ESAB ESP-1000 Plasmarc System Instruction manual

INSTRUCTION MANUAL
ESP - 1000 PLASMARC SYSTEM
MECHANIZED CUTTING WITH PT-15XL OR PT-19XLS
F15-116-D 07/2007
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions be­fore installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompa­nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme­diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser­vice facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENTS
SECTION TITLE PAGE PARAGRAPH
SAFETY PRECAUTIONS .....................................................................................................................................5
SECTION 1 INTRODUCTION ...................................................................................................................17
1.1 General ................................................................................................................................................................... 17
1.2 Features .................................................................................................................................................................. 17
1.3 Component Description ..................................................................................................................................18
SECTION 2 INSTALLATION ......................................................................................................................23
2.1 General ................................................................................................................................................................... 23
2.2 System Component Location ......................................................................................................................... 23
2.3 System Connections ..........................................................................................................................................24
2.4 Torch Components ............................................................................................................................................. 30
2.5 Installing Air Curtain ..........................................................................................................................................31
2.6 Bubble Muer Installation .............................................................................................................................. 32
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
SECTION 3 OPERATION.......................................................................................................................................................... 39
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
PT-19XLS Cutting Tables ................................................................................................................................... 56
3.9 Operating Techniques ....................................................................................................................................... 70
SECTION 4 TROUBLESHOOTING ....................................................................................................................................... 75
4.1 Programmable Logic Controller ....................................................................................................................75
4.2 Sequence Description ....................................................................................................................................... 75
4.3 Operating Information......................................................................................................................................77
4.4 Troubleshooting Guide .................................................................................................................................... 78
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TABLE OF CONTENTS
4
SAFETY PRECAUTIONS
Safety Precautions
WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the
references listed in Additional Safety Information section. Before performing any instal­lation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -­Some welding, cutting, and gouging processes are noisy and require ear
protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in
any work area, even if welding helmets, face shields, and goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when oper­ating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy
long-sleeve shirt, cuess 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 cus, 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 conned, 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 conned 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 specic 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 eects 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 specic 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 qualied personnel perform the instal­lation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied 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 Jeerson 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"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."
MEANING OF SYMBOLS - As used throughout this manual: Means Atten­tion! Be Alert! Your safety is involved.
Means immediate hazards which, if not avoided, will result in im­mediate, serious personal injury or loss of life.
Means potential hazards which could result in personal injury or loss of life.
Means hazards which could result in minor personal injury.
8
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 inamables o vapores tóxicos. No trabaje den­tro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.
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 connado 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 especícas 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 especícas 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 cualicado para efec­tuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualicado 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 modique 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 Sig­nican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.
Signica riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.
Signica el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.
Signica 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 an 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 an 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 ininammable an 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 ininammable.
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 susamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. 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 inammables 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 surchauer 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 an 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 eectuer 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 spéciques 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 eets 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 ecaces. Ne respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 an 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 spéciques 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 Jeerson 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 qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.
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'eectuez aucune modication.
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, signie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.
ATTENTION
Signie 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.
• DonottouchthetorchorchangetheconsumablesifinputpowertothePlasmarcpowersourcehasnotbeendiscon­nected.
• Donotstandon,touch,orinanywaycontacttheplatewhilecuttingvoltagesarepresent.
• Theworkpiecemustbeelectricallyconnectedtothepowersourceworkterminalforsafeoperationofthesystem.
• Donotperform maintenanceonanypart of the Plasmarc systemunlessall powerinputshavebeendisconnected
and locked out. This includes 115vac inputs as well as high voltage inputs.
• Troubleshootingrequiringpowertobeonshouldonlybedonebyqualiedpersonnel.
Hydrogen Explosions can cause injury or death.
• Seepage?????.
Fumes and Gases can cause discomfort or death. Do not breath fumes or gases.
• Donotcutcontainersoftoxicmaterialsorcontainersthathaveheldtoxicmaterials.Cleansuchcontainersthorough­ly before cutting.
• Beforecuttingacoatedmaterial,consultwithitsmanufacturerforpropersafetyprecautions.
Noise and Ultraviolet Light
• Thenoiselevelofplasmarccutting can be greater than110dbatadistanceof6feetfromthetorch.Wearproper
hearing protection.
• Reectionofultravioletlightfromareaswallsclosetothecuttingarccanbeminimizedbyselectingpaintshavinga
high percentage of ZnO and TiO2 pigments. Do not use paints containing metallic akes. Refer to “Ultraviolet Reec­tance of Paint” from the American Welding Society.
• Underwatercuttingisawellacceptedtechniqueforreducingthenoise,fumes,andUVradiationofthePlasmarccut­ting process. Often an air curtain or bubble muer is required for underwater cutting. Above water cutting with a water muer can also achieve much of the benets of underwater cutting.
16
SECTION 1 DESCRIPTION
1.1 GENERAL
The ESP-1000 is a full capability plasmarc cutting system that oers a wide variety of plasma cutting processes and applications. The system is designed specically for computer controlled mechanized cutting applications with expanded interfacing, exible conguration 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.
1.2 FEATURES
• Thesystemiscapableofwaterinjectioncutting
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.
• TheESP-1000canaccommodateallmajorcutting
gases including; oxygen, air, nitrogen or argon/ hydrogen mixture.
• The separatecomponent design,ow control,
plumbing box, power source provides maximum flexibility for system layout tailored to your needs.
• Selection from a varietyof power sources and
the paralleling capability allows a wide range of available cutting power to meet virtually any cutting condition.
• Patented ESAB technology allows underwater
cutting and beveling with excellent results.
• TheESP-1000usessimpleswitchsettingstosetup
process parameters for ow control and cutting power eliminating the diculty of adjustment associated with needle valves.
• Theshieldedconstructionoftheplasmatorches
and versatility of component location minimizes electrical interference with surrounding equip­ment.
• The ESP system uses advanced technologyfor
high quality cutting for a variety of common metals while keeping the operating costs at a minimum.
COOLANT
CIRCULATOR
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 specically to interface into a system for use in automated plasma cutting applications.
Refer tothe specic 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 rectier (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 specic 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 conguration. Refer to Instruction Manual for specic 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 specic 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 specic 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 dierences 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 Muer 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 Muer
The PT-19XLS water muer works much as the bubble muer 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 Muer
The Bubble Muer 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 signicant 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 muer. A separate water pump recycles ltered water from the water cutting table through the bubble muer.
Figure 1-12. PT-19XLS Water Muer 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
ESP-400C 460 V, 3-Phase, 60 Hz 0558001729 F-15-657 400 V, 3-Phase, 50 Hz CE 0558001730 F-15-681 575 V, 3-Phase, 50 Hz 0558001731 F-15-657
ESP-600C 460 V, 3-Phase, 60 Hz 35609 F-15-656 400 V, 3-Phase, 50 Hz CE 35610 F-15-682 575 V, 3-Phase, 60 Hz 35611 F-15-656
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 Muer System 2232615 F-15-127
PT-19XLS (and PT-600) Water Muer 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 conguration 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. Sucient 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 qualied 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 specic 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 muer 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 LENGTH CUT WATER HOSE COOLING WATER START GAS HOSE CUT GAS HOSE
25 FT. 33127 21588 33122 33117 50 FT. 33128 21574 33123 33118 75 FT. 33129 1575 33124 33119 100 FT. 33130 21576 33125 33120 125 FT. 33131 21577 33126 33121
TABLE 2-2. COOLING WATER HOSE ASSEMBLIES
CUT GAS HOSE Hose Assembly
25 FT. 33132 50 FT. 33133 75 FT. 33134 100 FT. 33135 125 FT. 33136
TABLE 2-3. INTERCONNECTION CABLES
CABLE
LENGTH
25 FT. 33219 33224 33253 33303 33253 50 FT. 33220 33225 33254 33304 33254 75 FT. 33221 33226 33255 33305 33255 100 FT. 33222 33227 33256 33306 33256 125 FT. 33223 33228 33257 33307 33257
Flow Control Remote Location- Flow Control to Power Source cable: 30 Ft. - 34378
FLOW CONTROL -
PLUMBING BOX
(Cable, 18 AWG,
8 conductor)
FLOW CONTROL
- CNC
(Cable, 16 AWG
12 conductor)
FLOW CONTROL
- WATER COOLER
(Cable, 18 AWG
3 conductor)
POWER SOURCE -
PLUMBING BOX
(Cable, Pilot Arc)
60 Ft. - 34377
CURTAIN
(Cable, 18 AWG
3 conductor)
AIR
27
SECTION 2 INSTALLATION
TABLE 2-3. RECOMMENDED REGULATORS
DESCRIPTION PART NUMBER
Station Regulator, O2, R-76-150-024* 19151
Station Regulator, N2, R-6703 22236 Two Stage Cylinder Regulator, O2, R-77-150-540** 998337 Two Stage Cylinder Regulator, N2, R-77-150-580** 998344
Two Stage Cylinder Regulator, H-35, R-77-150-350 998342
Liquid Cylinder Regulator, O2, R-76-150-540LC 19777
Liquid Cylinder Regulator, N2, R-76-150-580LC 19977
Water to Injection pump use Regulator R-6702 22235
* 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 dierences 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 Muer/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 muer 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 Muer 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 signicant sacrice of cut quality. This system also permits operation above water as the ow through the muer 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 muer is rec-
ommended for ease of installation.
2. Slide the chrome plated bubble muer 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 muer sleeve in the bubble muer main body. Maker sure it bottoms completely.
5. Install the bubble muer main body (with sleeve) over the assembled torch and snap it into place on the bubble muer clamp.
6. Adjust the position of the bubble muer 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 muer sleeve and the torch retaining cup.
7. Lock the bubble muer into position by tightening the allen screw on the bubble muer clamp.
A helpful hint for adjusting the Air Curtain or bubble Muf­er 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 Muer 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 Muer Assembly
The sleeve must remain completely bottomed in the Bubble Muer 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 Muf­er 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 muer water when checking for this interference.
Better centering of the bubble muer 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 Muer.
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 preow begins. The pump will recirculate approximately 20 gpm from the water table.
Further details and replacements parts for the air curtain and bubble muer 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
Item Part No. Length
Cable, 18 GA 3-Cond. P/N 33253 25 ft. Cable, 18 GA 3-Cond. P/N 33254 50 ft. Cable, 18 GA 3-Cond. P/N 33255 75 ft. Cable, 18 GA 3-Cond. P/N 33256 100 ft. Cable, 18 GA 3-Cond. P/N 33257 125 ft.
ITEM Part No. Quantity
Secondary Gas Metering
22178 1
Box
Hose Assy., 50 ft. w/
34033 1
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 preow 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 standos.
Note: Set piercing stando as specied 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 1 22174 FLOWMETER ASSEMBLY (See Fig.4) 2 3 10Z30 ADAPTOR B-A/W X 1/4 NPTM 3 1 19Z99 ADAPTOR 1/4 NPTM X .69 - 24F 4 1 82Z46 WASHER FLAT .61 X .32 X .06 NYLATRON 5 1 19906 VALVE RELIEF ASSEMBLY 6 1 22220 GAUGE 2.50, 100PSI 7 1 22181 HOSE ASSEMBLY FOR PRESSURE GAUGE 8 2 22182 HOSE ASSEMBLY FOR GAS IN & OUT
9 1 632904 VALVE NEEDLE 1/4PF X 1/4PF 3000PSI 10 2 11N16 ADAPTOR B/A-WF X 1/4 NPTM 11 1 522368 AIR REGULATOR (Discard Gauge) 12 3 639501 ADAPTOR 1/4-18NPT x 1/4 NPTM 13 1 636387 VALVE SOL. 1/4P 14 1 96W85 STRAIN RELIEF 15 1 951041 TERM BLOCK 4 POS. 16 1 636702 SWITCH TOGGLE DPDT 3 POS 15A
10
2,12,3,4,5
9
Figure 2-15. Secondary Gas Metering Box. P/N 22178
36
SECTION 2 INSTALLATION
6
10
8
9
11
12
13
7
5
4
1
3
2
ITEM NO. QTY REQ. PART NO. DESCRIPTION
1 1 22168 FLOWMETER BODY 2 2 86W62 O-RING 1.239ID X .070W NEOPR 70A 3 1 85W10 O-RING .239ID X .070W NEOPR 70A 4 1 639571 TUBE METER 1.4-33-G-5 GLS 5 1 53A61 BALL 0.250 DIA STAINLESS STEEL 6 1 22169 FLOAT STOP FLOWMETER 7 1 12N29 SPRING 0.75 X 0.63D 8 1 22170 CAP
9 8 61340006 SCREW STLZPC 0.190-32 X 0.50 (#10-32 X .5) 10 1 22171 SPIDER 11 8 64302920 WSR 52002 STLZPC 0.190 (WASHER #10) 12 2 22172 FRAME 13 1 22173 OUTER TUBE
Figure 2-16. Flowmeter Assembly, Secondary Gas, P/N 22174
37
SECTION 2 INSTALLATION
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
100 PSIG
80 PSIG
Pressures Shown Are Measured At Flowmeter Outlet
2
60 PSIG
SCFH N
Figure 5. Flowmeter Calibration Curves
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
38
2.0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700
1.0
Flowmeter Reading (Measured At Top Of Ball)
SECTION 3 OPERATION
3.1. GENERAL
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 specic 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 orices in each line of the four solenoid valves. The orices vary in size so that each is capable of doubling the ow, the largest orice 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 orice 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 dierent ows but the switch limit is eight settings. The HIGH/LOW switch is used to energize the solenoid with the largest orice 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 specic 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 orices in each line of the four solenoid valves. The orices vary in size so that each is capable of doubling the ow, the largest orice 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 orice 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 dierent ows but the switch limit is eight settings. The HIGH/LOW switch is used to energize the solenoid with the largest orice that allows using the remainder of the ows.
switch, Flow Rate that is an
2/N2
TABLE 3-1. CUT WATER FLOW RATES
SWITCH SETTING/
FLOW RATE
0/LOW 0 1/LOW 0.03 2/LOW 0.07 3/LOW 0.10 4/LOW 0.14 5/LOW 0.17 6/LOW 0.21
7/LOW 0.24 0/HIGH 0.28 1/HIGH 0.31 2/HIGH 0.35 3/HIGH 0.38 4/HIGH 0.41 5/HIGH 0.45 6/HIGH 0.48 7/HIGH 0.51
CUT WATER GPM
TABLE 3-2. CUT GAS FLOW RATES
SWITCH SETTING/
FLOW RATE
0/LOW 0 1/LOW 20 2/LOW 40 3/LOW 60 4/LOW 80 5/LOW 100 6/LOW 120
7/LOW 140 0/HIGH 160 1/HIGH 180 2/HIGH 200 3/HIGH 220 4/HIGH 240 5/HIGH 260 6/HIGH 280 7/HIGH 300
CUT GAS (O2/N2)
SCFH
40
SECTION 3 OPERATION
POWER SOURCE (ESP-600C)
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 oers 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 dierent 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-
ting.
TABLE 3-3. TEST/RUN SELECTION DESCRIPTION
TEST POSITIONS ACTIVATED FUNCTION
START GAS CUT GAS CUT WATER HF
CUT GAS NO YES YES (if on) NO START GAS YES NO YES (if on) NO HF YES NO NO YES
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 insucient 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.
acorn
nut located on top of the
acorn
TABLE 3-4. RECOMMENDED REGULATOR PRESSURE SETTINGS (PSIG)
CUT GAS
TYPE
O
2
N
2
H-35 For PT-15XL 138 139 141 144 135 135 137 138 135 135 135 135
1/4-IN. ID HOSE
LENGTH IN FEET
12.5 25 50 100 12.5 25 50 100 12.5 25 50 100 100 100 100 100 100 100 100 100 100 100 100 100 100 103 104 105 100 100 100 102 100 100 100 100
5/16-IN. ID HOSE
LENGTH IN FEET
42
3/8-IN. ID HOSE
LENGTH IN FEET
SECTION 3 OPERATION
CUT WATER BLOWDOWN
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 dierent 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 muer, 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
20398 20763XL 0.099 260A 20751 8-HOLE
ELECTRODE NOZZLE ASSEMBLY SWIRL BAFFLE
Diameter RATING P/N standard optional
35666XL
(FLAT)
0.099 REV.
0.116
0.120
0.116 REV.
0.120 REV.
260A 20920 8-HOLE
300A 340A
300A 35663 8-HOLE
340A 35665
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
MATERIAL
THICKNESS
(CARBON
STEEL)
1/8 200 120-125 LOW 5 HIGH 7 175-200 1/2" FOR 1/4 260 120-125 LOW 5 HIGH 7 150-170 PIERCING 1/2 260 125-130 LOW 5 HIGH 7 90-100 1/8-5/32" 3/4 260 130-135 LOW 5 HIGH 7 60-70 FOR
*1 260 135-140 LOW 5 HIGH 7 40-50 CUTTING
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.
CURRENT
AMPS
VOLTAGE
SETTING
OXYGEN
CUT GAS
FLOW
NOTES
CUT
WATER
FLOW
CUT
SPEED
(Inches
per min-
ute)
STANDOFF (TORCH TO
WORK - inches)
• Cuttingspeedsgivenareaverage.Theymayvarywithmaterialcompositionandsurfacecondition.
• Onlyceramicbaesmaybeusedwithoxygencutting.
• Useofmorethan260ampswhencuttingwithoxygenwillreduceelectrodeandnozzlelife.
• Thenozzlesforoxygenservice,PN20751and20920,arefactoryassembledandshouldnotbetakenapart.Itmust
be replaced as a complete unit.
• Thenozzlesforoxygenservice,PN21206Band21207B,haveareplaceableinsulator,PN21193.
• Replaceelectrode,PN20763XL,whenthecavityinthehafniuminsertreaches0.09"indepthor0.12"indiameter.
• Removingthenozzlefromthetorchtocheckelectrodeweargreatlyreduceselectrodelife.Removenozzleonlywhen
changing electrode or cut quality has deteriorated.
• Reversenozzleandswirlbaesareusefulinapplicationswheretwoplasmatorchesarecuttingwith onecutting
mirror images.
• 8-HolebaesarerecommendedforESPsystems.Consumablelifeisextended.
• Cuttingconditionshavebeendevelopedupto360amps.
46
SECTION 3 OPERATION
TABLE 3-7. HIGH CURRENT OXYGEN CUTTING WITH PT15XL
MATERIAL
THICKNESS
(CARBON
STEEL)
1/4 300 126 HIGH 1 HIGH 7 225-250 5/32 3/8 300 128 HIGH 1 HIGH 7 165-180 5/32 1/2 300 130 HIGH 1 HIGH 7 135-145 5/32 3/4 300 144 HIGH 1 HIGH 7 75-85 1/4
1 300 148 HIGH 1 HIGH 7 50-60 1/4
3/4 340 130-132 LOW 6 HIGH 7 85-100 5/32-3/16
1 340 128-135 LOW 6 HIGH 7 59-65 5/32-1/4 1-1/4 340 140 LOW 6 HIGH 7 40-45 1/4 1-1/4 360 140 LOW 6 HIGH 7 45-50 1/4
MATERIAL
THICKNESS
(CARBON
STEEL)
1/4 300 126 HIGH 1 225-250 5/32 20 3/8 300 127 HIGH 1 165-180 5/32 20 1/2 300 132 HIGH 1 135-145 5/32 30 3/4 300 144 HIGH 1 75-85 1/4 30
1 300 148 HIGH 1 50-60 1/4 30
3/4 340 131 LOW 6 75-95 5/32 20
1 340 130 LOW 6 59-65 5/32 20 1-1/4 340 140 LOW 6 40-45 1/4 30 1-1/4 360 140 LOW 6 45-50 1/4 30
CURRENT
AMPS
TABLE 3-8. OXYGEN UNDERWATER CUTTING WITH PT-15XL
CURRENT
AMPS
VOLTAGE
SETTING
Cut water ow setting should be HIGH 7
VOLTAGE
SETTING
OXYGEN
CUT GAS
FLOW
OXYGEN
CUT GAS
FLOW
CUT
WATER
FLOW
CUT
SPEED
(Inches per
minute)
CUT
SPEED
(Inches
per min-
ute)
STANDOFF
(TORCH
TO
WORK -
inches)
STANDOFF (TORCH TO
WORK - inches)
AIR CURTAIN
PRESSURE
(PSIG)
Cut water ow setting should be at HIGH 7.
NOTES
Nitrogen Start Gas setting should be at 26 psig for both above and under water cutting.
Torch components for both above and underwater oxygen cutting with a PT-15XL are:
Nozzle - PN 35662 or 35663 reverse up to 300 amps PN 35664 or 35665 reverse for over 340 to 360 amps
Swirl Bae - PN 35660 or 35661 reverse
Electrode - PN 35666XL
47
SECTION 3 OPERATION
TABLE 39. LOW CURRENT CUTTING CONDITIONS WITH PT15 ABOVE WATER
MATERIAL TYPE/ THICKNESS
CS/ 0.078 70 125 OXY  LOW 5 LOW 5 240 0.156 CS/0.125 70 129 OXY  LOW 5 LOW 5 165 0.156 CS/0.188 90 129 OXY  LOW 5 LOW 5 140 0.156 CS/0.250 90 134 OXY  LOW 5 LOW 5 120 0.156 CS/0.312 125 134 OXY  LOW 5 LOW 5 120 0.156
SS/0.062 60 128 OXY  LOW 5 LOW 5 150 0.156 SS/0.125 65 130 OXY  LOW 5 LOW 5 100 0.156 SS/0.188 75 132 OXY  LOW 5 LOW 5 125 0.156 SS/0.250 90 136 OXY  LOW 5 LOW 5 100 0.156 SS/0.312 125 137 OXY  LOW 5 LOW 5 90 0.156
AL/0.062 100 136 OXY  LOW 5 LOW 5 175 0.156 AL/0.125 100 128 OXY  LOW 5 LOW 5 125 0.156 AL/0.250 100 135 OXY  LOW 5 LOW 5 75 0.156 AL/0.312 125 136 OXY  LOW 5 LOW 5 75 0.156 AL/0.375 125 149 OXY  LOW 5 LOW 5 50 0.156
CURRENT AMPS
VOLTAGE SETTING
CUT GAS FLOW
CUT WATER FLOW
CUT SPEED IPM
STANDOFF TORCH TO WORK  IN.
SS/0.062 80 155 NIT  LOW 5 LOW 4 275 0.156 SS/0.125 100 150 NIT  LOW 5 LOW 4 150 0.156 SS/0.188 125 155 NIT  LOW 5 LOW 5 100 0.156 SS/0.250 125 156 NIT  LOW 5 LOW 5 90 0.156 SS/0.312 125 162 NIT  LOW 5 LOW 5 75 0.156
AL/0.062 65 160 NIT  LOW 5 LOW 5 150 0.156 AL/0.125 65 160 NIT  LOW 5 LOW 5 100 0.156 AL/0.250 125 160 NIT  LOW 5 LOW 5 100 0.156 AL/0.312 125 167 NIT  LOW 5 LOW 5 50 0.156 AL/0.375 125 179 NIT  LOW 5 LOW 5 45 0.156
NOTES: 1. N
2. When using the ESP-300 power supply, low range must be used for current under 80 amps. High range
3. Gas Bae: 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.
ELECTRODE
HOLDER
2075343 600236 .125 250A 2075691 2075341 948142
ELECTRODE NOZZLE ASSEMBLY SWIRL BAFFLE
Diameter RATING P/N standard optional
.156 400A 2075611 4-HOLE 4-HOLE .200 600A 2075612 PLASTIC CERAMIC .230 750A 2075613
REVERSE
.125 250A 2075692 2075360 948143 .156 400A 2075614 4-HOLE 4-HOLE .200 600A 2075615 PLASTIC CERAMIC .230 750A 2075690
NOZZLE RETAINING
CUP
NOZZLE ASSEMBLY
Figure 3-3. Nitrogen Components for PT-15XL
ELECTRODE HOLDER
BODY ASSEMBLY
FRONT BODY
INSULATOR SWIRL BAFFLE
ELECTRODE
49
SECTION 3 OPERATION
TABLE 3-11. PARAMETERS FOR NITROGEN CUTTING WITH PT-15XL
MATERIAL
THICKNESS
1/32 250 NA LOW 6 LOW 6 1/4 1/16 NA 350 385 400 1/8 150-155 265 290 340 3/16 155-160 200 220 270 1/4 160-165 140 155 200 3/8 165-1170 ----- ----- 180 1/16 400 NA LOW 7 HIGH 0 3/8 1/8 NA 330 360 400 3/16 NA 250 280 320 1/4 145-150 160 180 240 3/8 150-155 135 145 210 1/2 155-165 110 120 170 3/4 165-175 60 70 110 1 175-180 45 50 60 1/2 600 140-150 HIGH 1 HIGH 3 3/8 3/4 155-160 75 80 130 1 160-170 65 75 100 1-1/2 175-185 1/2 33 36 50 2 180-190 22 24 38 3/4 750 160 HIGH 4 HIGH 7 5/8 1 170 75 80 ----­1-1/2 185 40 44 ----­2 190 28 30 45 3 210 13 14 30
CUR-
RENT
AMPS
VOLTAGE
SETTING
NITROGEN
CUT GAS
CUT WATER
FLOW
STANDOFF
(INCH)
CUT SPEED (IPM)
carbon
steel
500 550 600
450 490 500
130 140 190
90 98 -----
stainless
steel
alumi-
num
NOTE
When changing consumables always wipe any water
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 aected. 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.
50
SECTION 3 OPERATION
TABLE 3-12. UNDERWATER CUTTING SPEEDS
MATERIAL
THICKNESS
(inches)
1 0.200 1-1/2 175-185 1/2 30 33 50 2 0.200 2-1/2 190 5/8 ---- ---- 28 3 210 5/8 ---- ---- 20
1-1/2 0.230 2 190 5/8 20 20 ---­3 0.230
2075612
REVERSE 2075615
2075613
REVERSE 2075690
NOZZLE
ASSEMBLY
DIA./ PN
CUR-
RENT
AMPS
600 160-170 1/2 50 65 80
750 185 5/8 35 35 ----
VOLTAGE
SETTING
180-190 1/2 15 18 35
210 5/8 8 8 ----
STANDOFF
(INCH)
3.6. H-35 CUTTING WITH THE PT-15XL
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
NOZZLE
ELECTRODE
HOLDER
2075343 600236 .250
ELECTRODE NOZZLE ASSEMBLY SWIRL BAFFLE
Diameter RATING P/N standard optional
ELECTRODE HOLDER
ELECTRODE
875A to
1000A
C. Set Control CUT WATER ON/OFF to ON.
BAFFLE
2075586
2075587
8-HOLE
CERAMIC
NONE
51
SECTION 3 OPERATION
TABLE 3-14. CONTROL SETTINGS FOR H-35 CUTTING
MATERIAL
THICKNESS
(inches)
CUR-
RENT
AMPS
VOLTAGE
SETTING
H-35
CUT GAS
CUT WATER
FLOW
STANDOFF
(INCH)
CUT SPEED (IPM)
carbon
steel
stainless
steel
3 875 215 HIGH 7 HIGH 7 3/4 13 13 27 4 220 10 10 15 5 1000 230 HIGH 7 HIGH 7 3/4 5 6 10 5-1/2 235 4 5 9 6 240 3 4 8
D. Purge cut gas lines.
1. Disconnect O
. Place the Flow Control TEST/RUN
2
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.
alumi-
num
Shield Retainer ­37081
Shield 50A - 21795 100-250A - 21802 250-600A - 21945
Nozzle Retainer Cup ­37082
Diuser 50A - 21796 100-600A - 21944 100-600A Rev - 22496
Nozzle Assembly 250A - 21822 360A - 35885 400A - 22195 600A - 22401
Nozzle Tip
50A - 22026 100A - 22029 150A - 22030 200A - 22031
Electrode
/Air - 34086XL
O
2/N2
H-35 - 34557 400A, O2, N2, Air, H-35 - 22196 600A, N2, H-35 - 22403
Electrode Holder -
Nozzle Base 50A - 22027 100-200A - 22028
37068
Gas Bae 50-200A - 948142 250-600A - 35660 400A, O
- 22194
2
Figure 3-5. PT-19XLS Components
Reference only. Refer to your torch manual for specic or updated instructions
52
SECTION 3 OPERATION
Table 3-15 COMPONENT SELECTION FOR PT-19XLS
Application
Current & Thickness Shield Diuser Nozzle Electrode Gas Bae 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
Teon 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.
TORCH COMPONENTS FOR HIGH CURRENT CUTTING
NOZZLE 360A P/N 35885 ELECTRODE 360A P/N35886XL HEAT SHIELD 360A P/N 21945 DIFFUSER 360A P/N 21944 BAFFLE 8-HOLE P/N 35660 START GAS N
@ 25 PSIG
2
55
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
A.
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.
ection on
Cutting Data:
NOZZLE
50-65 AMP
MATERIAL THICK­NESS
IN MM START
.063 1.6 30/2.1 60/4 2.2 .250 6 .125 3 115 50 180 4572 .125 3 30/2.1 60/4 2.2 .250 6 .125 3 115 50 110 2294 .250 6 30/2.1 60/4 3.5 .250 6 .156 4 128 65 65 165
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
50 ALUMINUM
VOLTAGE
Cutting Data:
50-65 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
50 ALUMINUM
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
AIR AIR AIR
MIN
MIN
N
2
N
2
N
2
.063 1.6 30/2.1 60/4 2.2 .250 6 .125 3 118 50 180 4572 .125 3 30/2.1 60/4 2.2 .250 6 .125 3 117 50 120 3048 .250 6 30/2.1 60/4 3.5 .250 6 .125 3 125 65 70 1778
Cutting Data:
50-65 AMP
MATERIAL THICK­NESS
IN MM START
.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 111 50 180 4572 .125 3 30/2.1 60/4 2.2 .250 6 .156 4 119 65 80 2032 .250 6 30/2.1 60/4 3.5 .250 6 .156 4 118 65 60 1524
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
50 STAINLESS STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
56
AIR AIR AIR
MIN
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
START GAS
50-65 AMP
MATERIAL THICK­NESS
IN MM START
.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 119 50 180 4572
.125 3 30/2.1 60/4 2.2 .250 6 .156 4 125 65 80 2032 .250 6 30/2.1 60/4 3.5 .250 6 .156 4 127 65 55 1397
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
50 ALUMINUM
VOLTAGE
Cutting Data:
50-65 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
50 CARBON STEEL
VOLTAGE
CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
N N N
MIN
AIR AIR AIR
MIN
2
2
2
.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 115 50 220 5588
.125 3 30/2.1 60/4 2.2 .250 6 .125 3 112 50 120 3048 .125 3 30/2.1 60/4 2.2 .250 6 .125 3 110 65 120 3048 .187 5 30/2.1 60/4 2.2 .250 6 .156 4 118 65 95 2413 .250 6 30/2.1 60/4 3.5 .250 6 .156 4 120 65 80 2032
Cutting Data:
100 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 45/3.1 3.5 .375 10 .187 5 154 100 100 2540
.375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 174 100 70 1778 .500 13 25/1.7 45/3.1 4.4 .375 10 .312 8 183 100 50 1270 .750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 30 762
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
NOZZLE
100 ALUMINUM
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
AIR AIR AIR
MIN
57
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
100 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 45/3.1 4.4 .375 10 .125 3 154 100 55 1397 .375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 165 100 35 889 .500 13 25/1.7 45/3.1 3.5 .375 10 .312 8 180 100 25 635 .750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 10 254
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
100 STAINLESS STEEL
VOLTAGE
Cutting Data:
100 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
100 STAINLESS STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
AIR AIR AIR
MIN
N N N
MIN
2
2
2
.250 6 25/1.7 35/2.4 4.4 .375 10 .125 3 153 100 55 1397 .375 10 25/1.7 35/2.4 4.4 .375 10 .187 5 157 100 45 1143 .500 13 25/1.7 35/2.4 4.4 .375 10 .187 5 162 100 35 889 .750 19 25/1.7 35/2.4 3.5 .500 13 .312 8 185 100 13 330
Cutting Data:
100 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 35/2.4 4.4 .375 10 .125 3 153 100 55 1397 .375 10 25/1.7 35/2.4 4.4 .375 10 .187 5 157 100 45 1143 .500 13 25/1.7 35/2.4 4.4 .375 10 .187 5 162 100 35 889 .750 19 25/1.7 35/2.4 3.5 .500 13 .312 8 185 100 13 330
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
NOZZLE
100 STAINLESS STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
N N AIR
MIN
2
2
58
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
100 AMP
MATERIAL THICK­NESS
IN MM START
.188 4 25/1.7 45/3.1 5.2 .375 10 .125 3 148 100 150 3810
.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 154 100 120 3048 .375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 159 100 65 1651 .500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 162 100 50 1270 .625 16 25/1.7 45/3.1 3.5 .500 13 .281 7 175 100 35 889 .750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 184 100 20 508
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
100 CARBON STEEL
VOLTAGE
Cutting Data:
100 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
100 CARBON STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
TRAVEL SPEED
AIR AIR AIR
MIN
N O AIR
MIN
2
2
.188 4 25/1.7 45/3.1 4.4 .375 10 .156 4 135 100 150 3810
.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 133 100 120 3048 .375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 149 100 80 2032 .500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 141 100 60 1524 .625 16 25/1.7 45/3.1 3.5 .500 13 .312 8 159 100 37 940 .750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 162 100 20 508
Cutting Data:
150 AMP
MATERIAL THICK­NESS
IN MM START
.188 4 20/1.4 LOW 3 4.4 .375 10 .187 5 148 150 200 5080
.250 6 20/1.4 LOW 3 4.4 .375 10 .187 5 149 150 140 3556 .375 10 20/1.4 LOW 3 3.5 .375 10 .250 6 159 150 105 2667 .500 13 20/1.4 LOW 3 4.4 .375 10 .312 8 174 150 80 2032 .750 19 20/1.4 LOW 3 3.5 .500 13 .312 8 180 150 45 1143 1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 184 150 30 762
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
NOZZLE
150 ALUMINUM
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
AIR AIR AIR
MIN
59
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
150 AMP
MATERIAL THICK­NESS
IN MM START
.188 4 20/1.4 LOW 4 3.5 .375 10 .187 5 136 150 200 5080 .250 6 20/1.4 LOW 4 3.5 .375 10 .250 6 141 150 150 3810 .375 10 20/1.4 LOW 4 3.5 .375 10 .250 6 145 150 110 2794 .500 13 20/1.4 LOW 4 3.5 .375 10 .312 8 155 150 90 2286 .750 19 20/1.4 LOW 4 3.5 .500 13 .375 10 166 150 50 1270 1 25 20/1.4 LOW 4 3.5 .500 13 .375 10 171 150 30 762
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PSI/BAR
CUT PSI/BAR
MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
NOZZLE
150 ALUMINUM
Cutting Data:
150 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
150 STAINLESS STEEL
START GAS CUT GAS SHIELD GAS
ARC
VOLTAGE
CUR­RENT
START GAS CUT GAS SHIELD GAS
ARC
VOLTAGE
CUR­RENT
N2 OR H-35 H-35 N
2
TRAVEL SPEED
TRAVEL SPEED
MIN
AIR AIR AIR
MIN
.188 4 20/1.4 LOW 3 4.4 .375 10 .187 5 138 150 200 5080 .250 6 20/1.4 LOW 3 3.5 .375 10 .187 5 146 150 165 4191 .375 10 20/1.4 LOW 3 3.5 .375 10 .250 6 155 150 95 2413 .500 13 20/1.4 LOW 3 3.5 .375 10 .312 8 163 150 60 1524 .750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 175 150 25 635 1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 185 150 15 381
Cutting Data:
NOZZLE
150 AMP
MATERIAL THICK­NESS
IN MM START
.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 132 150 200 5080 .250 6 20/1.4 LOW 3 4.4 .375 10 .187 5 140 150 130 3302 .375 10 20/1.4 LOW 3 4.4 .375 10 .187 5 143 150 85 2159 .500 13 20/1.4 LOW 3 4.4 .375 10 .250 6 154 150 60 1524 .750 19 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 18 457 1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 179 150 10 254
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
150 STAINLESS STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
MIN
N N AIR
2
2
60
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
150 AMP
MATERIAL THICK­NESS
IN MM START
.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 127 150 160 4064
.250 6 20/1.4 LOW 3 2.6 .375 10 .187 5 130 150 150 3810 .375 10 20/1.4 LOW 3 3.5 .375 10 .187 5 134 150 90 2286 .500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 142 150 75 1905 .625 16 20/1.4 LOW 3 4.4 .500 13 .312 8 151 150 55 1397 .750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 157 150 45 1143 1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 160 150 25 635
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
150 CARBON STEEL
VOLTAGE
Cutting Data:
150 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
150 CARBON STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
MIN
AIR AIR AIR
MIN
N O AIR
2
2
.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 143 150 160 4064
.250 6 20/1.4 LOW 3 3.1 .375 10 .125 3 145 150 140 3556 .375 10 20/1.4 LOW 3 3.1 .375 10 .187 5 156 150 90 2286 .500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 160 150 75 1905 .625 16 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 50 1270 .750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 179 150 45 1143 1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 184 150 25 635
Cutting Data:
200 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 4 3.5 .375 10 .312 8 146 200 155 3937
.375 10 25/1.7 LOW 4 2.6 .375 10 .250 6 148 200 120 3048 .500 13 25/1.7 LOW 4 2.6 .375 10 .312 8 155 200 110 2794 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 166 200 60 1524 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 40 1016
1.25 32 25/1.7 LOW 4 4.4 NR NR .375 10 175 200 26 660
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
200 ALUMINUM
START GAS CUT GAS SHIELD GAS
VOLTAGE
ARC CUR-
RENT
N2 or H-35 H-35 N
2
TRAVEL SPEED
MIN
61
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
200 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 4 4.4 .375 10 .187 5 155 200 125 3175 .375 10 25/1.7 LOW 4 4.4 .375 10 .250 6 165 200 110 2794 .500 13 25/1.7 LOW 4 4.4 .375 10 .250 6 167 200 85 2159 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 182 200 60 1524 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 189 200 40 1016
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
200 ALUMINUM
VOLTAGE
Cutting Data:
200 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
200 ALUMINUM
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
MIN
N N AIR
MIN
AIR AIR AIR
2
2
.250 6 25/1.7 LOW 4 3.5 .375 10 .187 5 151 200 180 4572 .375 10 25/1.7 LOW 4 3.5 .375 10 .187 5 155 200 110 2794 .500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 159 200 70 1778 .750 19 25/1.7 LOW 4 3.5 .500 13 .250 6 170 200 55 1397 1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 177 200 30 762
Cutting Data:
200 AMP
MATERIAL THICK­NESS
IN MM START
.500 13 25/1.7 LOW 4 4.4 .500 13 .375 10 163 200 50 1270 .625 19 25/1.7 LOW 4 4.4 .500 13 .312 8 162 200 47 1194 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 32 813 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 175 200 17 432
1.25 32 25/1.7 LOW 4 3.5 NR NR .500 13 191 200 10 254
1.50 38 25/1.7 LOW 4 3.5 NR NR .625 16 203 200 8 203
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
200 STAINLESS STEEL
START GAS CUT GAS SHIELD GAS
VOLTAGE
ARC CUR-
RENT
N2 OR H-35 H-35 N
2
TRAVEL SPEED
MIN
62
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
200 AMP
NOZZLE MATERIAL
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 4 4.4 .375 10 .125 3 142 200 140 3556
.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 150 200 125 2667 .500 13 25/1.7 LOW 4 4.4 .375 10 .187 5 154 200 85 2159 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 174 200 55 1397 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 180 200 20 508
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
200 STAINLESS STEEL
VOLTAGE
Cutting Data:
200 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
200 STAINLESS STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
AIR AIR AIR
MIN
N N AIR
MIN
2
2
.250 6 25/1.7 LOW 4 4.4 .375 10 .250 6 158 200 165 4191
.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 149 200 105 2667 .500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 150 200 90 2286 .750 19 25/1.7 LOW 4 2.6 .500 13 .250 6 159 200 45 1143 1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 169 200 20 508
Cutting Data:
NOZZLE
200 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 143 200 150 3810
.375 10 25/1.7 LOW 4 3.5 .375 10 .125 3 146 200 100 2540 .500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 158 200 95 2413 .625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 160 200 75 1905 .750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 165 200 65 1651 1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 180 200 35 889
1.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 182 200 25 635
1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 189 200 15 380
1.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 201 200 10 255 2 50 25/1.7 LOW 4 2.2 NR NR .375 10 211 200 6 152
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
200 CARBON STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
63
AIR AIR AIR
MIN
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
NOZZLE
200 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 129 200 170 4318 .375 10 25/1.7 LOW 4 3.5 .375 10 .187 4 133 200 110 2794 .500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 136 200 95 2413 .625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 139 200 75 1905 .750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 142 200 55 1397 1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 155 200 40 1016
1.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 164 200 25 635
1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 166 200 20 508
1.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 185 200 10 255 2 50 25/1.7 LOW 4 2.2 NR NR .500 13 205 200 5 127
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
MATERIAL
200 CARBON STEEL
VOLTAGE
Cutting Data:
250 CARBON STEEL
250 AMP
NOZZLE MATERIAL
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
N O AIR
MIN
N O AIR
2
2
2
2
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 5 4.0 .375 10 .125 3 130 250 170 4318 .375 10 25/1.7 LOW 5 4.0 .375 10 .187 5 135 250 125 3175 .500 13 25/1.7 LOW 5 4.0 .500 13 .219 5.6 138 250 100 2540 .750 19 25/1.7 LOW 5 4.0 .500 13 .250 13 142 250 65 1650 1 25 25/1.7 LOW 5 4.0 .500 13 .375 10 155 250 50 1270
325 AMP
MATERIAL THICK­NESS
IN MM START
.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 130 325 130 4572 .750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 132 325 90 2286 1 25 25/1.7 LOW 5 7.5 .625 16 .250 6 141 325 55-65
1.25 32 25/1.7 LOW 5 7.5 .625 16 .250 6 146 325 35-40
GAS SET UP STANDOFF ARC
VOLTAGE
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
Cutting Data:
NOZZLE MATERIAL
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
360 CARBON STEEL
VOLTAGE
ARC CUR-
RENT
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
TRAVEL SPEED
MIN
N O AIR
MIN
2
2
64
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
360 AMP
MATERIAL THICK­NESS
IN MM START
.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 132 360 140 3556
.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 135 360 90-100 1 25 25/1.7 LOW 5 8.7 .625 16 .250 6 141 360 65-70
1.25 32 25/1.7 LOW 5 8.7 .625 16 .250 6 146 360 45 1143
1.50 38 25/1.7 LOW 5 8.7 .625 16 .312 8 153 360 30-35
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
360 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 HIGH 5 8.7 .500 13 .250 6 160 360 230 5842
.500 13 25/1.7 HIGH 5 7.5 .625 16 .250 6 163 360 110 2794 .750 19 25/1.7 HIGH 5 8.7 .625 16 .375 10 176 360 80 2032 1 25 25/1.7 HIGH 5 8.7 .625 16 .500 13 192 360 45 1143
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
Cutting Data:
NOZZLE MATERIAL
360 CARBON STEEL
VOLTAGE
360 STAINLESS STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
N O AIR
MIN
N N AIR
MIN
2
2
2
2
360 AMP
MATERIAL THICK­NESS
IN MM START
1 25 25/1.7 HIGH 5 8.7 .625 16 .625 16 190 360 30 762
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PSI/BAR
CUT PSI/BAR
Cutting Data:
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
360 STAINLESS STEEL
START GAS CUT GAS SHIELD GAS
VOLTAGE
ARC CUR-
RENT
H-35 or N H-35 N
2
TRAVEL SPEED
65
2
MIN
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
360 AMP
MATERIAL THICK­NESS
IN MM START
.250 6 25/1.7 LOW 7 9.5 .500 13 .375 10 158 360 250 6350 .500 13 25/1.7 LOW 7 9.5 .625 16 .375 10 160 360 160 4064 .750 19 25/1.7 LOW 7 9.5 .625 16 .375 10 164 360 90 3386 1 25 25/1.7 LOW 7 9.5 .625 16 .375 10 171 360 60 1524
360 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
Cutting Data:
NOZZLE MATERIAL
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
360 ALUMINUM
360 ALUMINUM
VOLTAGE
START GAS CUT GAS SHIELD GAS
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
H-35 or N H-35 N
ARC CUR-
RENT
TRAVEL SPEED
2
N N N
MIN
MIN
2
2
2
2
.500 13 25/1.7 HIGH 1 9.5 .625 16 .375 10 157 360 150 3810 .750 19 25/1.7 HIGH 1 9.5 .625 16 .375 10 176 360 90 2286 1 25 25/1.7 HIGH 1 9.5 .625 16 .375 10 180 360 60 1524
Cutting Data:
400 AMP
MATERIAL THICK­NESS
IN MM START
.750 19 25/1.7 LOW 7 7 .625 16 .188 4 134 400 110 2794 1 25 25/1.7 LOW 7 7 .625 16 .250 6 140 400 80 2032
1.25 32 25/1.7 LOW 7 4.5 .625 16 .438 11 150 400 60 1524
1.50 38 25/1.7 LOW 7 3 .625 16 .438 11 155 400 42 1067
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
400 CARBON STEEL
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
N O AIR
MIN
2
2
66
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
VOLTAGE
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
Cutting Data:
410 AMP
NOZZLE MATERIAL
MATERIAL THICK­NESS
IN MM START
.750 19 25/1.7 HIGH 0 6.5 .625 16 .312 8 132 410 140 3556
1 25 25/1.7 HIGH 0 6.5 .625 16 .438 11 135 410 110 2794
1.25 32 25/1.7 HIGH 0 6.5 .625 16 .500 13 141 410 85 2159
1.50 38 25/1.7 HIGH 0 6.5 .625 16 .500 13 146 410 65 1651 2 50 25/1.7 HIGH 0 6.5 .625 16 .500 13 153 410 45 1143
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
400 ALUMINUM
Cutting Data:
450 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
450 STAINLESS STEEL
H-35 H-35 N
TRAVEL SPEED
TRAVEL SPEED
2
MIN
MIN
N N AIR
2
2
.750 19 25/1.7 LOW 7 7 .625 16 .375 10 160 450 100 2540
1 25 25/1.7 LOW 7 7 .625 16 .250 6 163 450 70 1778
1.25 32 25/1.7 LOW 7 4.5 .625 16 .375 10 176 450 52 1321
1.50 38 25/1.7 LOW 7 3 .625 16 .500 13 192 450 33 838
Cutting Data:
600 AMP
MATERIAL THICK­NESS
IN MM START
1 25 RUN 2 HIGH 4 8* .750 19 .625 16 172 600 80* 2032*
1.50 38 RUN 2 HIGH 4 8* .750 19 .625 16 177 600 65* 1651* 2 50 RUN 2 HIGH 4 8* moving .750 19 192 600 30* 762* 3 75 RUN 2 HIGH 4 8 moving .750 19 212 600 15 381
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
600 ALUMINUM
VOLTAGE
ARC CUR-
RENT
H-35 H-35 N
2
TRAVEL SPEED
MIN
67
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
NOZZLE
600 AMP
MATERIAL THICK­NESS
IN MM START
1.50 38 RUN 2 HIGH 4 8 .750 19 .625 16 172 600 75 1905 2 50 RUN 2 HIGH 4 6 mov-
3 75 RUN 2 HIGH 4 8 mov-
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
ing
ing
PSI/BAR
CUT PSI/BAR
MATERIAL
Cutting Data:
600 ALUMINUM
600 AMP
MATERIAL THICK­NESS
IN MM START
GAS SET UP STANDOFF ARC
PSI/BAR
CUT PSI/BAR
SHIELD @ 60 PSI / 4
BAR
NOZZLE MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
600 ALUMINUM
VOLTAGE
.750 19 192 600 40 1016
.750 19 205 600 20 508
START GAS CUT GAS SHIELD GAS
VOLTAGE
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
N N AIR
ARC CUR-
RENT
TRAVEL SPEED
2
2
H-35 H-35 Air
MIN
MIN
1 25 RUN 2 HIGH 0 8 .625 16 .375 10 158 600 100 2540
1.50 38 RUN 2 HIGH 0 7 .625 16 .375 10 168 600 60 1524
Cutting Data:
600 AMP
MATERIAL THICK­NESS
IN MM START
1 25 RUN 2 HIGH 4 8 .750 19 .500 13 163 600 40 1016
1.50 38 RUN 2 HIGH 4 8 .750 19 .625 16 186 600 18 457 2 50 RUN 2 HIGH 4 6 mov-
3 75 RUN 2 HIGH 4 8 mov-
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PIERCE CUT IPM MM/ IN MM IN MM
ing
ing
PSI/BAR
CUT PSI/BAR
NOZZLE MATERIAL
600 STAINLESS STEEL
VOLTAGE
.750 19 204 600 12 305
.750 19 206 600 9 229
START GAS CUT GAS SHIELD GAS
ARC CUR-
RENT
TRAVEL SPEED
H-35 H-35 N
2
MIN
68
SECTION 3 OPERATION
CUTTING TABLES FOR PT19XLS AND PT600
Cutting Data:
NOZZLE
600 AMP
MATERIAL THICK­NESS
IN MM START
1 25 RUN 2 HIGH 0 8 .625 16 .500 13 160 600 70 1778
1.5 38 RUN 2 HIGH 0 8 .625 16 .500 13 163 600 40 1016
GAS SET UP STANDOFF ARC
SHIELD @ 60 PSI / 4
BAR
PSI/BAR
CUT PSI/BAR
MATERIAL
PIERCE CUT IPM MM/ IN MM IN MM
600 STAINLESS STEEL
START GAS CUT GAS SHIELD GAS
VOLTAGE
ARC CUR-
RENT
N
2
N
2
AIR
TRAVEL SPEED
MIN
Notes on 600A Cutting
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 bae 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 sacriced.
PT-15XL Bevel Angles
PLATE
THICKNESS
(IN.)
1/4 2075691 (0.125) 35 3/4 2075611 (0.156) 40
1-1/2 2075612 (0.200) 45
2 2075613 (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 muer 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 eect 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
a b
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 eective 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 aected. 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 muer.
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 Muer (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 reecting 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 muer, underwater cutting with air curtain or cutting with a water muer.
Another method of fume control is to use the water
muer, above or underwater. For maximum eec­tiveness, the water muer 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 muer is less eective in controlling noise and UV radiation than underwater cutting. The water muer 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 Muer (Option) PT-15XL & Water Muer
(Option) PT-19XLS
The bubble muer can be viewed as a combination air
curtain and water muer. 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 anity 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. Rell 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 conned 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 predened 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 predened outputs in response to in­puts from external devices. This exchange of signals can be conrmed 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 condent that the LEDs are working the presence of a signal can be conrmed 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 dierent 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 - Preow state
The "Preow" state is a xed duration and is reached only from state "0". Nitrogen is always the preow gas in RUN 1 position. Selected cut gas type and ow is the preow gas in RUN 2 position. Cut water ow during preow 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 preow, 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 Postow State provides the minimum post­ow of nitrogen gas and cut water ow necessary before a restart is possible. The time is dierent 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 Postow State provides the time during which nitrogen gas and cut water ow cools the torch. This state immediately follows the Priority Postow state, a restart is possible during postow.
When the time for postow 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 Postow 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 orice 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 aected by the current setting. If parts are operated above their recom­mended current level, life deteriorates quickly. Improper cutting and parts programming can adversely eect 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 specic material. Some materials, including certain steels, are dicult, 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 qualied mainte­nance technician is contacted.
TROUBLESHOOTING GUIDE
Problem Probable Cause Remedy
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 bae (O2). Install correct gas bae (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 aect 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)
Problem Probable Cause Remedy
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 preow and postow 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
Problem Probable Cause Remedy
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 dicult to avoid entirely but careful part programming can minimize the problem.
80
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
Problem Probable Cause Remedy
2. Reduced nozzle life (N2, O2 and ArH2) ­(cont)
catching on piece
Air curtain/bubble muer 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)
Problem Probable Cause Remedy
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 muer.
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 eect on bevel angle.
82
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
Problem Probable Cause Remedy
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).
Insucient 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.
Insucient Open Circuit Voltage (OCV).
Gas ow improperly set.
Improper clamping of stain­less steel torch body.
Conductive water muer 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.
Refer to Power Source manual.
Refer to paragraph 3.1.1.
Clamp onto nonconductive sleeve above indicated mark.
Replace with nonconductive hoses.
Determine cause of leak.
83
SECTION 4 MAINTENANCE
TROUBLESHOOTING GUIDE - (Cont)
Problem
4. No pilot arc - (cont)
5. No arc transfer.
Probable Cause Remedy
Cut Water Flow Switch (CWFS) not activated (water injection only).
Blown fuse in P.A. or starting circuits.
Insucient 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 preow.
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 qualied technician performs this check.
Check input 10 on PLC in Flow Control. Should be lit to enable operation. Ensure qualied 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 qualied 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.
Insucient 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 satised - 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 muer air supply does not come on.
10. Bubble muer 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 muer 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)
Problem Probable Cause Remedy
11. Poor cut quality with Bubble Muer or Air Curtain installed. (Cuts are good above water with Bubble Muer 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 Muer 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.
89
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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IF YOU DO NOT KNOW WHOM TO CALL
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or
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F15-116-D 07/2007
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