ESAB EtchArc -1125 Plasma Marking System Instruction manual

Installation, Operation and Maintenance for the

®

EtchArc

-1125

PLASMA MARKING SYSTEM

F15-727

May, 2005

411 South Ebenezer Road Florence, SC 29501-0545

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

Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold be ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB’s responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total customer satisfaction. We constantly look for ways to improve our products, service and documentation. As a result, we make enhancements and/or design changes as required. ESAB makes every possible effort to ensure our documentation is current. We cannot guarantee that each piece of documentation received by our customers reflects the latest design enhancements. Therefore, the information contained in this document is subject to change without notice.

This manual is ESAB Part Number F15727

This manual is ESAB Part Number F15727This manual is ESAB Part Number F15727

....

This manual is for the convenience and use of the cutting machine purchaser. It is not a contract or other obligation on the part of ESAB Cutting Systems.

Printed in U.S.A.

©

©©

EtchArc-1125 Table of Contents

Page

Section 1 Safety

1.1 Introduction.................................................................................................... 1

1.2 Safety Notations And Symbols........................................................................ 1

1.3 General Safety Information.............................................................................. 2

1.4 Installation Precautions................................................................................... 3

1.5 Electrical Grounding ....................................................................................... 4

1.6 Operating A Plasma Cutting Machine.............................................................. 4-7

1.7 Service Precautions........................................................................................ 8

1.8 Safety References .......................................................................................... 9

1.8.1 National Standards................................................................................. 9

1.8.2 International Standards........................................................................... 10-11

Section 2 Description

2.1 Introduction Overview...................................................................................... 1

2.1.1 Interconnection Diagram......................................................................... 2

2.2 System Description ........................................................................................ 3

2.2.1 EtchArc-1125 Systems........................................................................... 3

2.2.2 EtchArc-1125 Power Supply (only).......................................................... 3

2.2.3 PM60 Plasma Marker Torch.................................................................... 4

2.2.4 PM60 Torch Lead Assemblies ................................................................ 4

2.2.5 Options .................................................................................................. 4

Section 3 Installation

3.0 General .......................................................................................................... 1

3.1 Interface......................................................................................................... 2

3.2 Requirements................................................................................................. 3

3.3 Connecting the EtchArc.................................................................................. 4

3.3.1 Rear Panel.............................................................................................. 4

3.3.2 Converting a 230 VAC unit to a 208 VAC unit.......................................... 5

3.3.3 Torch Lead Connections, Front Panel ..................................................... 6-7

3.3.4 Torch Bundle (Leads) to PM60 Torch...................................................... 8-13

i

EtchArc-1125 Table of Contents

Page

Section 4 Operation

4.0 Set-up ............................................................................................................ 1

4.1 Power Supply ................................................................................................. 1

4.2 Gas Set-up..................................................................................................... 2

4.3 CNC Set-up.................................................................................................... 3

4.4 Process Data................................................................................................... 4-10

Section 5 Maintenance

5.0 General........................................................................................................... 1

5.1 Routine Maintenance ...................................................................................... 2

5.2 Flow Switch .................................................................................................... 3

Section 6 Troubleshooting

6.0 General........................................................................................................... 1

6.1 Troubleshooting Guide.................................................................................... 1-5

6.2 Power Supply Schematic, 208/230v (P/N 0588000967)................................. 6-7

6.3 Wiring Diagram, 208/230v............................................................................... 8-11

6.4 Power Supply Schematic, 460v (P/N 0588000949)........................................ 12-13

6.5 Wiring Diagram, 460v...................................................................................... 14-17

6.6 Power Supply Schematic, 575v (P/N 0588000966)........................................ 18-19

6.7 Wiring Diagram, 575v...................................................................................... 20-23

6.8 Plasma (CUT) Gas Circuit................................................................................ 24

ii

EtchArc-1125 Table of Contents

Page

Section 7 Replacement Parts

7.1 General .......................................................................................................... 1

7.2 Ordering......................................................................................................... 1

7.3 EtchArc-1125, Front and Rear Exterior, all models .......................................... 2-3

7.4 EtchArc-1125, Right interior view, 208/230V model......................................... 4-5

7.5 EtchArc-1125, Left interior view, 208/230v model ........................................... 6-7

7.6 EtchArc-1125, Top interior view with cover removed, 208/230v model ............ 8-9

7.7 EtchArc-1125, Top interior cross section view 1, 208/230v model................... 10-11

7.8 EtchArc-1125, Top interior cross section view 2, 208/230v model................... 12-13

7.9 EtchArc-1125, Right interior view, 460v and 575v models............................... 14-15

7.10 EtchArc-1125, Left interior view, 460v and 575v models ............................... 16-17

7.11 EtchArc-1125, Top interior view with cover removed, 460v and 575v models 18-19

7.12 EtchArc-1125, Top interior cross section view 1, 460v and 575v models....... 20-21

7.13 EtchArc-1125, Top interior cross section view 2, 460v and 575v models....... 22-23

7.14 TechArc-1125 Inside View, 460v and 575v models ....................................... 24-25

7.15 Argon Gas Circuit (Cut Gas).......................................................................... 26-27

7.16 PM60 Plasma Torch..................................................................................... 28-29

7.17 Torch Leads and Other System Parts............................................................ 30-31

7.18 PM-60 Plasma Marking Torch Starter Spare Parts Kit.................................... 32-33

Back Manual

Customer/Technical Information

Cover

iii

EtchArc-1125 Table of Contents

This page intentionally left blank

iv

SECTION 1 Safety

1.1 Introduction

The process of cutting metals with plasma equipment

1.2 Safety Notations And Symbols

!

DANGER

!

provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness. Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be accomplished. Failure to observe certain precautions could result in serious personnel injury or severe equipment damage. The following precautions are general guidelines applicable when working with cutting machines. More explicit precautions pertaining to the basic machine and accessories are found in the instruction literature. For a wide scope of safety information on the field of cutting and welding apparatus, obtain and read the publications listed in the Recommended References.

The following words and symbols are used throughout this manual. They indicate different levels of required safety involvement.

ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used with other symbols and information.

Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury or loss of life.

WARNING

!

CAUTION

!

CAUTION

NOTICE

EtchArc-1125 Power Source 1-1

Used to call attention to potential hazards that could result in personal injury or loss of life.

Used to call attention to hazards that could result in minor personal injury or equipment damage.

Used to call attention to minor hazards to equipment.

Used to call attention to important installation, operation or maintenance information not directly related to safety hazards.

SECTION 1 Safety

1.3 General Safety Information

WARNING

!

Machinery often starts automatically.

This equipment moves in various directions and

This equipment moves in various directions and This equipment moves in various directions and speeds.

speeds.

speeds.speeds.

• Moving machinery can crush.

Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

• Only qualified personnel should operate or

Only qualified personnel should operate or

Only qualified personnel should operate or Only qualified personnel should operate or service this power source.

service this power source.

service this power source.service this power source.

• Keep all personnel, materials, and equipment

Keep all personnel, materials, and equipment

Keep all personnel, materials, and equipment Keep all personnel, materials, and equipment not involved in prod

not involved in production process clear of

not involved in prodnot involved in prod entire system area.

entire system area.

entire system area.entire system area.

• Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel Fence off entire work cell to prevent personnel from passing through area or standing in the

from passing through area or standing in the

from passing through area or standing in the from passing through area or standing in the working envelope of the equipment.

working envelope of the equipment.

working envelope of the equipment. working envelope of the equipment.

• Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every work Post appropriate WARNING signs at every work cell entrance.

cell entrance.

cell entrance. cell entrance.

• Follow lockout proced

Follow lockout procedure before servicing any

Follow lockout procedFollow lockout proced equipment.

equipment.

equipment.equipment.

uction process clear of

uction process clear of uction process clear of

ure before servicing any

ure before servicing any ure before servicing any

Failure to follow operating instructions

WARNING

!

could result in death or serious injury.

Read and understand this operator’s manual before

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

using machine.

using machine.using machine.

• Read entire procedure before operating or

Read entire procedure before operating or

Read entire procedure before operating or Read entire procedure before operating or performing any system maintenance.

performing any system maintenance.

performing any system maintenance. performing any system maintenance.

• Special attention must be given to all hazard

Special attention must be given to all hazard

Special attention must be given to all hazard Special attention must be given to all hazard warnings that provide essential information

warnings that provide essential information

warnings that provide essential information warnings that provide essential information re

regarding personnel safety and/or possible

garding personnel safety and/or possible

rere

garding personnel safety and/or possible garding personnel safety and/or possible

equipment damage.

equipment damage.equipment damage.

• All safety precautions relevant to electrical

All safety precautions relevant to electrical

All safety precautions relevant to electrical All safety precautions relevant to electrical equipment and process operations must be

equipment and process operations must be

equipment and process operations must be equipment and process operations must be strictly observed by all having system

strictly observed by all having system

strictly observed by all having system strictly observed by all having system responsibility or access.

responsibility or access.

responsibility or access. responsibility or access.

• Read all safety publications made available

Read all safety publications made available by

Read all safety publications made availableRead all safety publications made available your company.

your company.

your company.your company.

by

by by

EtchArc-1125 Power Source 1-2

SECTION 1 Safety

Failure to follow safety warning label

WARNING

!

1.4 Installation Precautions

instructions could result in death or serious injury.

Read and understand all safety warning labels on

Read and understand all safety warning labels on Read and understand all safety warning labels on machine.

machine.

machine.machine.

Refer to operator’s manual for additiona

Refer to operator’s manual for additional safety

Refer to operator’s manual for additionaRefer to operator’s manual for additiona information.

information.

information.information.

l safety

l safety l safety

WARNING

!

Improperly Installed Equipment Can Cause Injury Or Death.

Follow these guidelines while installing machine:

Follow these guidelines while installing machine:Follow these guidelines while installing machine:

• Contact your ESAB representative before

Contact your ESAB representative before

Contact your ESAB representative before Contact your ESAB representative before installation. He can suggest certain precautio

installation. He can suggest certain precautions

installation. He can suggest certain precautioinstallation. He can suggest certain precautio regarding piping installation and machine lifting,

regarding piping installation and machine lifting,

regarding piping installation and machine lifting, regarding piping installation and machine lifting, etc. to ensure maximum security.

etc. to ensure maximum security.

etc. to ensure maximum security.etc. to ensure maximum security.

• Never attempt any machine modifications or

Never attempt any machine modifications or

Never attempt any machine modifications or Never attempt any machine modifications or apparatus additions without first consulting a

apparatus additions without first consulting a

apparatus additions without first consulting a apparatus additions without first consulting a qualified ESAB representative.

qualified ESAB representative.

qualified ESAB representative.qualified ESAB representative.

• Observe machine clearance requirements for

Observe machine clearance requirements for

Observe machine clearance requirements for Observe machine clearance requirements for prope

proper operation and personnel safety.

r operation and personnel safety.

propeprope

r operation and personnel safety. r operation and personnel safety.

• Always have qualified personnel perform

Always have qualified personnel perform

Always have qualified personnel perform Always have qualified personnel perform installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of installation, troubleshooting and maintenance of this equipment.

this equipment.

this equipment.this equipment.

• Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with Provide a wall mounted disconnect switch with proper fuse sizes close to the power supply.

proper fuse sizes close to the power supply.

proper fuse sizes close to the power supply.proper fuse sizes close to the power supply.

ns

ns ns

EtchArc-1125 Power Source 1-3

SECTION 1 Safety

1.5 Electrical Grounding

Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions.

Electric shock hazard.

WARNING

!

1.6 Operating A Plasma Cutting Machine

Improper grounding can cause severe injury or

Improper grounding can cause severe injury or Improper grounding can cause severe injury or death.

death.

death.death.

Machine

Machine must be properly grounded before put into

MachineMachine service.

service.

service.service.

must be properly grounded before put into

must be properly grounded before put into must be properly grounded before put into

Flying debris and loud noise

WARNING

!

hazards.

• Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying debris generated during

debris generated during operation.

debris generated during debris generated during

operation.

operation.operation.

• Chipped slag may be hot and fly far.

Chipped slag may be hot and fly far.

Chipped slag may be hot and fly far. Chipped slag may be hot and fly far. Bystanders should also wear goggles and

Bystanders should also wear goggles and

Bystanders should also wear goggles and Bystanders should also wear goggles and safety glasses.

safety glasses.

safety glasses.safety glasses.

• Noise from plasma arc can damage hearing.

Noise from plasma arc can damage hearing.

Noise from plasma arc can damage hearing. Noise from plasma arc can damage hearing. Wear correct ear protection when cutting above

Wear correct ear protection when cutting above

Wear correct ear protection when cutting above Wear correct ear protection when cutting above water.

water.

water. water.

Burn hazard.

WARNING

!

Hot metal can burn.

Hot metal can burn.Hot metal can burn.

• Do not touch m

Do not touch metal plate or parts immediately

Do not touch mDo not touch m after cutting. Allow metal time to cool, or douse

after cutting. Allow metal time to cool, or douse

after cutting. Allow metal time to cool, or douse after cutting. Allow metal time to cool, or douse with water.

with water.

with water.with water.

• Do not touch plasma torch immediately after

Do not touch plasma torch immediately after

Do not touch plasma torch immediately after Do not touch plasma torch immediately after cutting. Allow torch time to cool.

cutting. Allow torch time to cool.

cutting. Allow torch time to cool.cutting. Allow torch time to cool.

etal plate or parts immediately

etal plate or parts immediately etal plate or parts immediately

EtchArc-1125 Power Source 1-4

SECTION 1 Safety

g

!

can kill.

• Do NOT touch plasma torch, cutti

Do NOT touch plasma torch, cutting table or

Do NOT touch plasma torch, cuttiDo NOT touch plasma torch, cutti

cable connections during plasma cutting process.

cable connections during plasma cutting process.cable connections during plasma cutting process.

• Always turn power off to plasma power

Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

supplies before touching or servicing plasma torch.

supplies before touchin

• Always turn power off to plasma power

Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

supplies before servicing any system component.

supplies before servicing any system component.supplies before servicing any system component.

• Do not touch live

Do not touch live electrical parts.

Do not touch liveDo not touch live

• Keep all panels and covers in place when

Keep all panels and covers in place when

Keep all panels and covers in place when Keep all panels and covers in place when

machine is connected to power source.

machine is connected to power source.machine is connected to power source.

• Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to Wear insulating gloves, shoes and clothing to

insulate yourself from workpiece and electrical

insulate yourself from workpiece and electrical insulate yourself from workpiece and electrical ground.

ground.

ground.ground.

• Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and

equipment d

equipment dry.

equipment dequipment d

• Replace worn or damaged cables.

Replace worn or damaged cables.

Replace worn or damaged cables.Replace worn or damaged cables.

ry.

ry.ry.

or servicing plasma torch. supplies before touching or servicing plasma torch.

electrical parts.

electrical parts. electrical parts.

ng table or

ng table or ng table or

WARNING

Hazardous voltages. Electric shock

WARNING

!

Fume hazard.

Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting process can be hazardous to your health.

process can be hazardous to your health.

process can be hazardous to your health.process can be hazardous to your health.

• Do NOT breathe fumes.

Do NOT breathe fumes.

Do NOT breathe fumes.Do NOT breathe fumes.

• Do not operate plasma torch without fume

Do not operate plasma torch without fume

Do not operate plasma torch without fume Do not operate plasma torch without fume

removal system operating properly.

removal system operating properly. removal system operating properly.

• Use additional

Use additional ventilation to remove fumes if

Use additionalUse additional

necessary.

necessary.necessary.

• Use approved respirator if ventilation is not

Use approved respirator if ventilation is not

Use approved respirator if ventilation is not Use approved respirator if ventilation is not

adequate.

adequate.adequate.

• Provide positive mechanical ventilation when

Provide positive mechanical ventilation when

Provide positive mechanical ventilation when Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper,

cutting galvanized steel, stainless steel, copper, cutting galvanized steel, stainless steel, copper, zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe these zinc, beryllium, or cadmium. Do not breathe these fumes.

fumes.

fumes.fumes.

Do

Do not operate near degreasing and spraying

•

Do Do

operations. Heat or arc rays can react with

operations. Heat or arc rays can react with operations. Heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vapors to form phosgene, chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases. a highly toxic gas and other irritant gases.

not operate near degreasing and spraying

not operate near degreasing and spraying not operate near degreasing and spraying

ventilation to remove fumes if

ventilation to remove fumes if ventilation to remove fumes if

EtchArc-1125 Power Source 1-5

SECTION 1 Safety

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn skin.Arc rays can injure eyes and burn skin.

• Wear corre

Wear correct eye and body protection.

Wear correWear corre

• Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side

shields. Refer to following chart for recommended

shields. Refer to following chart for recommended shields. Refer to following chart for recommended lens shades for plasma cutting:

lens shades for plasma cutting:

lens shades for plasma cutting:lens shades for plasma cutting:

Arc Current

Up to 100 Amps

100

200

Over 400 Amps

• Replace glasses/goggles when lenses are pitted or broken

pitted or broken

pitted or brokenpitted or broken

• Warn others in area not to look directly at the arc unless wearing appropriate safety glasses.

arc unless wearing appropriate safety glasses.

arc unless wearing appropriate safety glasses.arc unless wearing appropriate safety glasses.

• Prepare cutting area to reduce reflection and transmission

transmission of ultraviolet light.

transmissiontransmission

Arc Current Lens Shade

Arc CurrentArc Current

Up to 100 Amps Shade No. 8

Up to 100 AmpsUp to 100 Amps

100----200 Amps

100100

200----400

200200

Over 400 Amps Shade No. 14

Over 400 AmpsOver 400 Amps

Replace glasses/goggles when lenses are

Replace glasses/goggles when lenses are Replace glasses/goggles when lenses are

Warn others in area not to look directly at the

Warn others in area not to look directly at the Warn others in area not to look directly at the

Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection and Prepare cutting area to reduce reflection and

§ Use special paint on walls to absorb UV light.

light.

light.light.

ct eye and body protection.

ct eye and body protection.ct eye and body protection.

Lens Shade

Lens Shade Lens Shade

Shade No. 8

Shade No. 8Shade No. 8

200 Amps Shade No. 10

200 Amps200 Amps

400 Amps

400 400

of ultraviolet light.

of ultraviolet light. of ultraviolet light.

Use special paint on walls to absorb UV

Use special paint on walls to absorb UV Use special paint on walls to absorb UV

Shade No. 10

Shade No. 10Shade No. 10

Amps Shade No. 12

Shade No. 12

AmpsAmps

Shade No. 12Shade No. 12

Shade No. 14

Shade No. 14Shade No. 14

§ Install protective screens or curtains to

Install protective screens or curtains to

Install protective screens or curtains to Install protective screens or curtains to

reduce ultraviolet transmission.

reduce ultraviolet transmission.reduce ultraviolet transmission.

EtchArc-1125 Power Source 1-6

SECTION 1 Safety

!

WARNING

!

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

Do not cut near combustible material.

Do not cut near combustible material.Do not cut near combustible material.

• Do

Do not have on your person any combustibles

not have on your person any combustibles

DoDo

not have on your person any combustibles not have on your person any combustibles

(e.g. butane lighter).

(e.g. butane lighter).(e.g. butane lighter).

• Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle

away from yourself and others when activating

away from yourself and others when activating away from yourself and others when activating plasma process.

plasma process.

plasma process.plasma process.

• Wear correct eye and body protection.

Wear correct eye and body protection.

Wear correct eye and body protection.Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

• WWWWear flame

ear flame----retardant clothing covering all

ear flameear flame

exposed areas.

exposed areas.exposed areas.

• Wear cuffless trousers to prevent entry of

Wear cuffless trousers to prevent entry of

Wear cuffless trousers to prevent entry of Wear cuffless trousers to prevent entry of

sparks and slag.

sparks and slag.sparks and slag.

• Have fire extinguishing equipment available for

Have fire extinguishing equipment available for

Have fire extinguishing equipment available for Have fire extinguishing equipment available for

use.

use.use.

retardant clothing covering all

retardant clothing covering all retardant clothing covering all

Explosion hazard.

• Certain molten aluminum

Certain molten aluminum----lithium (Al

Certain molten aluminumCertain molten aluminum

can cause explos

can cause explosions when plasma cut OVER

can cause exploscan cause explos water.

water.

water. water.

§ These alloys should only be dry cut on a

These alloys should only be dry cut on a

These alloys should only be dry cut on a These alloys should only be dry cut on a

dry table.

dry table.dry table.

§ DO NOT dry cut over water.

DO NOT dry cut over water.

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

ions when plasma cut OVER

ions when plasma cut OVER ions when plasma cut OVER

lithium (Al----Li) alloys

lithium (Allithium (Al

Li) alloys

Li) alloys Li) alloys

WARNING

Burn Hazard.

§ Contact your aluminum supplier for

Contact your aluminum supplier for

Contact your aluminum supplier for Contact your aluminum supplier for

additional safety information regarding

additional safety information regarding additional safety information regarding hazards associated with these alloys

hazards associated with these alloys

hazards associated with these alloyshazards associated with these alloys

Do not cut in atmospheres con

Do not cut in atmospheres containing

•

Do not cut in atmospheres conDo not cut in atmospheres con

explosive dust or vapors.

explosive dust or vapors.explosive dust or vapors.

•

Do not carry any combustibles on your person

Do not carry any combustibles on your person Do not carry any combustibles on your person

(e.g. butane lighter)

(e.g. butane lighter)(e.g. butane lighter)

• Do not cut containers that have held

Do not cut containers that have held

Do not cut containers that have held Do not cut containers that have held

combustibles.

combustibles.combustibles.

EtchArc-1125 Power Source 1-7

taining

taining taining

.

SECTION 1 Safety

g

1.7 Service Precautions

!

CAUTION

!

can kill.

• Do NOT touch plasma torch

Do NOT touch plasma torch, cutting table or

Do NOT touch plasma torchDo NOT touch plasma torch

cable connections during plasma cutting process.

cable connections during plasma cutting process.cable connections during plasma cutting process.

• Always turn power off to plasma power

Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

supplies before touching or servicing plasma torch.

supplies before touchin

• Always turn power off to plasma power

Always turn power off to plasma power

Always turn power off to plasma power Always turn power off to plasma power

supplies before removing covers or panels to

supplies before removing covers or panels to supplies before removing covers or panels to service any s

service any system component.

service any sservice any s

• Do not touch live electrical parts.

Do not touch live electrical parts.

Do not touch live electrical parts.Do not touch live electrical parts.

• Keep all panels and covers in place when

Keep all panels and covers in place when

Keep all panels and covers in place when Keep all panels and covers in place when

machine is connected to power source.

machine is connected to power source.machine is connected to power source.

• Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and

equipment dry.

equipment dry.equipment dry.

• Inspect power and ground leads cables for

Inspect power and ground leads cables for

Inspect power and ground leads cables for Inspect power and ground leads cables for

wear or cracking. Repl

wear or cracking. Replace worn or damaged

wear or cracking. Replwear or cracking. Repl cables. Do not use if damaged.

cables. Do not use if damaged.

cables. Do not use if damaged.cables. Do not use if damaged.

• Never bypass safety interlocks.

Never bypass safety interlocks.

Never bypass safety interlocks.Never bypass safety interlocks.

• Follow lock

Follow lock----out procedures.

Follow lockFollow lock

Establish and adhere to preventive maintenance.

Establish and adhere to preventive maintenance. Establish and adhere to preventive maintenance. A composite program can be established from

A composite program can be established from

A composite program can be established from A composite program can be established from recommended schedules.

recommended schedules.

recommended schedules.recommended schedules.

Avoid leaving test equ

Avoid leaving test equipment or hand tools on

Avoid leaving test equAvoid leaving test equ machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage could occur to equipment or machine.

could occur to equipment or machine.

could occur to equipment or machine.could occur to equipment or machine.

Extreme caution should be used when probing

Extreme caution should be used when probing Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter.

circuitry with an oscilloscope or voltmeter.

circuitry with an oscilloscope or voltmeter. circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over volta

Integrated circuits are susceptible to over voltage

Integrated circuits are susceptible to over voltaIntegrated circuits are susceptible to over volta damage. Power off before using test probes to

damage. Power off before using test probes to

damage. Power off before using test probes to damage. Power off before using test probes to prevent accidental shorting of components.

prevent accidental shorting of components.

prevent accidental shorting of components.prevent accidental shorting of components.

All circuit boards securely seated in sockets, all

All circuit boards securely seated in sockets, all All circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and

cables properly connected, all cabinets closed and

cables properly connected, all cabinets closed and cables properly connected, all cabinets closed and locked, all guards and covers replaced before

locked, all guards and covers replaced before

locked, all guards and covers replaced before locked, all guards and covers replaced before power is turned

power is turned on.

power is turnedpower is turned

ystem component.

ystem component.ystem component.

out procedures.

out procedures.out procedures.

on.

on. on.

or servicing plasma torch. supplies before touching or servicing plasma torch.

ace worn or damaged

ace worn or damaged ace worn or damaged

ipment or hand tools on

ipment or hand tools on ipment or hand tools on

, cutting table or

, cutting table or , cutting table or

ge

ge ge

WARNING

Hazardous voltages. Electric shock

EtchArc-1125 Power Source 1-8

SECTION 1 Safety

1.8 Safety References -- Regulations, Standards, Guidelines

1.8.1 Domestic

The following recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are not related specifically to this type of industrial cutting apparatus, the principles of safety apply equally.

• “Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting Systems.

• “Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529. ESAB Cutting Systems.

• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

• “Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

• “Recommended Practices for Arc Cutting” - AWS C5.2, American

Welding Society.

• “Safe Practices” - AWS SP, American Welding Society.

• “Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B, National Fire Protection Association, 60 Batterymarch Street, Boston, Massachusetts, 02110.

• “Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51, National Fire Protection Association.

• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting Systems. Obtainable through your ESAB representative or local distributor.

• "Design and Installation of Oxygen Piping Systems," Form 5110.

ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed Gases in

Cylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with gaseous materials is also available from the Compressed Gas Association, Inc., 500 Fifth Ave., New York, NY 10036.

EtchArc-1125 Power Source 1-9

SECTION 1 Safety

1.8.2 International

Accident Prevention

VBG 1 General Provisions

VDE Regulations

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working

methods

VBG 48 Shot Blasting Works

VBG 61 Gases

VBG 62 Oxygen

VBG 87 Operating liquid jet cutting machines

VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE 0100 Erection of power installations with normal

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users

VDE 0837-

50

voltages up to 1000 volts

guide (DIN EN 60825) Specification for laser guards

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-204 Acetylene lines

TRG Technical Rules for Pressure gases

EtchArc-1125 Power Source 1-10

TRAC-206 Acetylene cylinder battery systems

TRAC-207 Safety devices

TRG 100 General regulations for pressure gases

TRG 101 Pressure gases

TRG 102 Technical gas mixtures

TRG 104 Pressure gases; alterative use of

compressed gas tanks

SECTION 1 Safety

DIN Standards

DIN EN ISO Harmonized Standards

DIN 2310

Part 1

DIN 2310

Part 2

DIN 2310

Part 4

DIN 2310

Part 5

DIN 4844

Part 1

DIN EN 292/1 and 2 DIN EN 559 Hoses for welding, cutting and allied

DIN EN 560 Hose connections and hose couplings for

DIN EN 561 Gas welding equipment hose couplings

Thermal cutting; terminology and nomenclature Thermal cutting; determination of quality of cut faces Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances Thermal cutting; laser beam cutting of metallic materials; process principles Safety markings (DIN EN 7287)

Safety of machinery

processes

equipment for welding, cutting and allied processes

DIN EN

626-1

DIN EN

848-1

DIN EN

1829

DIN EN

9013

DIN EN

12584

DIN EN

12626

DIN EN

28206

DIN EN

31252

DIN EN

31553

DIN EN

60204-1

DIN EN

60825

DIN EN 999 Arrangement of protection devices

Safety of machines, reduction of risks to health Single spindle vertical milling machines

High pressure water jet machines

Thermal cutting, oxygen cutting, process principles, dimensional tolerances Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma Laser processing machines

Acceptance testing for oxygen cutting machines Laser Equipment

Laser and laser related equipment

Electrical equipment of machines

Radiation safety of laser products

VDI Guidelines

EtchArc-1125 Power Source 1-11

VDI 2906 Quality of cut faces on metallic workpieces;

abrasive water jet cutting and arc plasma cutting

VDI 2084 Room air; Technical systems for welding

workshops

SECTION 1 Safety

This page intentionally left blank.

EtchArc-1125 Power Source 1-12

SECTION 2 System Description

2 Introduction

2.1 Overview

The EtchArc Plasma Marker is a constricted arc low amperage plasma marking torch. It marks at speeds between 100 and 500 ipm.

The plasma marking process is similar to the plasma cutting process. However, rather than piercing through the plate, the low amperage plasma arc merely cuts the surface of the plate material between .0002 and .005 deep. Voltage height control maintains a constant torch standoff for consistent, high speed, accurate pattern layout.

When the EtchArc Plasma Marker is used in conjunction with ESAB’s Vision CNC, Dynamic Current Control is used to precisely control width and depth of marks by proportionally ramping current up and down as the machine accelerates and decelerates. This minimizes pitting at the beginning, corners, and end of the mark.

Accurate positioning of the layout lines and marks depends on using the automatic marker offsets executed by the CNC during Automatic Mode. However, the marker can be used manually for testing and setup.

In automatic operation, the part program controls:

All of these steps can be performed by the operator for manual operation.

The EtchArc-1125 Plasma Marking Power Supply

consists of a modified PCM-1125 capable of supplying up to 35 amperes. Modifications include an added argon solenoid, pressure switch, gas connections, marker control board and cable connection. Unused manual controls were removed or disconnected from the PCM-1125.

• machine motion

• offsets torch

• turns on automatic height control

• fires the torch and begins marking.

The marking torch has only three consumable parts: the electrode, nozzle and shield cup. Argon cut gas provides long electrode and nozzle life.

EtchArc-1125 Plasma Marking System 2-1

SECTION 2 System Description

2.1.1 Interconnecting Diagram

EEEE

ttttcccc

hhhh

AAAA

rrrr

cccc

2

F

9

10

3

B

4

1

7

8

5

12

6

15

13

16

11

14

F

EtchArc----1125 Front Connections

EtchArcEtchArc

1125 Front Connections

1125 Front Connections1125 Front Connections

B

EtchArc

EtchArc----1125 Back Connections

EtchArcEtchArc

1125 Back Connections

1125 Back Connections1125 Back Connections

EtchArc

1 Vision CNC (relay box) 9 Air Regulator 2 CNC Control Cable 10 Air Supply Hose 3 Argon Gas Hose to torch 11 Argon Supply Hose 4 Work Cable 12 Primary Power Cable 5 Torch Bundle 13 Argon Gas Supply 6 Marking Torch 14 Compressed Air Supply 7 Work Piece 8 Earth Ground

15

16 Wall disconnect

EtchArc-1125 Plasma Marking System 2-2

Fused Disconnect (mounted on machine, used when EtchArc-1125 has been mounted on the machine)

SECTION 2 System Description

2.2 System Description

2.2.1 EtchArc Systems

Includes power supply, torch and necessary cables and hoses.

19 ft. (5.8 m) P/N 0560989772

25 ft. (7.6 m) P/N 0560989773

40 ft. (12.2 m) P/N 0560989774

50 ft. (15.2 m) P/N 0560989775

2.2.2 EtchArc-1125 Power Supply

208/230 V, 50/60Hz, 1 or 3 phase

208/230 V, 50/60Hz, 1 or 3 phase P/N 0588000967

208/230 V, 50/60Hz, 1 or 3 phase208/230 V, 50/60Hz, 1 or 3 phase

460 V, 50/60 Hz, 3 phase

460 V, 50/60 Hz, 3 phase P/N 0588000949

460 V, 50/60 Hz, 3 phase460 V, 50/60 Hz, 3 phase

575 V, 60 Hz, 3 p

575 V, 60 Hz, 3 phase

575 V, 60 Hz, 3 p575 V, 60 Hz, 3 p

Rated Inputs

Rated Inputs Rated Outputs

Rated InputsRated Inputs

hase P/N 0588000966

hasehase

Rated Outputs

Rated OutputsRated Outputs

Phases

Phases Volts

PhasesPhases

Volts Amps

VoltsVolts

1

3

Amps

AmpsAmps

Power

Power Power Factor

Factor

FactorFactor

Duty Cycle

Duty CycleDuty Cycle

Output Amps*

Output Amps* Output Amps*

@ 120 VDC

@ 120 VDC@ 120 VDC

Open Circuit

Open Circuit Open Circuit

Voltage

VoltageVoltage

Power

64

208

73% 100% 35* 280 VDC

55

58

230

73% 100% 35* 270 VDC

55

208 28 100% 100% 35* 285 VDC

230 25 100% 100% 35* 275 VDC

460 14 100% 100% 35* 285 VDC

575 11 100% 100% 35* 260 VDC

* Output amperage is limited by the marker control board (P/N 38138) to 35 amperes.

EtchArc-1125 Plasma Marking System 2-3

SECTION 2 System Description

2.2.3 PM60 Plasma Marker Torch Assembly

P/N 0560988474

Gas

Gas Dual (Argon and Air)

GasGas

Cooled

Cooled Air

CooledCooled

Amperes

Amperes Variable -- 35 Amperes Maximum

AmperesAmperes

2.2.4 PM60 Torch Lead Assembly

2.2.5 Option

Remote Arc Starter

Remote Arc StarterRemote Arc Starter

(Required if torch lead to exceed 50 ft.)

19 Ft.

19 Ft.19 Ft.

25 ft.

25 ft. P/N 0560986664

25 ft.25 ft.

40 ft.

40 ft. P/N 0560987587

40 ft.40 ft.

50 ft.

50 ft. P/N 0560986685

50 ft.50 ft.

P/N 0560988947

P/N 0558002819

EtchArc-1125 Plasma Marking System 2-4

SECTION 3 Installation

3 Installation

Electric Shock Can Kill!

WARNING

!

Ensure primary power source is off

Ensure primary power source is off Ensure primary power source is off and disconnected before making any

and disconnected before making any

and disconnected before making any and disconnected before making any electrical connections.

electrical connections.

electrical connections. electrical connections.

Only a qualified technician should

Only a qualified technician should Only a qualified technician should install and service this equipment.

install and service this equipment.

install and service this equipment. install and service this equipment.

CAUTION

!

Ensure Your EtchArc-1125 is being supplied with the appropriate power.

This equipment comes in 208/230 VAC 1-phase, 208/230 VAC 3-phase, 460 VAC 3-phase and 575 VAC 3phase. Connecting to incorrect power could damage your machine.

EtchArc-1125 Plasma Marking System 3-1

SECTION 3 Installation

3.1 Interface

The EtchArc Plasma Marker system interfaces with any cutting machine controller via the standard ESP open interface. This interface provides an amphenol connector for linking the appropriate control wiring. The schematic below illustrates interfacing with an EtchArc and ESAB Vision or ESAB Series 2000 CNC. The customer must provide the external requirements shown below when interfacing with a control other than these types.

External

Requirements

Start signal (Close

contacts to start

arc)

ESP Interface

Plug (J2)

J2-N

J2-M

EtchArc-1125

Power Supply

Start signal to power supply

Arc ON signal to

CNC

Current control

signal (Variable

DC Voltage)

Vmax = 3.5 V

Vmin = 0.3 V

Voltage divider

signal to voltage

height control

(+)

(-)

J2-I

J2-G

J2-L

J2-J

J2-C

J2-H

ESP Interface

Contact closes when arc starts

(+)

3.5 V = 35 A

0.3 V = 3.0 A

(-)

Work

20:1

Electrode

EtchArc-1125 Plasma Marking System 3-2

SECTION 3 Installation

3.2 Requirements

Electrical Input Requirements

Rated primary input @ 35A / 120V output:

A fused breaker (either on the cutting machine

Recommended sizes for input conductors and

• 208/230VAC, 1 Phase 64/58A, 50/60 Hz.

• 208/230/400/575 VAC, 3 Phase

28/25/16/11A, 50/60 Hz.

gantry or wall mounted) is required to disconnect power to the EtchArc-125 power supply. A machine mounted disconnect should be used when the power supply is mounted on the cutting machine.

line fuses:

Rated Input Input & Gnd

Conductor

Volts Amps Phase CU/AWG Amps

208 64 1 No. 4 90 230 58 1 No. 4 90 208 28 3 No. 10 50 230 25 3 No. 10 40 400 16 3 No. 10 25 575 11 3 No. 10 20

Fuse Size

Gas Supply Requirements

Argon 100 psi (¼ NPT)

99.999% Pure

Service Air 100 psi (¼ NPT)

Clean, dry, oil-free

EtchArc-1125 Plasma Marking System 3-3

SECTION 3 Installation

3.3 Connections to the EtchArc-1125

3.3.1 Back

Shield Gas (Air)

Primary Power

Plasma Gas

(Argon)

There are 3 input lines to connect to the power supply. These are made to the back of the unit

• Shield Gas

• Plasma Gas

• Primary power

Shield Gas

Shield GasShield Gas

Prefiltered (clean and dry) Air) customer supplied, 90 to 150 PSI max. ¼ NPT

Plasma Gas

Plasma GasPlasma Gas

99.999% purity, 100 PSI, ¼ NPT

Primary Power

Primary PowerPrimary Power

3 prong plug used on

the single phase

208/230 VAC EtchArc-

1125

Red lead terminated and

not used on the

1-phase EtchArc-1125

Inside the 3 prong plug

208/230 VAC unit is supplied with a 3-prong plug on a 10 ft. power cable when used as a single phase EtchArc power supply. If used as a 3-phase unit, disassemble plug and discard. Un-tape red lead and connect. The EtchArc 460 and 575 VAC power supplies are 3-phase and must be hard wired into the wall disconnect box.

EtchArc-1125 Plasma Marking System 3-4

SECTION 3 Installation

3.3.2 Converting a 230 VAC power supply to 208 VAC

D2 D1

TB5-2

TB5-1 Gray Lead

TB3

The EtchArc-1125 is factory wired for 1-phase 230 volts AC. If using 208 VAC, the EtchArc must be reconnected as follows before connecting to your input primary power.

A. Remove cover from the EtchArc Power

Supply.

B. Locate output bridge (D2) and TB3 on left

side towards the front panel.

C. Disconnect X2 and X3 leads from these two

locations and interchange wire connections. D. Move X2 from D2-3 to TB3. E. Move X3 lead that was on TB3 to D2-3.

F. Locate the input bridge (IBR) and TB5

terminal block on the left side towards the

rear panel. G. Disconnect gray lead from TB5-2 and

reconnect to TB5-1

TB5-2 to TB5-1

EtchArc-1125 Plasma Marking System 3-5

SECTION 3 Installation

3.3.3 Torch Lead Connections to EtchArc-1125

Torch Lead Bundle

Torch Lead

Connections

Shield Gas Hose/ Plasma Arc Lead

Argon Hose (Cut Gas)

Pilot Arc Cable

The torch lead bundle consists of; one hose for the plasma gas, one cable for the pilot arc current, and one combination gas hose and cable for the

shield gas/plasma current. (The current conductor is inside the air shield gas hose).

The torch lead to torch connections are covered in section 3.3.4

Torch Lead Connection Access Panel

Remove the torch lead connection access panel to connect the shield gas and pilot arc cable.

EtchArc-1125 Plasma Marking System 3-6

SECTION 3 Installation

Pilot Arc

Connection

Shield Gas

Connection

Connect pilot arc cable and shield gas hose. (The plasma arc connection is made when the shield gas hose is threaded into the bulkhead fitting.)

Connect plasma gas hose the bulkhead.

Replace access panel.

Plasma Gas Connection (Argon)

EtchArc-1125 Plasma Marking System 3-7

SECTION 3 Installation

3.3.4 Torch Bundle To Torch

Handle adapter removed for illustration

Pilot Arc ShieldGas/

Plasma Gas

1 ½” dia. heat shrink

Power

The torch has three connection points.

• Shield Gas (Air)/Plasma Arc

• Pilot Arc

• Plasma Gas

Procedure A). Unscrew handle from marker torch. Slide two (2) pieces of black heat shrink (provided— 1 ½ dia) onto the torch bundle.

B). Slide the torch handle on the torch bundle far enough to allow access to connection points. This may require a slight back and forth twisting motion of the handle.

EtchArc-1125 Plasma Marking System 3-8

SECTION 3 Installation

2

C). Shield Gas/Power Connection

Shield Gas/Power Connection

Shield Gas/Power Connection Shield Gas/Power Connection

• Slide two (2) pieces of clear ¾ KYNAR heat shrink on to the air/power connection of the

1

torch body as shown.

• Tighten the Air/Power Hose to the torch

2

connection.

1

• Position 1 piece or heatshrink over the air/power connection so that all metal is covered and shrink into place.

• Repeat procedure with the second piece of heatshrink.

Shield

Gas/Plasma

Arc

EtchArc-1125 Plasma Marking System 3-9

SECTION 3 Installation

4

3

Cut Gas (Argon)

D. Cut Gas hose connection

Cut Gas hose connection

Cut Gas hose connectionCut Gas hose connection

• Assemble 2 pieces of ½ X 3 of Kynar heatshrink on to the argon hose .

3

4

• Trim argon hose to length.

• Position cut gas hose clamp on to argon hose

about 1 to 2 inches past end of hose as shown.

• Slip hose on barbed fitting of torch body.

• Position clamp over barb and hose with

oreientation of clamp ears as shown .

10

• Position 1 piece of heatshrink over clamp and hose.

• Shrink into place. Repeat.

10

EtchArc-1125 Plasma Marking System 3-10

SECTION 3 Installation

7

6

E. Pilot Arc Connection

Pilot Arc Connection

Pilot Arc ConnectionPilot Arc Connection

• Remove H.F. connector from pilot arc

5

cable and place on arc wire of torch body to determine pilot arc cable length.

• Trim, strip and re-tin end of pilot arc cable.

5

• Remove from torch body and reassemble cable connector to pilot arc cable.

• Tighten set screw.

• Place 2 -- 3 long pieces of 3/8 diameter

Kynar heatshrink onto pilot arc cable .

6

7

• Assemble H.F. connector to body and tighten setscrew.

• Position 1 piece of heatshrink over the connector and shrink in place. Repeat

Pilot Arc

EtchArc-1125 Plasma Marking System 3-11

SECTION 3 Installation

H). Using a slight back and forth twisting motion, slide the torch handle to the torch body handle adapter.

I). Remove screw from torch handle adapter

J). Holding torch handle stationary, thread handle adapter into handle.

Do not rotate handle or torch body

CAUTION

to thread into adapter. This may twist the bundle components inside

Hold handle stationary. Do not rotate.

Rotate torch adapter to thread into sleeve

handle and damage torch.

Hold torch body stationary. Do not rotate

EtchArc-1125 Plasma Marking System 3-12

SECTION 3 Installation

K). Replace screw.

L). Position 1 ½ diameter heat shrink over the end of the torch handle as shown and shrink with heat until tight. Shrink one piece in place. Slide second into position and shrink with heat.

Torch Bundle

Heat shrink Torch

Handle

EtchArc-1125 Plasma Marking System 3-13

SECTION 3 Installation

This page intentionally left blank.

EtchArc-1125 Plasma Marking System 3-14

SECTION 4 Operation

4 Operation --Setup

4.1 EtchArc-1125 Setup

The ETCHARC-1125 control panel should be set properly before the marking operation. Check the following items:

GAS TEST - Place this switch in the OPERATE

POWER

PRESSURE

(70 psig)

CNC

AIR

FAULT

EtchArc-1125

GAS

TEST

OPERATE

10

5

CURRENT CONTROL 15

A

0

20

25

30

35 MAX

position for normal operation. TEST position energizes the gas solenoids to allow presetting of the argon and air gases.

CURRENT CONTROL - The Current Control knob can be left in any position. This potentiometer is normally disconnected for remote current control. (Plasma Marking current is controlled by the cutting machine CNC.) If the control does not support remote current, the current control potentiometer can be reconnected. (Wiring Diagrams in Section 6)

POWER - The Power On lamp should be on.

FAULT - The Fault lamp should be off.

ARGON

WORK

TORCH

EtchArc-1125 Plasma Marking System 4-1

SECTION 4 Operation

4.2 Gas Setup

Test/Operate Switch

Air Pressure Gage

Air Pressure Regulator

Argon Pressure Gauge

Argon Pressure

Regulator

The plasma marking system uses two compressed gases for operation. Compressed air is used for electrode cooling and shield gas, argon is used as plasma gas. The plasma gas constricts the arc as it exits through the nozzle orifice. The shield gas creates a secondary shield around the arc and improves torch cooling.

Before operating the system, check gas pressure settings for both compressed gases.

A. Set the Test/Operate switch to the TEST

position to energize the solenoid valves for both compressed air and argon.

B. Adjust the air pressure regulator on the rear of

the unit while observing the pressure gauge on the front of the unit. Set pressure to 90 PSI while the air is flowing.

C. The argon pressure is adjusted at the separate

regulator panel mounted to the cutting machine. While the argon is flowing, set the pressure to 75 psi.

D. When finished adjusting gas pressures, set the

TEST/OPERATE switch back to the OPERATE position.

EtchArc-1125 Plasma Marking System 4-2

SECTION 4 Operation

4.3 CNC Setup

Standoff

Initial Height

Plasma Travel Delay

Marker Remote Current

The EtchArc plasma marker may be interfaced to any cutting machine CNC. The following parameters may or may not be supported by your interface. Before plasma marking, check these parameters, or their equivalents, at the machine control:

On the Vision CNC, this parameter adjusts the actual cutting height (or arc voltage) the torch will maintain after the arc has started.

Sets the distance the torch will be raised after sensing the plate. When VHC is turned on, the torch will lower to the plate, then retract this distance before starting the arc.

Sets the length of time the machine will remain motionless after the arc strikes. Set to zero for the plasma marking process.

This parameter sets the marking current in amperes.

These parameters are preset when using SDP* marker files.

*The Vision family of CNCs allows the user to store multiple process parameter files. The files, called SDP files (ScheidDatenPaket = Cutting data package), contain all the same information that can be manually adjusted on the process parameter screen. (See your programming manuals for more information)

EtchArc-1125 Plasma Marking System 4-3

SECTION 4 Operation

4.4 Process Data

The EtchArc Plasma Marker can produce marked lines in a wide range of widths and depths, ranging from poor to excellent quality. It can also operate over a wide range of speeds. The operator must balance these two factors based on the requirements for a specific job.

The following pages provide process data for the six different amperage settings. Each page shows the setup parameters for that amperage and a chart with marking speed range. From the chart, the operator should select the speed setting based on the quality of mark that can be accepted.

EtchArc-1125 Plasma Marking System 4-4

SECTION 4 Operation

10 Amp Marking

Electrode

2237857

Nozzle 56996876

CURRENT:

NOZZLE:

MATERIAL:

PLASMA GAS:

SHIELD GAS:

PIERCE HEIGHT:

ARC VOLTAGE:

10 Amps

.030 PN: 56996876

CARBON STEEL

ARGON @ 75 PSI (5 bar)

AIR @ 90 PSI (6 bar)

.125 (3 mm)

66

Shield Cup 2237859

Travel Plasma

Speed Mark

inch/min mm/min Width Depth Quality

100 2540 .040-.050 .0013 FAIR 200 5080 .040-.050 .0005 GOOD 300 7620 .040-.050 .0004 GOOD 400 10160 .040-.050 .0004 EXCELLENT 500 12700 .040-.050 .0003 EXCELLENT

Notes

1. Corner current set for 5 Amps in machine MIP.

2. Slow travel speeds usually have top spatter on mark edges.

3. Width and depth of mark will vary slightly depending on measuring methods. This information is for estimated results.

EtchArc-1125 Plasma Marking System 4-5

SECTION 4 Operation

15 Amp Marking

Electrode 2237857

Nozzle 56996876

CURRENT:

NOZZLE:

MATERIAL:

PLASMA GAS:

SHIELD GAS:

PIERCE HEIGHT:

ARC VOLTAGE:

15 Amps .030 PN: 56996876

CARBON STEEL

ARGON @ 75 PSI (5 bar)

AIR @ 90 PSI (6 bar)

.125 (3 mm)

66

Shield Cup 2237859

Travel Plasma

Speed Mark

inch/min mm/min Width Depth Quality

100 2540 .040-.050 .0043 POOR 200 5080 .040-.050 .0021 FAIR 300 7620 .040-.050 .0013 GOOD 400 10160 .040-.050 .0003 EXCELLENT 500 12700 .040-.050 .0002 EXCELLENT

Notes

1. Corner current set for 5 Amps in machine MIP.

2. Slow travel speeds usually have top spatter on mark edges.

3. Width and depth of mark will vary slightly depending on measuring methods. This information is for estimated results.

EtchArc-1125 Plasma Marking System 4-6

SECTION 4 Operation

20 Amp Marking

CURRENT:

20 Amps

Electrode 2237857

Nozzle 56996876

NOZZLE:

MATERIAL:

PLASMA GAS:

SHIELD GAS:

PIERCE HEIGHT:

ARC VOLTAGE:

.030 PN: 56996876

CARBON STEEL

ARGON @ 75 PSI (5 bar)

AIR @ 90 PSI (6 bar)

.125 (3 mm)

66

Shield Cup 2237859

Travel Plasma

Speed Mark

inch/min mm/min Width Depth Quality

200 5080 .040-.050 .0028 POOR 300 7620 .040-.050 .0011 FAIR 400 10160 .040-.050 .0008 GOOD 500 12700 .040-.050 .0002 GOOD

Notes

1. Corner current set for 5 Amps in machine MIP.

2. Slow travel speeds usually have top spatter on mark edges.

3. Width and depth of mark will vary slightly depending on measuring methods. This information is for estimated results.

EtchArc-1125 Plasma Marking System 4-7

SECTION 4 Operation

25 Amp Marking

Electrode 2237857

Nozzle 56996876

CURRENT:

NOZZLE:

MATERIAL:

PLASMA GAS:

SHIELD GAS:

PIERCE HEIGHT:

ARC VOLTAGE:

25 Amps

040 PN: 2237858

CARBON STEEL

ARGON @ 75 PSI (5 bar)

AIR @ 90 PSI (6 bar)

.125 (3 mm)

66

Shield Cup 2237859

Travel Plasma

Speed Mark

inch/min mm/min Width Depth Quality

200 5080 .050-.060 .0051 POOR 300 7620 .050-.060 .0034 FAIR 400 10160 .050-.060 .0032 GOOD 500 12700 .050-.060 .0014 GOOD

Notes

1. Corner current set for 5 Amps in machine MIP.

2. Slow travel speeds usually have top spatter on mark edges.

3. Width and depth of mark will vary slightly depending on measuring methods. This information is for estimated results.

EtchArc-1125 Plasma Marking System 4-8

SECTION 4 Operation

30 Amp Marking

Electrode 2237857

Nozzle

2237858

CURRENT:

NOZZLE:

MATERIAL:

PLASMA GAS:

SHIELD GAS:

PIERCE HEIGHT:

ARC VOLTAGE:

30 Amps

.040 PN: 2237858

CARBON STEEL

ARGON @ 75 PSI (5 bar)

AIR @ 90 PSI (6 bar)

.125 (3 mm)

66

Shield Cup 2237859

Travel Plasma

Speed Mark

inch/min mm/min Width Depth Quality

200 5080 .050-.060 .0033 POOR 300 7620 .050-.060 .0030 FAIR 400 10160 .050"-.060 .0023 FAIR 500 12700 .050-.060 .0029 GOOD

Notes

1. Corner current set for 5 Amps in machine MIP.

2. Slow travel speeds usually have top spatter on mark edges.

3. Width and depth of mark will vary slightly depending on measuring methods. This information is for estimated results.

EtchArc-1125 Plasma Marking System 4-9

SECTION 4 Operation

35 Amp Marking

Electrode 2237857

Nozzle

2237858

CURRENT:

NOZZLE:

MATERIAL:

PLASMA GAS:

SHIELD GAS:

PIERCE HEIGHT:

ARC VOLTAGE:

35 Amps

.040 PN: 2237858

CARBON STEEL

ARGON @ 75 PSI (5 bar)

AIR @ 90 PSI (6 bar)

.125 (3 mm)

66

Shield Cup 2237859

Travel Plasma

Speed Mark

inch/min mm/min Width Depth Quality

300 7620 .050-.060 .0012 POOR 400 10160 .050-.060 .0024 FAIR 500 12700 .050-.060 .0032 FAIR

Notes

1. Corner current set for 5 Amps in machine MIP.

2. Slow travel speeds usually have top spatter on mark edges.

3. Width and depth of mark will vary slightly depending on measuring methods. This information is for estimated results.

EtchArc-1125 Plasma Marking System 4-10

SECTION 5 Maintenance

5 Maintenance

The Plasma Marking System consists of an EtchArc-1125 plasma power supply, the marking torch and argon supply.

Electric Shock Can Kill or Injure!

WARNING

!

Ensure the wall disconnect switch (or Circuit breaker) is open before removing cover or doing maintenance.

Electric Shock Can Kill!

WARNING

!

Ensure power supply power switch is OFF before servicing the PM-60 EtchArc Torch.

EtchArc-1125 Plasma Marking System 5-1

SECTION 5 Maintenance

5.1 Routine Maintenance

CAUTION

!

The following routine maintenance should be performed on the plasma marker system.

Compressed Air May Displace Debris Causing Eye Injuries.

Always wear approved safety eye and face protection whenever using compressed air to clean equipment. Dust and debris can be deflected back towards the face, possibly resulting in a serious eye injury. Ensure others nearby are protected also.

CAUTION

Water And Oil Contaminants in Compressed Air May Damage Power Supply Components.

Shop air occasionally contains accumulated oil or water. Before using compressed shop air to clean the interior of the power supply, redirect the first air blast away from power supply.

• Inspect the supply hoses, torch leads, ground cable and interface cables for damage or wear weekly.

• Inspect and clean the EtchArc-1125 monthly. The unit can be blown out using a clean, dry gas source, such as compressed air or nitrogen.

• Occasionally drain all water from beneath the air filter-regulator.

EtchArc-1125 Plasma Marking System 5-2

SECTION 5 Maintenance

Flow Switch

The Flow Switch (P/N 951202) may need to be cleaned if excessive contamination is found in the air supply.

Flow Switch Location

Piston Plug

Spring

Piston

Flow Switch Body

Note: The flow switch can be disassembled and cleaned without extraction from the power supply.

1) Turn Off power supply

2) Remove piston plug

3) Remove the spring. Use care when handling spring to prevent distortion.

4) Remove the piston.

5) Clean all parts with warm water and a mild detergent. Allow parts to dry thoroughly before reassembly.

6) Reassemble switch in reverse order.

EtchArc-1125 Plasma Marking System 5-3

SECTION 5 Maintenance

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EtchArc-1125 Plasma Marking System 5-4

SECTION 6 Troubleshooting

6 Troubleshooting

WARNING

!

WARNING

!

Electric Shock Can Kill!

Ensure that all primary power to the machine has been externally disconnected.

Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside the power supply.

High Voltages Can Cause Serious Injury Or Death.

Voltage in plasma equipment is high enough to cause serious injury or death.

Be particularly cautious when around equipment when covers are removed.

6.1 Troubleshooting Guide

Power Light Does Not Come on.

Location of fuse (F1)

A) Visually inspect the machine for damage.

B) Check if the cooling fan is running. If not, then check the following:

B1) Check if the machine power cord is plugged into the input power receptacle.

B2) Measure the input power at the receptacle. If not present, check the wall disconnect switch and related fuses.

B3) Check fuse (F1). If fuse is ok, check the input circuit breaker (CB1) for proper operation. Replace if defective.

C) If above items check OK, the problem is internal. Send unit to an Authorized Repair Station.

C1) If cooling fan is running, measure voltage between pins P2-11 and P2-14 of the control board. Should be 115 VAC. If there is no voltage, then replace transformer T2.

C2) If voltage is present, the pilot light may be burned out.

EtchArc-1125 Plasma Marking System 6-1

SECTION 6 Troubleshooting

No air flow.

Over Temperature

• Check air inlet supply. Unit requires 320 CFH at 65 psig.

• Check air hose connections.

• Does air flow when “air test” switch is in test position?

o If not, check torch consumables, replace if

necessary.

o If above items check OK, the problem is internal.

Take unit to an Authorized Repair Station.

• The fault light will be illuminate for 1/10 of a second every second. This generally indicates that the air flow has been blocked. Clear blockage and allow the power supply to cool before operating.

• Thermal switch may be open. It will open if the heat sink temperature reaches 80 degrees C. With the machine power off, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then the ohmmeter should read a direct short. If not, then it should read open.

Over current.

Arc does not transfer to plate.

• If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing switch.

• The fault light will be continuously illuminated. This indicates the input current to the main transformer has exceeded preset limits.

• To check if the output is shorted, measure resistance by putting ohmmeter leads (ensure HI Freq leads are disconnected) “+” of the meter to torch, “+” output terminal and work, “-“ lead of the meter to the “-“ output terminal. Reading should be about 2K OHMS. Reverse the voltmeter leads, the resistance reading should be less than 1.5 OHMS.

• Resistance reading is different than above, check torch, the output bridge and filter board (PCB5).

• Make sure work clamp has a good connection to material to be marked.

• Check consumables. Replace if necessary.

EtchArc-1125 Plasma Marking System 6-2

SECTION 6 Troubleshooting

Poor marking performance

• Check gas regulators. Should be set to 65 to 70 psig.

• The air supply should be free of oil/water.

• Check condition of consumables.

• Check open circuit voltage.

o With high frequency leads disconnected, measure

open circuit voltage. It should be 275 VDC between “Work” and “Torch” terminals. If not then check one of the following:

o Check operation of the Thermal Switch. (See Over

Temperature)

Gas does not shut off.

o Check Air Flow Switch for internal short. Should have

Fault Light. Light blinking off for 1/10

th

second every second indicates low air flow. Put the Gas Test Switch to TEST. Air should flow through torch. If not then the flow switch may be stuck in the open position. To check if switch is open, put voltmeter leads between P1-12 and P1-1. It should read about 12VDC. When switch closes, voltage drops to zero volts. Clean or replace switch. (see instructions in Section 5)

• Check gas solenoids for operation.

• Does gas flow when CNC cable is unplugged. If yes, repair

torch. If no, send unit to an authorized repair station for repair.

• C) Check voltage to solenoid coils. If present when start contact is disconnected, replace PCB1 (marker board). If voltage is “0”, replace solenoid valve.

EtchArc-1125 Plasma Marking System 6-3

SECTION 6 Troubleshooting

Fault light activates when start

contacts are closed.

The fault light is used to monitor conditions necessary for the safe operation if the EtchArc-1125. The fault light will glow amber under the following conditions and the unit will stop working:

• High/Low Voltage

High/Low Voltage. The fault light will rapidly blink on and off (5

High/Low VoltageHigh/Low Voltage times per second). This indicates that the input voltage is outside the “+” or “-“ 15% safe operating range.

• Flow Fault

Flow Fault. The fault light will be mostly on but will blink off for

Flow FaultFlow Fault 1/10 of a second every second. This indicates the gas flow is low.

o B1) Check gas pressure at the machine regulator. It

should be adjusted to 65 psig. If no gas pressure, check the gas at the supply point. Also check for obstructions in the gas hose.

o B2) Gas flow may be blocked at the torch tip. Check

torch consumables. Also check for any obstructions in the torch leads.

• Note. If above items check OK, the problem is internal will have to be sent to an authorized repair station.

o B3) Put the Gas Check switch to the on position. Gas

should flow through the torch. If not, then the flow switch may be stuck due to oil or dirt in the gas. Clean flow switch per instructions in the maintenance section or replace switch. To check if the flow switch is open, put a voltmeter leads between P1-12 and P1-1. It should read 12VDC. When the switch closes, voltage will drop to “0”.

o B4) Gas Test Switch may be malfunctioning.

EtchArc-1125 Plasma Marking System 6-4

SECTION 6 Troubleshooting

Gas is on but nothing

happens when start contacts

are closed.

• Check the pilot arc fuse located on the rear panel. If open, replace.

• Check to ensure high frequency is present at the torch. If not, then listen for high frequency at the high frequency generator. It is located on the bottom/right side of the unit. The high frequency gap is to 0.030 inches. Disconnect HI Frequency leads. Check for 115 supply voltage between P2-12 and P2-13 of the control board.

• With high frequency leads disconnected, measure open circuit voltage. It should e 275 VDC between “work” and Torch terminals. If not present, then any on of the following may not be working properly:

• Check for operation of the thermal switch. (see over voltage)

• Check Gas Check switch operation. It might be stuck in the ON

position. Pilot arc will not initiate if the switch is in the ON position.

• Check Gas flow Switch. There may be an internal short.

• Measure voltage across C1 and C2 capacitors. It should be as

follows:

o Measure voltage across C1 and C2 capacitors.

Readings should be as follows:

§ approx. 294 VDC with 208v unit

§ approx. 325 VDC with a 230v unit

§ approx. 325 VDC with a 460v unit

§ approx. 400 VDC with a 575v unit.

• NOTE: If readings are not correct then one of the following could be malfunctioning.

• Check capacitors C1 and C2 for damage.

• Check input bridge/SCR Module (IBR). Replace if

malfunctioning.

• Check Inrush Current Resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace if necessary.

• Check current output. Use a calibrated current probe capable of measuring 100 amps in the presence of high frequency.

Main arc is difficult to start

• Worn of missing consumables. Check and replace if necessary.

• Input gas (argon or air) must be clean and dry.

• Input air pressure is between 65 and 75 psig.

• Torch connections must be tight

• Work cable or clamp must make a good electrical connection to

the material to be marked.

• Initial height is too far from plate. (see marking data for recommended distances)

• Pilot arc is missing or weak.

• Check spark gap

• Check pilot arc fuse

EtchArc-1125 Plasma Marking System 6-5

SECTION 6 Troubleshooting

6.2 System Schematic 208/230V P/N 0588000967

BLK

L1

T1 T2

3

M

V

O

275V275V

I

B

(+)(+)

1

0

R

22

10,50W10,50W

(+)(+)

C2E1C2E1

Q2Q

C2E1C2E1

11

39K,2W39K,2W

22

40UF,400VDC40UF,400VDC

208/230208/230

Schematic Page 1 of 2

VAC

50/6050/60

HZ

RED

L2

1 AND 31 AND 3

PH

M

2

M

V

O

275V275V

AC3AC3

D6D6

R

D5D5

GG

11

Q1Q

R9R9

C4C4

RR

D4D4

R2R2

5

1

R

2

R2R

1

G1G1

E1E1

P1-4P1-4

V V

P1-4P1-4

G1G1

E1E1

2

33

44

L3

T3

1

V

O

AC2AC2

TT

SS

C3C3 C1C1

1800UF,450VDC1800UF,450VDC

C2C2

1800UF,450VDC1800UF,450VDC

2

B

C

P

2

B

C

P

V V

P1-3P1-3

3

B

C

P

B

C

P

P1-3P1-3

0.022UF,1KV0.022UF,1KV

1010

OHM,50W

WHT

AC1AC1

D3D3 (-)(-)

D2D2

D1D1

1

C

10K,25W10K,25W 10K,25W10K,25W 1UF,600V1UF,600V

G2G2

P1-1P1-1VP1-2P1-2

V

P1-1P1-1VP1-2P1-2

G2G2

C10C10

R7R7

1010

S1S

9

V

1

.22UF,1KV.22UF,1KV

22

11

208V208V

H2H2 208V208V

X6X6

X5X5

12V12V 24V24V

V V V V

P1-5P1-5

M

Control

Board

P

3

8

8 ,

300W

R12

K

R

W

O

(-)

3

H2H2

230V230V

TB5-2TB5-2

H3H3

230V230V

P1-6P1-6

r

a

/

N

1

V

400V400V

H4H4

X8X8

X7X7

P2-1P2-1

k

e

r

k

e

r

3

8

R13

.82UF

630VDC

K1

L3

T3

P.A.P.A.

P1-1P1-1

P

B

C

P

B

C

TB5-1TB5-1

22

11

1

M1M

H1H1

00

T2T2

F1F1

3A,600VAC3A,600VAC

22 11

X2X2

2

L2L

X1X1

R1R1

10K,2W10K,2W

MAXMAX

11

22

33

C16C16

SEE NOTE 1

C15C15

11

1UF1UF

600V600V

H1H1

1

T1T

22

H2H2

1

S

T

22

X3X3

230V230V

208V208V

X2X2

230V230V

X1X1

E2E2 22

C1C1

33

E2E2

(-)(-)

E2E2

C1C1

33

E2E2

22

1uf1uf 600V600V

11

4

T4T

TB3TB3

R5

11122

R3R3

11

20,25W20,25W

V V

V V V

V V

V V V V

V V V V V

V

22

.01UF,1KV.01UF,1KV20,25W20,25W

(+)(+)

1

22

.01UF,1KV.01UF,1KV

X1X1

12V12 V

V

P5-3P5-3

P2-5P2-5

P2-6P2-6

P6-13P6-13 P6-14P6-14 P6-12P6-12

P1-1P1-1

P1-2P1-2

P3-2P3-2

P3-1P3-1

P3-3P3-3 P3-4P3-4

P4-4P4-4

P4-3P4-3

P4-1P4-1

P4-2P4-2

P1-7P1-7

P1-8P1-8

C7C7

11

3

C5C5

112222 11

.01UF,1KV.01UF,1KV

X2X2

V

P5-4P5-4

22

.01UF,1KV.01UF,1KV

C6C6

X3X3

V

P1-9P1-9

C8C8

11

2

D2D2

D1D1

2

X4X4

18V18V

P1-10P1-10

P6-10P6-10

P6-11P6-11

VV

REDRED BLKBLK

6

R6R

11

22

20,25W20,25W

(-)(-)

R4R4

11 22

20,25W20,25W

X11X11

11

P2-11P2-11

G

115V115V

SHS

(+)(+)

N

N 5

H

D

H1H1

X12X12

22

44 33

22

0.047uf0.047uf

P2-14P2-14

300W

R11

11

C

2

C

2

660V660V

L1L

8 ,

1

1 2

X10X10

X9X9

20V20V

V

V V V

P2-4P2-4

330K

,1W

C21

K1

T2

L2

5

P1-6P1-6

P1-2P1-2

P1-3P1-3

V

P1-3P1-3

P1-4P1-4

PILOT

K1

ARC

T1L1

.022UF,

C20

1KV

GND

3

V V V

3

(+)(+)

4

(-)(-)

5

NOTE 1) Potentiometer is d isconnected. The current command is provided by the cutti ng machine. On machines that do not have remote current capabi lities, the POT is re-connected. (Retro-Fits)

SCHEMATIC EtchArc-1125 208v/230v

EtchArc-1125 Plasma Marking System 6-6

SECTION 6 Troubleshooting

Page 2 of 2 Schematic

REMOTE

CURRENT

COM SIG

J

1

B

T

(SEE(SEE

CHART)

4

ARC

ON

GL

I

112233

START

M

N

44

2

V V

P6-9P6-9

P6-7P6-7

P2-3P2-3

P2-4P2-4

P1-12P1-12

P1-11P1-11

VDR

(+) (-)

C

HKD

55

66

(+)(+) (-)(-)

V

VV

PREFLOW/ GAS TEST

AIR

11

S

FSF

1

CNC PLUG

33

22

11

S2

66

55

44

22

PRES. SW

ARGON

M

a

r

k

e

r

M

a

r

k

e

r

Control

Board

/

P

N

3

8

1

3

8

3

P2-2P2-2

V VV

P2-3P2-3

P5-5P5-5

V

P5-6P5-6

V

P5-1P5-1

V

P5-2P5-2

-

1

H1H1 X1X1

H2H2

.01UF,250.01UF,250

1

C

.01UF.01UF

1KV1KV

11

1

C

25002500

PF,15KV

X2X2

115115

VAC

C9C

G

T5T

SGS

3

9

N

N 4

5

G

T3T

P2-13P2-13

V

D

C

.01UF.01UF

1KV1KV

3

1

P2-12P2-12

V

1

B

T

O

S

O

S

2

L

P

8

1

C

.022UF.022UF 250VAC250VAC

T

2

H2H2

X2X2

22

C

B

T

H1H1

X1X1

1

L

1

L

N

G

N

G

2

1

B

4

1

2

11

22

++

C

.022UF.022UF

250VAC250VAC

D

-

2

25002500

PF,15KV

C

R

O

T

C

R

O

T

11

75mA75mA

1

D

Z

--

7

1

AA

1

K1K

BB

H

60V60 V

22

SHIELDSHIELD

2

L

O

S

2

L

O

S

3

L3L

4T4T

V

11

TORCHTORCH

1

J1J

SWITCH

V

22

4

5

SCHEMATIC EtchArc-1125 208v/230v

EtchArc-1125 Plasma Marking System 6-7

SECTION 6 Troubleshooting

6.3 Wiring Diagram 208/230V (4 pages)

Page 1 of 4 for

Page 1 of 4 for 208/230v Wiring Diagram

Page 1 of 4 forPage 1 of 4 for

208/230v Wiring Diagram

208/230v Wiring Diagram 208/230v Wiring Diagram

J1 SHIELD

8

1

C

7

1

C

P5-1 P5-2

Markerboard P6-12

GND 2

P5

P6

J L K D

Markerboard P6-6

P4

Marker PCB

(SEE CHART)

6 5 4 3 2 1

P3

GIMNCH

S2-2

P1

P2

CNC Plug

S2-3

TB4

PCB5 P1-3 VIO

PCB5 P1-2 BLU

J1-2 BLK J1-1 GRY

*

T3-H2 RED

T3-H1 RED

T5-X1 RED

765

FS

1 2

SG

342

1

2

SPLICE

TB2

C

1

4

1

TB4

PCB1 P6-7 YEL

PCB1 P6-9 ORN

RED

*

3

T5-X2 RED

PCB1 P1-11 RED

S2-5 RED

1 2

ARGON

PRESSURE

SWITCH

TB1-2 BLK

TB1-1 BLK

*

SG-1 RED

*

H1 H2

X1

PCB1 P2-12 BLU

*

T5

X2

SG-2 RED

P.A. BUS ORN

L1 L2

R13

C21

A

T1 T2

BLU

K1

BLU

L3

B

PCB1 P2-13 BLU

T3

R11-2 YEL

EtchArc-1125 Plasma Marking System 6-8

SECTION 6 Troubleshooting

Page 2 of 4 for 208/230v Wiring Diagram

Page 2 of 4 for 208/230v Wiring DiagramPage 2 of 4 for 208/230v Wiring Diagram

DETAIL "A" (PCB1)

P1

1TS1-1 2TS1-2

T2-X9 43T2-X10 5T2-X5

7T4-1 8T4-2 9

T2-X3 10 T2-X4

FS-111 12 S2-4

P2

T2-X7VIO 1 VIO 2 BRN33 BRN

ORN 5

WHT67 WHT 8 9 RED 9 BLK 10

SOL1-1

SOL1-2

S2-3

T2-X8BLU 4

IBR-G

IBR(+)ORN

11

PL1-1

11

TB1-1

12 12

K1-A

TB1-2

13 13

K1-B

PL1-2

14

T2-X1214 VIO

WHT 2 GRY

YEL BRN

VIO YEL BLU BLU BLU

BLU YEL

1ORN

3 4GRY 5ORN

7 8

10 11 12T2-X11

J1-2 T2-X1 T2-X2

PL2-(-) BLKS2-2 ORN4BLUT2-X6 666

P5

CLR (TP)J1-1 BLK (TP)

YEL YEL REDPL2-(+)

BLK

P6

S3-11 2S3-2 3 4 5

7 8

8 9TB4-2 10 PCB4-3

12 COM-SIG-J 13 14 R1-2

BLU BLU

COM-SIG-L

TB4-1

YEL

ORN BLK (TP)

PCB4-4RED (TP)11

R1-3

RED WHT

GRN

GND1

IBR(R) BLK

IBR(S) BLK

IBR(T) BLK

BLK RED

WHT

INPUT POWER CABLE

S1

L1

T1

L2

T2 T3

L3

RED

BLK

WHT

1

2

+

PL2

-

PCB1 P1-12 BLK

PCB1 P2-4 ORN

RED T2-H1 BLK M1-2

*

BLK TB5-2

*

F1-1

YEL PCB1 P2-11

Y

E

B

L

P

C

1

PL1

PCB1 P5-5 RED

PCB1 P5-6 BLK

RED FS-2

4

65

GRY PCB1 P2-3

2

3

1

S2

F1

*

1

4

1

2 IBR (T) BLK

1

M1

2

*

BLK

P

-

2

Note 3: R1 is disconnected for CNCs with Remote Current Control. If the CNC does not support remote current, R1 can be reconnected.

EtchArc-1125 Plasma Marking System 6-9

Note 3

PCB1 P6-13 RED

PCB1 P6-14 WHT

PCB1 P6-12 BRN

3

2

R1

1

SECTION 6 Troubleshooting

Page 3 of 4 for 208/230v Wiring Diagram

Page 3 of 4 for 208/230v Wiring DiagramPage 3 of 4 for 208/230v Wiring Diagram

PCB5

B

PILOT ARC

*

T3-X2 BLK

TORCH

F

1

*

R15

*

D1-3 BLK

2

*

TB3 BLK

PCB5 P1-6 BLK

H2

C2(+) RED

D1/D2-2 BLK

C2(-) BLK

H1

*

L1

D2-3 BLK

L1-H2 BLK

TB2 RED

SG-1 RED

TORCH

T3-X1

R11

*

C4-4

*

Q2-C2E1

C1(-) BLK

C1(+) RE D

X1

X3

X2

*

H1

H2

T1

*

X2

H2

H1

X1

T3

F

2

1

R2

2

D

*

C1(-)

IBR(-)

X2

X1

L2

T2

GND 4

2

1

C

CC

D

TB1

RIGHT SIDE VIEW

PCB4

(SHUNT)

EE

TB5

T2-H2 BLK

T2-H3 GRY

M1-1 BLK

*

* *

MOV

3

2

1

1 2

S1-T2 BLK

PCB1-P4

1432

2

C10

WHT

C16

RED

PCB3

C2E1

Q2

4321

WHT

RED

C1

E2

T1-H1

R15-2 RED

PCB1 P5-2 BLK(TP)

PCB1 P2-2 WHT

ZD1

1

SOL1

1

SOL2

PCB1 P5-1 CLR(TP)

*

T1-X3

TB3

P.A. BUS

PCB1 P2-3 GRY

2

TB4-3 GRY

GND 3

K1-L1 ORN

2

1

J1

C20

L3

BLK

CLR

TB4-4 BLK

+

C2

-

*

T1-X1 BLK

3

C6

D1

2

R4

C5

1

R3

L1-H1 BLK

PCB4-2 BLU

R15-1 BLK

*

T1-X2 BLK

3

C8

D2

2

R6 C7

1

R5

P3PCB1-

3241

WHT

RED

PCB2

C1

C15

E2

C2E1

Q1

R7

2

*

T1-H2

1

2

T4

ORN PCB1 P1-8

R9

C4

WHT

1

TS1

R7-1 BLU

4

3

IBR(+) RED

+

R10

R2-1 RED

C1

-

PCB1 P1-2 VIO

PCB1 P1-1 VIO

C4-2 RED

C4-4 BLU

2

1

ORN

2

PCB1 P1-7 ORN

1

LEFT SIDE VI EW

1432

GRY

S

1

-

T

1

B

L

K

F1-2 BLK

S1-T3 BLK

*

L2-X1

C3

R2-2 BLK

IBR

PCB1 P2-5 YEL

YEL

C1(+) RED

R2R

S

G

C19

+

T

-

Y

E

L

*

L2-X2

PCB1 P2-6 BRN

1

Q1-C2E1 RED

EtchArc-1125 Plasma Marking System 6-10

SECTION 6 Troubleshooting

Page 4 of 4 for 208/230v Wiring Diagram

Page 4 of 4 for 208/230v Wiring DiagramPage 4 of 4 for 208/230v Wiring Diagram

TB5

T2-H2 BLK

T2-H3 GRY

M1-1 BLK

*

FOR 208 VAC INPUT

CHG IBR(R) LEAD FROM

TB5-2 TO TB5-1

REVERSE T1-X2 & T1-X3 LEADS

GRY

2

1

IBR

RR2

G

S

+

T

-

TB3

33

D2

22

11

T1-X2

T1-X3

*

GND 5

D1

PCB4

(SHUNT)

C23

WORK

TP

RED PCB1 P6-11

BLK PCB1 P6-10

34

PCB5 P1-1 RED

+

D1/D2-1 BLU

-

12

VIEW B-B

R11-1 BLU

L1-H2 BLK

PCB5

TB4-6 VIO

P1

21

6

543

6

VIEW E-E

PCB1 P2-14 VIO

PCB1 P2-11 VIO

TB4-5 BLU

PCB4-1 RED

PCB1 P1-4 BRN PCB1 P1-3 BRN PCB1 P2-4 ORN PCB1 P2-1 ORN

TOP X12

X11 X10

X9

X8

X7

TOP

PCB1 P5-3 YEL

X1

PCB1 P5-4 YEL

X2

PCB1 P1-9 WHT

X3

T2

X4

X5

X6

PCB1 P1-5 BLU PCB1 P1-6 BLU

PCB1 P1-10 WHT

H4

H3

H2

BOTTOM

H1

*

BLU

TB5-2 GRY

TB5-1 BLK

F1-1 RED

*

VIEW C-C

TOP AND BOTTOM

1

PCB4-2 BLU

1

R11

BLU

R12

2

K1-T3 YEL

2

VIEW F-F

GND 4

C11

C9

C12

TB1

T5-H2 BLK

PCB1 P2-13 BLU

2

1

PCB1 P2-12 BLU

T5-H1 BLK

*

VIEW D-D

EtchArc-1125 Plasma Marking System 6-11

SECTION 6 Troubleshooting

6.4 Schematic 480 Volt AC P/N 0588000949

Page 1 of 2 EtchArc

Page 1 of 2 EtchArc----1125 480V schematic

Page 1 of 2 EtchArcPage 1 of 2 EtchArc

1125 480V schematic

1125 480V schematic1125 480V schematic

0

1

R

10,50W

1

2

(+)

R2

G

R

C

(+)

R

13

39K,2W

C

2

40UF,400VDC

5

1

5

1

2

C

9

4

M

V

O

M

3

510V510V

M

510V

S

I

B

R

10K,20W

1 UF

630VDC

1800uf

450VDC

(-)

6

1

C

2 UF 800VDC

CH2 CH1

AH2 AH1

V

O

1

V

O

2

T

(-)

R

C

C2E1

2

E2

1

C1

3

(+)

0.022UF

0

1

C

4

2

10

10 OHM,50W

1

2

L

3

1

1KV

2

R

BH1BH2

460 VAC

50/60 HZ

3 PH

9

1

C

0.22UF,1KV

10K,20W

1 UF

630VDC

1800uf

450VDC

G2

2

E2

1

3

E1

G1

4

1

Q

7

1

575V

P5-4

PILOT ARC

.022UF, 1KV

GND 3

(+)

(-)

5

4

3

2 1

T1

L1

3

BLK

L2

T2

T3

S

3A,600VAC

V

C

P

V

4

T

1

F

(-)

2

B

H1

T

2

H2

RED

L3

WHT

12

R

10K,2W

1

2

SEE NOTE 1

1

2

1

H1

0

2

T

X2

X1

24V

V

P2-4

P2-1

P2-7

V V

1

MAX

3

1

S

T

2

X3

X2

20,25W

X1

P2-8

P6-13

V

P6-6

P6-12

V V

P6-5

V

P6-4

P1-1

VV

P1-2

V

P3-4

V

P3-5

V

P4-4

P4-5

V

P1-7

V

P1-8

(400V - DASHED LINE)

(460V - S OLID LI NE)

460V

3

B

T

400V

460V

C7

R5

2211

.01UF,1KV

1

(+)

1

C5

R3

22

1

20,25W

1

.01UF,1KV

C8

2

.01UF,1KV

3

D2

D1

3

C6

2

1

.01UF,1KV

M

X3

X4

18V

V V

P1-3

R

1

1 2

20,25W

2

(-)

2

R4

1

20,25W

12

1

V

P1-4

P6-11

P6-10

V V

BLKRED

6

G

2

X11

X12

2

1

V

P2-11

P2-14

8 ,

300W

R11

H

S

34

2

1

(PCB4)

2

3

C

0.047uf

D

5

N

660V

H1 H2

1

L

V

P1-5

8 ,

300W

R12

(-)(+)

TB5-1

230V

H2

X5

X6

V

P1-6

k

a

M

r

Control

Board

N

P

/

3

1

8

R

O

K

W

V

400V

H3

X7

V

P1-9

r

e

8

P5-9

V

R13

R16

100K

.82UF 630VDC

2W

K1

T3

P.A.

P1-1

P

C

X8

L3

5

B

TB5-2 H4

V

P1-10

330K ,1W

L2

P1-6

P1-2

P1-3

460V

V V

C21

K1

T2

X9

P5-3

T1

V

H5

X10

12V18V12V115V

K1

L1

C20

EtchArc-1125 Plasma Marking System 6-12

SECTION 6 Troubleshooting

Page 2 of

Page 2 of 2 EtchArc

Page 2 of Page 2 of

5

4

2 EtchArc----1125 480V schematic

2 EtchArc2 EtchArc

1125 480V schematic

1125 480V schematic1125 480V schematic

REMOTE

CURRENT

COM SIG

JL

4

B

T

ARC

START

ON

I

G

M

N

1122334455

(+)(+)

VDR

(+) (-)

C

H

66

PREFLOW/ GAS TEST

KD

(-)(-)

CNC PLUG

VV

P6-9

P6-7

M

r

a

r

e

k

M

r

a

r

e

k

Control

Board

/

P

N

8

3

1

8

3

P2-12

V

.01UF,250 VAC

-

1

B

T

1

C

.01UF

1KV

H1

X1

1

2500 PF,15KV

H2

3

X2

P2-3

P2-4

P1-12

P1-11

P2-2

P2-3

P5-5

P5-6

P5-1

P5-2

115 VAC

9

C

D

N

G

1

.01UF

5

T

G

S

3

1

C

3

T

4

C

1KV

2

1

2

X1

V

AIR

1122

V

S

FSF

1

V

O

S

O

S

V

2

L

P

V

8

1

C

.022UF

250VAC

P2-13

V

-

1

B

T

2

H2 X2

4

1

C

2500 PF,15KV

2

B

T

H1

T

33

22

11

S2

66

55

44

ARGON

PRES. SW

2

L

O

S

2

L

O

S

11

1

L

1

L

22

+

.022UF 250VAC

D

2

N

G

A

1

K

H

C

R

O

11

1

D

Z

75mA75mA

22

60V60V

-

3

L

7

1

C

B

4T

SHIELD

NOTE 1) Poteniometer is disconnected. The current cammand is provided by the cutting machine. On machines that do not have remote current capabilities, the POT is reconnected. (Retro-fits)

1

V

1

J

TORCH SWITCH

2

V

2 1

EtchArc-1125 Plasma Marking System 6-13

SECTION 6 Troubleshooting

6.5 460V Wiring Diagram (4 pages)

Page 1 of 4 for 460v Wiring Diagram

Page 1 of 4 for 460v Wiring DiagramPage 1 of 4 for 460v Wiring Diagram

J1 SHIELD

18

C

17

C

P5-1 P5-2

Markerboard P6-12

GND 2

P5

P6

J L K D

Markerboard P6-6

P4

Marker PCB

(SEE CHART)

6 5 4 3 2 1

P3

GIMNCH

S2-2

P1

P2

CNC Plug

S2-3

TB4

PCB5 P1-3 VIO

PCB5 P1-2 BLU

J1-2 BLK J1-1 GRY

*

T3-H2 RED

T3-H1 RED

T5-X1 RED

76

FS

1 2

5

SG

342

1

2

SPLICE

TB2

C

1

4

1

3

1

TB4

PCB1 P6-7 YEL

PCB1 P6-9 ORN

RED

*

PCB1 P1-11 RED

1 2

T5-X2 RED

EtchArc-1125 Plasma Marking System 6-14

S2-5 RED

ARGON

PRESSURE

SWITCH

TB1-2 BLK

TB1-1 BLK

*

SG-1 RED

*

H1 H2

X1

T5

*

X2

*

L2

IBR-T

IBR-S

IBR-R

C

*

SG-2 RED

H2

H1

B

H1

A

H1

*

S1-T1

S1-T2

S1-T3

SECTION 6 Troubleshooting

Page 2 of 4 for 460v Wiring Diagram

Page 2 of 4 for 460v Wiring DiagramPage 2 of 4 for 460v Wiring Diagram

DETAIL "A" (PCB1)

P1

1TS1-1 2TS1-2

T2-X3 43T2-X4 5T2-X5

7T4-1 8T4-2 9

T2-X7 10 T2-X8

FS-111 12 S2-4

L2-CH1 *

L2-BH1 *

L2-AH1 *

BLK RED WHT

P2

T2-X1VIO 1 VIO 2 BRN33 BRN

ORN 5

WHT67 WHT 8 9 RED 9 BLK 10

SOL1-1

SOL1-2

S2-3

T2-X2BLU 4

IBR-G

IBR(+)ORN

11

PL1-1

11

TB1-1

12 12

K1-A

TB1-2

13 13

K1-B

PL1-2

14

T2-X1214 VIO

S1

T1 T2

WHT 2 GRY

YEL BRN

VIO YEL BLU BLU BLU

BLU YEL

L1 L2

T3

L3

RED

BLK

1ORN

J1-2 T2-X9

3

T2-X10

4GRY 5ORN

PL2-(-) BLKS2-2 ORN4BLUT2-X6 666

PCB1 P6-10 7 8

10 11 12T2-X11

WHT

P5

CLR (TP)J1-1 BLK (TP)

YEL YEL REDPL2-(+)

RED T2-H1 BLK M1-2

*

BLK TB5-2

*

2S3-2 3 4 5

7TB4-1

BLK

8 8 9

10 PCB4-3

12 COM-SIG-J 13 14 R1-2

* *

BLK

F1-1

P6

S3-11

BLU BLU

COM-SIG-L

YEL

TB4-2

ORN

PCB4-4 RED (TP)11

R1-3

F1

2 IBR (T) BLK

1

2

BLK (TP)

RED WHT

M1

PCB1 P5-6 BLK

1

GRN

GND1

INPUT POWER CABLE

Note 3: R1 is disconnected for CNCs with Remote Current Control. If the CNC does not support remote current, R1 can be reconnected.

YEL PCB1 P2-11

1

2

+

PL2

-

PCB1 P1-12 BLK

PCB1 P2-4 ORN

Note 3

PCB1 P6-13 RED PCB1 P6-14 WHT PCB1 P6-12 BRN

Y

E

L

P

1

C

B

PL1

PCB1 P5-5 RED

PCB1 P5-6 BLK

RED FS-2

654

GRY PCB1 P2-3

2

3

1

S2

3

2

R1

1

P

-

4

2

1

EtchArc-1125 Plasma Marking System 6-15

SECTION 6 Troubleshooting

Page 3 of 4 for 460v Wiring Diagram

Page 3 of 4 for 460v Wiring DiagramPage 3 of 4 for 460v Wiring Diagram

4

2

T2-H3 BLU

T2-H4 WHT

MOV 3

MOV 2

MOV 1

TB5

*

2

1

L2-CH2

L2-BH2

L2-AH2

F1-2 BLK

*

G

RY

R R2

S

C4-2 YEL R2-1 RED

IBR

PCB1 P2-5 YEL

YEL

G

+

T

-

PCB1 P2-6 BRN

C3

C19

Y

E

L

+

C1

-

C4-4 BLU

K

L

B

R10

21

C1(+) YEL

RED

R2-2 BLK

PCB1 P1-2 VIO PCB1 P1-1 VIO

1

R7

*

T1-H2

ORN

1

2

T4

ORN

2

PCB1 P1-7 ORN

1

LEFT SIDE VIEW

PCB1-P3

WHT

2

ORN PCB1 P1-8

R9

C4

C16

1

2

TS1

R7-1 BLU

4

3

32431

RED

C10

WHT

RED

4

213

PCB3

C1

E2

C2E1

Q1

1

WHT

PCB1-P4

T1-H1

C8

R6

C7

R5

*

C2

T1-X2 BLK

3D23

2

1

R15-2 BLK

-

+

R15-1 RED

*

T1-X1 BLK

C6

D1

2

C5

1

L1-H1 BLK

PCB4-2 BLU

C15

PCB1 P5-2 BLK(T P) PCB1 P5-1 CLR(T P)

*

T1-X3

*

R4

R3

*

PCB1 P2-2 WHT

TB3

ZD1

1

SOL1

1

SOL2

GND 3

L3

C20

K1-L1 ORN

PCB1 P2-3 GRY

P.A. BUS

2

TB4-4 BLK

BLK

CLR

2

1

J1

PCB4

(SHUNT)

TB4-3 GRY

B

1

R

*

1

*

PCB5

B

E

PILOT ARC

PCB5 P1-6 BLK

T3-X2 BLK

E

TORCH

5

*

2

C2(-) BLK

D1/D2-2 BLK

C2(+) RED

H1

H2

L1

*

T3-X1

D1-3

*

TB3

D2-3

L1-H2 BLK

TB2 RED

SG-1 RED

TORCH

R11

*

C4-4

*

Q1-C2E1

C1(-) BLK

X1X3

H2H1

T1

X2

*

X2

*

H2

H1

*

X1

*

T3

FF

2

1

C1(+) RED

R2

2

P.A. BUS ORN

C T2 C

GND 4

2

1

D

C

TB1

BLU

D

B

L3

L2K1T2

L1

A

C21

R13

PCB1 P2-13 BLU

R11-2 YEL

T3

BLU

T1

PCB1 P2-12 BLU

RIGHT SIDE VIEW

EtchArc-1125 Plasma Marking System 6-16

SECTION 6 Troubleshooting

Page 4 of 4 for 460v Wiring Diagram

Page 4 of 4 for 460v Wiring DiagramPage 4 of 4 for 460v Wiring Diagram

TB4-6 VIO

TB4-5 BLU

PCB4-1 RED

PCB5

TOP AND BOTTOM

PCB4-2 BLU

1

R11

R12

BLU

2

K1-T3 YEL

2

VIEW F-F

TP

L1-H2 BLK

6

562143

P1

1

PCB1 P1-9 WHT

PCB1 P1-6 BLU

PCB1 P1-5 BLU

PCB1 P1-3 BRN

PCB1 P1-4 BRN

PCB1 P2-11 VIO PCB1 P2-14 VIO

F1-1 RED

SPLICE (M1-1) GRY

VIEW E-E

*

X5

X6

BOTTOM

* *

X11

X12

X4

TOP

T2

TOP

H2H5H4

H1

*

PCB1 P1-10 WHT

PCB1 P5-3 YEL

PCB1 P5-4 YEL

X10

X7

X9

X8

PCB1 P2-4 ORN

PCB1 P2-1 ORN

X2

X3

X1

H3

TB5-2 WHT

*

BLU

TB5-1

ORN

*

* *

*

NOT USED

GND 5

(SHUNT)

C23

PCB4

BLK PCB1 P6-10

3

1

WORK

PCB5 P1-1 RED

VIEW B-B

RED PCB1 P6-11

4

+

2

D1/D2-1 BLU

R11-1 BLU

VIEW C-C

TOP AND BOTTOM

C11

TB1

T5-H2 BLK

*

PCB1 P2-13 BLU

GND 4

C9

2

1

PCB1 P2-12 BLU T5-H1 BLK

*

C12

VIEW D-D

EtchArc-1125 Plasma Marking System 6-17

SECTION 6 Troubleshooting

6.6 Schematic 575 Volt AC P/N 0588000966

Page 1 of 2 EtchArc

Page 1 of 2 EtchArc----1125 575V schematic

Page 1 of 2 EtchArcPage 1 of 2 EtchArc

0

1

R

10,50W

1

2

(+)

R2

G

1

R

C

(+) (-)

2

C

9

R

13

39K,2W

4

C

20UF,600VDC

1125 575V schematic

1125 575V schematic1125 575V schematic

2

L

CH2 CH1

AH2 AH1

M

V

O

M

V

O

1

3

625V

M

V

O

2

625V

T

(-)

S

I

R

B

5

1

5

2

C

0.68 UF

1200VDC

R

1

1 UF

1800uf

(-)

6

C2E1

E2

1

4

10

2

C1

3

(+)

0

1

C

2

1

0.22UF,1KV

2

R

10K,25W

3

C

1 UF

630VDC630VDC

1

C

1800uf

500VDC500VDC

G2

E2

E1

G1

1

Q

0.022UF 1KV

7

R

10 OHM,50W

BH1BH2

575VAC

50/60 HZ

3 PH

1

9

C

2

1

3

4

1

T1

L1

3

BLK

L2

T2

T3

S

3A,600VAC

V

C

P

V

4

T

1

F

2

B

2

L3

1

12

10K,2W

1

SEE NOTE 1

H1

1

T

H2

RED

WHT

R

2

1

H1

0

2

T

X2

X1

24V

V

P2-4

P2-1

P2-7

V V

V V V

V

VV V

V

R5

2211

.01UF,1KV

1

(+)

1

R3

1 22 1

.01UF,1KV

P6-13

P6-12

P1-7

C7

C5

P2-8

P6-6

P6-5 P6-4

P1-1

P1-2

P3-4

P3-5

P4-4

P4-5

P1-8

2

.01UF,1KV

3

C6

21

.01UF,1KV

C8

D2

D1

1

MAX

3

1

S

T

2

X2

20,25W

X1

20,25W

M

X3

X4

18V

V

P1-3

1

1 2

20,25W

2

R4

1

20,25W

12

1

V

P1-4

P6-10

P6-11

V

6

R

(-)

2

X11

X12

1

V V

P2-11

BLKRED

H

S

2

5

D

N

G

H1 H2

2

P2-14

8 ,

300W

R11

34

(PCB4)

1

2

C

0.047uf 660V

1

L

TB5-1

230V

H2

X5

V

P1-5

(-)(+)

3

W

8 ,

300W

R12

O

X6

Control

K

R

V

P1-6

a

M

Board

P

P 8

3

1

V

/

k

r

N

3

H3

e

8

P5-9

V

100K

400V

X7

V V

P1-9

r

R13

R16

.82UF 630VDC

2W

K1

T3

P.A.

P1-1

P

B

C

X8

L3

5

TB5-2

460V

H4

V

P1-10

330K ,1W

C21

K1

T2

L2

P1-6

P1-2

P1-3

575V

H5

X10

X9

12V18V12V115V

V

P5-4

P5-3

PILOT

K1

ARC

L1

T1

C20

.022UF, 1KV

GND 3

V

(+)

VV

(-)

5

4

3

2 1

EtchArc-1125 Plasma Marking System 6-18

SECTION 6 Troubleshooting

Page 2 of 2 EtchArc

Page 2 of 2 EtchArc----1125 575V schematic

Page 2 of 2 EtchArcPage 2 of 2 EtchArc

5

4

1125 575V schematic

1125 575V schematic1125 575V schematic

REMOTE

CURRENT

COM SIG

JL

4

B

T

ARC

START

ON

I

G

M

N

1122334455

(+)(+)

VDR

(+) (-)

C

H

66

(-)(-)

PREFLOW/ GAS TEST

CNC

KD

PLUG

VV

P6-9

P6-7

M

r

a

r

e

k

M

r

a

r

e

k

Control

Board

/

P

N

8

3

1

8

3

P2-12

V

.01UF,250 VAC

-

1

B

T

1

C

.01UF

1KV

H1

X1

1

2500 PF,15KV

H2

3

X2

P2-3

P2-4

P1-12

P1-11

P6-1

P6-2

P2-2

P2-3

P5-5

P5-6

P5-1

P5-2

115 VAC

9

C

D

N

G

1

.01UF

5

T

G

S

3

1

C

3

T

4

C

1KV

2

1

2

X1

V

AIR

1122

V

S

FSF

1

V

O

S

O

S

V

2

L

P

V

8

1

C

.022UF

250VAC

P2-13

V

-

1

B

T

2

H2 X2

4

1

C

2500 PF,15KV

2

B

T

H1

T

33

22

11

S2

66

55

44

ARGON

PRES. SW

S

F

1

3

2

S

3

2

L

O

S

2

L

O

S

11

1

L

1

L

22

+

.022UF 250VAC

D

2

N

G

A

1

K

H

C

R

O

11

1

D

Z

75mA75mA

22

60V60V

-

3

L

7

1

C

B

4T

SHIELD

NOTE 1) Poteniometer is disconnected. The current cammand is provided by the cutting machine. On machines that do not have remote current capabilities, the POT is reconnected. (Retro-fits)

1

V

1

J

TORCH SWITCH

2

V

2 1

EtchArc-1125 Plasma Marking System 6-19

SECTION 6 Troubleshooting

6.7 575V Wiring Diagram (4 pages)

Page 1 of 4 for 575v Wiring Diagram

Page 1 of 4 for 575v Wiring DiagramPage 1 of 4 for 575v Wiring Diagram

J1 SHIELD

8

1

C

7

1

C

P5-1 P5-2

Markerboard P6-12

GND 2

P5

P6

J L K D

Markerboard P6-6

P4

Marker PCB

(SEE CHART)

6 5 4 3 2 1

P3

GIMNCH

S2-2

P1

P2

CNC Plug

S2-3

TB4

PCB5 P1-3 VIO

PCB5 P1-2 BLU

J1-2 BLK J1-1 GRY

*

T3-H2 RED

T3-H1 RED

T5-X1 RED

76

FS

1 2

5

SG

342

1

2

SPLICE

TB2

C

1

4

1

3

1

TB4

PCB1 P6-7 YEL

PCB1 P6-9 ORN

RED

*

T5-X2 RED

PCB1 P1-11 RED

1 2

S2-5 RED

ARGON

PRESSURE

SWITCH

TB1-2 BLK

TB1-1 BLK

*

SG-1 RED

*

H1 H2

X1

T5

X2

*

IBR-T

IBR-S

IBR-R

*

SG-2 RED

H2

L2

*

S1-T1

S1-T2

S1-T3

C

H1

B

H1

A

H1

EtchArc-1125 Plasma Marking System 6-20

SECTION 6 Troubleshooting

Page 2 of 4 for 575v Wiring Diagram

Page 2 of 4 for 575v Wiring DiagramPage 2 of 4 for 575v Wiring Diagram

DETAIL "A" Markerboard (PCB1)

P1

1TS1-1 2TS1-2 3

T2-X3 T2-X4

4 5T2-X5

7T4-1 8T4-2 9

T2-X7

10 T2-X8

FS-111

12 S2-4

L2-CH1 *

L2-BH1 *

L2-AH1 *

BLK RED WHT

P2

T2-X1VIO 1 VIO 2 BRN33 BRN

ORN 5

WHT67 WHT 8 9 RED 9 BLK 10

SOL1-1

SOL1-2

S2-3

T2-X2BLU 4

IBR-G

IBR(+)ORN

11

PL1-1

11

TB1-1

12 12

K1-A

TB1-2

13 13

K1-B

PL1-2

14

T2-X1214 VIO

S1

T1 T2 T3

WHT 2 GRY

YEL BRN

VIO YEL BLU BLU BLU

BLU YEL

L1 L2

L3

RED

BLK

1ORN

J1-2 T2-X9

3

T2-X10

4GRY 5ORN

PL2-(-) BLKS2-2 ORN4BLUT2-X6 666

PCB1 P6-10 7 8

10 11 12T2-X11

WHT

P5

CLR (TP)J1-1 BLK (TP)

YEL YEL REDPL2-(+)

RED T2-H1 BLK M1-2

*

BLK TB5-2

*

2S3-2 3 4 5

7

BLK

8 8 9

10 PCB4-3

12 COM-SIG-J 13 14 R1-2

* *

BLK

F1-1

P6

BLU

S3-11

BLU

COM-SIG-L TB4-1

YEL

TB4-2

ORN

PCB4-4RED (TP)11

R1-3

F1

2 IBR (T) BLK

1

2

BLK (TP)

RED WHT

M1

PCB1 P5-6 BLK

1

GRN

GND1

INPUT POWER CABLE

Note 3: R1 is disconnected for CNCs with Remote Current Control. If the CNC does not support remote current, R1 can be reconnected.

1

2

+

PL2

-

PCB1 P1-12 BLK

PCB1 P2-4 ORN

Note 3

PCB1 P6-13 RED PCB1 P6-14 WHT PCB1 P6-12 BRN

YEL PCB1 P2-11

Y

E

L

P

C

1

B

PL1

PCB1 P5-5 RED

PCB1 P5-6 BLK

RED FS-2

4

65

GRY PCB1 P2-3

2

3

1

S2

3

2

R1

1

P

-

4

2

1

EtchArc-1125 Plasma Marking System 6-21

SECTION 6 Troubleshooting

Page 3 of 4 for 575v Wiring Diagram

Page 3 of 4 for 575v Wiring DiagramPage 3 of 4 for 575v Wiring Diagram

4

2

FASTON TERMINAL

PINK MALE

P/N A-950904

MOV 3

MOV 2

MOV 1

T2-H5 ORN

FASTON TERMINAL

PINK FEMALE

P/N A-950906

Y

R

G

R R2

*

L2-CH2

L2-BH2

L2-AH2

F1-2 BLK

S

*

C4-2 YEL R2-1 RED

IBR

PCB1 P2-5 YEL

YEL

G

+

T

-

PCB1 P2-6 BRN

C3

C19

Y

E

L

+

C1

-

C4-4 BL U

K

L

B

R10

21

C1(+) YEL

RED

R2-2 BLK

PCB1 P1-2 VIO

PCB1 P1-1 VIO

1

T1-H2

ORN

1

2

ORN

2

PCB1 P1-7 ORN

1

LEFT SIDE VIEW

PCB1-P3

WHT

2

R7

*

T4

ORN PCB1 P1-8

R9

C4

C16

1

2

TS1

R7-1 BLU

4

3

32431

RED

C10

WHT

RED

4

213

PCB3

C1

E2

C2E1

Q1

1

PCB1-P4

T1-H1

C8 R6 C7 R5

*

C2

T1-X2 BLK

3D23

2

1

R15-2 BLK

-

+

R15-1 RED

*

T1-X1 BLK

C6

D1

2

R4

C5

1

R3

L1-H1 BLK

PCB4-2 BLU

C15

PCB1 P5-2 BLK(TP) PCB1 P5-1 CLR(TP)

*

T1-X3

*

ZD1

PCB1 P2-2 WHT

TB3

1

SOL1

1

SOL2

GND 3

C20

K1-L1 ORN

PCB1 P2-3 GRY

P.A. BUS

2

TB4-4 BLK

CLR

BLK

2

1

J1

L3

PCB4

(SHUNT)

TB4-3 GRY

B

D1-3

*

R11

*

C4-4

*

Q1-C2E1

C1(-) BLK

X1X3

H2H1

T1

X2

*

X2

*

H2

H1

*

X1

T3

1

R

*

1

*

PCB5

B

E

PILOT ARC

PCB5 P1-6 BLK

T3-X2 BLK

E

TORCH

5

*

2

*

T3-X1

TB3

D2-3

L1-H2 BLK

TB2 RED

SG-1 RED

TORCH

C2(-) BLK

D1/D2-2 BLK

C2(+) RED

H1

H2

L1

FF

2

1

C1(+) RED

R2

2

P.A. BUS ORN

C T2 C

GND 4

2

1

D

C

TB1

BLU

D

B

L3

L2K1T2

L1

A C21 R13

PCB1 P2-13 BLU

R11-2 YEL

T3

BLU

T1

PCB1 P2-12 BLU

RIGHT SIDE VIEW

EtchArc-1125 Plasma Marking System 6-22

SECTION 6 Troubleshooting

Pag

Page 4 of 4 for 575v Wiring Diagram

e 4 of 4 for 575v Wiring Diagram

PagPag

e 4 of 4 for 575v Wiring Diagrame 4 of 4 for 575v Wiring Diagram

TB4-6 VIO

TB4-5 BLU

PCB5

L1-H2 BLK

PCB4-1 RED

P1

562143

1

6

TOP AND BOTTOM

PCB4-2 BLU

1

R11

2

BLU

1

R12

2

K1-T3 YEL

VIEW F-F

TP

PCB1 P1-9 WHT

PCB1 P1-6 BLU

PCB1 P1-5 BLU

PCB1 P1-3 BRN

PCB1 P1-4 BRN

PCB1 P2-11 VIO PCB1 P2-14 VIO

F1-1 RED

SPLICE (M1-1) GRY

VIEW C-C

TOP AND BOTTOM

VIEW E-E

*

X5

X6

BOTTOM

* *

X11

X12

X4

TOP

T2

TOP

H2H5H4

H1

*

PCB1 P1-10 WHT

PCB1 P5-3 YEL

PCB1 P5-4 YEL

X10

X7

X9

X8

PCB1 P2-4 ORN PCB1 P2-1 ORN

X2

X3

X1

H3

IBR(R) ORN

*

* *

*

NOT USED

GND 4

GND 5

C11

C9

C12

(SHUNT)

C23

TB1

1

PCB4

2

BLK PCB1 P6-10

RED PCB1 P6-11

3

1

WORK

4

+

2

D1/D2-1 BLU

PCB5 P1-1 RED

VIEW B-B

T5-H2 BLK PCB1 P2-13 BLU

PCB1 P2-12 BLU T5-H1 BLK

R11-1 BLU

*

VIEW D-D

EtchArc-1125 Plasma Marking System 6-23

SECTION 6 Troubleshooting

6.8 Plasma Gas Circuit

The plasma gas circuit consists of a pressure switch and a solenoid. The pressure switch is a normally opened, non-adjustable switch. The switch closes when sufficient pressure is applied. It comes preset to 15 psi. These parts were some of the modifications on the original PCM-1125.

EtchArc-1125 Plasma Marking System 6-24

SECTION 7 Replacement Parts

7.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate.

7.2 Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor or from:

ESAB Welding and Cutting Products

ATTN: Customer Service Department PO Box 100545 Ebenezer Road Florence, SC USA 29501-0545 Phone (843) 664-4405

(800) ESAB-123 (372-3123)

ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario, Canada L5T 1X9 Phone (905) 670-0220 Fax (905) 670-4879

ESAB Cutting Systems GmbH Robert-Bosch-Strasse 20 P.O. Box 1128 D-61184 Karben Phone +011 49 60 39 400 Fax +011 49 60 39 40301 02 http://www.esab.de

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the last page of this manual for a list of customer service phone numbers.

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-1

temtem

SECTION 7 Replacement Parts

7.3 EtchArc-1125 -- Front and Rear View all models

FAULT

POWER

FAULTFAULT

POWERPOWER

AIR

AIRAIR

PRESSURE

PRESSUREPRESSURE

(70 psig)

(70 psig)(70 psig)

5

3

CNC

CNCCNC

2

ARGON

ARGONARGON

EtchArc-1125

EtchArc-1125EtchArc-1125

CURRENT

10

1010

5555

CURRENTCURRENT CONTROL

CONTROL

CONTROLCONTROL

15

1515

AAAA

0000

20

2020

35 MAX

35 MAX35 MAX

GAS

GASGAS

TEST

TESTTEST

OPERATE

OPERATEOPERATE

6

25

2525

30

3030

7

9

1

8

10

11

12

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-2

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 23602576 Strain Relief

2 Reference Bulkhead Connector (See Argon Circuit)

3 1 6271128 Conn Box Recpt 14 MP Shell 20 CNC Plug

5 1 21711

6 1 13730611 Knob

1 0558001176

7 1 951474 Switch Seal

1 634518 Switch Toggle DPDT 2 Pos 15A 125V S2

8 1 993426

9 2 951575 Handle

10 1 21710 Filter Regulator

1 10Z30

11 1 952559 Fuse, 3A Fast Acting F1

12 1 36107 Switch, Power 600 V 63A

Qty Part Number

QtyQty

Part Number Desc

Part NumberPart Number

Description

ription Circuit Symbol

DescDesc

riptionription

Circuit Symbol

Circuit SymbolCircuit Symbol

Gauge -- 1.50 dia – 160 PSI -- white

POT. 10K 2W (Nomex insulation—

676876)

Rubber Grommet 1.50 x 1.76 O.D.

Adapter, B/A—WM x ¼ NPTM

R1

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-3

temtem

SECTION 7 Replacement Parts

7.4 EtchArc-1125 Inside Right View –208/230v P/N 0588000967

1

2

3

4

5

10

9

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

8

tem 7-4

temtem

7

6

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 31488 Shunt Board Assembly PCB4

1 951515 Capacitor, 0.047uf, 660 VAC C23

2 1 37603 Main Transformer Assembly T1

3 2 17300012 Resistor, 300W 12 ohm R11, R12

4 1 952232 Inductor, PFC L2

5 1 35940 XFMR Assembly Control T2

6 1 950487 Term. Block, 2 pos, 20A TB1

7 1 0558001245 Wire Kit T3

8 1 0558001180 Spark Gap Assembly SG

9 1 37699 Reactor Assembly, HI Freq

10 4 182W12 Rubber Foot

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-5

temtem

SECTION 7 Replacement Parts

7.5 EtchArc-1125 Inside Left View –208/230v- P/N 0588000967

14

1

2

3

4

5

13

12

11

10

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

9

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

6

8

tem 7-6

temtem

7

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 36822

2 2 951940 Capacitor, 1uf, 630W VDC C15, C16

3 2 0558001177 PCB Assembly, 1GBT Driver Board PCB2, PCB3

4 2 952237 Capacitor, 1800uf, 450 VDC C1, C2

5 .75 ft. 90858003

6 1 952002 Core, Saturable L3

7 2 951185

8 4 17721020

4 951313 Capacitor, Pulse, 0.01uf, 1KV C5,6,7,8

9 1 952255 Capacitor, 40uf, 400 VDC C4

10 1 950711 Thermal Switch, 195 degrees F TS1

11 1 17750010 Resistor, WW, 50W, 3%, 10 ohm R7

12 1 17250010 Resistor, WW, 50W, Fixed, 10 ohm R10

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Hose Assembly, B/A x ¼ NPT Rub

Plastic Tubing, 0.250 o.d. x 0.04 w Blk (9”)

Bridge, 100ADC, 100NS, 600v (includes Pad – 951516) Resistor, WWFAHT, 25W, 1%, 20 ohms NI

Circuit Symbol

Circuit SymbolCircuit Symbol

D1, D2

R2,3,4,5

13 2 952873 Module, Dual IGBT, 200A, 600V Q1, Q2

14 1 952871 Module, Input Bridge/SCR 100A, 1600V IBR

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-7

temtem

SECTION 7 Replacement Parts

7.6 EtchArc-1125 Inside Top View (cover removed) –208/230v -- P/N 0588000967

1

2

3

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-8

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 38138 Marker Control Board PCB1

2 2 0588000980 PC Board, Start Up PCB5

3 1 Reference Pressure Gauge

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-9

temtem

SECTION 7 Replacement Parts

7.7 EtchArc-1125 Inside Top View Cross Section 1 –208/230v -- P/N 0588000967

1

2

3

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-10

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 951182 Fan, AC Axial, M1

2 2 17240310 Resistor, 10K, 25W R2, R15

3 1 952233 Inductor, Output L1

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-11

temtem

SECTION 7 Replacement Parts

7.8 EtchArc-1125 Inside Top View Cross Section 2–208/230v -- P/N 0588000967

8

7

6

5

4

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-12

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

4 1 673458 Contactor, 3 Pole, 110VAC, 40A K1

5 1 0558001180 Spark Gap Assembly SG

6 1 951202 Switch, Flow, .25GPN SPST FS

7 1 950249

8 1 952026 Terminal Block, 7 pos, 25A, 12-18 ga, TB4

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Valve, Solenoid, ¼ NPT. 165 PS1, 24VAC

Circuit Symbol

Circuit SymbolCircuit Symbol

SOL1

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-13

temtem

SECTION 7 Replacement Parts

7.9 EtchArc-1125 Inside Right View – 460v P/N 0588000949 & 575v P/N 0588000966

2

1

3

4

5

10

9

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

8

tem 7-14

temtem

6

7

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 31488 Shunt Board Assembly PCB4

1 951515 Capacitor, 0.047uf, 660 VAC C23

2 1 37603 Main Transformer Assembly T1

3 2 17300012 Resistor, 300W 12 ohm R11, R12

4 1 673458 Contactor, 3 pole, 110VAC, 40A K1

5 1 35940 XFMR Assembly Control T2

6 1 950487 Term. Block, 2 pos, 20A TB1

7 1 0558001245 Wire Kit T3

8 1 0558001180 Spark Gap Assembly SG

9 1 37699 Reactor Assembly, HI Freq

10 4 182W12 Rubber Foot

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-15

temtem

SECTION 7 Replacement Parts

7.10 EtchArc-1125 Inside Left View –460v P/N 0588000949 & 575v P/N 0588000966

14

15

1

2

3

4

5

6

13

12

11

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

10

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-16

temtem

7

8

9

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 36822

2 2 951940 Capacitor, 1uf, 630W VDC C15, C16

3 2 0558001197 PCB Assembly, 1GBT Driver Board PCB2 4

(460V)

4

(575V)

5 .75 ft. 90858003

6

(460v)

6

(575v)

7 1 952002 Core, Saturable L3

8 2 951185

9 4 17721020

4 951313 Capacitor, Pulse, 0.01uf, 1KV C5,6,7,8

10

(460v)

10

(575v)

11 1 32958 XFMR Assembly, Current T4

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

Hose Assembly, B/A x ¼ NPT Rub

2 952237

2 952562

Capacitor, 1800uf, 450 VDC (460v unit only)

Capacitor, 1800uf, 500 VDC (575v unit only) Plastic Tubing, 0.250 o.d. x 0.04 w Blk (9”)

1 952872

1 951831

Module, Dual IGBT, 200A, 1200v (460v unit) Module, Dual IGBT, 200A, 1400v (575v unit)

Bridge, 100ADC, 100NS, 600v (includes Pad – 951516)

Resistor, WWFAHT, 25W, 1%, 20 ohms NI

1 952255 Capacitor, 40uf, 400 VDC (460v unit only) C4

1 952585 Capacitor, 20uf, 600 VDC (575v unit only) C4

C1, C2

Q1

D1, D2

R2,3,4,5

12 1 17750010 Resistor, WW, 50W, 3%, 10 ohm R7

13 1 17250010 Resistor, WW, 50W, Fixed, 10 ohm R10

14 1 952235 Module, Input Bridge/SCR 75A, 1600V IBR

15 1 950711 Thermal Switch, 195 degrees F TS1

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-17

temtem

SECTION 7 Replacement Parts

7.11 EtchArc-1125 Inside Top View – 460v P/N 0588000949 & 575v P/N 0588000966

1

2

3

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-18

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 38138 Marker Control Board PCB1

2 2 0588000980 PC Board, Start Up PCB5

3 1 Reference Pressure Gauge

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-19

temtem

SECTION 7 Replacement Parts

7.12 EtchArc-1125 Inside Top View Cross 1 – 460v P/N 0588000949 & 575v P/N 0588000966

1

2

3

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-20

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 951182 Fan, AC Axial, M1

2 2 17240310 Resistor, 10K, 25W R2, R15

3 1 952233 Inductor, Output L1

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-21

temtem

SECTION 7 Replacement Parts

7.13 EtchArc-1125 Inside Top View Cross 2 – 460v P/N 0588000949 & 575v P/N 588000966

9

8

6

5

4

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-22

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

4

(460v)

4

(575v)

5 1 0558001245 Wire Kit, Primary

6 1 0558001180 Spark Gap Assembly SG

7 1 951202 Switch, Flow, .25GPN SPST FS

8 1 950249

9 1 952026 Terminal Block, 7 pos, 25A, 12-18 ga, TB4

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

1 37565 Wire Kit, Primary (460v unit only)

1 37566 Wire Kit, Primary (575v unit only)

Valve, Solenoid, ¼ NPT. 165 PS1, 24VAC

SOL1

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-23

temtem

SECTION 7 Replacement Parts

7.14 EtchArc-1125 Inside Top View – 460v P/N 0588000949 & 575v P/N 588000966

1

2

3

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-24

temtem

SECTION 7 Replacement Parts

Item No

Item No Qty

Item NoItem No

1 1 38138 Marker Control Board PCB1

2 2 0588000980 PC Board, Start Up PCB5

3 1 Reference Pressure Gauge

Qty Part Number

QtyQty

Part Number Description

Part NumberPart Number

Description Circuit Symbol

DescriptionDescription

Circuit Symbol

Circuit SymbolCircuit Symbol

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-25

temtem

SECTION 7 Replacement Parts

7.15 Argon Gas Circuit (cut gas)

1

4

5

2

3

8

7

6

5

4

EtchArc

EtchArc----1125 Plasma Marking Sys

EtchArcEtchArc

1125 Plasma Marking System

1125 Plasma Marking Sys1125 Plasma Marking Sys

tem 7-26

temtem

ESAB EtchArc -1125 Plasma Marking System Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1 Safety

1.2 Safety Notations And Symbols

1.3 General Safety Information

1.4 Installation Precautions

1.5 Electrical Grounding

1.6 Operating A Plasma Cutting Machine

1.7 Service Precautions

1.8 Safety References -- Regulations, Standards, Guidelines

1.8.1 Domestic

1.8.2 International

2 Introduction

2.1 Overview

2.1.1 Interconnecting Diagram

2.2 System Description

2.2.1 EtchArc Systems

2.2.2 EtchArc-1125 Power Supply

2.2.3 PM60 Plasma Marker Torch Assembly

2.2.5 Option

3 Installation

3.1 Interface

3.2 Requirements

3.3 Connections to the EtchArc-1125

3.3.1 Back

3.3.2 Converting a 230 VAC power supply to 208 VAC

3.3.3 Torch Lead Connections to EtchArc-1125

3.3.4 Torch Bundle To Torch

4 Operation --Setup

4.1 EtchArc-1125 Setup

4.2 Gas Setup

4.3 CNC Setup

4.4 Process Data

5 Maintenance

5.1 Routine Maintenance

6 Troubleshooting

6.1 Troubleshooting Guide

6.4 Schematic 480 Volt AC P/N 0588000949

6.6 Schematic 575 Volt AC P/N 0588000966

6.8 Plasma Gas Circuit

7.1 General

7.2 Ordering

7.3 EtchArc-1125 -- Front and Rear View all models

7.4 EtchArc-1125 Inside Right View –208/230v P/N 0588000967

7.5 EtchArc-1125 Inside Left View –208/230v- P/N 0588000967

7.6 EtchArc-1125 Inside Top View (cover removed) –208/230v -- P/N 0588000967

7.7 EtchArc-1125 Inside Top View Cross Section 1 –208/230v -- P/N 0588000967

7.8 EtchArc-1125 Inside Top View Cross Section 2–208/230v -- P/N 0588000967

7.9 EtchArc-1125 Inside Right View – 460v P/N 0588000949 & 575v P/N 0588000966

7.10 EtchArc-1125 Inside Left View –460v P/N 0588000949 & 575v P/N 0588000966

7.11 EtchArc-1125 Inside Top View – 460v P/N 0588000949 & 575v P/N 0588000966

7.12 EtchArc-1125 Inside Top View Cross 1 – 460v P/N 0588000949 & 575v P/N 0588000966

7.13 EtchArc-1125 Inside Top View Cross 2 – 460v P/N 0588000949 & 575v P/N 588000966

7.14 EtchArc-1125 Inside Top View – 460v P/N 0588000949 & 575v P/N 588000966

7.15 Argon Gas Circuit (cut gas)