

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

•

Make small incremental adjustments when making corrections.

•

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

•

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

95

InstallatIon

CAUTION

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

Cut Data manual.

Cut Angle

Negative Cut Angle

Top dimension is greater than the bottom.

•

Misaligned torch

•

Bent or warped material

•

Worn or damaged consumables

•

Standoff low (arc voltage)

•

Cutting speed slow (machine travel rate)

Part

Part

Positive Cut Angle

Top dimension is less than the bottom dimension.

•

Misaligned torch

•

Bent or warped material

•

Worn or damaged consumables

•

High standoff High (arc voltage)

•

Cutting speed fast

•

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

Drop

Part

Drop Part

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InstallatIon

Cut Flatness

Top And Bottom Rounded. Condition usually occurs when material is .25" thick (6.4mm) or less.

•

High current for given material thickness.

(See Cut Data manual for proper settings).

Drop Part

Top Edge Undercut

•

Standoff low (Arc Voltage).

Drop Part

97

InstallatIon

Surface Finish

Process Induced Roughness

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

•

Incorrect Shield Gas mixture (See Cut Data manual).

•

Worn or damaged consumables.

Machine Induced Roughness

Can be difficult to distinguish from Process Induced

Roughness. Often confined to only one axis. Roughness is inconsistent.

•

Dirty rails, wheels and/or drive rack/pinion.

•

Carriage wheel adjustment.

Top View

Cut Face

Process

Induced

Roughness or

Machine

Induced

Roughness

Dross

Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Cut Data manual.

High Speed Dross

Material weld or rollover on bottom surface along kerf. Difficult to remove. May require grinding or chipping. “S” shaped lag lines.

•

Standoff high (arc voltage).

•

Cutting speed fast.

Lag Lines

Cut Face

Rollover

Side View

Lag Lines

Cut Face

Slow Speed Dross

Forms as globules on bottom along kerf. Removes easily.

•

Cutting speed slow.

Globules

Side View

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CAUTION

InstallatIon

Recommended cutting speed and arc voltage will give optimal cutting performance in most cases. Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings.

Top Dross

Appears as splatter on top of material. Usually removes easily.

•

Cutting speed fast

•

Standoff high (arc voltage)

Intermittent Dross

Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross.

•

Possible worn consumables

Other Factors Affecting Dross;

•

Material temperature

•

Heavy mill scale or rust

•

High carbon alloys

Side View

Splatter

Cut Face

CAUTION

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

Dimensional Accuracy

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

NOTICE

Recommended cutting speed and arc voltage will give optimal cutting performance.

Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings. Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in the Cut Data manual.

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