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.
1.1 General ................................................................................................................................................................... 17
1.2 Features .................................................................................................................................................................. 17
2.1 General ................................................................................................................................................................... 23
2.2 System Component Location ......................................................................................................................... 23
2.3 System Connections ..........................................................................................................................................24
2.5 Installing Air Curtain ..........................................................................................................................................31
2.7 WATER MUFFLER SYSTEM FOR THE PT-19XLS .......................................................................................... 33
2.8 AIR CURTAIN/BUBBLE MUFFLER CONTROL BOX INSTALLATION ........................................................ 33
2.9 WATER INJECTION PUMP .................................................................................................................................33
2.10 INSTALLATION OF THE SECONDARY GAS METERING BOX ...................................................................34
3.1 General ................................................................................................................................................................... 39
3.2 Controls and Indicators .................................................................................................................................... 39
3.3 Pre-Operation Test and Checkout ................................................................................................................41
3.4 Oxygen Cutting with PT-15XL ........................................................................................................................ 44
3.5 Nitrogen Cutting with PT-15XL ......................................................................................................................49
3.6 H-35 Cutting with PT-15XL .............................................................................................................................. 51
3.7 CUTTING WITH THE PT-19XLS and PT-600 TORCHES ............................................................................ 52
3.8 High Current Cutting with PT-19XLS ...........................................................................................................55
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, heavy
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.
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 work piece has been completely cleaned so
that there are no substances on the work piece
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, Battery march Park,
Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO
NOT use AC welding current in damp
areas, if movement is conned, or if there is danger
of falling.
5
SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical
ground.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in 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
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
SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
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
SEGURIDAD
Safety - Spanish
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas
hacen resumen de información proveniente de las referencias listadas en la sección
"Información Adicional Sobre La Seguridad". Antes
de hacer cualquier instalación o procedimiento
de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación
así como también todo manual, hoja de datos de
seguridad del material, calcomanias, etc. El no
observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y otras radiaciones
que pueden dañar la piel y los ojos. El metal caliente
causa quemaduras. EL entrenamiento en el uso propio
de los equipos y sus procesos es esencial para prevenir
accidentes. Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el 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 corriente alterna
(AC) en áreas húmedas, de movimiento
connado en lugares estrechos o si hay
posibilidad de caer al suelo.
9
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
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
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
SÉCURITÉ
Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de pré-
caution provenant des références dans
la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser
l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les
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. Les personnes se trouvant à proximité doivent également
porter des lunettes étanches par dessus leur lunettes
de sécurité.
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des 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'ex tinction
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 mortelles. NE PAS
utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint
ou si un danger de chute se pose.
13
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
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
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.
Additional Safety Information for Mechanized Plasmarc Cutting Systems:
Electrical Shock can kill or cause severe burns. Plasmarc cutting uses DC currents at dangerously high voltages.
high percentage of ZnO and TiO2 pigments. Do not use paints containing metallic akes. Refer to “Ultraviolet Reectance of Paint” from the American Welding Society.
•Underwatercuttingisawellacceptedtechniqueforreducingthenoise,fumes,andUVradiationofthePlasmarccutting process. Often an air curtain or bubble muer is required for underwater cutting. Above water cutting with a
water muer can also achieve much of the benets of underwater cutting.
16
SECTION 1 DESCRIPTION
1.1 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.
with the PT-15XL torch and gas shielded underwater cutting can be accomplished at most
current levels with appropriate accessories with
the PT-19XLS torch.
•TheESP-1000canaccommodateallmajorcutting
gases including; oxygen, air, nitrogen or argon/
hydrogen mixture.
•The separatecomponent design,ow control,
plumbing box, power source provides maximum
flexibility for system layout tailored to your
needs.
high quality cutting for a variety of common
metals while keeping the operating costs at a
minimum.
COOLANT
CIRCULATOR
TORCH
(PT-15XL or PT-19XLS)
FLOW
CONTROL
CUT WATER
PUMP
PLUMBING
BOX
SECONDARY
GAS METERING
BOX
POWER SOURCE
(ULTRA LIFE 300, ESP-
400 or ESP-600C)
Figure 1-1. ESP-1000 Major Components
17
SECTION 1 DESCRIPTION
VOLTS
AMPS
OUTPUT
ACTUAL AMPS
PRESET AMPS
LOW
HIGH
PILOT
ARC
50
MIN
100
200
300
400
500
600
MAX
0
MAIN
POWER
CURRENT
PANEL
REMOTE
OVER
TEMP
CONTACTOR
ON
FAULT
POWER
RESET
FAULT
400C
1.3 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 tothe 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.
Figure 1-3 ESP-400C Power Source
Figure 1-2. Ultra Life 300 Power Source
The solid state circuitry of the Ultra Life 300 produces
stable cutting current and eliminates changes in output
current as components heat up to operating temperature. Fluctuations in line voltage within +/- 10% of normal
and/are extremely low ripple output current is produced,
which results in longer consumable life.
Refer to Instruction Manual F-15-141 for specic details
for the Ultra Life 300.
ESP-400C Power Source
The ESP-400C Power Source is a solid state DC pwoer source
capable of producing up tp 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 ESP400C 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.
18
SECTION 1 DESCRIPTION
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
Connections to the ow control are Oxygen In, Nitrogen
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 generator. Connection of functions through the plumbing box
include; cut gas, start gas, cut water, torch coolant, pilot
arc, cutting current and height control.
Figure 1-4. ESP-600C Power Source
For currents beyond the ESP-600C capability 2 units can be
connected in a parallel conguration. Refer to Instruction
Manual for specic details of the ESP-600C.
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, cut water pump, plumbing box, coolant circulator, air curtain and the cutting
machine control.
Figure 1-6. Plumbing Box Assembly
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 Instruction Manual F-15-138 for detailed
information on the WC-7C unit.
Figure 1-5. Flow Control Assembly
19
SECTION 1 DESCRIPTION
10
9
8
7
6
5
4
3
2
1
0
PRESSURE
FLOW
OFF
ON
AUTO
PRESSURE
ADJUSTMENT
INLET
FLOW
ADJUSTMENT
OUTLET
READ TOP
OF BALL
0
50
100
PLASMARC
SECONDARY SHIELD
GAS FLOW CONTROL
Secondary Gas Metering Box
Figure 1-7A
The secondary shield/PT-19XLS improves the cut squareness. The secondary gas metering box measures the ow
rate of shield gas (nitrogen or air).
Adaptor: PT-19XLS to Plumbing Box for shield gas connection to torch.
PT-15XL Plasma Torch
The PT-15XL is designed for high current plasma cutting with water injection. Cutting is accomplished with
nitrogen cut gas up to 750 amps, oxygen cut gas up to
360 amps. Use of H-35 mixture for cut gas extends current capability up to 1000 amps. Each condition requires
specic torch components for the type of cut gas and
current level.
Figure 1-8. PT-15XL Plasma Torch
The PT-15XL is designed to eliminate double arcing, high
frequency leakage, and electrolytic corrosion of parts.
The electrode cooling and nozzle concentricity makes arc
ignition more reliable, longer life of the nozzle, electrode
and other consumable parts. Operating details for specic
cutting conditions are presented in later sections of this
manual. Refer to Form F-15-031 for detailed information
of the PT-15XL torch.
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 ofwater injection.
Figure 1-7A
Figure 1-9. PT-19XLS Plasma Torch
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. Connections, mounting and process data are identical.
20
SECTION 1 DESCRIPTION
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. Further details of the PT-19XLS are contained in
Form F-15-430.
Water Pump
The Water Pump is used to supply de-ionized cut water
to the PT-15XL torch for water injected cutting.
Air Curtain
Figure 1-11. Bubble Muer Assembly
The Air Curtain assembly provides improved cutting
performance of the PT-15XL and PT-19XLS 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.
PT15XL H.D.
AIR CURTAIN
Figure 1-10. Air Curtain Assembly
PT-19XLS
AIR CURTAIN
PT-19XLS Water Muer
The PT-19XLS water muer works much as the bubble
muer described above.
Underwater Cut quality and speed are enhanced when
using the air curtain for all PT-19XLS cutting applications
and PT-15XL O2/water injection cutting.
Bubble Muer
The Bubble Muer system creates a bubble of air surrounded by water that allows the PT-15XL 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 bubble muer. A separate water
pump recycles ltered water from the water cutting table
through the bubble muer.
Figure 1-12. PT-19XLS Water Muer Assembly
21
SECTION 1 DESCRIPTION
TABLE 1-1. ESP 1000 COMPONENTS
DESCRIPTION PART NUMBER INSTRUCTION MANUAL
Power Sources
Ultra Life 300 460/575 V, 3-Phase, 60 Hz 33520 F-15-141
Plasma Torches:The basic torch body can be supplied in seven lead lengths between the plumbing box and torch. The replaceable
PT-15XL - 4.5 ft. 21307 F-15-031
PT-15XL - 6 ft. 21304 PT-15XL - 12 ft. 21305 PT-15XL - 15 ft. 21301 PT-15XL - 17 ft. 21306 PT-15XL - 20 ft. 21302 PT-15XL - 25 ft. 21303
PT-19XLS - 4.5 ft. 37086 F-15-430
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 F-15-646
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
Flow Control: Provides interface for uids, gases and 21294 F-15-106
power.
torch components are selected for the type of cut gas and current level used.
Plumbing Box: Provides interconnection between torch 21295 F-15-107
and rest of system includes adaptor for
shield gas connection.
WC-7C Water Recirculator: Circulates coolant for the torch 33859 F-15-138
Cut Water Pump:
Supplies cut water to torch for water injection cutting 33772 F-15-131
Air Curtain:
PT-19XLS and PT-600 37440 F-15-475
Heavy Duty PT-15XL 21856 F-15-189
PT-15XL Beveling (PT-19XL and PT-600) 34752 F-15-189
Bubble Muer System 2232615 F-15-127
PT-19XLS (and PT-600) Water Muer 37439 F-15-474
Secondary Gas Metering Box (for PT-19XLS) 22178 See pages 28 - 32 of this manual.
22
SECTION 2 INSTALLATION
ing. In relationship to a cutting machine, the power
source can be positioned virtually anywhere that will
WARNING
READ THIS MANUAL COMPLETELY PRIOR TO
INSTALLING AND OPERATING THE ESAB SMART
PLASMA (ESP) 1000 SYSTEM.
not interfere with machine travel. Accessories on the
cutting machine are available to carry hoses and cables
without interference with machine travel.
Flow Control
2.1 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.
2.2 System Component Locations
Power Source
WARNING
When lifting the Power Source using the lifting
lugs, ensure the lifting 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.
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 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.
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:
1. There should be space for the box door to be
opened fully .
2. Sucient space should be provided on all
sides to permit easy connection of gas/water
hoses and electrical cables to the box.
Secondary Gas Metering Box
The gas metering box can be mounted on the cutting machine or a convenient wall with the owmeter
vertical. The hose supplied is used to connect metering
box to torch shield gas using the adaptor supplied with
the plumbing box. The gas metering box must be connected to a source of dry oil free shop air or N2 capable
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 troubleshoot-
23
SECTION 2 INSTALLATION
2.3. SYSTEM CONNECTIONS
Power Source
WARNING
Before making any connections to the output bus bars,
make sure the power source is de-energized by opening
the line (wall) disconnect switch. To be doubly safe, have a
qualied person check the output bus bars with a voltmeter
to be sure all power is o.
Input Power Connections
The power sources (ESP-600C, ESP-400 or Ultra Life 300) used
with the ESP-1000 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 heavy rubber covered
cable or may run in a solid or exible conduit.
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 connected.
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.
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 and water connections while the top row is for electrical
connections. The uid connections should be made rst.
Fluid Hookups (See Table 2-1 for hose assemblies)
1. OXYGEN (O
tting. Connect the supply hose from the oxygen
regulator to this point.
2. NITROGEN (N2) IN - This is a "B" size IAA tting.
Connect the supply hose from the nitrogen
regulator to this point.
3. START GAS OUT - This is a "B" size IAA tting. From
this point connect the hose to Start Gas INPUT on
the Plumbing Box.
4. CUT GAS OUT - This is a "B" size oxygen tting.
The hose is connected from this point to the Cut
Gas INPUT on the Plumbing Box.
Electrical Hookups (See Table 2-2 for cables)
1. PARALLELED POWER SOURCE - A cable from a
second power source connects to this receptacle
whenever two power sources are used in parallel. It parallels all control connections between
the power source and ow control.
2. AIR CURTAIN - This is used to connect the coil of
a solenoid valve in the air curtain control (when
used) or to control a relay coil in the water muer
pump unit.
3. CUT WATER PUMP - Provides connection to a relay
coil in the cut water pump unit
4. WATER COOLER - This point is used to connect to
the relay coil in the water cooler.
5. PLUMBING BOX - This cable connection goes to
the gas solenoid valves, ow switch, interlock
switch and provides power to the primary of
the high frequency transformer in the plumbing
box.
6. CUTTING MACHINE NUMERICAL CONTROL (CNC)
- This connection provides a current reference
signal to the plasma power source and provides
control signals to and from the ow control circuits, Start Process Command, Arc On, Process
Fault, and E-Stop Interlock.
7. 115 VAC AUXILIARY POWER - This optional connection allows the Flow Control to be energized
without powering up the system. Disconnect
after test function is completed.
) IN - This is a "B" size CGA oxygen
2
24
SECTION 2 INSTALLATION
Oxygen
Nitrogen
Gas Regulators
Cut
Water
Pump
On-O
Flow Control
Wall Box
Input
Power
Cooler and
Pump
Start Gas Solenoid
Cut Gas Solenoid
High Freq. On-O
Interlocks
Injection Water
Start Gas
Cut Gas
Voltage Feedback
Power Source
Coolant Return
Coolant Output
(+) Work
(-) Electrode
Pilot Arc
Plumbing Box
Process OK
Interlocks
Current Ref.
E-Stop
Process
O
Cutting Machine Control
Height
Reference
Legend
Electrical Connections
Fluid Lines
*For use on the PT-19XLS and PT-600 only. For
dry cutting the cut water switch on the ow
control must be in the "OFF" position.
Figure 2-2. ESP-1000 Interface Block Diagram
Workpiece
Voltage
Height
Control
25
Torch
PT-15XL or
PT-19XLS or
PT-600
Work Piece
Gas
Metering
Box
Shield
Air Supply
Gas*
Secondary
Shield Gas
Cut Gas
Pilot Arc High Freq.
Water Injection
Coolant To
(-) Current To
Coolant From
(-) Current To
SECTION 2 INSTALLATION
TO PARALLEL
115 VAC
AUXILIARY POWER
FOR TESTING
(DISCONNECT FOR
CUTTING OPERATION)
POWER SOURCE
TO AIR
CURTAIN
TO CUT WATER
PUMP
O2 IN
FROM
REGULATOR
N2 IN
FROM
REGULATOR
START GAS
OUT TO
PLUMBING
BOX
CUT GAS
OUT TO
PLUMBING
BOX
POWER
SOURCE
CUT WATER
IN FROM CUT
WATER PUMP
Figure 2-4. Flow Control Connections
TO WATER
COOLER
TO PLUMBING
BOX
TO CUTTING
MACHINE CNC
CUT WATER
OUT TO PLUMBING
BOX
26
SECTION 2 INSTALLATION
TABLE 2-1. HOSE ASSEMBLIES
CABLE LENGTHCUT WATER HOSECOOLING WATERSTART GAS HOSECUT GAS HOSE
* 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.
28
SECTION 2 INSTALLATION
Plumbing Box Connections
B. Connect the Pilot Arc cable from the torch bundle
WARNING
Make sure that all connections are properly made to
prevent any leaks. Any leakage during actual operation could lead to a hazardous situation because of
the high voltages involved.
C. Connect the Cut Water hose to the CUT WATER
to the stud marked PILOT ARC TORCH (TB1) located inside the Plumbing Box.
TO TORCH connector on the top section of the
Plumbing Box.
NOTE
To make the following connections, the door must be
opened and the cover removed.
Cut Gas to Torch
Cut Water
To Torch
D. Connect the Cut Gas hose to the GAS TO
TORCH connector on top section of Plumbing
Box.
Start Gas
Cut Gas
Coolant Out
Coolant In
Control Cable
(from Flow
Control)
Pilot Arc
from Power
Source
4/0 Power
Cables
from Power
Source
To Height Control
Figure 2-5. Plumbing Box Connections
To Torch
1. Connect the torch bundle to the plumbing box. Check
that the box location permits torch movement as
required.
A. Connect the cooling water (coolant) in and out
(with the internal power cable) to the connectors on the main power junction bus bar inside
the plumbing box. Refer to Figure 2-6. 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.
To Power Source
2. Connect the 4/0 power cable(s) to the studs on the
main power bus bar TB3 (see Figure 2-6). The number
of cables depends on the maximum cutting thickness
capacity for the installation. Three cables must b e
connected to carry the full 1000 amperes.
Select plasma cutting output cables on the basis of
one 4/0 AWG, 600 volt insulated copper cable for each
400 amperes of output current. Do not use ordinary
100 volt insulated welding cable.
Each 4/0 cable must be terminated with the correct
lug prior to attempting connection to the bus bar.
29
SECTION 2 INSTALLATION
Each cable goes through one of three strain reliefs on
the box. Ensure neither lugs nor bare wires touch the sheet metal of the box.
3. Connect the Pilot Arc cable from the power source
through its strain relief (PILOT CURRENT) to the stud
TORCH PILOT
ARC
CABLE STUD
PILOT
CURRENT STUD
(FROM POWER
SOURCE)
COOLANT
IN AND OUT
CONNECTORS
4/0 POWER CABLE
CONNECTING STUDS
Figure 2-6. Plumbing Box Internal Connections
FRONT BODY
INSULATOR
ASSEMBLY
BODY
ASSEMBLY
NOZZLE
RETAINING
CUP
ELECTRODE
)
TIP (N
2
NOZZLE
ASSEMBLY
GAS SWIRL
BAFFLE
ELECTRODE
HOLDER
Figure 2-7. PT-15XL Plasma Torch Components
WARNING
Electric shock can kill! Before touching the torch, be
sure the power source is shut o by turning o the
3-phase power input to the power source.
WARNING
Never use oil or grease on this torch. Handle parts only
with clean hands and lay parts only on a clean surface.
Oil and grease are easily ignited and burn violently in
the presence of oxygen under pressure. Use silicone
lubricate only where indicated.
(TB2) on the side of the high frequency box inside the
Plumbing Box. This cable runs uninterrupted from the
power source to the termination in the plumbing box,
so it is essential that it be the proper length. Use # 6
AWG 600 volt wire with ring terminals to t the 1/4inch stud.
2.4 TORCH COMPONENTS
Refer to your torch manual for detailed
installation instructions.
PT-15XL
The PT-15XL torch is supplied with front end parts for water
injection cutting using nitrogen cutting gas at currents
up to 400 amps DCSP. Nozzles for other applications are
available and are referenced in the Cutting Data Tables
in Section 3.
PT-19XLS
The PT-19XLS is a water-cooled plasma arc torch designed
for mechanized cutting at currents up to 350 Amps with
oxygen and up to 600 Amps with nitrogen or H-35.
ELECTRODE HOLDER -
ELECTRODE
NOZZLE BASE
NOZZLE TIP
NOZZLE RETAINING CUP
DIFFUSER
SHIELD
SHIELD RETAINER
NOZZLE RETAINING CUP, AIR CURTAIN
Figure 2-8. PT-19XLS Components
30
GAS BAFFLE
SECTION 2 INSTALLATION
WARNING
Make sure that the heat shield, shield retainer,
and other front end parts are cool before handling.
2.5. INSTALLING AIR CURTAIN
The Air Curtain is a device used to improve performance
of the PT-15XL and PT-19XLS when cutting underwater.
Cut quality and cutting speed are enhanced when using the air curtain with all PT-19XLS cutting and PT-15XL
oxygen/water injection cutting. The device mounts onto
the torch and produces a curtain of air around the cutting
area producing a relatively dry area.
Installation procedures of the air curtain for the PT-15XL
and PT-19XLS are very similar with slight dierences in the
nozzle clearance positioning.
1. Remove the torch nozzle retaining cup.
2. Slide the chrome plated Air Curtain Body.
NOTE: It will ease assembly if all O-rings in the air curtain
body are lightly lubricated with silicone grease,
77500101 (5.3 oz.) or 17672 (1 oz.).
3. Replace the nozzle retaining cup and any front-end
parts that may have removed from the torch.
4. Install the air curtain sleeve over the assembled torch
and snap it into place.
5. Secure the air curtain sleeve by installing the air curtain retainer. The Retainer rotates to lock in place with
the locking pins.
6. Adjust the position of the air curtain on the torch
until:
A. PT-15XL - a gap from 0.040 to 0.060 inch is ob-
tained between the air curtain sleeve and the
nozzle retaining cup.
B. PT-15XL - the nozzle is recessed 0.10 inch from
the end of the air curtain sleeve.
C. PT-19XLS - the nozzle extends 0.06 inch from the
end of the air curtain sleeve.
7. Lock the air curtain into place by tightening the al-
len screw on the air curtain body. Refer to Figure
2-9.
NOTE: The air curtain sleeve must remain completely bot-
tomed in the air curtain body for the adjustment in
step 6 to be correct.
After tightening the allen screw, the gap between
the sleeve and torch cup should be uniform all the
way around.
With PT-15XL torches, verify that the Bubble Muer/Air
Curtain air does not excessively interfere with the injection
spray pattern. A small interference is normal, as long as it
is uniform. If not uniform, try turning the sleeve. This will
at times correct the problem. Turn o muer water when
checking for this interference.
BUSHING
ALLEN
SCREW
.040 - .062
PT-15XL
TORCH
BODY
ALLEN
SCREW
AIR
CURTAIN
BODY
RETAINER
AIR
INLET
PT-15XL BEVEL
Figure 2-9. Air Curtain Installation
31
0.10"
BUSHING
AIR CURTAIN
BODY
AIR
INLET
RETAINER
TORCH
BODY
PT-19XLS
0.06"
AIR
INLET
SECTION 2 INSTALLATION
2.6. BUBBLE MUFFLER INSTALLATION
The bubble Muer creates a bubble of air surrounded
by water so that a PT-15XL plasma torch can be used
underwater with oxygen/water injection cutting without
signicant sacrice of cut quality. This system also permits
operation above water as the ow through the muer
reduces fumes, noise and arc UV radiation.
Installation and Adjustment
1. Remove the brass nozzle retaining cup from the
torch.
NOTE: Lubrication of O-rings in the bubble muer is rec-
ommended for ease of installation.
2. Slide the chrome plated bubble muer clamp onto
the torch about 1/2 inch up the torch sleeve (body).
3. Replace the nozzle retaining cup and any front-end
torch parts that may have removed from the torch.
4. Install the bubble muer sleeve in the bubble muer
main body. Maker sure it bottoms completely.
5. Install the bubble muer main body (with sleeve)
over the assembled torch and snap it into place on
the bubble muer clamp.
6. Adjust the position of the bubble muer on the torch
until a gap of .040 to .060 (use 1/16 inch allen wrench
for gapping) is obtained between the inside wall of
the muer sleeve and the torch retaining cup.
7. Lock the bubble muer into position by tightening
the allen screw on the bubble muer clamp.
A helpful hint for adjusting the Air Curtain or bubble Mufer for proper location on the PT-15XL:
1. Mark the nozzle retaining cup and back it up 3/4 to 1
turn from fully tight.
2. Install the Air Curtain or Bubble Muer sleeve and
push the assembly up the torch until the sleeve bottoms out against the nozzle retaining cup.
3. Lock into position with the allen screw.
4. Retighten the nozzle retaining cup.
ALLEN
SCREW
MAIN
BODY
SLEEVE
.040 - .060
Figure 2-10. Bubble Muer Assembly
The sleeve must remain completely bottomed in
the Bubble Muer body for the adjustment in step 6 to
be correct.
After tightening the allen screw, the gap between
the sleeve and torch cup should be uniform all the way
around.
With PT-15XL torches, verify that the Bubble Mufer air does not excessively interfere with the injection
spray pattern. A small interference is normal, as long as
it is uniform. IF not uniform, try turning the sleeve. This
will at times correct the problem. Turn o muer water
when checking for this interference.
Better centering of the bubble muer sleeve can
be obtained by putting 3 evenly spaced (120" interval)
pads of tape of electrical tape on the nozzle retaining
cup.
NOZZLE
RETAINING
CUP
CLAMP
TORCH
RETAINING
CUP
32
2-3 LAYERS ELECTRICAL
TAPE AT 3 PLACES
SPACED 120
Figure 2-11. Centering Tape on Retaining Cup
o
SECTION 2 INSTALLATION
2.7 WATER MUFFLER SYSTEM FOR THE PT19XLS
This system is similar to the PT-15XL
Bubble Muer.
2.8. AIR CURTAIN/BUBBLE MUFFLER
CONTROL BOX INSTALLATION
1. Mount the Control Box at a convenient location and use the
hose supplied to connect the box with the unit mounted
on the torch.
2. Connect the Control Box to a source of oil free shop air
capable of delivering at least 20 scfm at 80 psig. The hose
used should be at least 3/8 inch inside diameter. Refer to
Figure 2-12 for plumbing hookup.
3. Use SJO wire to connect the control to the cutting machine
control. If the ESP system is used, the connection may be
made to the appropriate amphenol connector on the
back of the Flow Control. The connection of the control is
made at terminals marked FC. An appropriate cable may
be selected from the table of optional accessories.
2.9. WATER INJECTION PUMP
The Water Injection Pump is intended to supply cut water
to the PT-15XL water injection torch. It may be used in
other applications where water requirements do not exceed the pump capacity of 0.5 gpm @ 200 psig. See Figure
2-13 for Installation Diagram.
CONTROL CABLE
PUMP
APPROPRIATE AMPHENOL
CONNECTOR ON FLOW
CONTROL OR CNC
POWER
AIR CURTAIN
CONTROL BOX
Figure 2-12. Electrical Connections for Water Pump
CONTROL CABLE
115VAC
OPTIONAL
4. The user supplied 115 volt AC may be connected to the
terminals so marked. This will allow manual operation of
the air curtain control.
5. Connect a ground wire to the stud provided in the control
box.
6. Provide air to the control box. Energize solenoid in control
box and adjust regulator screw from 15 - 30 psig delivery.
Adjust within range for best cut quality.
7. Place switch in AUTO. The system should turn on when the
preow begins. The pump will recirculate approximately
20 gpm from the water table.
Further details and replacements parts for the air curtain and
bubble muer are depicted in instruction manuals, F-15-189
& F-15-127, 15-474 & 15-475.
3/8" ID
HOSE
3/8" ID
HOSE
3/4" ID
HOSE
PUMP
WATER
INLET
AIR CURTAIN
CONTROL BOX
TORCH
BUBBLE MUFFLER
WATER
TABLE
STRAINER
AIR
Figure 2-13. Plumbing Connections for Water Pump
To prevent damage to pump, do not operate water injection pump with delivery pressure above 220 psig. Do not
operate for more than 2 minutes without ow (with the
pump deadheaded). Do not operate for extended periods
of time with less than 0.2 gpm ow.
33
SECTION 2 INSTALLATION
INTERMEDIATE
WATER QUALITY INDICATOR
FILTER TO
PROTECT
TANKS
LIGHT (50,000 OHM RATING)
TAP
WATER
IN
R-5702 REGULATOR
(PN 639629) SET TO
DELIVER 25-30 PSIG
CATION
TANK
TO
CUT WATER
PUMP
ANION
TANK
Figure 2-14. Deionizer System for Plasma Cut Water
The PT-19XLS incorporates arrangements for secondary gas shielding to improve cut squareness. A secondary gas metering box and accessories are required.
The adaptor for torch to gas metering box is supplied
with the plumbing box.
The installation, operation and replacement parts
for the secondary gas metering box will be covered in
this section.
Required Accessories
ItemPart No.Length
Cable, 18 GA 3-Cond.P/N 3325325 ft.
Cable, 18 GA 3-Cond.P/N 3325450 ft.
Cable, 18 GA 3-Cond.P/N 3325575 ft.
Cable, 18 GA 3-Cond.P/N 33256100 ft.
Cable, 18 GA 3-Cond.P/N 33257125 ft.
ITEMPart No.Quantity
Secondary Gas Metering
221781
Box
Hose Assy., 50 ft. w/
340331
5/8" 18f Fittings
30 MICRON FILTER
TO PROTECT SYSTEM
WHEN TANKS ARE
CHANGED
2.10 INSTALLATION OF THE SECONDARY GAS
METERING BOX
1. Mount the gas metering box at a convenient location
with the owmeter vertical and use the hose supplied
to connect the box with the unit mounted on the
torch.
2. Connect the gas metering box to a source of dry oil
free shop air capable of delivering at least 11 scfm at
80 psig. The hose used should be at least 3/8" ID.
3. Use SJO wire to connect the gas metering box to the
cutting machine control. If the ESP system is used,
then the connection may be made to the "Air Curtain"
amphenol connector on the back of the ow control.
See Figure 2-16 if Air Curtain is already installed. The
connection of the gas metering box is made at the
terminals marked F. C. An appropriate cable may be
selected from the table of required accessories.
4. User supplied 115 V ac may be connected to the ter-
minals so marked. This will allow manual operation
of the gas metering box assembly.
5. Connect a ground wire to the stud provided in the
control box.
Note: For dry cutting, turn o the "cut water switch" on ow
control.
MIXED
BED
TANK
FINAL WATER
QUALITY INDICATOR
LIGHT
(200,000 OHM RATING)
34
SECTION 2 INSTALLATION
Plumbing Box Connections
Remove the hose nut from adaptor assembly. Place the
adaptor over the "cut water" tting as shown in gure 2-15
and screw the hose nut previously removed onto the "cut
water" tting and assemble as shown.
Operation
1. Provide gas metering box with oil free air at 80 psig
minimum. Energize solenoid in control box and adjust
regulator screw to the desired pressure and throttle
valve to set the desired ow. Refer to the appropriate
cutting parameter charts starting on page 49.
2. Place switch to AUTO. The system should turn on when
the preow begins.
3. Cutting stando (Torch to Work Distance) must now
be measured from the bottom of the Secondary Shield
Assembly. Refer to appropriate tables for proper
standos.
Note: Set piercing stando as specied in the appropri-
ate parameter chart.
WARNING
Electric shock can kill. Disconnect power from power
source before touching or servicing the Secondary
Shield at the torch. Disconnect power to the Control
Box before servicing.
Figure 2-15 Plumbing Box Connections
AIR CURTAIN
AMPHENOL
Terminal
Strip
Figure 2-16. Air Curtain, Secondary Gas Metering Box and Pump Motor
35
SECTION 2 INSTALLATION
1
14
16
15
12
13
2
8
6
7
11
ITEM NO.QTY REQ.PART NO.DESCRIPTION
1 122174 FLOWMETER ASSEMBLY (See Fig.4)
23 10Z30ADAPTOR B-A/W X 1/4 NPTM
3119Z99ADAPTOR 1/4 NPTM X .69 - 24F
4 182Z46WASHER FLAT .61 X .32 X .06 NYLATRON
5119906VALVE RELIEF ASSEMBLY
61 22220GAUGE 2.50, 100PSI
7 1 22181HOSE ASSEMBLY FOR PRESSURE GAUGE
82 22182HOSE ASSEMBLY FOR GAS IN & OUT
Operating with a plasma system such as the ESP-1000
contains a great number of variables to achieve quality
cutting over a wide range of applications. The setup and
operating characteristics for specic applications depend
on, type of material, thickness of material, type of cut gas,
dry cutting, water injection cutting or underwater cutting.
The information in this section will provide standard procedures and general guidelines for application.
WARNING
Electric shock can kill! Do not operate this equipment
with any covers removed. Take all precautions to remove power before attempting any service or maintenance inside cabinets or torch.
Arc rays can burn eyes and skin, noise can damage
hearing! Wear welding helmet with appropriate lter.
Wear ear and body protection.
3.2. CONTROLS AND INDICATORS
A. TEST/RUN
This area includes a 5-position switch, the CUT
WATER FLOW meter and the CUT WATER
PRESSURE SET regulator. The functions are:
1. CUT GAS position permits testing the cut gas ow
or purging the system without actually cutting.
2. START GAS permits testing the start gas ow or
purging the system without cutting.
3. RUN 1 position is used when cutting is to start with
the start gas, and after arc transfer occurs to switch
automatically to cut gas. This is one of two positions for actual cutting to occur. (Oxygen cutting is
normally performed in this position.)
4. RUN 2 position is used when the start of the process
is done with the same gas and ow as the cutting
process. (This position is normally used when Nitrogen and Argon-Hydrogen cutting is performed.
5. HF position permits testing of the high frequency
without cutting.
FLOW CONTROL
All controls are located on the front of the Flow Control.
The control panel is laid out in three sections, TEST/RUN,
CUT WATER, CUT GAS, plus, the Power Switch.
B. CUT WATER
This area pertains to control of the cut water ow for PT-
15XL only. The approximate ow rates for each position
are given in Table 3-1.
Figure 3-1. Flow Control Front Panel
39
SECTION 3 OPERATION
1. The ON/OFF switch is used to select whether or
not cut water is to be used. If ON, the ow rate is
determined by the setting of the ow rate switches.
This switch should always be ON for cutting with
the PT-15XL torch and o with the PT-19XLS (PT-
600).
2. FLOWRATE switches. The 8-position rotary switch
and two position toggle switch are used to set the
cut water ow rate. The 8-position switch (0-7) is
used for inputs within the ow control that determines the water ow rates. The switch operates
a combination of three of four solenoid valves in
parallel. The fourth valve is operated by the HIGH/
LOW switch. The cut water ows through measuring orices in each line of the four solenoid valves.
The orices vary in size so that each is capable of
doubling the ow, the largest orice delivers eight
times the ow as the smallest.
In the 0/ LOW setting no solenoid is energized. Posi-
tion 1 energizes the solenoid valve in the smallest
orice line. Position 2 energizes the valve next in
line of ow rate. Position 3 energizes both of these
valves. The progression continues to provide more
ow at each higher numbered position in equal
increments. In combination the four valves are
capable of providing dierent ows but the switch
limit is eight settings. The HIGH/LOW switch is used
to energize the solenoid with the largest orice that
allows using the remainder of the ows.
C. CUT GAS
This area includes the O
8-position switch and HI/LOW toggle switch. Refer to Table
3-2 for approximate ow rate for specic settings.
1. The O2/N2 switch selects the type of cut gas being
used for cutting.
2. FLOWRATE switches. The 8-position rotary switch and
two position toggle switch are used to set the cut
gas ow rate. The 8-position switch (0-7) is used for
inputs within the ow control that determines the
gas ow rates. The switch operates a combination of
three of four solenoid valves in parallel. The fourth
valve is operated by the HIGH/LOW switch. The cut
gas ows through measuring orices in each line of
the four solenoid valves. The orices vary in size so
that each is capable of doubling the ow, the largest
orice delivers eight times the ow as the smallest.
In the 0/ LOW setting no solenoid is energized. Posi-
tion 1 energizes the solenoid valve in the smallest
orice line. Position 2 energizes the valve next in
line of ow rate. Position 3 energizes both of these
valves. The progression continues to provide more
ow at each higher numbered position in equal
increments. In combination the four valves are
capable of providing dierent ows but the switch
limit is eight settings. The HIGH/LOW switch is used
to energize the solenoid with the largest orice that
allows using the remainder of the ows.
All control functions are provided through one receptacle
located on the front panel of the power source. A 19-pin receptacle allows plugging in the cable from the ow control.
All control signals are routed through this connection.
A. The current control mode for the power source is set
using the PANEL/REMOTE switch.
1. With the switch in the PANEL position, output current
is controlled by setting the power source current
control potentiometer (CCP).
2. With the switch in the REMOTE position, output
current is controlled from a remote device such as
a cutting machine CNC.
B. When using an ESP-600C power source, the LED indica-
tor lights on the front panel are used to help check for
proper operation of the unit.
1. OVER TEMP - illuminates should the power source
become over heated.
2. CONTACTOR ON - This light indicates that the main
power contactor has been energized and voltage is
being applied to the cutting circuit.
3. FAULT INDICATOR - illuminates should abnormalities
occur in the cutting process or if the input line voltage falls outside of the nominal value by +/- 10%.
F. AMMETER displays the arc current level when cut-
ting.
For control descriptions pertaining to the ESP-400
and Ultra Life 300 refer to the appropriate instruction
manual.
3.3. PRE-OPERATION TEST/CHECKOUT
The pre-operation testing and checking oers the advantage of having the parameters set and established in
proper order before starting to cut actual material.
A. TEST FUNCTIONS
The TEST/RUN portion of the Flow Control front panel
allows the user to test parts of the system, purge gas,
water lines and to select between two dierent RUN
modes.
B. RUN MODES
The rst run mode (RUN 1) starts with start gas (at start
gas ow) and switches over to cut gas when the arc
transfers.
The start gas is taken from the N2 gas input on the back
of the ow control box. The cut gas is taken either from
the N2 or the O2 input on the back of the ow control
box. The selection of the cut gas is accomplished with
the O2/N2 selector switch on the front panel.
4. POWER RESET FAULT - illuminates when a serious
fault is detected. Input power must be disconnected
far at least 5 seconds and then reapplied.
C. MAIN POWER indicator illuminates when input power is
applied to the Power Source.
D. PILOT ARC HIGH/LOW switch allows selection of the
pilot arc range HIGH or LOW.
E. VOLTMETER displays the arc voltage value when cut-
The second run mode (RUN 2) starts directly with cut
gas ow. In this case the gas used for cutting must
be connected to the N2 input on the back of the ow
control.
NOTE
Purging of gas leads should be possible even if insucient
gas pressure exists on incoming gas pressure switches.
41
SECTION 3 OPERATION
C. TEST FUNCTIONS
The tests are used to test and purge gas and water. The
test of the HF unit is made without activating the main
contactor of the power source. Since water is tested
at the same time, some of the tests are combined to
reduce the number of positions on the switch.
WARNING
Never operate the power source with the cover removed. In addition to the safety hazard, improper
cooling may cause damage to internal components.
Keep side panels closed when unit is energized. Also,
make sure you are adequately protected before you
start to cut.
Ensure that the power cable connections are properly
made to prevent water leaks. Any leakage during operation could be hazardous because of high voltage
and current.
CUT GASES
A. Set the delivery pressure of the gas supply regula-
tors according to the Table 3-4 (with gas owing).
For example, the recommended delivery pressure
for nitrogen cut gas and 50 feet of 1/4 inch ID hose is
104 psig. Delivery gauge mounted on regulator must
not read greater than 200 psig. Refer to Table 2-3 for
recommended gas regulators.
NOTE
Do not use hoses less than 1/4 inch ID in
the system.
CUT WATER
A. Basic Requirements
The PT-15XL requires a supply of clean cut water with
high electrical resistance.
1. To adjust the delivery pressure of the water injection
pump, remove the
pump and turn screw "in" to increase pressure or "out"
to reduce pressure. After adjusting replace the
nut.
2. The water injection pump must be supplied with
water from a source capable of delivering at least 1/2
gpm @ 25 psig minimum. The water injection pump
boosts this pressure to 190 to 200 psig for delivery to
the ow control.
3. Cut water must have a high electrical resistance (at
least 200,000 ohm-cm is recommended) and low
hardness (0.5 grains per gallon maximum). Conductive water can cause problems with starting reliability, high frequency noise problems with the cutting
machine or height control, and can cause corrosion of
torch parts such as; cups, nozzles. These deposits will
reduce cooling, lower cut quality by disrupting ow
through the nozzle, and can clog the ow control.
Tribed deionizer systems have generally proved to be the
best solution to supplying good quality cut water. Some
sources of deionizer systems are:
Culligan Water Treatment 708-205-6000
ECO Water Systems 513-423-9421
Master Chemical Corporation 419-874-7902
Local distributors can be found in the phone book or by
calling one of the above numbers.
After deionizing, water should pass through a 30-micron lter
before going to the cut water pump. Refer to Figure 2-13 for
further details of installation.
B. Cut Water Flow System Calibration
If the equipment is to be exposed to freezing temperatures
(while during non-operative time), water lines should be
blown out to prevent freeze damage to torch and equipment.
This is done to calibrate the cut water system when used
with the PT-15XL torch. Once it is completed, the cut
water ow is set with the ow rate switches for each case
according to the dierent cutting cable sizes.
1. Make sure that the Flow Control is turned on, the ON/
OFF switch is in the ON position and the indicator
light is lighted.
2. Set TEST/RUN selection switch to either CUT GAS or
START GAS position.
3. Set CUT WATER ON/OFF switch to ON.
4. Set CUT WATER HIGH/LOW switch to HIGH.
5. Set FLOW RATE switch to position 5.
6. Adjust CUT WATER pressure adjusting screw until the
CUT WATER FLOW gauge reads 0.45 gpm at the top
of the ball. Ensure that cut water pump gauge reads
no more than 220 psig. The preferred reading is 190
to 200 psig.
7. Toggle the CUT WATER ON/OFF switch a few times to
ensure any creep is out of the regulator adjustment.
Readjust if necessary.
The cut water system is now calibrated. This calibration
should be checked occasionally.
NOTE
Blowdown of the coolant system is not required if Plasma
Torch Coolant is used.
To blowdown the water injection system, disconnect water
supply to the Water Injection Pump and connect a supply
of nitrogen or clean air at 130 to 150 psig. Set the system
in test and set cut water ow to HIGH 7. Let the gas ow
until water stops coming out the front of the torch. It is
important that the Start Gas or Cutting Gas continues to
be supplied (at the same time as the purging air/nitrogen),
to prevent water feedback into the gas lines.
To blowdown the cooling system, disconnect the hose
from the cooler or pump and connect it to nitrogen or
clean air at 20 psig. The return hose should be connected
to drain. Blow gas through the system until coolant no
longer comes out the drain line. Do Not operate the coolant circulator without using plasma coolant 156F05 . The
coolant provides lubrication of the internal pump parts.
Algae growth and damage to the pump may occur if plain
water is substituted.
NOTE
Contact the supplier of the deionizer to discuss freezing
of the deionizing system.
POWER SOURCE
COOLANT
Cooling of the plasma torch is usually accomplished with a
coolant circulator. This circulator should be lled with plasma
torch coolant. Always use torch coolant, it lubricates the internal parts of the pump.
WARNING
Settings over 150 psig will cause premature failure of the
pump and/or motor-to-pump coupling.
Check out the coolant ow with the power source ON, by
observing the return water at the cooler. Coolant ow with N2
consumables should be 1.4 to 1.6 gpm. Coolant ow with O2
consumables should be 1.25 gpm. Coolant can be conveniently
checked at the return line by using a suitable container.
WARNING
Never operate the power source with the cover removed, in addition to the safety hazard, improper
cooling can cause damage to internal components.
Keep side panels closed when unit is energized. Also,
make sure you are adequately protected before you
start to cut.
The Power Source controls and their functions are described in the following sequence.
A. Check the secondary output connections to the posi-
tive and negative output bus bar terminals.
B. Verify that the control connections have been prop-
erly made.
43
SECTION 3 OPERATION
C. Determine the current control mode the power source is
to be operated in and set the Control Switch in the desired
position. With this switch in the PANEL position, output
current is controlled by setting the power source current
potentiometer. When the power source output current
is controlled by a cutting machine control system, place
this switch in the REMOTE position.
D. If the primary electrical input connections to the power
source have been installed correctly, close the main line
(wall) disconnect switch. Power will be applied and the
Pilot Light on the front panel will be on. The cooling fans
will come on when cutting starts.
E. Adjust the desired output current level at the power
source or at the remote control location.
F. Operate the starting switches on the cutting control to
energize the power source main contactor. Power will
appear at the power source output bus bar terminals.
G. After cutting has started, observe the ammeter, voltmeter
and/or the cutting operation. If necessary readjust the
current control as required.
H. The cutting arc will extinguish and the power source will
shut o automatically when the torch travels beyond the
edge of the work piece. The nozzle and electrode will
experience excessive wear (especially with O2). Therefore,
extinguishing the arc with an Arc Stop Signal before running o the work piece is recommended.
A properly installed and operating power source should function as follows:
A. After energizing the power source (at the disconnect
switch), the Main Power light (on the front panel) will illuminate and the Fault Indicator light will ash and then
go out.
B. When the contactor signal is received ( the "Contactor
On" indicator will light) and power is applied to the main
transformer, Open Circuit Voltage is available at the power
source output terminals as indicated on the voltmeter.
C. Upon transfer of the main arc to the work, a current de-
tector circuit senses the current and sends an "ARC ON"
signal to the Flow Control.
3.4. OXYGEN CUTTING WITH PT-15XL
The procedures presented in this section pertain to use of
Oxygen as the cutting gas in conjunction with the PT-15XL
plasma cutting torch. The information is relative to setting
parameters for various types and thicknesses of materials.
Refer to the torch instruction manual F-15-031 for details
of the torch assembly.
WARNING
Electric shock can kill! Before touching the torch, be
sure the power source is shut o by removing the
3-phase power input to the power source.
A. Ensure that the torch is assembled correctly for oxy-
gen cutting. Internal parts of torch must be clean and
dry.
B. If using an air curtain or bubble muer, be sure instal-
lation and setup are correct.
C. Set Flow Control O2/N2 switch to O2 position.
D. Set the Flow Control CUT WATER ON/OFF switch to
ON.
E. Set the Cut Water and Cut Gas ow as indicated in
Table 3-6.
NOTE
Cut Water must be calibrated as described on Page 27.
F. Set Flow Control TEST/RUN switch to CUT GAS TEST
position.
1. Ensure that O2 regulator is set to 100 psig.
2. Observe torch spray pattern. It should be rela tively even, regular and steady.
G. Set Flow Control TEST/RUN switch to START GAS TEST
position.
H. Set start gas regulator on Plumbing Box to 26 psig.
Check N2 regulator setting per Table 3-4.
I. After changing consumables or a substantial break in
cutting operations, purge the torch in CUT GAS TEST
position for at least 60 seconds before cutting.
J. Set the TEST/RUN switch in the RUN 1 position. The
system is ready to cut.
44
SECTION 3 OPERATION
GAS
BAFFLE
OXYGEN
ELECTRODE
BODY
ASSEMBLY
NOZZLE
NOZZLE RETAINING
CUP
Figure 3-2. PT-15XL Torch Components for Oxygen Cutting
TABLE 3-5. COMPONENTS FOR OXYGEN CUTTING WITH PT-15XL
OXYGEN
ELECTRODE
HOLDER
ELECTRODE
HOLDER
2039820763XL0.099260A207518-HOLE
ELECTRODENOZZLE ASSEMBLYSWIRL BAFFLE
DiameterRATINGP/Nstandardoptional
35666XL
(FLAT)
0.099
REV.
0.116
0.120
0.116
REV.
0.120
REV.
260A209208-HOLE
300A
340A
300A356638-HOLE
340A35665
35662
35664
FRONT BODY
INSULATOR
ASSEMBLY
NOTE: Refer to F-15-031 for part
numbers and options.
4-HOLE
CERAMIC
2075586
CERAMIC
REVERSE
20918
8-HOLE
CERAMIC
35660
CERAMIC
REVERSE
35661
CERAMIC
948142
4-HOLE
CERAMIC
REVERSE
948143
N/A
45
SECTION 3 OPERATION
TABLE 3-6. OXYGEN CUTTING CONTROL SETTINGS WITH PT-15XL
Higher speed is sometimes obtained on thicker plate by increasing gas setting to LOW 6.
* Dross free conditions on 1" are more easily obtained at 300 to 340 amps.
2. When using the ESP-300 power supply, low range must be used for current under 80 amps. High range
3. Gas Bae: 948142 "4x030"
948143 "4x30 Rev."
Electrode: 35666XL
Nozzle: 37317 "Nozzle low current PT-15XL"
37318 "Nozzle low current PT-15 Rev."
itrogen generally produces smoother cut surfaces on stainless steel and aluminum, but with
somewhat more bevel and top edge rounding than oxygen. Oxygen generally has a wider
dross free speed range.
will produce less ripple on the cut face and can usually be user at current over 80 amps. The cut face
ripple is most noticeable on stainless steel cut with nitrogen.
48
SECTION 3 OPERATION
3.5. NITROGEN CUTTING WITH PT-15XL
WARNING
Electric shock can kill! Before touching the torch, be
sure the power source is shut o by turning o the
3-phase power input to power source.
The procedures presented in this section pertain to use
of Nitrogen as the cutting gas in conjunction with the
PT-15XL plasma cutting torch. The information is relative
to setting parameters for various types and thicknesses of
materials. Refer to the torch instruction manual F-15-031
for details of the torch assembly.
A. Ensure that the torch is correctly assembled for nitro-
gen cutting. (Refer to Table 3-9 for components.)
TABLE 3-10. COMPONENTS FOR NITROGEN CUTTING WITH PT-15XL
B. Set Flow Control switch O2/N2 in the N2 position.
C. Set Flow Control CUT WATER ON/OFF switch to ON
position.
D. Set CUT WATER and CUT GAS ow per Table 3-10.
NOTE
Cut water must be calibrated as described on page 26.
E. Set Flow Control TEST/RUN switch in CUT GAS TEST
position.
1. Ensure that N2 regulator is set per Table 3-4.
2. Observe spray pattern. It should be relatively
even, regular and steady.
or coolant from new parts before restarting a torch.
The electrode removal nut driver must be clean. It
must not leave any contamination on the electrode.
F. After changing consumables or any substantial break
in cutting operations, purge the torch in START GAS
TEST for at least 60 seconds before cutting.
CAUTION
Purge the gas line with the Flow Control TEST/RUN
switch in the CUT GAS position for three minutes when
switching from O2 to ArH2 or N2 cutting. This will ensure
that no O2 exists in the cut gas lines. Small amounts of
O2 will cause rapid erosion of the tungsten electrode
that is used for cutting with N2 or ArH2.
G. Set Flow Control TEST/RUN switch in the RUN 2 posi-
tion.
The system is now ready to cut.
Underwater Nitrogen Cutting
When cutting plates up to 1 inch thick using N2 underwater, cutting speeds and cut surface appearance are not
appreciably aected. Therefore, the data in Table 3-10 are
suitable for both above and underwater cutting.
Cut quality and cutting speed diminish when cutting
1-to-3 inch thick materials underwater, particularly aluminum. The 0.230 inch nozzle is not recommended for cutting under water; however, the 0.200 inch nozzle assembly
may be used for cutting up to 3 inch thick aluminum at
600 amps and still give a reasonable appearing cut. The
approximate cutting speeds for underwater cutting of materials 1-to-3 inches are given in Table 3-12. Flow settings
for each nozzle are the same as given in Table 3-11.
DANGER
Hydrogen explosion hazard! Read the precautions on
page 42 before starting under water cutting.
H-35 is a mixture of hydrogen and argon that is used
for cutting material thicknesses of 3 to 6 inches. The
hydrogen component of the gas is ammable, requiring
certain precautions. Underwater cutting with H-35 is not
recommended. Table 3-14 provides the control settings
for cutting conditions.
When changing consumables, always wipe any water or
coolant from parts before installing and restarting torch.
The electrode removal nut driver must be clean. It must
not leave any contamination on the electrode.
B. Set Flow Control O2/N2 switch to N2.
CUT SPEED (IPM)
carbon
steel
stainless
NOTE
steel
alumi-
num
A. Install high current parts in torch per Table 3-13.
RETAINING
CUP
Figure 3-4. PT-15XL Front End Assembly for H-35 Cutting
TABLE 3-13. COMPONENTS FOR H-35 CUTTING WITH PT-15XL
switch in the CUT GAS TEST position. Purge with
N2 for three minutes.
2. Connect H-35 to the Flow Control N2 IN connector
and purge N2 from the lines for 60 seconds.
E. Set H-35 regulator in accordance with Table 3-4.
3.7. CUTTING WITH THE PT-19XLS and
PT-600 TORCHES
The PT-19XLS and PT-600 are mechanized plasma cutting
torches designed for cutting without water injection. Cutting can be performed using air, oxygen, nitrogen or H-35
as the cut gas at currents ranging from 50 to 360 amperes.
Underwater cutting can be performed with the PT-19XLS
by using an Air Curtain at 150 amps or higher. Refer to
your torch manual.
F. Set Flow Control TEST/RUN switch to RUN 2 posi tion. The system is now ready for cutting.
Gas Bae
50-200A - 948142
250-600A - 35660
400A, O
- 22194
2
Figure 3-5. PT-19XLS Components
Reference only. Refer to your torch manual for specic or updated instructions
52
SECTION 3 OPERATION
Table 3-15 COMPONENT SELECTION FOR PT-19XLS
Application
Current & Thickness Shield Diuser Nozzle Electrode Gas Bae
Plasma Gas & Material
50-65A 1.16 to 6mm 50A 50A Tip-22026 34086XL 948142
Air & N2 CS, SS, AL 21795 21796 Base-22027 4 Hole STD
100A 4 to 19mm 100A-250A 100-360A Tip 22029 34086XL 948142
, O2 CS, SS, AL 21802 21944 Base 22028 4-Hole STD
Air, N
2
948143
22496Rev. 4 Hole Rev
150A 6 to 25mm 100A-250A 100 -360A Tip 22030 34086XL 948142
Air, N2, O2 CS, SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.
150A 6 to 25mm 100A-250A 100-360A Tip 22030 22403 948142
N2, H35 SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.
200A 6 to 50mm 100A - 250A 100 - 360A Tip 22031 34086XL 948142
Air, N2, O2 CS, SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.
200A 6 to 38mm 100A-250A 100-360A Tip 22031 22403 948142
N2, H35 SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.
250A 6 to 50mm 100A-250A 100-360A 21822 34086XL 35660
Air, O2 CS, SS, AL 21802 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.
250A 6 to 50mm 100A-250A 100-360A 21822 22403 35660
N2, H35 SS, AL 21802 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.
325-360A 13 to 50mm 360A 100-360A 35885 35886XL 35660
Air, N2, O2 CS, SS, AL 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.
325-360A 13 to 50mm 360A 100A-360A 35885 22403 35660
N2,H35 CS, SS, AL 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.
400-450A 19 to 50mm 360A 100A-360A 22195 22196 22194
O2 CS, SS, AL 21945 21944 (1-Piece 32 x .023
400-450A 19 to 50mm 360A 100A-360A 22195 22403 35660
N2, H35 AL, SS 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047Rev.
600A 25 to 75mm 360A 100-360A 22401 22403 35660
N2, H35 CS, SS, AL 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047Rev.
Recommended Replacement Parts
53
SECTION 3 OPERATION
NOTE
For expanded details of the PT-19XLS (PT-600) refer to the
your torch manual.
LOW CURRENT CUTTING WITH AIR AND PT-19XLS (50
to 100 Amps)
1. Ensure that the correct components are assembled
in the PT-19XLS (PT-600) for the cutting conditions.
Refer to Table 3-15.
ADAPTOR
999304
1/4 NPTM*
B-OXY -F*
CHECK VALVE
ASSEMBLY - 21124
HEX. NIPPLE
639501
4. Set the O2/N2 switch to N2 position.
5. Place CUT WATER switch to OFF.
6. Set CUT GAS Flow Rate as shown in Table 3-14.
7. Position TEST/RUN switch to RUN 1.
AIR REGULATOR
ASSEMBLY -522368
CONNECTOR
3389
1/4 NPTM*
1/4 NPTF*
* Use Locktite pipe sealant on threads, DO NOT use
Teon tape.
Figure 3-5. PT-19XLS (PT-600) Regulator Assembly
2. To cut with air, disconnect N2 supply from the Flow
Control. Connect a supply of clean, ltered air (approximately 100 psig to the N2 inlet on the Flow
Control.
3. For low current cutting with the PT-19XLS (PT-600)
and ESP-1000 a cut gas regulator system is required
for air. See gure 3-5 for assembly details.
(2) 1/8" NPT
PIPE PLUGS
643792
8. Set start gas pressure as follows:
A. TEST/RUN switch to START GAS TEST.
B. Adjust start gas regulator to 30 psig.
C. Return TEST/RUN switch to RUN 1.
9. Set cut gas pressure as follows:
A. TEST/RUN switch to CUT GAS TEST
B. Adjust cut gas regulator to 60 psig.
1/4 NPTF*
1/4 NPTM*
B-OXY-M*
C. Return TEST/RUN switch to RUN 1 position.
54
SECTION 3 OPERATION
PT-19XLS (PT-600) H-35 CUTTING AT 150 TO 300
WARNING
AMPS
Electric shock can kill! Before touching torch, be sure
power source is shut o by turning o the 3-phase
power input to the power source.
OXYGEN AND AIR CUTTING WITH PT-19XLS (PT-600)
(100 - 360 AMPS)
1. Ensure that the torch is assembled correctly for oxygen or air cutting at the selected current level. See
Table 3-15 for parts and setup information.
2. If using PT-19XLS air curtain, see Form 15-475 for correct installation and setup.
3. Set Flow Control O2/N2 switch to O2 position.
4. Set Flow Control Cut Water ON/OFF switch to OFF.
5. Set CUT GAS Flow per Cutting Tables starting on page
50.
6. Set Flow Control TEST/RUN switch to CUT GAS TEST.
Check that O2 regulator is set at 100 psig.
7. Set Flow Control TEST/RUN switch to START GAS TEST
switch. Adjust Start Gas regulator, on Plumbing Box, to
25 psig. Check that N2 regulator is set to 100 psig.
8. Purge torch in START GAS TEST position for at least
60 seconds before cutting after changing consumables.
9. Set Flow Control TEST/RUN switch in the RUN 1 position. The system is ready for cutting.
H-35 is a mixture of hydrogen and argon that can be
used with the PT-19XLS (PT-600) for cutting stainless and
aluminum. This mixture is ammable requiring certain
precautions. Underwater cutting with H-35 is not recommended.
1. Install H-35 torch parts for the chosen current level
per Table 3-15.
2. Set the Flow Control O2/N2 switch in the N2 position.
3. Set Flow Control CUT WATER ON/OFF switch to OFF.
4. Purge gas lines:
A. Disconnect O2, with the Flow Control in the CUT
GAS TEST position, purge with N2 for three minutes.
B. Connect H-35 to the Flow Control N2 Inlet con-
nection and purge N2 from the lines for 60 seconds.
5. Check H-35 regulator for setting of 100 psig.
6. Adjust gas setting per Cutting Tables. The system is
now ready to cut.
3.8. HIGH CURRENT CUTTING CONDITIONS
PT-19XLS (PT-600)
PT-19XLS (PT-600) NITROGEN CUTTING AT 150 AND
250 AMPS
1. Ensure that the torch is assembled correctly for nitrogen cutting at the selected current level. See Table
3-15 for parts and setup information.
2. If using a PT19XLS air curtain, see Form F-15-475 for
correct installation and setup.
3. Set Flow Control O2/N2 switch to N2 position.
4. Set Flow Control CUT WATER ON/OFF switch to OFF
position.
5. Set CUT GAS ow per Cutting Tables starting on page
50.
6. Set Flow Control TEST/RUN switch to START GAS TEST.
Adjust Start Gas Regulator, on Plumbing Box, to 26
psig. Check that N2 regulator is set to 100 psig
7. Purge torch in CUT GAS TEST position for at least 60
seconds after changing consumables before cutting.
8. Set Flow Control TEST/RUN switch to RUN 1. The system is now ready to cut.
By using special components in the front end assembly
of the PT-19XLS (PT-600) cutting can be accomplished at
higher current and faster speeds. Cutting carbon steel
can be performed either above water of underwater,
cutting stainless steel and aluminum underwater is not
recommended.
The cutting speeds listed in the following tables are average values. Variations may occur depending on material
composition, surface conditions, etc. Practice cuts in a
scrap area of new material are recommended before
starting production cuts.
To use the 50A or 100A nozzles with the ESP-1000 System, you must install a regulator at the Cut Gas conn
the Plumbing Box. See Figure 3-5.
B. Cut Gas & Start Gas input pressures to the ow control should be 100 psig (6.9 Bar) for all Nozzles and Gases.
c. Refer to torch manual for recommended torch parts for these cutting conditions.
H-35 plasma gas/nitrogen shield produces good to excellent cut quality on 1" to 3" aluminum. H -35 plasma gas/air shield
produces cut quality nearly as good on 1-1/2" to 3" aluminum. Nitrogen plasma gas/air shield produces fair quality cuts on
1“ to 1-1/2 “ aluminum.
H-35 plasma gas/nitrogen shield yields the best quality on 1“ to 3“ stainless steel, with smooth surfaces and moderate
quantities of dross. Nitrogen plasma gas/air shield may be used to achieve good cuts on 1“ and fair cuts on 1-1/2“ stainless
steels at higher speeds than H-35.
Piercing of plate 2" to 3" thick is best accomplished with the moving pierce technique: Start the arc at 3/4" stando, 250
amps, and 35 to 40 ipm. Immediately upon arc transfer, raise the stando to a cutting voltage of 225 to 240 volts. After the
arc has been on about one second, ramp the current up to 600 amps over a two second interval. After another two second
delay, reduce the speed to about half the recommended cutting speed until the arc burns through the plate.
69
SECTION 3 OPERATION
3.9. OPERATING TECHNIQUES
Mirror Image Cutting
If desiring to cut with two torches simultaneously, with one
moving in the mirror image of the other, the standard gas
bae can be replaced by their reverse swirl counterparts
so that the right-edge remains square.
Bevel Cutting with Standard Parts
Bevel cutting requires the same setup considerations
as standard straight cutting with a few exceptions. The
thickness of the cut is longer than the material thickness
therefore the nozzle assembly and cutting speed must
be selected accordingly. Illustrated in Figure 3-5 are the
maximum bevel angles that can provide good quality cuts
with each nozzle based on 1/8 inch clearance (not stando) between torch and work piece. Large bevel angles can
be made by reducing the clearance and increasing the arc
length if cut quality can be sacriced.
PT-15XL Bevel Angles
PLATE
THICKNESS
(IN.)
1/42075691 (0.125)35
3/42075611 (0.156)40
1-1/22075612 (0.200)45
22075613 (0.230)40-45
XR NOZZLE
ASSEMBLY
PART NO.
MAXIMUM
BEVEL ANGLE
(A)
o
o
o
o
The resulting bevel angle setting, particularly on thin materials, may be 5 degrees greater than the torch angle. The
bevel retaining cup has smaller feet and steeper sloped
sides required to angle the torch without hitting the work
piece. The bevel retaining cup is also usable for straight
cutting required with an air curtain or bubble muer
although there is less protection than with the standard
cup. Normally used with oxygen.
Special nozzles for oxygen beveling are available. See Form
F-15-031 Instructions or PT-15XL Plasmarc torch.
A
ARC LENGTH
1/8"
Figure 3-6. Bevel Cutting Characteristics
Piercing
Piercing can be accomplished on plates up to about 1-1/2
inches thick by delaying carriage movement until the arc
penetrates through the plate. The following are typical
delay timer settings:
PLATE
THICKNESS
1/2 IN.1/4 SEC.
1 IN. 3/4 SEC.
1-1/2 IN. 1-1/2 SEC.
SET CARRIAGE
DELAY TO
When piercing plate 1-1/2 to 3 inches thick, allow the
carriage to move (no delay) at about 1/2 the normal cutting speed. Permit the arc to slice through the plate and
produce a rooster-tail eect of molten spray. As soon as
the arc penetrates through the plate, adjust the carriage
travel to the normal cutting speed. Piercing requires practice and skill. Piercing is made at a higher stando than
actual cutting. This helps prevent spatter from destroying
the nozzle.
70
ab
c
d
SECTION 3 OPERATION
1/4 SPEED
2/3 OF
THICKNESS
Figure 3-7. High Current Cutting Thick Plate
PT-15XL Cutting with High Current Nozzles (4 to 6
inch Plates)
Normally, only a slight carriage delay (1/2 to 2 seconds depending on plate thickness) is required to allow cutting arc
to penetrate through a plate, then cutting can continue at
the recommended speed. However, when cutting plate 4
inches or more thick, a little more consideration is required
for starting and ending a cut. The following procedures are
recommended (refer to Figure 3-6).
a. Start at edge of plate as normal.
b. Delay carriage movement until arc penetrates
about two-thirds of the plate thickness. (2-1/2 to
3 seconds.)
c. Start carriage movement about 1/4 of the recom-
mended speed until arc cuts through the lower
corner of the plate edge and then cut at the
recommended speed. The molten spray from the
bottom of the plate should be lagging slightly
behind the arc cutting at the top of plate.
d. When about 1 inch from end of cut, reduce the
speed slowly, allowing the molten spray to catch
up to the arc cutting at the top.
FULL
SPEED
LAG
1"
REDUCE
SPEED
1. Underwater Cutting: PT-15XL & N2 Plasma Gas
It has been found that an eective means of reducing
the cutting noise level to 85 db or lower is by cutting
under 2 to 3 inches of water. Fumes and UV radiation
are substantially reduced. No plasma arc equipment
change or accessory is required for underwater cutting. However, an automatic cutting system requires
controlling the initial stando when starting the cut.
In cutting materials up to 1-inch thick underwater,
neither cutting speed nor cut surface appearance is
appreciably aected. Cutting speed and cut surface
quality diminishes when cutting plates between 1 and
3 inches thick. Underwater cutting of plates 3-inches
or thicker is not recommended. Underwater cutting
with oxygen requires the use of an air curtain or bubble
muer.
NOTE
When cutting underwater, care must be taken when
a rust inhibitor is used in the water. Some inhibitors
contain enough conductive materials to prevent
arc starting. CM-1000S (manufactured by Chemicals
Methods, Inc.) is one satisfactory inhibitor.
2. Water Muer (Option) PT-15XL & N2 Plasma Gas
Noise, Fume and UV Radiation Considerations
The noise level of plasma cutting is greater than 110 db 6
ft. or 1.8 m from torch and depending on location of torch
with respect to sound reecting surfaces and the power
level used for cutting. OSHA allows exposure to 95 db on
a 50% duty cycle (4 hours out of an 8 hour shift) and to
90 db on a 100% duty cycle.
There are currently several methods of attenuating noise,
fumes and UV radiation of the plasma arc process; underwater cutting, underwater cutting with bubble muer,
underwater cutting with air curtain or cutting with a
water muer.
Another method of fume control is to use the water
muer, above or underwater. For maximum eectiveness, the water muer is recommended for use
in conjunction with a water table to eliminate 99.5%
of noxious gases and particulate emissions from the
plasma arc cutting operation. The water muer is less
eective in controlling noise and UV radiation than
underwater cutting. The water muer is not recommended for use with oxygen cutting.
3. Air Curtain (Option) PT-15XL & PT-19XLS
The air curtain uses air to provide a "dry" area around
the arc during underwater cutting. The air curtain is
recommended for use with oxygen cutting as the most
economical approach to fume and noise control.
71
SECTION 3 OPERATION
4. Bubble Muer (Option) PT-15XL & Water Muer
(Option) PT-19XLS
The bubble muer can be viewed as a combination air
curtain and water muer. It is recommended for use
with oxygen when both underwater and above water
cutting are to be used.
WARNING
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:
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 anity 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.
A. Clean the slag (especially ne particles) from the
bottom of the table frequently. Rell 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 rst plate is laid
in position. This will allow accumulated hydrogen
in the refuse to break loose and dissipate before
it is conned by a plate on the table. This might
be accomplished by laying the rst plate onto
the table with a slight jolt, then raising the plate
to permit hydrogen to escape before it is nally
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.
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.
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.
H. Programmed part spacing should be a minimum
of twice the kerf width to ensure material is aluminum under the arc.
72
SECTION 3 OPERATION
DANGER
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) X8192 (Alcoa)
Alithally (Alcoa) Navalite (U. S. Navy)
2090 Alloy (Alcoa) Lockalite (Lockhead)
X8090A (Alcoa) Kalite (Kaiser)
X8092 (Alcoa) 8091 (Alcan)
For additional details and information on the safe use
from the hazards associated with these alloys, contact
your aluminum supplier.
73
SECTION 3 OPERATION
74
SECTION 4 MAINTENANCE
4.1. PROGRAMMABLE LOGIC CONTROLLER (PLC)
The PLC is located in the top section of the Flow Control and
is a device capable of providing predened outputs depending on the state of the inputs. The precise conditions are
programmed and permanently stored in the PLC. Because
it is a solid state device the PLC is inherently very reliable. It
is also relatively compact.
The PLC will provide predened outputs in response to inputs from external devices. This exchange of signals can be
conrmed by observing the LEDs on the top of the PLC while
troubleshooting. These indications are useful in isolating a
system failure to the most likely device. They can be seen
through window in the Flow Control top cover.
The LEDs are divided into two groups; Input (0-15) and Output (0-11). Input LEDs light when the corresponding signal is
detected by the PLC. Output LEDs light when the PLC issues a
signal to an external device. The fault LED (output 1) indicates
the PLC has detected an error within the ESP and has caused
the system to enter the not ready (fault) state.
LEDs are highly reliable indicators. It is not likely that one will
burn out. However, if the technician is not condent that the
LEDs are working the presence of a signal can be conrmed
by using a meter to measure the appropriate pin. Refer to
the schematic and wiring diagrams.
The signal exchange between the PLC and external devices
are both time dependent and condition dependent. If a
required signal is not received in the proper sequence, the
PLC will discontinue the process and generate a fault signal
to the CNC.
TABLE 4-1 PLC INPUT/OUTPUT LEDs
INPUT OUTPUT
LED FUNCTION LED FUNCTION
0 Start/Stop 0 Process Running
1 Current Detector 1 Fault Signal
2 Nitrogen Pressure 2 Power Source On/O
3 Oxygen Pressure 3 Cut Water On/O
4 Interlock Plumb.Box 4
5 Cooling Water Flow 5
6 Cut Water Flow 6 Air Curtain
7 Cut Gas Pressure 7 Cut Gas Metering
8 Run 1 8 Cut Gas On/O
9 O2/N2 Select 9 Start Gas On/O
10 Emergency Stop 10 HF On/O
11 Cut Water On/O 11
12 Test Cut Gas
13 Test Start Gas
14 Run 2
15 Test HF
4.2 Sequence Description
The program controlling the plasma system sequence
is made with the help of a group of conditional states.
Inputs from sensors, and the cutting machine are continuously evaluated by the PLC to determine whether the
program stays in its present state or makes a transition to
another state.
The dierent states are shown as rectangles in gure 4-2.
The function of the seven states are described in the following paragraphs.
0 - Ready state
The "Ready" state is the normal state for the system to be
in when not executing the cutting process. In this state,
the system awaits the start signal from the cutting machine and monitors the selection keys and safety switches.
While in this state it is possible to activate the gas ows
and cut water ow for testing and purging the system.
Figure 4-1. PLC LED Panel (Partial View)
1 - Preow state
The "Preow" state is a xed duration and is reached only
from state "0". Nitrogen is always the preow gas in RUN 1
position. Selected cut gas type and ow is the preow gas
in RUN 2 position. Cut water ow during preow whenever a water injection torch is used and cut water is switched
on at the front panel. The air curtain output is energized
at this time also.
2 - Open Circuit Voltage State
The main contactor of the power source is activated after
the preow, and a short time is allowed for the open circuit voltage to be reached.
75
SECTION 4 MAINTENANCE
3 - PILOT ARC STATE
The Pilot Arc State is started by activating the high frequency unit. The time allowed between this and the requirement of a current ow signal from the power source
is a xed time. If the signal from the power source is not
received during this time, the state is transferred to the
not ready state 7.
4 - CUTTING STATE
In the Cutting State, the cut gas is turned on and the start
gas o if using RUN 1. A signal is sent to the cutting machine control indicating that the process is running. This
is the normal state to be in during cutting.
5 - PRIORITY POSTFLOW STATE
The Priority Postow State provides the minimum postow of nitrogen gas and cut water ow necessary before
a restart is possible. The time is dierent depending upon
whether cutting with nitrogen or oxygen. This state is
reached when the START/STOP goes low or current ow
through the arc is lost.
6 - FINAL POSTFLOW STATE
The Final Postow State provides the time during which
nitrogen gas and cut water ow cools the torch. This state
immediately follows the Priority Postow state, a restart is
possible during postow.
When the time for postow has elapsed, the program
transfers to the 0 Ready state. If a new start signal has been
given from the cutting machine control after it stopped
the process, a fast restart will be executed directly from the
Postow state to state 2 that turns on the main contactor
in the power source.
7 - NOT READY STATE
During the Not Ready State (fault state) the Programmable
Logic Controller (PLC) is sending a fault signal to the cutting machine.
It is possible to test gas/water ows in this state. The HF
unit can be run for test purposes in this state.
Figure 4-2. Plasma Sequence Flow Diagram
76
SECTION 4 MAINTENANCE
4.3. OPERATING INFORMATION
MAXIMIZING CONSUMABLE LIFE
Plasma torch electrode and nozzle life is a function of many
factors, some of which are under control of the operator. When using oxygen as the plasma gas in a properly
operating system, electrode wear and life is a function of
the number of arc starts, the total duration of the cutting
time and the current level. The longer the cut time for a
part being cut, the fewer the number of arc starts on an
oxygen electrode before it must be replaced. The graph
below shows the relationship between the two.
ELECTRODE LIFE
LINE
# OF STARTS
CLEANING OXYGEN NOZZLES
As the electrode wears considerable deposits of hafnium
oxide and silver can build up in the nozzle. Calcium carbonate can also build up at he nozzle exit if the cut water
is not adequately treated. These deposits can sometimes
cause substantial reductions in cut quality, speed and
consumable life.
Nozzle performance can be restored by removing these
deposits from the inside of the nozzle and the nozzle exit. A
twisted piece of very ne sandpaper or crocus cloth usually
cleans the nozzle well enough. Care must be taken not to
damage the thin copper edge at the nozzle exit. The 340
amp nozzles have a heavier less easily damaged exit as
compared to the 260 and 300 amp nozzles.
Nozzle performance is also degraded by nicks and elongation of the orice due to double arcs or mechanical damage. Cleaning will not restore a damaged nozzle.
Whenever a nozzle is removed for cleaning the electrode
should be inspected. If the wear is greater than 0.090 inch
or very irregular, the electrode should be replaced.
DURATION OF CUT
Figure 4-3. Oxygen Electrode Life Graph
Oxygen electrode and nozzle life are also aected by the
current setting. If parts are operated above their recommended current level, life deteriorates quickly. Improper
cutting and parts programming can adversely eect oxygen consumable life, so it is important that proper techniques be used. Oxygen plasma nozzles and electrodes
are less forgiving of improper operation than nitrogen
nozzles and electrodes. When using nitrogen or argon/
hydrogen as a plasma gas, nozzle and electrode life are
primarily a function of current level. The higher the current
the shorter the life.
CUT QUALITY
Maximum attainable cut quality is highly dependent on
the material being cut. With the wide variety of commercial
metals and alloys being cut with plasma, optimum cut
quality can vary widely from situation to situation. Suggested cut parameters given in this manual are starting
points only for general cases. Fine tuning of the various
parameters may be required to get the best possible cut of
a specic material. Some materials, including certain steels,
are dicult, if not impossible to cut dross free. Likewise, in
carbon steels, variations in plate composition, treatment
while rolling, contaminants and other factors can cause the
dross generated to vary from heat to heat, plate to plate
and area to area on a plate. As a general rule, using oxygen
as a plasma gas produces less dross variation on carbon
steel as a result of these factors, but is not a guarantee that
"dross free" cuts will be produced.
77
SECTION 4 MAINTENANCE
4.4. TROUBLESHOOTING
The following troubleshooting guide is primarily an operationally oriented guide. If a problem exists in one of the system
components, the guide will direct you to that manual. When directed to another manual, be sure a qualied maintenance technician is contacted.
TROUBLESHOOTING GUIDE
ProblemProbable CauseRemedy
1. Reduced consumable
(electrode) life (O2 and N2
cutting)
Excessive current.Check Power Source ammeter (Refer to
Power Source Manual).
Gas settings - inlet pressure.Check that settings are in accordance with
charts. Use gas ow check kit.
Gas or water leak.Check for leaks.
Inadequate cooling.Check water cooler for proper operation.
Single phasing of Power Source.Refer to Power Source manual.
Wrong gas bae (O2).Install correct gas bae (O2).
Moisture in system.Purge system of moisture for a minimum of
30 seconds after long idle time.
Cut water setting.If set to high, it can cause water to reach the
electrode.
Process factors:
Running o work.Extinguish arc with Arc Stop Signal prior to
running o work or use a waste plate to run
o on. This is most important with O2 cut-
ting.
Flipping or twisted parts hitting
torch.
Skeleton cutting.Cutting skeletons to facilitate their removal
Change program or x table.
from the table can adversely aect electrode
life by:
A. Causing the torch to run o the work. (see
above)
78
B. Causing multipop edge starts. (see below)
C. Greatly increasing the frequency of starts.
This is mainly a problem for O2 cutting and
can be alleviated by choosing a path with a
minimum number of starts or by bridging
gaps in the skeleton with water plates.
D. Increased 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 stand-
o and reducing cutting speeds.
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
ProblemProbable CauseRemedy
1. Reduced consumable (electrode) life
(O2 and N2 cutting) (cont)
Height control problems.
Piercing stando too low.
Starting on edges with multipop
starts.
Drawn arc from falling part.
Purity and dryness of gas.
Gas switching is not activating.
Since many of these problems are most severe with O
when it may be practical to cut skeletons
with N2 consumables:
A. When you will be changing to N2
consumables for the next plate anyway.
B. When one plasma station on the
machine is not being used for part
cutting and could be used for cutting
skeletons with N2.
On machine with Oxweld or Purox torch,
it may be practical to use the gas torch for
skeleton cutting.
See crashing/diving in item 2 below.
Increase piercing stando.
Position torch more carefully or use a waster
plate to start on. This is most important for
O2 cutting.
Change program.
Verify purity to be 99.55% O2 . Verify dew
point. Verify purity of N2 to be 99.995%.
This pertains to O2 cutting only. Check to
make sure that switch is in Run 1 mode so
that the arc begins in N2 and switches to O2.
This may be checked by installing the gas
test ow-meter rst on the N2 line into the
ow control to see that N2 is owing during
preow and postow only. Then install it
on the O2 line into the ow control to check
that O2 is owing only during the cut. O2
should never ow when cutting with N2.
cutting consumables, consider
2
79
SECTION 4 MAINTENANCE
ProblemProbable CauseRemedy
1.Reduced consumable
(electrode) life (O
and
2
N2 cutting) - (cont)
2.Reduced nozzle life
(N2, O2 and ArH2)
O2 present at start.
Using non-genuine consumables.
Incorrect cut water sequence.
When O
cutting, check above for gas switch-
2
ing.
When N2 cutting, any presence of O2 will
result in rapid electrode wear. Make sure
system has been purged in cut gas test.
Check for gas or water leaks in torch or hoses.
Check gas quality. Ensure that O2 OSV in ow
control is not leaking by disconnecting O2
from the ow control purging system.
N2 cutting is done with a tungsten electrode.
Tungsten will turn blue or yellow in the presence of oxygen from any source.
Replace with genuine consumables.
Correct cut water sequence. Cut water must
be on when arc starts. PT-15XL only.
Cut water quality.
Cut water settings.
Improper pierce height.
Contacting work:
Diving
See section 3.
Review and set proper cut water settings per
instructions in Section 3.
Refer to appropriate application Table for
correct setting.
Diving is usually caused by a change in arc
voltage when an automatic height control is
in use. Diving can result in loss of cut damage to the nozzle. Usually the voltage change
is as the result of a change of direction or
speed to negotiate a corner or as a result
of plate falling away from the arc. These
problems can be dealt with by disabling the
height control in such situations and by extinguishing the arc earlier when nishing the cut
on falling plate.
Diving may also be caused by a problem with
the height control or the signals fed to it.
Work ipping
The nozzle may sometimes be damaged if the
torch hits a ipped up part. This is dicult to
avoid entirely but careful part programming
can minimize the problem.
80
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
ProblemProbable CauseRemedy
2. Reduced nozzle life
(N2, O2 and ArH2) (cont)
catching on piece
Air curtain/bubble muer
alignment
Excessive speed
Excessive pilot arc on
time.
Process factors:
Cut water not at torch when arc
starts.
Inadequate initial delay.
Pierce not complete before
starting.
This refers to crashes or nozzle damaged
caused by the front end of the torch catching
on top spatter after a pierce. Hold the torch
at a high stando for a longer lead-in to avoid
this problem.
Refer to paragraphs 3.3.7 and 3.3.8 to make
necessary adjustments.
Reduce speed to prevent rooster tailing
during cut. Reduce speed corners if rooster
tailing occurs only coming out of corners.
Same as for electrode above.
Check cut water system.
Increase delay time.
Excessive initial delay.
Improper torch assembly.
Improper piercing
technique.
Running pilot arc without
transfer.
Using non-genuine
consumables.
Improper connection or inadvertent grounding of pilot
arc cable running from Power
Source to Plumbing Box.
Worn feet on retaining
Decrease initial delay.
Reassemble torch properly. Check for gas
and water leaks.
Refer to paragraph 3.3.6.
Running pilot arcs without transfer is very
damaging to nozzles. Check stando and
work connections.
Replace with genuine consumables.
Connect wire properly in the Power Source.
Make sure there are no breaks in the insulation.
Replace retaining cup.
81
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
ProblemProbable CauseRemedy
3. Poor cut quality.
Dross and cut surface:
Varying characteristics of material
being cut.
Incorrect speed
Incorrect stando
Incorrect gas or cut water ow.
Incorrect alignment or improper
operation of air curtain or bubble
muer.
Damaged or worn consumables.
Using non-genuine consumable
part.
Gas selection.
No remedy.
Adjust to correct speed.
Refer to paragraph for applicable cutting
technique.
Refer to paragraph 3.1.1.
Refer to paragraph 3.3.7 or 3.3.8.
Replace.
Replace with genuine consumable part.
N2 produces smoother surfaces on Al and SS
than O2. O2 sometimes produces less dross on
C.S. than N2.
Torch alignment to work.
Incorrect current.
Cutting over slats.
Cutting machine or torch
vibrates.
Mixing standard and
reverse swirl parts.
Bevel Angle:
Verify and correct torch alignment.
Verify correct current. Refer to appropriate table
in section 3.
Cutting over slats will cause some bottom dross.
If the cut runs along the slat, it can produce other
cut quality problems. The only solution is to try
to avoid running along the slats.
Make sure brackets and height control are rigid
and properly adjusted.
Check to be sure swirl is in the same direction.
Remove swirl parts that are marked with an "R".
Same as Dross and Cut surface above
except varying characteristics of material being
cut and cutting machine or torch vibrations.
Stando and speed have considerable eect
on bevel angle.
82
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
ProblemProbable CauseRemedy
3. Poor cut quality (cont)
4. No pilot arc.
Damaged nozzle
Wrong travel direction
(good angle on scrap side)
Plate shifting while being
cut.
Slag buildup on cut table.
Contaminated electrode.
Excessively conductive
cut water (injection water).
Insucient spark gap
setting (in plumbing box).
Pilot Arc Contactor (PAC)
malfunctioning.
Plate not level - ensure work is level. Torch
not perpendicular to work - ensure torch is
plumb (perpendicular) to work.
With standard swirl parts the most square
side of the cut is on the right side of the
direction of travel.
Small, thin, or light weight plates can shift
while cutting. Clamp them down.
Clean slag from cut table.
Clean or replace electrode.
Check injection water instructions in Section 3. PT-15XL only.
Set spark gap to 0.040+.004".
Refer to Power Source manual.
Blown fuse in P.A. or starting
circuit.
Improperly assembled torch
or broken torch pilot xar
cable.
Broken or improperly connected P.A. cable between
Plumbing Box and Power
Source.
Insucient Open Circuit
Voltage (OCV).
Gas ow improperly set.
Improper clamping of stainless steel torch body.
Conductive water muer
hoses.
Water leak in torch.
Refer to Power Source manual.
Reassemble torch properly or replace torch
pilot arc cable.
Replace or verify connections between
Plumbing Box and Power Source.
Cut Water Flow Switch (CWFS)
not activated (water injection
only).
Blown fuse in P.A. or starting
circuits.
Insucient Open Circuit Voltage (OCV).
Gas ow improperly set.
Stando too high or torch
centered o edge of work.
Poor connection to workpiece.
Heavy mill scale or nonconductive surface on work.
Power Source current setting
too low.
Check for adequate cut water ow. Check
CWFS.
Refer to Power Source manual.
Refer to Power Source manual.
Refer to Section 3.
Check cutting technique or position torch to be
over work.
Check connection.
Clean mill scale or ensure conductive surface
on work.
Refer to Power Source manual.
6. No preow.
Defective power source.
No start signal.
Emergency stop signal open.
Door opened on Plumbing
Box allowing interlock to
open.
Shorted, closed or jumpered
out CWFS.
No cooling water.
N2 pressure switch not activated.
O2 pressure switch not activated when N2/O2 switch is set
to O2.
See Power Source manual.
Check input 0 on PLC in Flow Control. Should
be lit when receiving start signal. Ensure
qualied technician performs this check.
Check input 10 on PLC in Flow Control. Should
be lit to enable operation. Ensure qualied
technician performs this check.
Close door.
Check input 6 on PLC. Should be o before
start signal applied. Should be on when in
test. Ensure qualied technician performs
this check.
Check Flow Switch.
100 psig N
the ow control.
100 psig O2 (gas owing) should be supplied to
the ow control.
(gas owing) should be supplied to
2
84
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
Problem
7. No cut water ow when in
Test Position.
8. Arc extinguishes during a
cut or shuts down immediately after transfer.
Probable Cause
No power to pump.
Relay in pump not activated.
Failed pump and/or motor.
Insucient or no water
supply.
Back pressure regulator set
above 115 psig.
Cut water regulator on Flow
Control set too low.
Loss of start signal.
Interlock not satised - loss
of gas pressure or water
ow.
Remedy
Apply power.
Check for 110 V ac from ow control.
Replace.
Make sure pressure is set to 190 to 200
psig. Correct or provide water supply. 20
psig should be supplied to pump.
Reset to 90 to 115 psig.
Adjust as necessary.
Check signal from cutting machine.
Check PLC inputs.
9. Bubble muer air supply
does not come on.
10. Bubble muer under
pump does not come on.
Water hose kinked.
Running across very large
kerf or o plate.
Speed too low.
Switch on air curtain control
box in the OFF position.
Air curtain control box is not
receiving signal from ow
control.
Starting relay on bubble
muer is not receiving signal from ow control.
Pump is not connected to
main power.
Pump is running backwards.
Straighten water hose.
Check part program.
Increase speed as necessary.
Switch to AUTO.
Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of ow control. Check wiring.
Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of ow control. Check wiring.
Check wiring and fuses.
Check wiring.
85
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
ProblemProbable CauseRemedy
11. Poor cut quality with
Bubble Muer or Air
Curtain installed. (Cuts
are good above water
with Bubble Muer or
Air Curtain turned o.
Cuts are bad under-water with device operating.)
12. Cut water ow inadequate. Cannot reach
proper ow setting.
Sleeve not bottomed out on the
Main Body.
O-rings missing or broken.
Air Pressure set too high, or air shut
o.
Sleeve spacing between Air Curtain or Bubble Muer and Torch
Retaining Cup incorrect.
Sleeve not centered in reference to
the Torch Retaining Cup.
Dirt in Sleeve holes.
Holes in Sleeve align with air input
port.
Internal cut water lter (in Flow
Control) is clogged.
Reseat Sleeve.
Replace O-rings in Main Body.
Set air pressure between 15-30 psi. Some
trails should be made on scrap plate to nd
the optimum pressure for your conditions.
Adjust spacing. See Section 3.
Center Sleeve. Clamp may be cocked on
torch handle or O-rings may be damaged.
Remove sleeve and clean.
Rotate Sleeve 5°.
Replace internal lter of ow control. Check
all external water lters.
86
SECTION 4 MAINTENANCE
87
NOTES
88
REVISION HISTORY
Revision 07/2007 - RE-Formatted manual for German translation per R. Chico.1.
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
Visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
F15-116-D 07/2007
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