INSTRUCTION MANUAL for the
ETCHARC
PLASMA MARKING SYSTEM
F14-109
February, 1997
411 South Ebenezer Road
Florence, SC 29501-0545
ESAB Cutting Systems, 1997
This manual is ESAB Part Number F14109
This manual is intended for the convenience and use of the cutting
machine purchaser. It is not a contract or other obligation on the
part of ESAB.
Printed In U.S.A.
Contents
1 Safety....................................................................................................1
2 Introduction...........................................................................................5
EtchArc Plasma Marker
1.1 Introduction ...............................................................................1
1.2 General Safety Information........................................................2
1.3 Plasma Marking Precautions.....................................................3
1.3.1 Electrical Shock Prevention ...........................................3
1.3.2 Eye Safety .....................................................................3
1.4 Skin Safety................................................................................4
1.5 Electrical Grounding..................................................................4
2.1 Overview...................................................................................5
2.2 System Description....................................................................6
3 Installation.............................................................................................7
3.1 Interface....................................................................................7
3.2 Requirements............................................................................8
4 Setup ....................................................................................................9
4.1 PCM-500i Setup........................................................................9
4.2 Gas Setup...............................................................................10
4.3 CNC Setup..............................................................................11
5 Process Data ......................................................................................12
6 Maintenance .......................................................................................19
6.1 Routine Maintenance...............................................................19
6.2 System Interface .....................................................................20
6.3 Pressure Switch Adjustment....................................................21
7 Replacement Parts..............................................................................22
7.1 General Information.................................................................22
7.2 Ordering Information ...............................................................23
7.3 Plasma Marker System ...........................................................24
7.4 Marker Power Supply Assembly..............................................26
7.5 Plasma Marking Torch.............................................................28
7.6 Torch Lead Assembly..............................................................30
1 Safety
1.1 Introduction
EtchArc Plasma Marker
ESAB arc marking products are designed to
provide both safety and efficiency in operation.
However, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of safety.
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 injury to
personnel or severe damage to the equipment.
The following precautions are specific guidelines
applicable to the plasma marking process. More
general precautions are presented in the instruction
literature pertaining to the cutting machine.
Safety Page 1
Section 1
1.2 General Safety Information
All personnel, materials, and equipment not
involved in the production process must be
kept clear of the entire system area. Only
qualified personnel should be allowed to
operate or service the equipment.
Read entirely through a procedure to become
familiar with the task before operating or
performing maintenance on any part of the
system. Special attention must be given to all
WARNINGS, CAUTIONS, and NOTES which
provide essential information regarding
personnel safety and/or possible damage to
equipment.
All safety precautions relevant to electrical
equipment and the process operations must
be strictly observed by all who have
responsibility or access to the system. DO
NOT touch the plasma marking torch during
operation. Do not operate any part of the
system with any of the protective covers
removed or electrical component boxes open.
Refer to all safety publicati ons made available
by your company.
Fence off the entire work cell to prevent
personnel from passing through the area or
standing within the working envelope of the
equipment. Post appropriate CAUTION signs
at every entrance to the work cell area.
Page 2 Safety
1.3 Plasma Marking Precautions
1.3.1 Electrical Shock Prevention
EtchArc Plasma Marker
The plasma arc marking process employs high
voltages. High voltage can kill. Do NOT touch the
marking torch, cutting table or cable connections
during the plasma cutting process.
Electrical Shock Can Kill You!
• Always turn off power to the plasma power
supplies before touching or servicing a plasma
marking torch.
• Always turn off power to the plasma power
supplies before opening or servicing the plasma
power supply or interface box.
1.3.2 Eye Safety
• Do not touch live electrical parts.
• Keep all panels and covers in place when the
machine is connected to a power source.
• Insulate yourself from the workpiece and
electrical ground: wear insulating gloves, shoes
and clothing.
• Keep gloves, shoes, clothing, work area, and
this equipment dry.
Arc rays can injure eyes and burn skin.
To protect your eyes from burns caused by high
intensity ultraviolet light, sparks and hot metal :
• Do not look at the arc.
• Wear correct eye protection. Wear dark safety
glasses or goggles with side shields.
• Replace glasses/goggles when the lenses
become pitted or broken
• Warn other people in the area not to look
Safety Page 3
Section 1
1.4 Skin Safety
directly at the arc unless they wear appropriate
safety glasses.
• Prepare the cutting area in a manner that
reduces the reflection and transmission of
ultraviolet light:
• Paint walls and other surfaces with dark colors
to reduce reflections.
• Install protective screens or curtains to reduce
ultraviolet transmission.
To protect skin against burns caused by high
intensity ultraviolet light, sparks and hot metal:
• Wear protective clothing:
1.5 Electrical Grounding
• Wear gauntlet gloves.
• Wear flame-retardant clothing which covers all
exposed areas.
• Wear cuffless trousers to prevent entry of
sparks and slag.
• Do not touch the torch when it is about to sta rt
or while marking. After marking, allow time for
the front of the torch to cool.
Electrical grounding is imperative for proper
machine operation as well as for SAFETY.
All ESAB Shape Cutting Machines must have a
good electrical connection to earth ground.
Page 4 Safety
2 Introduction
2.1 Overview
EtchArc Plasma Marker
The EtchArc Plasma Marker is a constricted arc
plasma torch marking device. The plasma marker
is a low amperage plasma torch designed for high
accuracy line marking on metal plate. It produces
high quality, durable marks at speeds between 100
and 500 inches per minute. It can greatly enhance
production by performing plate layout and marking
with computer controlled accuracy and speed.
The plasma marking process is similar to the
plasma cutting process. However, rather than
making a cut into the plate, the low amperage
plasma arc merely marks the plate in the pattern
produced by the machine motion. Voltage height
control maintains a constant torch standoff for
consistent marking. This allows for high speed,
highly 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 accellerates
and decelerates. This minimizes cratering or pitting
on starts, in corners, and at the end of the mark.
The Plasma Marker system is intended to be used
during an automatic cutting cycle. 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 the purpose of
testing and setup.
For automatic operation the control will execute the
necessary steps, according to the part program, to
offset the torch, turn on the Automatic Height
Control, fire the torch, and begin marking.
For manual operation, all of these steps must be
performed by the operator.
Introduction Page 5
Section 2
2.2 System Description
The Plasma Marking System consists of a modified
PCM-500i plasma power supply, a marker add-on
box, the marking torch, and Argon supply regulator.
The PCM-500i is an inverter power supply capable
of supplying 35 Amps. It is modified to interface
with a CNC, and the manual controls are disabled
to prevent accidental misadjustment.
The marker add-on box interfaces the marking
torch to the power supply, providing the necessary
electrical connections, pilot arc control, and
additional gas control.
The marking torch is designed for simplicity and
long consummable life. There are only three
consummable parts, the electrode, nozzle, and
shield cup. Argon cut gas provides long electrode
and nozzle life.
Page 6 Introduction
3 Installation
3.1 Interface
EtchArc Plasma Marker
The EtchArc Plasma Marker system is designed to
be interfaced with any cutting machine controller via
the standard ESP open interface. This interface
provides an amphenol connector to which the
customer may connect the appropriate control
wiring.
The schematic below shows the standard ESP
open interface, as it must be used with the plasma
marking system. When interfacing with a control
other than the ESAB Vision CNC or Series 2000
CNC, the customer must provide the external
requirements shown below.
ESP Interface
Installation Page 7
Section 3
3.2 Requirements
Rated primary input @ 35A / 120V output: 200/230VAC, 1 Phase 30/25A, 50/60 Hz.
Electrical Input Requirements
220/380/415 VAC, 3 Phase 14/8/7.5 A, 50/60 Hz.
A fused breaker (either on the cutting machine
gantry or wall mounted) is required to disconnect
power to the PCM-500i power supply.
Recommended sizes for input conductors and
line fuses:
Rated Input Input & Gnd
Conductor
Volts Amps Phase CU/AWG Amps
200 30 1 No. 10 40
230 25 1 No. 10 40
220 14 3 No. 12 20
380 8 3 No. 12 15
415 7.5 3 No. 12 15
Gas Supply Requirements
Argon 150 PSI (1/4 NPT)
99.999% Pure
Fuse Size
Service Air 100 PSI (1/4 NPT)
Page 8 Installation
Clean, Dry, Free of oil
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