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 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.
©
© ESAB Cutting Systems, 2005
©©
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 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 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.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 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: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 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.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.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 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.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.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 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 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. removal system operating properly.
• Use additional
Use additional ventilation to remove fumes if
Use additionalUse additional
necessary.
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.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, 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 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.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 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.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. 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).(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 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.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.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.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.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 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.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 Do not carry any combustibles on your person
(e.g. butane lighter)
(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.combustibles.
EtchArc-1125 Power Source 1-7
taining
taining taining
.
SECTION 1 Safety
g
1.7 Service Precautions
!
CAUTION
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.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 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 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.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.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. 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 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 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
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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 Cycle
Duty CycleDuty Cycle
Output Amps*
Output Amps*
Output Amps* Output Amps*
@ 120 VDC
@ 120 VDC
@ 120 VDC@ 120 VDC
Open Circuit
Open Circuit
Open Circuit Open Circuit
Voltage
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 Starter
Remote Arc StarterRemote Arc Starter
(Required if torch lead to exceed 50 ft.)
19 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 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 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 Gas
Shield GasShield Gas
Prefiltered (clean and dry) Air) customer supplied,
90 to 150 PSI max. ¼ NPT
Plasma Gas
Plasma Gas
Plasma GasPlasma Gas
99.999% purity, 100 PSI, ¼ NPT
Primary Power
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
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