ESP1000 PLASMARC SYSTEM
Mechanized Cutting with PT-600, PT-19XLS or PT-36
Instruction Manual
0558005872 04/2007
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ....................................................................................5
1.1 Safety - English .................................................................................5
1.2 Safety - Spanish.................................................................................9
1.3 Safety - French.................................................................................13
2.0 Introduction .........................................................................................17
2.1 General ........................................................................................17
2.2 Features .......................................................................................17
2.3 Component Description........................................................................18
3.0 Installation.......................................................................................... 23
3.1 System Component Locations.................................................................. 23
3.2 System Connections ............................................................................24
3.3 Torch Components .............................................................................32
3.4 Installing Air Curtain ........................................................................... 36
3.5 Water Muer Installation .......................................................................37
3.6 Air Curtain / Water Muer Control Box Installation.............................................. 38
4.0 Operation........................................................................................... 39
4.1 Controls and Indicators ........................................................................ 39
4.2 Pre-Operation Test / Checkout ................................................................. 44
4.3 Cutting With Plasma Torches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
4.4 High Current Cutting Conditions PT-19XLS and PT-600 ...........................................51
4.5 Cutting With Plasma Torches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.6 Operating Techniques ........................................................................ 155
5.0 Troubleshooting ................................................................................... 159
5.1 Programmable Logic Controller (PLC).......................................................... 159
5.2 Sequence Description.........................................................................160
5.3 Operating Information........................................................................ 162
5.4 Troubleshooting Guide .......................................................................163
WARNING
PLASMA CUTTING WITH GAS MIXTURES CONTAINING HYDROGEN (H) OR METHANE (CH4)
CAN RESULT IN AN EXPLOSION.
FAILURE TO COMPLY WITH THE INFORMATION LISTED BELOW CAN RESULT IN DEATH, SEVERE
PERSONAL INJURY OR SERIOUS EQUIPMENT DAMAGE.
HYDROGEN OR METHANE GAS MIXTURES SHOULD NEVER BE USED FOR PLASMA CUTTING
UNDERWATER.
CUTTING WITH COMBUSTIBLE GAS MIXTURES OVER A WATER TABLE CAN RESULT IN THE ACCUMULATION OF EXPLOSIVE GAS POCKETS BETWEEN THE CUTTING TABLE AND THE WORK
PIECE. THESE POCKETS WILL EXPLODE WHEN IGNITED BY SPARKS FROM THE PLASMA ARC.
TO REDUCE, BUT NOT ELIMINATE, THE POSSIBILITY OF AN EXPLOSION THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN:
LOWER WATER LEVEL IN THE WATER TABLE 4 TO 6 INCHES (100 TO 150MM) BELOW THE •
WORK PIECE.
BEFORE CUTTING, BE AWARE OF POSSIBLE EXPLOSIVE GAS SOURCES IN THE WATER TA-•
BLE SUCH AS MOLTEN METAL REACTION, SLOW CHEMICAL REACTION AND SOME PLASMA GASES.
CLEAN SLAG (ESPECIALLY FINE PARTICLES) FROM BOTTOM OF TABLE FREQUENTLY. RE-•
FILL TABLE WITH CLEAN WATER.
DO NOT LEAVE WORK PIECE ON TABLE OVERNIGHT.•
IF WATER TABLE HAS NOT BEEN USED FOR SEVERAL HOURS, VIBRATE OR JOLT IT TO •
BREAK UP GAS POCKETS BEFORE LAYING WORK PIECE ON THE TABLE.
IF POSSIBLE, CHANGE WATER LEVEL BETWEEN CUTS TO BREAK UP GAS POCKETS.•
MAINTAIN WATER PH LEVEL NEAR 7 (NEUTRAL).•
PROGRAMMED PART SPACING SHOULD BE A MINIMUM OF TWICE THE KERF WIDTH TO •
ENSURE MATERIAL IS ALWAYS UNDER THE KERF.
FANS SHOULD BE USED TO CIRCULATE AIR BETWEEN WORK PIECE AND WATER SURFACE. •
A TABLE WATER AERATION SYSTEM SHOULD ALSO BE USED.
4
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
WARNING: These Safety Precautions are
for your protection. They summarize precautionary information from the references
listed in Additional Safety Information section. Before performing any installation or operating
procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, Thick long-
sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
1.1 Safety - English
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
5
SECTION 1 SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommendations. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current owing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects which
are unknown.
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
6
SECTION 1 SAFETY PRECAUTIONS
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
SECTION 1 SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
SECCION 1 SEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el ltro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-amable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
SECCION 1 SEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.
10
SECCION 1 SEGURIDAD
5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
SECCION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
SECTION 1 SÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres ltrants et de
plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.
6. Portez des lunettes étanches par dessus vos lunettes
de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
L es p er so n ne s se tr o uv an t à p r ox im it é do ive n t é ga l e ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
13
SECTION 1 SÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-
teur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.
14
SECTION 1 SÉCURITÉ
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
15
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
SECTION 2 INTRODUCTION
2.1 General
The ESP-1000 is a full capability plasmarc cutting system that oers a wide variety of plasma cutting processes and applications. The system is designed specically for computer controlled mechanized cutting applications with expanded interfacing, exible conguration from a selection of packages and versatile ease of operation. By selecting the components that
best suit your needs the ESP system can fully automate your cutting process.
2.2 Features
The system is capable of water injection cutting and gas shielded underwater cutting can be accomplished at most •
current levels with appropriate torch and accessories.
The ESP-1000 can accommodate all major cutting gases including; oxygen, air, nitrogen or argon/hydrogen mixture.•
The separate component design, ow control, plumbing box, power source provides maximum exibility for system •
layout tailored to your needs.
Selection from a variety of power sources and the paralleling capability allows a wide range of available cutting power •
to meet virtually any cutting condition.
Patented ESAB technology allows underwater cutting and beveling with excellent results.•
The ESP-1000 uses simple switch settings to setup process parameters for ow control and cutting power eliminating •
the diculty of adjustment associated with needle valves.
The shielded construction of the plasma torches and versatility of component location minimizes electrical interference •
with surrounding equipment.
The ESP system uses advanced technology for high quality cutting for a variety of common metals while keeping the •
operating costs at a minimum.
Coolant
Circulator
Flow
Control
Plumbing
Box
Power Source
(Ultra Life 300, ESP-400
Or ESP-600C)
Figure 2-1 Major Components
17
Torch (PT-600 or PT-19XLS)
SECTION 2 INTRODUCTION
2.3 Component Description
The components that make up an ESP-1000 are designed specically to interface into a system for use in automated plasma
cutting applications.
Refer to the specic equipment manual for detailed information.
Ultra Life 300 Power Source
Designed for high speed plasma cutting, the Ultra Life 300 is basically a silicon controlled rectier (SCR) DC unit with solid
state circuitry. The unit can be operated from 50 to 300 amperes output (cutting) current.
The solid state circuitry of the ESP ULTRA-LIFE 300 produces stable cutting current and eliminates changes in output current as components heat up and/or if input line voltage changes within ±10% of nominal. This feature ensures consistency
in cutting conditions. The oxygen consumable life is extended by using a ripple cancellation technique. This technique is
achieved by connecting two power sources in parallel in a manner whereby the ripple from one power source cancels the
ripple from the other. Actual load current and voltage are indicated by an ammeter and voltmeter mounted on the front
panel. Refer to the power source manual for further instructions.
ESP-400C Power Source
The ESP-400C Power Source is a solid state DC power source capable of producing up to 400 amperes. The design of the
solid state circuitry produces stable cutting current and eliminates changes in output current as components heat up to
operating temperature and/or uctuations in line voltages within + or - 10% of nominal. If cutting currents above the rating
is required, two ESP-400C units can be paralleled. Refer to the power source manual for installation instructions.
ESP-600C Power Source
The ESP-600C is normally used in mechanized cutting applications for high speed cutting. The ESP-600C is a solid state DC
power source capable of producing 100 to 600 amperes of cutting current at 100% duty cycle (no cool down requirements).
The extremely low ripple current is produced by a ripple cancellation technique and results in increased life of plasma
consumables. “Current slope up” is also featured with the ESP-600C.
For currents beyond the ESP-600C capability 2 units can be connected in a parallel conguration. Refer to the power source
manual for installation instructions.
Figure 2-2 Ultra Life 300 Power Source Figure 2-3 ESP-400C Power Source
18
Connections to the flow control are Oxygen In, Nitro-
gen In, Start Gas Out, Cut Gas Out, Cut Water In and
Cut Water Out.
Plumbing Box
The ESP Plumbing Box is an interconnecting device
between the torch and other system components. It
also contains the arc starting high frequency genera-
tor. Connection of functions through the plumbing box
include; cut gas, start gas, cut water, torch coolant,
pilot arc, cutting current and height control.
SECTION 2 INTRODUCTION
SECTION 1 INTRODUCTION
For currents beyond the ESP-600C capability 2 units
can be connected in a parallel configuration. Refer to
Instruction Manual for specific details of the ESP-600C.
Connections to the flow control are Oxygen In, Nitro-
gen In, Start Gas Out, Cut Gas Out, Cut Water In and
Cut Water Out.
Plumbing Box
The ESP Plumbing Box is an interconnecting device
between the torch and other system components. It
also contains the arc starting high frequency genera-
tor. Connection of functions through the plumbing box
include; cut gas, start gas, cut water, torch coolant,
pilot arc, cutting current and height control.
Figure 1-6. Plumbing Box Assembly
Coolant Circulator
The WC-7C circulator is a radiator type cooler for cir-
culating a coolant fluid through the plasma torch pro-
viding heat exchanger action for the internal parts of
the torch. Though the system refers to water, it is not
recommended that water be used. For the protection
of internal parts and lines a specially formulated cool-
ant liquid is available that prevents production of cor-
rosion and mineral buildup. Refer to Instruction Manual
F-15-138 for detailed information on the WC-7C unit.
Flow Control
The Flow Control is a programmable Logic Control
(PLC) based unit. This device provides all the neces-
sary control functions for various fluids and signals to
and from other components of the system. Control In-
puts/Outputs are connected to the power source, cut
water pump, plumbing box, coolant circulator, air cur-
tain and the cutting machine control.
Figure 1-4. ESP-600C Power Source
L
O
W
H
I
G
H
L
O
W
H
I
G
H
C
U
T
G
A
S
C
U
T
A
W
T
E
R
T
E
S
T
R
U
N
2.3 Component Description (con’t.)
Figure 2-4 ESP-600C Power Source
Flow Control
The Flow Control is a programmable Logic Control (PLC) based unit. This device provides all the necessary control functions
for various uids and signals to and from other components of the system. Control Inputs/Outputs are connected to the
power source, plumbing box, coolant circulator, air curtain and the cutting machine control.
Connections to the ow control are Oxygen In, Air In, Alternate Gas In, Nitrogen In, Start Gas Out, Cut Gas Out, Shield Gas
Out.
Plumbing Box
The ESP Plumbing Box is an interconnecting device between the torch and other system components. It also contains the
arc starting high frequency generator. Connection of functions through the plumbing box include; cut gas, start gas, shield
gas, torch coolant, pilot arc, cutting current and height control.
Figure 2-5 Flow Control Assembly
Figure 2-6 Plumbing Box Assembly
19
SECTION 2 INTRODUCTION
November, 2005
Installation, Operation, and Maintenance for the
PT-600 Mechanized
Plasma Cutting Torch
2.3 Component Description (con’t.)
Coolant Circulator
The WC-7C circulator is a radiator type cooler for circulating a coolant uid through the plasma torch providing heat exchanger action for the internal parts of the torch. Though the system refers to water, it is not recommended that water be
used. For the protection of internal parts and lines a specially formulated coolant liquid is available that prevents production
of corrosion and mineral buildup. Refer to the power source manual for installation instructions.
PT-19XLS Plasma Torch
The PT-19XLS Torch is designed with all the quality standards and feature characteristics of the PT-15XL. The dierences are
primarily in applications and conditions for which the PT-19XLS is to be used. The PT-19XLS is a mechanized torch designed
for high speed, high current cutting using gas shielding instead of water injection.
The PT-19XLS is intended for applications of dry cutting using air (clean & dry) for the cut gas at current levels up to 200
amps. Oxygen (to 360A) or H-35 (to 600A) can be used with the PT-19XLS, however these gases are not recommended for
some materials. Use of an air curtain kit permits the PT-19XLS to be used for underwater cutting. Refer to the torch manual
for further details.
PT-600 Plasma Torch
The PT-600 torch is a PT-19XLS with reduced manufacturing tolerances. The result is improved torch component concentricity and cut accuracy.
PT-36 Plasma Torch
The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the eld.
Only the torch front-end has replaceable parts.
Figure 2-7 PT-19XLS and PT-600 Torches Figure 2-8 PT-36 Torch
20
SECTION 2 INTRODUCTION
Figure 1-11. Bubble Muffler Assembly
PT-19XLS
AIR CURTAIN
This device also allows above water cutting with re-
duced fume, noise and UV radiation from the arc by
the flow of water through the bubble muffler. A sepa-
rate water pump recycles filtered water from the water
cutting table through the bubble muffler.
PT-19XLS Water Muffler
The PT-19XLS water muffler works much as the bubble
muffler described above.
2.3 Component Description (con’t.)
Air Curtain
The Air Curtain assembly provides improved cutting performance of the plasma torches when cutting underwater. A source
of oil free air at 80 psig is required to the air curtain control box. A curtain (wall) of air is created around the plasma arc area
allowing operation in a relatively dry zone, even with the end of the torch submerged 2 - 3 inches.
Underwater cut quality and speed are enhanced when using the air curtain for all plasma torch cutting applications.
Water Muer
The Water Muer system creates a bubble of air surrounded by water that allows the torch to be used underwater with
oxygen cut gas and water injection cutting without signicant loss of cut quality.
This device also allows above water cutting with reduced fume, noise and UV radiation from the arc by the ow of water
through the water muer. A separate water pump recycles ltered water from the water cutting table through the water
muer.
Figure 2-9 Air Curtain Assembly Figure 2-10 Water Muer Assembly
21
SECTION 2 INTRODUCTION
2.3 Component Description (con’t.)
Table 2-1 Components
DESCRIPTION PART NUMBER
Power Sources:
Ultra Life 300 460/575 V, 3-Phase, 60 Hz 33520
ESP-400C 4 60 V, 3-Phase, 60 Hz 0558001729
400 V, 3-Phase, 50 Hz CE 0558001730
575 V, 3-Phase, 50 Hz 0558001731
ESP-600C 460 V, 3-Phase, 60 Hz 35609
400 V, 3-Phase, 50 Hz 35610
575 V, 3-Phase, 60 Hz 35611
Plasma Torches: The basic torch body can be supplied in seven lead lengths between the plumbing box and torch. The
replaceable torch components are selected for the type of cut gas and current level used.
PT-19XLS - 4.5 ft. 37086
PT-19XLS - 6 ft. 37087
PT-19XLS - 12 ft. 37088
PT-19XLS - 15 ft. 37089
PT-19XLS - 17 ft. 37090
PT-19XLS - 20 ft. 37091
PT-19XLS - 25 ft. 37092
PT-600 - 4.5 ft. 0558001827
PT-600 - 6 ft. 0558001828
PT-600 - 12 ft. 0558001829
PT-600 - 15 ft. 0558001830
PT-600 - 17 ft. 0558001831
PT-600 - 20 ft. 0558001832
PT-600 - 25 ft. 0558001833
PT-36 - 4.5 ft. 0558003849
PT-36 - 6 ft. 0558003850
PT-36 - 12 ft. 0558003852
PT-36 - 25 ft. 0558003856
Flow Control: Provides interface for gases and power 0558005760
Plumbing Box: Provides interconnection between torch and
rest of system.
WC-7C Water
Recirculator:
Air Curtain:
PT-19XLS, PT-600
and PT-36 Water
Muer
Circulates coolant for the torch 33859
PT-19XLS, PT-600 and PT-36
PT-19XLS, PT-600 and PT-36 Beveling
0558005756
37440
34752
37439
22
SECTION 3 INSTALLATION
General
Proper installation substantially contributes to the satisfactory and trouble-free operation of the ESP-1000 System components. Each step in this section should be studied carefully and followed as closely as possible. Immediately upon receipt
of the ESP components, each should be inspected closely for damage which may have occurred in transit. Notify the carrier
of any damage or defects immediately. Instruction manuals for each component of the system are included in the package.
It is recommended that these manuals be collected and compiled in a common location.
Note
If the components are not to be immediately installed, store them in a clean, dry and well ventilated
area.
3.1 System Component Locations
Power Source
When lifting the Power Source using the lifting lugs, ensure the lifting
CAUTION
The location of the Power Source should be carefully selected to ensure satisfactory and dependable service. The Power
Source components are maintained at the proper operating temperatures by forced air that is drawn through the cabinet by
the fan units. For this reason, it is important that the Power Source be located in an indoor-open area where air can circulate
freely at the front, bottom, and rear openings of the cabinet. If space is a premium, leave at least two feet of clearance at
the rear of the cabinet.
The location should be such that a minimum of dirt, dust, or moisture will be drawn into the air stream. It is desirable to
locate the unit so that the top and side panels can be removed for cleaning and troubleshooting. In relationship to a cutting
machine, the power source can be positioned virtually anywhere that will not interfere with machine travel. Accessories on
the cutting machine are available to carry hoses and cables without interference with machine travel.
Flow Control
The Flow Control can be placed on the Power Source or mounted onto the cutting machine. It connects to the Power Source
by a control cable from 6’ to 125’ long. The Flow Control needs to be accessible for setting various cutting parameters. After
setting the cutting conditions, access to the Flow Control is not required during the cutting operation.
means is securely connected to BOTH lifting lugs to prevent damage to the
unit or injury to personnel. DO NOT USE ANY LEVER DEVICE WHICH COULD
DAMAGE THE UNIT.
23
SECTION 3 INSTALLATION
3.1 System Component Locations (con’t.)
Plumbing Box
The Plumbing Box is normally located on the cutting machine in close proximity to the torch station. Since the torch can
be equipped with various standard lengths of cable and hose, the exact location is determined by the conguration and
station load capacity of the machine.
Access to the Plumbing Box is not required during the standard operating procedures, location near the operator is not
required. Two important considerations pertain to the location of the plumbing box:
There should be space for the box door to be opened fully.1.
Sucient space should be provided on all sides to permit easy connection of gas/water hoses and electrical cables to 2.
the box.
3.2 System Connections
Power Source
BEFORE MAKING ANY CONNECTIONS TO THE OUTPUT BUS BARS, MAKE
SURE THE POWER SOURCE IS DEENERGIZED BY OPENING THE LINE WALL
WARNING
Input Power Connections
The power sources (ESP-600C, ESP-400 or Ultra Life 300) used with the system are 3-phase units and must be connected to
a 3-phase power line. Although designed with line voltage compensation, it is suggested that the unit be operated on a
separate line to ensure the performance of the power source is not impaired due to an overloaded circuit.
A line (wall) disconnect switch, with fuses or circuit breakers, shall be used at the main power panel. The primary power input
must have four insulated power leads (three power leads and one ground wire). The wires may be a Thick rubber covered
cable or may run in a solid or exible conduit.
DISCONNECT SWITCH. TO BE DOUBLY SAFE, HAVE A QUALIFIED PERSON
CHECK THE OUTPUT BUS BARS WITH A VOLTMETER TO BE SURE ALL POWER
IS OFF.
Note
The ground wire must be approximately six inches longer than the power leads. This is a safety measure
to ensure that in the event the power lines are accidently pulled out the ground wire will remain con-
nected.
Input conductors must be terminated with ring terminals sized for 1/2 inch hardware before being connected.
Note
Refer to the specic equipment manual for detailed installation instructions.
24
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Flow Control Connections
The Flow Control serves as a form of interface between the various process utilities to enable a central location for setup
adjustments. Connections are made to receptacles on the rear panel and are grouped into two sections, the bottom row is
for gas connections while the top row is for electrical connections. The gas connections should be made rst.
Fluid Hookups (See Table 3-1 for hose assemblies)
OXYGEN (O2) IN - This is a “B” size CGA oxygen tting. Connect the supply hose from the oxygen regulator to this 1.
point.
NITROGEN (N2) IN - This is a “B” size IAA tting. Connect the supply hose from the nitrogen regulator to this point.2.
AIR IN - This is a “B” size air tting. Connect the supply hose from the air regulator to this point.3.
ALTERNATE GAS IN - This is a “B” size CGA fuel gas tting. Connect the supply hose from the alternate gas regulator to 4.
this point.
START GAS OUT - This is a “B” size IAA tting. From this point connect the hose to Start Gas INPUT on the Plumbing 5.
Box.
CUT GAS OUT - This is a “B” size oxygen tting. The hose is connected from this point to the Cut Gas INPUT on the 6.
Plumbing Box.
SHIELD GAS OUT - This is a “B” size air / water tting. The hose is connected from this point to the shield gas input on 7.
the Plumbing Box.
Electrical Hookups (See Table 3-3 for cables)
PARALLELED POWER SOURCE - A cable from a second power source connects to this receptacle whenever two power 1.
sources are used in parallel. It parallels all control connections between the power source and ow control.
AIR CURTAIN - This is used to connect the coil of a solenoid valve in the air curtain control (when used) or to control a 2.
relay coil in the water muer pump unit.
WATER COOLER - This point is used to connect to the relay coil in the water cooler.3.
PLUMBING BOX - This cable connection goes to the gas solenoid valves, ow switch, interlock switch and provides power 4.
to the primary of the high frequency transformer in the plumbing box.
CUTTING MACHINE NUMERICAL CONTROL (CNC) - This connection provides a current reference signal to the plasma 5.
power source and provides control signals to and from the ow control circuits, Start Process Command, Arc On, Process
Fault, and E-Stop Interlock.
115 VAC AUXILIARY POWER - This optional connection allows the Flow Control to be energized without powering up 6.
the system. Disconnect after test function is completed.
25
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
(+) Work
Wall Box
Gas Regulators
Input
Power
Power Source
(-) Electrode
Air
Oxygen
Nitrogen
Alternate
Flow Control
Cooler and
Pump
Start Gas Solenoid
Cut Gas Solenoid
High Freq. On-O
Interlocks
Shield Gas
Start Gas
Cut Gas
Voltage Feedback
Workpiece
Voltage
Pilot Arc
Coolant Return
Coolant Output
Plumbing Box
Process OK
Interlocks
Current Ref.
Cutting Machine Control
Legend
Electrical Connections
Fluid Lines
E-Stop
Process
O
Height
Reference
Height
Control
Torch
PT-19XLS,
PT-600 or
PT-36
Workpiece
Figure 3-1 Interface Block Diagram
26
Shield Gas
Cut Gas
Pilot Arc High Freq.
Coolant To
(-) Current To
Coolant From
(-) Current To
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
To Parallel Power Source
115 VAC Auxiliary Power
For Testing (Disconnect
For Cutting Operation)
Power Source
Cut Gas Out To Plumbing Box
Air In From Regulator
Start Gas Out To Plumbing Box
In From Regulator
N
2
O2 In From Regulator
Alternate In From Regulator
To Air Curtain
To Water Cooler
To Plumbing Box
To Cutting
Machine CNC
Shield Gas Out To Plumbing Box
Figure 3-2 Flow Control Connections
27
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Table 3-1 Hose Assemblies
Cable Length Shield Gas Hose Cooling Water Start Gas Hose Cut Gas Hose
25 FT. 33127 21588 33122 33117
50 FT. 33128 21574 33123 33118
75 FT. 33129 21575 33124 33119
100 FT. 33130 21576 33125 33120
125 FT. 33131 21577 33126 33121
Table 3-2 Cooling Water Hose Assemblies
Cable Length Hose Assembly
25 FT. 33132
50 FT. 33133
75 FT. 33134
100 FT. 33135
125 FT. 33136
Table 3-3 Interconnection Cables
Flow Control -
Cable Length
25 FT. 33219 33224 33253 33303 33253
50 FT. 33220 33225 33254 33304 33254
75 FT. 33221 33226 33255 33305 33255
100 FT. 33222 33227 33256 33306 33256
125 FT. 33223 33228 33257 33307 33257
Plumbing Box
(Cable, 18 AWG,
8 Conductor)
Flow Control Remote Location - Flow Control to Power Source Cable:
Flow Control -
CNC
(Cable, 16 AWG,
12 Conductor)
30 Ft. - 34378
60 Ft. - 34377
Flow Control -
Water Cooler
(Cable, 18 AWG,
3 Conductor)
Power Source -
Plumbing Box
(Cable, Pilot Arc)
(Cable, 18 AWG,
3 Conductor)
Air Curtain
28
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Table 3-4 Recommended Regulators
Description Part Number
Station Regulator, O2, R-76-150-024* 19151
Station Regulator, N2, R-6703 22236
Two Stage Cylinder Regulator, O2, R-77-150-540** 998337
Two Stage Cylinder Regulator, N2, R-77-150-580** 998344
Two Stage Cylinder Regulator, H-35, R-77-150-350 998342
Liquid Cylinder Regulator, O2, R-76-150-540LC 19777
Liquid Cylinder Regulator, N2, R-76-150-580LC 19977
Station Regulator, Air 30338
* Station (line) regulators connect to station outlets of piping systems that transport
gas to welding or cutting stations. These regulators are intended for inlet pressures of
less than 200 psig. When used with plasma cutting systems, minimum inlet pressure
should be 120 psig.
** Two stage cylinder regulators provide a more constant delivery pressure than single
stage cylinder regulators. The delivery pressure of a single stage varies about 1 psig
per 10 psi of change in the inlet pressure as the cylinder empties.
29
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
MAKE SURE THAT ALL CONNECTIONS ARE PROPERLY MADE TO PREVENT
WARNING
To make the following connections, the door must be opened and the cover removed.
Plumbing Box Connections To Torch:
Connect the torch bundle to the plumbing box. Check that the box location permits torch movement as required.1.
Connect the cooling water (coolant) in and out (with the internal power cable) to the connectors on the main power A.
junction bus bar inside the plumbing box. One connection has right-hand threads and the other has left-hand
threads. Left-hand threads are indicated by a groove or notch on the hex of the tting.
Connect the Pilot Arc cable from the torch bundle to the stud marked PILOT ARC TORCH (TB1) located inside the B.
Plumbing Box.
Connect the Shield Gas Hose to the SHIELD GAS TO TORCH connector on the top section of the Plumbing Box.C.
Connect the Cut Gas hose to the GAS TO TORCH connector on top section of Plumbing Box.D.
ANY LEAKS. ANY LEAKAGE DURING ACTUAL OPERATION COULD LEAD TO
A HAZARDOUS SITUATION BECAUSE OF THE HIGH VOLTAGES INVOLVED.
Note
Cut Gas to Torch
Shield Gas
To Torch
Shield Gas
Start Gas
Cut Gas
Coolant In
Coolant Out
Control Cable
(from Flow
Control)
Pilot Arc
(from Power
Source)
4/0 Power
Cables (from
Power Source)
To Height Control
Figure 3-3 Plumbing Box Connections
30
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