ESAB M3 Plasma G2 Plasma System - ICH Instruction manual

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G2 Plasma System - ICH

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Instruction Manual

(use with EPP-202/362 Power Sources)

for cut data see manual: 0558011510

0558011719 07/2014

G2 Plasma System - ICH

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

G2 Plasma System - ICH

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

G2 Plasma System - ICH

Table of Contents

Safety

Safety - English .................................................................................................................................................13

Safety - Spanish .................................................................................................................................................................................. 17

Safety - French ....................................................................................................................................................................................21

System Diagrams

System Diagrams ..............................................................................................................................................27

G2 Plasma System - ICH EPP-202/362 Interconnect Diagram ........................................................................................... 28

Descriptions

Power Supplies .................................................................................................................................................31

380/400V Power Supplies ............................................................................................................................................................... 31

460/575V Power Supplies ............................................................................................................................................................... 31

380/400V Power Supplies ............................................................................................................................................................... 32

460/575V Power Supplies ............................................................................................................................................................... 32

Interface Control Hub (ICH) .............................................................................................................................33

Specications ...................................................................................................................................................................................... 33

ICH Mounting Dimensions .............................................................................................................................................................33

CNC Direct Board ..............................................................................................................................................................................34

Shield Gas Box ..................................................................................................................................................35

Plumbing Schematic ........................................................................................................................................................................ 40

Electrical Schematic ......................................................................................................................................................................... 41

Connections ........................................................................................................................................................................................ 42

Troubleshooting ................................................................................................................................................................................ 43

Replacement Parts ............................................................................................................................................................................ 43

Plasma Gas Box .................................................................................................................................................45

Plumbing Schematic ........................................................................................................................................................................ 49

G2 Plasma System - ICH

Electrical Schematic ......................................................................................................................................................................... 50

Connections ........................................................................................................................................................................................ 51

Troubleshooting ................................................................................................................................................................................ 51

Replacement Parts ............................................................................................................................................................................51

Remote Arc Starter (RAS) .................................................................................................................................52

Remote Arc Starter Connections .................................................................................................................................................53

RAS Box Mounting Dimensions ...................................................................................................................................................55

RAS Box Mounting Plate Dimensions ........................................................................................................................................55

Air Curtain (A/C) ................................................................................................................................................56

Water Injection Control (WIC) ..........................................................................................................................57

Automatic Height Control (AHC) .....................................................................................................................58

B4 Mounting Dimensions ............................................................................................................................................................... 59

Hoses and Cables ............................................................................................................................................. 60

PT-36 Mechanized Plasmarc Cutting Torch ................................................................................................... 68

Package Options Available ...........................................................................................................................................................69

Optional Accessories ........................................................................................................................................................................ 69

PT-36 Torch Consumable Kits ........................................................................................................................................................70

Recommended Regulators ............................................................................................................................................................ 72

Replacement Parts ............................................................................................................................................................................ 72

G2 Plasma System - ICH

Installation

Grounding .........................................................................................................................................................75

Introduction ........................................................................................................................................................................................ 75

Grounding Overview ....................................................................................................................................................................... 76

Basic Layout ........................................................................................................................................................................................77

Elements of a Ground System .......................................................................................................................................................78

Plasma Current Return Path ..........................................................................................................................................................78

Plasma System Safety Ground ...................................................................................................................................................... 79

Rail System Safety Ground ............................................................................................................................................................. 82

Earth Ground Rod ............................................................................................................................................................................. 83

Ground Rod ......................................................................................................................................................................................... 83

Soil Resistivity ..................................................................................................................................................................................... 83

Utility Power Electrical Ground ....................................................................................................................................................84

Multiple Ground Rods .....................................................................................................................................................................85

Machine Grounding Schematic....................................................................................................................................................86

Check upon receipt .......................................................................................................................................................................... 87

Before Installation ............................................................................................................................................................................. 87

Placement of Power Supply .............................................................................................................................87

Input Power Connection ................................................................................................................................................................ 87

Input Conductors .............................................................................................................................................................................. 87

Input Connection Procedure ........................................................................................................................................................88

Output Connection Procedure ..................................................................................................................................................... 89

Interface Cables/Connections.......................................................................................................................................................90

Placement of RAS Box ......................................................................................................................................92

Connections on the RAS Box ........................................................................................................................................................92

Torch Connections ............................................................................................................................................95

Connection of Torch to Plasma System ..................................................................................................................................... 96

Connection to the Remote Arc Starter Box ..............................................................................................................................96

Mounting Torch to Machine ........................................................................................................................................................ 97

Preparing to Cut...............................................................................................................................................................................100

G2 Plasma System - ICH

Placement of ICH ........................................................................................................................................... 106

Placement of SGC .......................................................................................................................................... 106

Placement of PGC .......................................................................................................................................... 106

Individual Component Connections ........................................................................................................................................107

Component Placement Example ...............................................................................................................................................108

Operation

Interface Control Hub ....................................................................................................................................110

ICH Operation .................................................................................................................................................112

ICH Connectors ................................................................................................................................................................................ 112

Display Screens ................................................................................................................................................................................ 113

Editing a Parameter on the Display .......................................................................................................................................... 113

Setup Descriptions.......................................................................................................................................................................... 118

Communication Options .............................................................................................................................................................. 119

Station Options ................................................................................................................................................................................ 120

Digital I/O ........................................................................................................................................................................................... 122

Digital Inputs .................................................................................................................................................................................... 122

Digital Outputs.................................................................................................................................................................................122

Modes of Operation: ......................................................................................................................................123

Remote Interface without Serial Communication ...............................................................................................................123

Operation sequence with ESAB supplied plasma lifter: ....................................................................................................125

Operation sequence with customer supplied plasma lifter: ............................................................................................129

Remote Interface with Serial Communication ...................................................................................................................... 132

Local Interface - Diagnostics Only ............................................................................................................................................. 132

Operation sequence: ...................................................................................................................................................................... 133

Interface Wiring Descriptions .....................................................................................................................................................135

Interface Wiring ...............................................................................................................................................................................135

G2 Plasma System - ICH

Maintenance/Troubleshooting

ICH Maintenance/Troubleshooting ..............................................................................................................143

Communication Problems ........................................................................................................................................................... 143

Digital Input Problems ..................................................................................................................................................................143

Digital Output Problems ............................................................................................................................................................... 143

Gas Problems ....................................................................................................................................................................................143

Power Supply Problems ................................................................................................................................................................ 143

Error Messages on the ICH Display ...........................................................................................................................................144

Module Errors ...................................................................................................................................................................................146

Module Errors ................................................................................................................................................................................... 147

Process Errors ....................................................................................................................................................................................148

Process Errors ....................................................................................................................................................................................149

Process Errors ....................................................................................................................................................................................150

Torch Front End Disassembly ...................................................................................................................................................... 153

Torch Front End Assembly ...........................................................................................................................................................156

Torch Front End Assembly using the Speedloader ............................................................................................................. 157

Torch Front End Disassembly (for Production Thick Plate) ...............................................................................................158

Torch Front End Assembly (for Production Thick Plate) .....................................................................................................161

Torch Body Maintenance ...........................................................................................................................................................163

Torch Body Removal and Replacement ..................................................................................................................................164

Reduced Consumable Life ........................................................................................................................................................166

Checking for Coolant Leaks ......................................................................................................................................................... 167

G2 Plasma System - ICH

Appendix

ESAB Serial Communication Interface ..........................................................................................................171

Introduction ...................................................................................................................................................................................... 171

System Requirements .................................................................................................................................................................... 171

Installation ......................................................................................................................................................................................... 172

Operation ........................................................................................................................................................................................... 174

ICH Serial Communication Protocol ..............................................................................................................185

Commands ........................................................................................................................................................................................185

ICH Communication Errors ..........................................................................................................................................................192

ICH Login Sequence .......................................................................................................................................................................192

ICH Communication Error Messages ........................................................................................................................................193

ICH Communication Error Messages ........................................................................................................................................194

ICH Communication Error Messages ........................................................................................................................................195

ICH Parameter Loading .................................................................................................................................................................196

Replacement Parts

General ................................................................................................................................................................................................199

Ordering .............................................................................................................................................................................................199

Safety

SAFETY

Safety - English

SAFETY

WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the

references listed in Additional Safety Information section. Before per forming any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear

protection. The arc, like the sun, e mits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in

any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuess trousers, high -topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ameproo f apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or curtains.

6. Use goggles over safety glasses when chipping

slag or grinding. Chipped slag may be hot and can y far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from ames and arcs can start res. Hot slag or sparks can also cause res and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce ammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable re extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a re hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later re. Use re watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batter y march Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conned, or if there is danger of falling.

SAFETY

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep ever ything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn o the power before removing your gloves.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of your body.

D. Connect the work cable to the work piece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conned spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specic grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any

conductor causes localized Electric

and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding

machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specic ventilation recommendations.

SAFETY

5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ttings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or xtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more

information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

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

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

SAFETY

MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

DANGER

CAUTION

WARNING

Enclosure Class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be used outside during precipitation unless sheltered.

CAUTION

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage.

CAUTION

If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and / or signicant damage to equipment is possible.

CAUTION

To avoid personal injury and/or equipment damage, lift using method and attachment points shown here.

Maximum

Tilt Allowed

15°

SAFETY

Safety - Spanish

ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas

hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precaucio nes de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren

protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente para

proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada

de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse de l calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en

las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chispas

calientes con una cortina adecuada no-amable como división.

6. Use careta protectora además de sus gafas de seguridad

cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de las amas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto:

. Remueva todo material combustible lejos del área de

trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases amables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.

4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equip o, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo

o muerte. NO use so ldadura de corriente alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos o si hay posibilidad de caer al suelo.

SAFETY

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de tierra física.

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. M antenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones especícas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica uye através de cualquier conductor causando a nivel local

Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo

o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomendaciones especícas en la ventilación.

SAFETY

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code

§25249.5 et seq.)

MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte.

Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modique el equipo en ninguna manera.

INFORMACION ADICIONAL DE SEGURIDAD -- Para

más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualicado para hacer el trabajo.

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

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

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

SAFETY

SIGNIFICADO DE LOS SIMBOLOS -- Según usted avanza en la lectura de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.

Signica riesgo inmediato que, de no ser evadido, puede resultar inmediata-

PELIGRO

mente en serio daño personal o la muerte.

ADVERTENCIA

CUIDADO

Clase de envolvente

El código IP indica la clase de envolvente, es decir, el grado de protección contra la penetración de objetos sólidos o agua. Se provee protección contra el toque con un dedo, penetración de objetos sólidos de un tamaño superior a 12 mm y contra rocío de agua de hasta 60 grados de la vertical. El equipo marcado IP21S se puede almacenar, pero no se debe usar en el exterior durante periodos de precipitaciones a menos que esté protegido.

ADVERTENCIA

Signica el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

Signica el posible riesgo que puede resultar en menores daños a la persona.

Este producto sólo se debe usar para corte por plasma Cualquier otro uso puede causar lesiones físicas y/o daños en los equipos.

ADVERTENCIA

Si el equipo se coloca sobre una supercie con una inclinación superior a 15°, se puede producir un volcamiento. Es posible que se produzcan lesiones físicas y/o daños importantes en los equipos.

ADVERTENCIA

Para evitar lesiones físicas y/o daños en los equipos, levante mediante el método y los puntos de sujeción que se indican en esta ilustración.

Inclinación

máxima permitida

15°

SAFETY

Safety - French

AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de pré-

caution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les ches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de

soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive.

L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de plaques protectrices appropriées an de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes an de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininammable an de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La

chaleur provenant des ammes ou de l'arc peut provoquer un incendie. Le

laitier incandescent ou les étincelles peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les p eintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinc tion d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA

02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces élec-

triques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

SAFETY

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion an d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez eectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — com-

portent un risque de danger. Le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magné-

tiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée de votre corps.

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer

l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'eectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation ecaces. Ne respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail an de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciques concernant la ventilation.

SAFETY

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans

observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz.

Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le

détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l'aide

d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne xez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes

fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute

source de chaleur, des étincelles et des ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez CGA

Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeerson Davis

Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe ment entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Eorcez-vous de toujours coner les tâches d'installation, de dépannage et d'entretien à un personnel qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des aques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES REL ATIVES À LA

SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à

observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

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

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

SAFETY

SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu.

DANGER

AVERTISSEMENT

ATTENTION

Classe de protection de l’enveloppe

L’indice de protection (codication IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale. Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

AVERTISSEMENT

Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

Signie un danger qui peut entraîner des blessures corporelles mineures.

Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.

AVERTISSEMENT

L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante.

AVERTISSEMENT

Soulevez à l’aide de la méthode et des points d’attache illustrés an d’éviter de vous blesser ou d’endommager l’équipement.

Angle

d’inclinaison

maximal

15°

System Diagrams

system diagrams

Below are some abbreviations used throughout this manual.

ABBREVIATIONS: A/C - Air Curtain

ACC - Air Curtain Control AHC - Automatic Height Control CGC - Combined Gas Control ICH - Interface Control Hub IGC - Integrated Gas Control PDB - Power Distribution Box RAS - Remote Arc Starter WIC - Water Injection Control

system diagrams

System Diagrams

The following pages illustrate dierent system congurations available on the m3 Generation 2 (m3 G2). With this system, ESAB oers 8 dierent congurations to meet customer’s requirements. Below are the descriptions of each conguration.

1. Base System

This system is the basic conguration for the m3 G2 Plasma System. It contains the major components, such as the Power Supply (EPP-202/362/540/720), PT-36 Torch, Remote Arc Starter (RAS), Plasma Gas Control (PGC), Shield Gas Control (SGC), and Interface Control Hub (ICH). This system will meet most customers’ needs in cutting carbon steel, stainless steel, and aluminum. It also has the functionality of marking on carbon steel and stainless steel with the same torch and the same consumables. By simply alternating cutting and marking mode on-the-y, this system is capable of cutting and marking in the same part program without changing the consumables. To use this system, customer CNC needs to send start signal and corner signal while in geometric corner; at the same time, customer CNC needs to monitor the fault signal and motion enable signal from ICH. This base system does not come with Automatic Height Control (AHC). Customer will have to provide AHC and control its sequence.

2. Base System + AHC

This system includes the Base System plus the ESAB AHC, called a “B4 lifter”. In this conguration, ICH will control plasma sequence, and also the AHC sequence. Customer CNC needs to provide the start signal and corner signal for normal cutting.

3. Base System + A/C

This system includes the above Base System and ESAB Air Curtain (A/C). Air Curtain is a device used to improve the performance of plasma arc when cutting underwater. ICH from the Base System will control the sequence and turn on/o the air.

4. Base System + WIC

This system is congured to introduce the Water Injection Control (WIC), a module used to regulate cut water ow to shield the cutting process. This conguration is to meet needs of a customer who wants to cut stainless steel without using H35. This system still uses the standard PT-36 torch, but a dierent set of consumables. Similar to the dry system, this WIC system can also do marking with water shield.

5. Base System + AHC + WIC

This system provides customer the Base System, AHC (Automatic Height Control), and WIC (Water Injection Control). With this system, customer needs only to provide start signal and corner signal for cutting stainless steel with water injection.

6. Base System + AHC + A/C

This system gives the customer the ability to cut under water with ESAB Automatic Height Control (AHC).

7. Base System + WIC + A/C

This system is the Base System adding Water Injection Control (WIC) and Air Curtain (A/C). Customer needs to provide their own Height Control and control its sequence.

8. Base System + AHC + WIC + A/C

This complete system gives the opportunity for customer to cut carbon steel, stainless steel, and aluminum with ESAB Auto Height Control (AHC). Customer has the capability to cut stainless steel with the Water Injection Control (WIC), and underwater with the help of Air Curtain (A/C).

(EPP-202/362)

G2 Base System

AHC + WIC + ACC

AHC

AHC-VDR

Power, Pilot Arc, Coolant

RAS-PGC

RAS-VDR

Height

Control)

(Automatic

AHC-CAN

AHC-AC IN

BPR

PGC-PWR

Regulator)

(Back Pressure

BPR-H2O

WIC-H2O OUT

PT-36 Torch

Shield Gas Hose

Plasma Gas Hose

PGC-SG or BPR-SG/H2O

PGC-PG

PGC-CAN

Air Curtain Hose

Shield Gas Hose

PG1

PG2

PG1 (Air/N2/O2)

PG2 (Air/N2/O2)

Hose

Air Curtain

H35

Argon

Air Curtain

PGC

(Plasma Gas Control)

G2 Plasma System - ICH EPP-202/362 Interconnect Diagram

RAS

RAS-PA

RAS-E(-)

RAS-PSC

RAS-TC IN

RAS-TC OUT

Interconnect Diagram

Power Cable

Pilot Arc Cable

m3 G2 Plasma System - ICH

PS & CC Control Cable

PS-PSC

PS(-)

(Power Supply)

PS-PA

Coolant Return Hose

Coolant Supply Hose

CAN BUS

AHC Input Power

(Remote Arc Starter)

RAS-ESTOP

PS-W

WIC-AC-IN

P/S-CAN

WIC

(Water Injection Control)

WIC-CAN

WIC-AIR IN

WIC-H2O IN

CNC

supplied)

(customer

Table

Work

ICH-WIC-CAN

ICH-AHC-CAN

ICH-AHC-PWR

CNC-ESTOP

CNC-IO

CNC-PWR

Air

Air Curtain Hose

CAN-PGC

ICH-CNC

ICH-PWR IN

ICH-P/S-CAN

CNC-WIC-PWR

SGC

(Shield Gas Control)

H35

CH4

Argon

SGC-ICH

GAS-PWR

ICH-SGC

BOLD FONT = Cable Connection Label

Customer Supplied

LIQUID

GAS

ICH

(Interface Control Hub)

Optional

POWER

DATA

THREE

PHASE

{

POWER

Descriptions

Description

Power Supplies

The IGC system can use dierent plasma power supplies. ESAB provides the EPP-202/362, with various input voltages and current output for your requirements. For details about our power supplies, please refer to the power supply’s specic manual.

380/400V Power Supplies 460/575V Power Supplies

EPP-202,

Part Number

Voltage 160 VDC

Output

(100 %

duty cycle)

Input

Weight - lbs (kg) 941 (427) 939 (426) 957 (434) 1085 (492)

Current range DC (marking) 10A to 36A Current range DC (cutting) 30A to 200A Power 32KW Open Circuit Voltage (OCV) 360 VDC 342/360 VDC 360 VDC 366 VDC Voltage (3-phase) 200/230/460 V 380/400 V 400 V 575 V Current (3- phase) 115/96/50 A RMS 60/57 A RMS 57 A RMS 43 A RMS Frequency 60 Hz 50 Hz 50 Hz 60 Hz KVA 39.5 KVA 39.5 KVA 39.5 KVA 39.5 KVA Power 35.5 KW 35.5 KW 35.5 KW 35.5 KW Power Factor 90% 90% 90% 90% Input Fuse (recommended) 150/125/70 A 80/75 A 75 A 60 A

200/230/460V,

60Hz,

0558 011310

EPP-202,

380/400V CCC,

50Hz,

0558 011311

EPP-202, 400V CE,

50Hz,

0558011312

EPP-202,

575V, 60Hz,

0558011313

Description

380/400V Power Supplies 460/575V Power Supplies

EPP-362,

Part Number

460V,

60Hz,

0558011314

Voltage 200 VDC

Output

(100 %

duty cycle)

Input

Weight - lbs (kg) 1130 (514) 113 0 (514) 114 0 ( 518) 1125 (512)

Current range DC (marking) 10A to 36A Current range DC (cutting) 30A to 360A Power 72KW Open Circuit Voltage (OCV) 360 VDC 364 VDC 360 VDC 360 VDC Voltage (3-phase) 460 V 380 V 400 V 575 V Current (3- phase) 109 A RMS 134 A RMS 128 A RMS 88 A RMS Frequency 60 Hz 50 Hz 50 Hz 60 Hz KVA 88.7 KVA 88.5 KVA 88.6 K VA 87. 7 KVA Power 83.7 KW 85.1 KW 84.7 KW 84.0 KW Power Factor 94% 96% 96% 96% Input Fuse (recommended) 150 A 175 A 175 A 125 A

EPP-362,

380V CCC,

50Hz,

0558 011315

EPP-362, 400V CE,

50Hz,

0558 011316

EPP-362,

575V, 60Hz,

0558 011317

Description

Interface Control Hub (ICH)

p/n 0558009607

The Interface Control Hub (ICH) provides the plasma process control including current, gas and torch height (if applicable). It also serves as the interface between the customer CNC and the ESAB m3 G2 plasma system. At the same time, it functions as a hub for CAN communication.

Specications

Dimensions: 7.50” (190.5 mm) high x 10.125” (257.2 mm) wide x 6.50” (165.1 mm) deep Weight: 8.5 lbs. (3.9 kg)

Operating Temperature 5-40°C (41-104°F) Max Humidity 95% non-condensing Enclosure Degree of Protection IP54

Input Power Reduction

ICH Mounting Dimensions

 0.28”

(7.1 m m)

3.00”

(76.2 mm)

230 VAC, 5 Amps 120 VAC, 3 Amps

11. 50 ”

(292.1 mm)

Description

CNC Direct Board

p/n 0558009991

The CNC Direct board is the control and interface board inside the ICH. It provides the process control, interface to customer CNC, system setup, panel interface, etc. Below is a skeleton of this CNC board. It shows the major components and the major connectors on the board. The table below gives the functions of these connections.

Port Function Port Function

X1 CNC Control, DB37 X2 RS232 X3 CAN1 and 24VDC input XP1 Programming port 1 X4 CAN2 XP2 Programming port 2 X6 Spare I/O S2, S3 ID switches, by default S2=1, S3=4 X7 Reserved V12 IC, Main processor X8 Aux Control, DB25 V13 EEPROM, Save data for system conguration, error history, etc. X9 ASIOB1 Communication V41 IC for ASIOB1

XS1 Switches: Plasma Start, Gas Test J1

XS2 Switches: Local/Remote, Station Select and Screen Select

DIP switches: 1- 120R for CAN1, 2- 120R for CAN2, 3- VCC to ASIOB1, 4- GND to ASIOB1 Default: 1 - ON, 2 - ON, 3 - OFF, 4 - OFF

Description

Shield Gas Box

p/n 0558010155

The Shield Gas Box selects dierent gases (Air, N2, O2, CH4) to mix shield gas (SG), plasma gas 1 (PG1), and plasma gas 2 (PG2). The selections are done through a group of solenoids integrated on a manifold. The ICH sends commands through CAN-bus to operate all these solenoids. The gas output of the Shield Gas Box is monitored and fed back through the CAN-bus to ICH for self-diagnosis. Also, the Shield Gas Box controls the solenoid for operation of the Air Curtain.

The default power input to Shield Gas Box is 230VAC. However, the Shield Gas Box input power is customer selectable, between 115 VAC and 230 VAC. This is accomplished by changing the input power switch inside the Shield Gas Box. The Shield Gas Box provides 24VDC and 24VAC power for the Plasma Gas Box.

Note:

Pressure Regulator is factory set

for carbon steel at 40 psi (2.8 bar).

If cutting stainless steel or alumi-

num set at 20 psi (1.4 bar).

Weight:

30.0 lbs. (13.6 kg)

Note:

For required gas specications see

manual 0558008682, Subsection 7.1

8.00”

(203.2 mm)

8.00”

(203.2 mm)

8.25”

(209.6 mm)

to bottom

feet

9.50”

(241.3 mm)

9.25”

(235.0 mm)

Description

Process

Controller

Component Locator Designation

(See following component illustrations)

Gas Controls Power Cable

CAN

Air Curtain

Air N2

CH4

H35

ARG

A B

C D

PT-36

m3 CAN

Plasma Torch/

Air Curtain

Air Curtain Hose

Shield Gas Hose

Shield Gas E F

Control

Power PG1 (Air/N2/O2) PG2 (Air/N2/O2)

Plasma

Gas Control

H35

ARG

Shield Gas Box Component Locator Designations

Note:

Refer to enclosed tables for all available hoses and cables.

I B A

Description

FE DC

GHJ

CAUTION

Voltage Select Switch

(cover must be re-

moved to access

switch)

Description

Voltage Select Switch MUST be set to the proper input voltage (115 or 230 volts - default setting is 230 volts) before energizing system. Failure to do so could result in personal injury or equipment damage.

Description

Shield Gas Box Mounting Hole Locations

(Bottom View)

1.75”

(44.5mm)

4.25”

(108.0mm)

5.00”

(127.0 mm)

2.25”

(57. 2mm)

Shield Gas Box Mounting

Plate Hole Locations

(0558008794)

 0.281

(7.1m m)

0.313”

(8.0mm)

M6-1

5.75”

(146.0mm)

0.50”

(12.7mm)

9.50”

(241.3mm)

Plumbing Schematic

Air

Description

S2,2

S2,1

S3,2

Air

PV1

PV2

∆P

SG1

∆P

SG2

CH4

S3,1

S0,1

S0,2

S0,3

S1,1

S1,2

S1,3

CH4

Air

PT = Pressure Transducer

PV = Proportional Valve

PG1

PG2

Air

S4,1

Air Curtain

Air

Electrical Schematic

Description

Con 6

Solenoid

Air Curtain

24VDC

AC2

AC1

DC Com

Regulator

+24VDC

24VAC

Transformer

Fan

CO 11

LED 2

LED 1

230VAC

115 VA C

Switch

Fuse

Con 3

115 / 230VAC

CAN H In

CAN L In

CAN Gnd

CAN H Out

CAN L Out

NCNCNC

Con 1

Description

Connections

There are three cables connected to the Shield Gas Box. They are 115/230 VAC power input, 24V power output, and CAN. There are ve gas inputs (Air, N2, O2, CH4 and Air Curtain), four gas outputs (SG, PG1, PG2 and Air Curtain), and two outboard connections (H35 and Argon). The ve inputs and two outboard connections are tted with porous bronze lters and "G-1/4" (BSPP) female RH or LH thread. Either of two adaptor tting kits are available to adapt standard metric or CGA hose connections. The gas ttings and adaptors are listed below.

Note:

Chassis must be connected to the machine ground.

Metric

Input

Adaptors

CGA

Input

Adaptors

Outputs

Gas Fitting

Air G-1/4” RH Male x G-1/4” RH Male 0558010163 N2 G-1/4” RH Male x G-1/4” RH Male 0558010163 O2 G-1/4” RH Male x G-1/4” RH Male 0558010163

CH4 G-1/4” LH Male x G-1/4” LH Male 0558010164

Air

Curtain

H-35

(outboard)

Argon

(outboard)

Air G-1/4” RH Male x “B” Air/Water RH Male 0558010165 N2 G-1/4” RH Male x “B” Inert Gas RH Female 0558010166 O2 G-1/4” RH Male x “B” Oxygen RH Male 0558010167

CH4 G-1/4” LH Male x “B” Fuel RH Male 0558010168

Air

Curtain

H-35

(outboard)

Argon

(outboard)

SG 1/4” NPT x 5/8"-18 LH Male 0558010223 PG1 1/4” NPT x “B” Inert Gas RH Female 74S76 PG2 1/4” NPT x “B” Oxygen RH Male 3389

Air

Curtain

H-35

(outboard)

Argon

(outboard)

G-1/4” RH Male x G-1/4” RH Male 0558010163

G-1/4” LH Male x G-1/4” LH Male 0558010164

G-1/4” RH Male x G-1/4” RH Male 0558010163

G-1/4” RH Male x “B” Air/Water RH Male 0558010165

G-1/4” LH Male x “B” Fuel RH Male 0558010168

G-1/4” RH Male x “B” Inert Gas RH Female 0558010166

1/4” NPT x “B” Inert Gas LH Female 11N16

1/8” NPT x “B” Fuel LH Male 11Z9 3

1/8” NPT x “A” Inert Gas RH Female 631475

ESAB

P/N

Description

Troubleshooting

On the Shield Gas Box, there are two LEDs displaying the status of the CAN-bus module. The states of these lights are shown in the table below.

LED Status Meaning

OFF Power OFF

Green

Yellow ON Station is selected

In normal operation, the green LED indicating the power must be ON. When the station is selected, the yellow LED should be ON all the time; and green LED will ash 90% ON and 10% OFF. Otherwise, there is a problem.

1. If the green light is not on, check the power input (cale connection) and fuse.

2. If the yellow light is not on and the green light is on, check can-bus connection. Make sure the station is selected.

10% ON, 90% OFF Boot loader is running 50% ON, 50% OFF Application is running 90% ON, 10% OFF Application is running, CAN is available

Replacement Parts

The Shield Gas Box is highly integrated and only a few parts can be replaced by a qualied service engineer or by the customer. These parts are listed below. Otherwise, the entire Shield Gas Box needs to return for repair. It is recommended that customers contact Technical Support before attempting repairs on these units.

Item No. Description part number

1 Transformer 0558008612 2 Fan 0558008614 3 Fuse - T630mA 250V, 5 x 20mm 0558008613 4 Solenoid 6240 for Air Curtain 0558008615 5 Pressure Gauge 0558008616 6 Pressure Regulator 0558008617

NOTE:

Additional Parts lists, Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm

(11” x 17”) paper are included inside the back cover of this manual.

Description

Plasma Gas Box

p/n 0558010156

The Plasma Gas Box regulates the output of the plasma gas (PG) selected from the four gas inlets (Argon, H35, PG1 and PG2). It is powered by 24 Volts (AC and DC) from the Shield Gas Box and receives commands via the CANbus directly from the ICH.

Like the Shield gas box, the gas output of the Plasma Gas Box is monitored and fed back through the CAN-bus to ICH for self-diagnosis.

Note: For required gas specications see manual 0558008682, Subsection 7.1

* 6.25”

(158.8 mm)

4.50”

(114 .3 mm)

NOTE:

CAN cable must be routed separate

from torch leads.

* 8.00” (203.2 mm) including ttings on front and back

Weight:

9.15 lbs. (4.2 kg)

4.50”

(114 .3 mm)

6.50”

(165.1 mm)

Shield Gas Bracket Assembly

(0558010161)

Description

NOTE:

The PT-36 Torch is shipped with hose lengths that will not allow the Plasma Gas Box to be mounted more than two meters (6.6 feet) away from the torch. Please make sure the routing of the standard hoses will allow them to bend and connect properly before permanently mounting the Plasma Gas Box.

If additional distance between the torch and box is required the standard torch hose assembly will need extension hoses to create longer lengths. Extension hoses can be ordered to connect to the existing hose assembly.

BOTH HOSES MUST BE ORDERED

Extension Hose, Plasma Gas, 1M (3.3 ft.) ESAB P/N 0558008996 Extension Hose, Shield Gas, 1M (3.3 ft.) ESAB P/N 0558008997

The longer hose lengths will require that the pierce time be increased and a longer lead-in time must be specied. This is due to the additional time required to purge the N2 start gas from the hose before the O2 cut gas becomes aective. This condition occurs when cutting carbon steel with oxygen.

PT-36

m3 CAN

Plasma Torch/

Air Curtain

Process

Controller

Air Curtain Hose

Shield

Gas Control

(See following component illustrations)

Shield Gas Hose

Power PG1 (Air/N2/O2) PG2 (Air/N2/O2)

H35 ARG

CAN

Component Locator Designation

Plasma Gas Box Component Locator Designations

Note:

Refer to enclosed tables for all available hoses and cables.

E F

Plasma

Gas Control

Plasma Gas Hose

Description

G B

C E F D

Description

Plasma Gas Box Mounting Hole Locations

(Bottom View)

M6 x 1

2.52”

(64.0mm)

0.90”

(22.9mm)

(9.5mm)

Plasma Gas Box Mounting

Plate Hole Locations

(0558008793)

 0.281

(7.1m m)

0.313”

(8.0mm)

0.37”

4.72”

(120.0mm)

4.00”

(101.6mm)

0.37”

(9.5mm)

7.5 0”

(190.5mm)

Plumbing Schematic

H35

Description

PT1

PV1

PT3

Plasma Gas

N2/O2/Air

PT2

∆P

PV2

PT = Pressure Transducer

PV = Proportional Valve

Electrical Schematic

Con 1

CAN

Con 2

POWER

Description

CAN H Out CAN L Out

CAN Gnd CAN H In

CAN L In NC NC

24VAC In 24VAC In

-24VDC In

+24VDC In

CO 1

15 16

10 12

LED 1

LED 2

Description

Connections

There are two cables connected to the Plasmas Gas Box: one is 24V power, the other is CAN. There are four gas inputs (Argon, H35, PG1 and PG2) and one gas output (PG). The gas ttings are listed below.

Note:

Chassis must be connected to the machine ground.

Gas Fitting

Argon 1/8” NPT x “A” Inert Gas RH Female 631475

H-35 1/4” NPT x “B” Fuel LH Male 83390

Inputs

PG1 1/4” NPT x “B” Inert Gas RH Female 74S76 PG2 1/4” NPT x “B” Oxygen RH Male 83389

Output PG

Connection, Male

0.125NPT to "A" Size

ESAB

P/N

20 64113

Troubleshooting

The Plasma Gas Box has two visible LEDs that indicate its’ status. When the GREEN LED is on, this indicates power is applied to the unit and the rate at which it is ashing shows the operational status of the unit (refer to the chart below). If the Green LED is not ON, check the power cable, which should carry 24VDC and 24VAC from the Shield Gas Box.

If the Yellow LED is not ON, either there is no power to the unit or the station is not selected.

The Plasma Gas Box is highly integrated and is treated as a “Black Box”. If one or more functions of the unit stop working, the unit must be returned for repair. Contact technical support for troubleshooting and RMA assistance.

LED Status Meaning

OFF Power OFF

10% ON, 90% OFF Boot loader is running

Green

50% ON, 50% OFF Application is running

90% ON, 10% OFF Application is running, CAN is available

Yellow ON Station is selected

Replacement Parts

NOTE:

Additional Parts lists, Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm

(11” x 17”) paper are included inside the back cover of this manual.

Description

Remote Arc Starter (RAS)

p/n 0558011591

The Remote Arc Starter is more commonly referred to as the RAS Box. The RAS box provides a voltage feedback to the plasma torch lift. This voltage is used to regulate the torch height while cutting, maintaining the proper height of the torch above the work piece.

Within the RAS box there is a High Frequency/Voltage Divider circuit board which provides pilot arc ionization and voltage divider functions to regulate torch height.

Coolant connections and torch power connections are made within the RAS box and provide an interface between the power supply, coolant circulator and the torch.

Specications

Dimensions: 8.75” (222.3 mm) high x 7.50” (190.5 mm) wide x 17.00” (431.8 mm) deep Weight: 28.5 lbs. (12.9 kg)

8.75”

(222.3 mm)

17.0 0”

(431.8 mm)

7.5 0”

(190.5 mm)

Description

Remote Arc Starter Connections

Note:

Chassis must be connected to

the machine ground.

G, H

Letter Description

A 3 Pin Voltage Divider Connection to the Lift

C 14 Pin Amphenol Power Supply Connection

D Power Supply Enable

E Coolant Inlet - Flowing to the Torch

Coolant Return - Flowing back to the Coolant Circu-

G, H Strain Relief Fittings

I Torch Shroud Connection

J Machine Ground Connection

lator from the Torch

Description

Component Locator Designation

(See following component illustrations)

Power

Supply

Control

Box

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose Coolant Return Hose

Power Supply Enable

Assembly

Arc

Starter

Power, Pilot Arc, Coolant

VDR Cable

AHC / Lift

( Optional )

Remote Arc Starter Box Component Locator Designations

NOTE: Refer to enclosed tables for all available hoses and cables.

PT-36

m3 CAN

Plasma

Torch

Description

RAS Box Mounting Dimensions

The box has four M6 x 1 threaded mounting holes shown in pattern below.

If fasteners are threaded into the box from below, the length of the fasteners

CAUTION

5.00”

(12 7.0 0 mm)

must not allow them to extend more than 0.25” beyond the edge of the internal female threads. If fasteners are too long they can interfere with the components inside the box.

1.00”

(2.54 mm)

2.75”

(69.85 mm)

RAS Box Mounting Plate Dimensions

p/n 0558008461

8.75"

(222.3 mm)

3.25"

7.50"

(190 .5 mm)

(82.6 mm)

6.50"

(165.1 m m)

13.75”

(349.25 mm)

18. 50"

(469.9 mm)

17. 50"

(444.5 mm)

Air Curtain (A/C)

Description

p/n 37440

The Air Curtain is a device used to improve the performance of plasma arc when cutting underwater. The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone to reduce noise, fume, and arc radiation, even though the torch has been submerged.

The Air Curtain requires a source of compressed air that needs to be clean, dry and oil-free. It should be delivered at 80 psi @ 1200 cfh (5.5 bar @ 34 CMH).

Description

Water Injection Control (WIC)

p/n 0558009370

The Water Injection Control (WIC) regulates the ow of cut water supplied to the plasma torch. This water is used as a shield in the cutting process. This shield assists in forming the plasma arc and also cools the cut surface. The selection and output of cut water is performed and controlled by the ICH. The WIC consists of a water regulator, pump and a closed feedback loop between proportional valve and ow sensor. This is controlled by a local Process Control Unit (PCU). The PCU communicates via CAN to the ICH while controlling the proportional and solenoid valves. The WIC is monitored and sends feedback signals through the CAN bus to the ICH for diagnostic purposes.

For more detailed information on the Water Injection Control (WIC), see manual #0558009491.

Specications

Dimensions (Electrical module) 163 mm x 307 mm x 163 mm (6.4 in x 12.1 in x 6.4 in) Dimensions (Pump Module) 465 mm x 465 mm x 218 mm (18.3 in x 18.3 in x 8.6 in) Weight (Electrical module) 15 lb. dry (6.8 kg) Weight (Pump Module) 60 lb. dry (27.2 kg)

Tap water with an allowable water hardness of <2 ppm as CaCO3 and Conductivity:

Water Requirements

Air Supply (anti-freezing function) 250 CFH @ 80 psi (7.1 cmh @ 5.5 bar)

Pump

Motor

Pressure Regulator

Pressure Transducer

Proportional Valve

Flow Sensor

Air Solenoid

>200,000 ohms per inch, ltered at 5 microns. 1 gpm (3.8 l/min) minimum ow rate @ 20 psi (1.4 bar).

Positive displacement, rotary vane with adjustable by-pass valve (250 psi / 17.2 bars maximum), CW rotation, Capacity: 1.33 GPM @ 150 psi (5.04 l/min @ 10.3 bar), Nominal speed: 1725 rpm, Temperature rating: 150

1/2 HP, 230 VAC single phase, 60 Hz, 1725 RPM, 3.6A current, Temperature rating: 150

Inlet water pressure: 100 psi (6.9 bar) maximum Outlet water pressure: 20 psi (1.4 bar) factory set

Maximum pressure range: 0 - 200 psi (0 - 13.8 bar) Temperature range: -40 Supply voltage: 24 VDC Pressure signal output: 4 mA for 0 psi, 20 mA for 200 psi (13.8 bar). Regulated to 1 to 5 VDC with 250 ohm resistor.

Supply voltage: 24 VDC Full load current: 500 mA, Input control signal: 0-10 VDC. Coil: Standard Voltage: 24 VDC, Operating current: 100-500 mA, Valve: Orice size: 3/32”, Cv:0.14 (fully open) Operating dierential pressure: 115 psi (8.0 bar) ; Max. ow 1.5 gpm Maximum uid temperature: 150

Maximum operating pressure: 200 psi (13.8 bar), Operating temperature: -4 mum, Output signal: 58 - 575 Hz, Flow range: 0.13 - 1.3 gpm

Supply voltage: 24 VDC, Maximum operating pressure: 140 psi (9.7 bar) , Operating temperature: 32

- 77o F (0 - 25o C)

F (66o C)

- 257o F (-40

- 212o F (-20o - 100o C), Input power: 5 - 24 VDC @ 50 mA maxi-

F (66o C)

- 125o C)

F (66o C)

Description

Automatic Height Control (AHC)

p/n 0560947166

The B4 lift assembly provides vertical motion for the PT-36 plasma torch, using a typical motor, screw, and slide conguration. The motor turns an enclosed spindle screw, which in turn raises/lowers the lifting plate along linear rails. Directional commands given from the plasma controller determine the direction of the travel. Fixed limit switches are included to prevent upper and lower lift’s over travel.

The lift assembly also contains components necessary to control height over work surfaces; initial, piercing, and cutting heights are encoder controlled during the plasma cycle. During part production, height is automatically controlled by taking voltage measurements between the torch electrode and work surface.

The B4 lifts utilize an Omni Soft Touch® assembly to protect the system during station crashes. Proximity switches monitor torch position in the torch holder. If the torch is jarred in any direction, the process will stop and an error report will be sent to the controller.

Specications

Dimensions:

6.0” (152.4 mm) wide x 8.5” (215.9 mm) deep x 31.5” (800.1 mm) high

Lift Speed: 315 IPM [8.0m per minute] Vertical Travel: 8.00” [200.0 mm] Approximate Weight including torch holder: 85 lbs. [38.5 kg] Torch Barrel Size: 85.7 mm

IHS Accuracy: ± 0.5 mm

Component Tolerances

Encoder Accuracy: ± 0.25 mm Voltage Accuracy: ± 1 volt

Description

B4 Mounting Dimensions

B4 lift hole patterns are provided below to aid end users in mounting the plasma station. An optional plasma bracket/nut plate is available. For more specic details, please refer to the B4 Lift manual.

2.50” [63.5mm]

4.47”

[113.5mm]

(6) M8 x 1.25 x 40 Socket Head Cap Screws

4.13” [104.9mm]

3.64” [92.4mm]

0.49” [12.4mm]

0.53” [13.5mm]

x6 M8x1.25 - 6H THRU HOLES

5.00”

[127.0mm]

Recommended Mounting Bracket/Nut Plate

Hoses and Cables

Description

Cable / Hose

Description

CAN Bus Cable

Available

Lengths

m ( ft. )

1m (3. 3’) 0558008464 2m (6.5’) 0558008465

3m (10’) 0558008466

4m (13’) 0558008467

5m (16’) 0558008468 6m (19 ’ ) 0558008469 7m (23’) 0558008470 8m (26’) 0558008471 9m (30’) 0558008472

10m (33’) 0558008473

11m (36’ ) 0558008474 12m (39’) 0558008475 13m (43’ ) 0558008476 14m (46’) 0558008477

15m (49’ ) 0558008478 20m (66’) 0558008479 25m (82') 0558008809

36m (118') 0558008480 30m (100') 0558008481 40m (131' ) 0558008482 45m (150') 0558008483 50m (164') 0558008484 55m (180') 0558008485 60m (200') 0558008486

ESAB

Part Number

Description

Cable / Hose

Description

Power Supply Enable

Gas Controls Power Cable

Cable / Hose

Description

VDR Cable

Available

Lengths

m ( ft. )

5m (16’) 0558008329 10m (33’) 0558008330 15m (49’) 0558008331 20m (66') 0558008807 25m (82') 0558008808

1m (3.3’) 0560947962 2m (6.4’) 0560946776

3m (10’) 0560947964

4m (13’) 0560947087

5m (16’) 0560947088

6m (19’) 0560947089

7m (23’) 0560947090

Available

Lengths

m ( ft. )

0.5m (1.7’) 0560947067

1.5m (5’) 0560947075 3m (10’) 0560947076 4m (13’) 0560947068 5m (16’) 0560947077 6m (19’) 0560947069

6.1m (20') 0560946782 7m (23’) 0560947070 8m (26’) 0560947071

9m (30’) 0560947072 10m (33’) 0560947078 15m (49’) 0560947073 20m (66’) 056 0947074 25m (82') 0560946758

ESAB

Part Number

ESAB

Part Number

Description

Cable / Hose

Description

Pilot Arc Cable

Torch

Description

PT-36 m3 CAN

Plasma Torch

Available

Lengths

m ( ft. )

1.4m (4.5’) 0558008310

1.8m (6’) 05580 08 311

3.6m (12’) 0558008312

4.6m (15’) 05580 08313

5.2m (17’ ) 0558008314

6.1m (20’) 05580 08315

7.6m (25’) 0558008316

4.5m (14.5’) 055800 8317

Available

Lengths

m ( ft. )

1.4m (4.5’) 0558008301

1.8m (6’) 0558008302

3.6m (12’) 0558008303

4. 3m (14’) 0558008308

4.6m (15’) 0558008304

5.2m (17’ ) 0558008305

6.1m (20’) 0558008306

7.6m (25’) 0558008307

ESAB

Part Number

ESAB

Part Number

Cable / Hose

Description

PS & CC Control Cable

Cable, Control (14PX-14S), Family

0558 011630

Available

Lengths

m ( ft. )

2.9m (9.5’) 0558011840

7.6m (25’) 10m (33’) 15m (50’)

20m (66’)

23m (75’)

25m (82’)

30m (100’)

35m (115’ ) 0558011963

40m (131’)

45m (150’) 0558011964

50m (164’)

55m (180’) 0558011965

60m (200’)

ESAB

Part Number

0558011631 0558011632 0558011633 0558011634 0558011635 0558011636 0558011637

0558011638

0558011639

0558011640

Description

Shield Gas Control to Plasma Gas Control Cables/Hoses

Cable / Hose

Description

N2 / PG-1 Hose

Cable / Hose

Description

O2 / PG-2 Hose

Available

Lengths

m ( ft. )

3m (10’) 0558008443 4m (13’) 0558008357

5m (16’) 0558006090 6m (20’) 0558006091 7m (23’) 0558006092 8m (26’) 0558006093 9m (30’) 0558006094

10m (33’) 0558006095 15m (50’) 0558006100

Available

Lengths

m ( ft. )

3m (10’) 0558008446

4m (13’) 0558008358 5m (16’) 0558006107

6m (20’) 0558006108 7m (23’) 0558006109 8m (26’) 0558 00 6110

9m (30’) 0 558 00 6111 10m (33’) 055 80 06112 15m (50’) 0 558 00 6117

ESAB

Part Number

ESAB

Part Number

Description

Shield Gas Control to Plasma Gas Control Cables/Hoses

Cable / Hose

Description

H35 / CH4 Hose

Hose

Description

Coolant Hose

Available

Lengths

m ( ft. )

3m (10’) 0558010193 4m (13’) 0558010194

5m (16’) 0558010195 6m (20’) 0558010196 7m (23’) 0558010197 8m (26’) 0558010198 9m (30’) 0558010199

10m (33’) 0558010200 15m (50’) 0558010201

Available

Lengths

m ( ft. )

10m (33') 0558005563 15m (49') 0558005564 20m (66') 0558005565

45m (115' ) 0558005566

50m (164') 0558005567

5m (16') 0558005246

30m (98') 0558005247 40m (131') 0558005248 77m (196') 0558005249

32m (82') 0558006629 59m (150') 0558006630 71m (180') 0558006631

ESAB

Part Number

ESAB

Part Number

Description

Shield Gas Control to Plasma Gas Control Cables/Hoses

Cable / Hose

Description

Argon Hose

Cable / Hose

Description

Air / Shield Gas Hose

Available

Lengths

m ( ft. )

3m (10’) 0558010182 4m (13’) 0558010183

5m (16’) 0558010184 6m (20’) 0558010185 7m (23’) 0558010186 8m (26’) 0558010187 9m (30’) 0558010188

10m (33’) 0558010189 15m (50’) 0558010190

Available

Lengths

m ( ft. )

3m (10’) 0558010171

4m (13’) 0558010172

5m (16’) 0558010173 6m (20’) 0558010174

7m (23’) 0558010175

8m (26’) 0558010176 9m (30’) 0558010177

10m (33’) 0558010178 15m (50’) 0558010179

ESAB

Part Number

ESAB

Part Number

Description

Shield Gas Control to Plasma Gas Control Cables/Hoses

Cable / Hose

Description

Air Curtain Hose

Available

Lengths

m ( ft. )

3m (10’) 0558010205

4m (13’) 0558010207

5m (16’) 0558010208 6m (20’) 0558010209 7m (23’) 0558010210 8m (26’) 055 8010211 9m (30’) 0558010212

10m (33’) 0558010213 15m (50’) 0558010214

Plasma Gas Control to Air Curtain Hoses

Cable / Hose

Description

Air Curtain Hose

Available

Lengths

m ( ft. )

2. 3m (7. 5’ ) 0558010204

3. 4m (11’ ) 0558010206

ESAB

Part Number

ESAB

Part Number

NOTE:

This cable is only used with a ICH to connect the second Interface Box.

For multiple CAN hubs on ESAB cutting machines use cable 0558008824.

Description

Cable / Hose

Description

CAN Bus Crossover Cable 0.5m (1.7’) 0558008524

115 / 230 VAC Input Power Cable

Plasma Gas Control Power Cable

Basic Flex Cable

Available

Lengths

m ( ft. )

5m (16’) 0558008261 10m (33’) 0558008262 15m (49') 0558008810 20m (66’) 0558008811 25m (82') 0558008812

1.5m (5’) 0560947079 3m (10’) 0560947080 4m (13’) 0560947061 5m (16’) 0560947081 6m (19 ’ ) 0560947062 7m (23’) 0560947063 8m (26’) 0560947064 9m (30’) 0560947065

10m (33’) 0560947082

12.8m (42') 0560946780 15m (49’ ) 0560947066 20m (66’) 0560947083

4.6m (15’) 0560936665

7.6m (25’) 0560936666 15m (50’) 0560936667

22.8m (75’) 0560936668 25m (82’) 0560948159

Part Number

ESAB

Description

PT-36 Mechanized Plasmarc Cutting Torch

p/n 0558008300

The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the eld. Only the torch frontend has replaceable parts.

The purpose of this section is to provide the operator with all the information required to install and service the PT-36 Mechanized Plasmarc Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package.

Specications

Type: Water cooled, Dual gas, mechanized plasmarc cutting torch Current Rating: 1000 Amps @ 100% duty cycle Mounting Diameter: 2 “(50.8 mm) Length of Torch without leads: 16.7 “(42 cm) IEC 60974-7 Voltage Rating: 500 volts peak Striking Voltage (maximum value of HI-FREQUENCY voltage): 8000 VAC Minimum Coolant Flowrate: 1.3 GPM (5.9 L/min) Minimum Coolant Pressure at Inlet: 175 psig (12.1 bar) Maximum Coolant Pressure at Inlet: 200 psig (13.8 bar) Minimum Acceptable Rating of Coolant Recirculator: 16,830 BTU/HR (4.9 kW) at High Coolant Temperature - Ambient

= 45°F (25°C) and 1.6 USGPM (6 L/min)

Maximum Safe Gas Pressures at Inlets to Torch: 125 psig (8.6 bar) Safety Interlocks: This torch is intended for use with ESAB plasmarc cutting systems and controls employing a water

ow switch on the coolant return line from the torch. Removal of the nozzle retaining cup to service the torch breaks the coolant return path.

Description

7.54"

(191. 5 mm)

2.00"

(50.8 mm)

9.13"

(231.9 mm)

6.17"

(156.7 mm)

Package Options Available

PT-36 package options available through your ESAB dealer. See Replacement Parts section for component part numbers.

10.50" (266.7 mm) Length of Sleeve

Optional Accessories

Bubble Muer - When used in conjunction with a water pump recirculating water

from the table and by using compressed air, this device creates a bubble of air which enables a PT-36 Plasmarc Cutting Torch to be used underwater with less sacrice of cut quality. This system also permits operation above water as the ow of water through the muer reduces fume, noise, and arc U.V. Radiation.

(for installation/operation instructions see manual 0558006722)..............................37439

Air Curtain - This device when supplied with compressed air is used to improve the performance of the PT-36 Plasmarc Cutting Torch when cutting underwater. The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone, even though the torch has been submerged to reduce noise, fume, and arc radiation. To be used in underwater applications only.

(for installation/operation instructions see manual 0558006404) .............................37440

Description

Speedloader assembly, handheld ...............................................................0558006164

NOTE:

Cannot be used with vent hole nozzles.

Speedloader assembly, 5 xtures ................................................................0558006165

PT-36 Torch Consumable Kits

PT-36 Repair & Accessories Kit ...................................................................................0558005221

Part Number Quantity Description

0558003804 1 Torch Body PT-36 w/O-rings 0004485648 10 O-ring 1.614 ID x .070 0558002533 2 Bae, 4 Hole x .032 0558001625 2 Bae, 8 Hole x .047 0558002534 1 Bae, 4 x .032 Reverse 0558002530 1 Bae, 8 x .047 Reverse 0558005457 1 Bae, 4 Hole x .022 0558003924 3 Electrode Holder PT-36 w/O-ring 0004485671 10 O-ring .364 ID x .070 0004470045 2 Nozzle Retaining Cup, Standard 0004470030 1 Shield Gas Diuser, Low Current 0004470031 5 Shield Gas Diuser, Standard 0004470115 1 Shield Gas Diuser, Reverse 0004470046 2 Shield Retainer, Standard 0558003858 2 Contact Ring w/screw 0004470044 6 Screw, Contact Ring 0004470049 2 Hex Key Wrench .109" 0558007105 1 Nut Driver 7/16" (Electrode tool) 0558003918 1 Electrode Holder Tool PT-36 0004470869 1 Silicon Grease DC-111 5.3oz

Description

PT-36 Start-Up Kits ..............................................................................................................................

0558010625

600 AMP

5 5 5 5 0558009400 ELECTRODE MICRO PT-36 5 5 5 5 0558003914 ELECTRODE O2 ULTRALIFE, Standard PT-36 5 - - - 0558003928 ELECTRODE N2/H35, Standard PT-36 5 5 5 5 0558009406 NOZZLE 0.6mm (.024") MICRO PT-36 5 5 5 5 0558009411 NOZZLE 1.1mm (.043") MICRO PT-36 5 5 5 5 0558006018 NOZZLE 1.8mm (.070") PT-36 5 5 5 5 0558006020 NOZZLE 2.0mm (.080") PT-36 5 5 5 - 0558006030 NOZZLE 3.0mm (.120") PT-36 5 5 - - 0558006028 NOZZLE 2.8mm (.109") Divergent (O2) PT-36 5 - - - 0558006041 NOZZLE 4.1mm (.161") PT-36 1 1 - - 0558009550 NOZZLE RETAINING CUP HD PT-36 5 5 5 5 0558009425 SHIELD 2.5mm (.099") MICRO PT-36 5 5 5 5 0558006141 SHIELD 4.1mm (.160") PT-36 5 5 5 - 0558006166 SHIELD 6.6mm (.259") PT-36 5 5 - - 0558009551 SHIELD 5.1mm (.200") HD PT-36 5 - - - 0558006199 SHIELD 9.9mm (.390") PT-36 1 1 - - 0558009548 SHIELD RETAINER HD PT-36 5 5 5 5 181W89 O-RING 1.114 ID x .070 CR 1 1 1 1 950561 TOOL BOX

0558010624

450 AMP

0558010623

360 AMP

0558010622

200 AMP

Part No Description

Description

PT-36 H35 Heavy Plate Start-up Kit ............................................................................0558005225

Part Number Quantity Description

0558003963 5 Electrode, Tungsten 3/16"D 0558003965 5 Nozzle H35 .198" Divergent 0558003964 2 Collet 3/16"D Electrode 0558005689 2 Electrode/Collet Holder PT-36 0558003967 2 Collet Body 0558002532 5 Bae, 32 Hole x .023 0558006688 5 Shield High Current 0558003918 1 Electrode Holder Tool PT-36 0558003962 1 Tungsten Electrode Tool 0558008737 2 Nozzle Retaining Cup Assy High Current

Recommended Regulators

Liquid Cylinder Service:

O2 : R-76-150-540LC ................................................................................................................P/N 19777

N2 : R-76-150-580LC ................................................................................................................P/N 19977

High Pressure Cylinder Service:

O2 : R-77-150-540 .........................................................................................................P/N 0558010676

Ar & N2 : R-77-150-580 .................................................................................................P/N 0558010682

H2 & CH4 : R-77-150-350 ............................................................................................P/N 0558010680

Industrial Air : R-77-150-590 ...................................................................................P/N 0558010684

Station/Pipeline Service:

O2 : R-76-150-024 .........................................................................................................P/N 0558010654

Ar & N2 : R-76-150-034 .................................................................................................P/N 0558010658

Air, H2, & CH4 : R-6703 .............................................................................................................P/N 22236

Replacement Parts

NOTE:

Additional Parts lists, Schematics and Wiring Diagrams on 279.4 mm x 431.8 mm

(11” x 17”) paper are included inside the back cover of this manual.

Installation

InstallatIon

Grounding

Introduction

Machine grounding is an important part of the installation process, which can be greatly simplied if prepared in advance. The most dicult part of the grounding process is designing and installing a low impedance Earth ground rod. However, the better the Earth ground rod, the less chance there is of having electromagnetic interference problems after the installation is complete.

Most national electric codes address grounding for the purpose of re prevention and short circuit protection; they do not address equipment protection and electromagnetic interference noise reduction. Therefore, this manual presents more stringent requirements for machine grounding.

WARNING

Electric Shock Hazard.

Improper grounding can cause severe injury or death.

Improper grounding can damage machine electrical components.

Machine must be properly grounded before putting it into service.

The cutting table must be connected to machine earth grounding rod.

A common symbol used to identify

a chassis ground on drawings.

InstallatIon

Grounding Overview

There are three parts to a ground system;

•Component or "chassis" ground

•Earth ground

•Protective Earth ground

Component grounding connects all pieces to a single component, like the machine chassis, which is then connected to a common point known as the star point. This provides a path for electromagnetic interference (EMI) from the enclosure to ground.

An earth ground provides a electromagnetic interference (EMI) to return to its source.

A protective earth (PE) ground provides a safe path for fault current. Without a properly grounded system, an unintended path through people or sensitive equipment may be found, resulting in serious injury, death, and/or premature equipment failure.

A common symbol used to identify an earth ground on drawings.

A common symbol used to identify a protective earth (PE) ground.

This section focuses on machines with a plasma cutting system. Machines with plasma cutting capability are particularly prone to electromagnetic interference problems and often utilize dangerous voltages and currents. All machines must have electrical components grounded and attached to an earth ground, regardless of process type (shape cutting, marking, or other material preparation).

Basic Layout

InstallatIon

The electrical ground layout is similar for both large and small machines. The chassis ground , plasma positive electrical lead and the rail ground cables are attached to a common point on the cutting table. This common connection is referred to as a star point (see illustration below). One cable connects the star point to the Earth ground rod . The size of ground cables is dependant on the maximum current output of the plasma power supply . Specication of cable sizes is discussed later in this manual. Some country standards or directives require a separate ground rod for the plasma power supply. Consult your machine schematics for more information.

6 8

Note: The three phase electrical input to the plasma power supply must include an electrical ground.

This illustration demonstrates multiple ground cables fastened with a single bolt to create a star point . The location of the star point on the cutting table will vary.

InstallatIon

Elements of a Ground System

The ground system consists of ve main components:

•plasma current return path

•plasma system safety ground

•utility power electrical ground

•cutting machine chassis ground

•rail system safety ground.

Ensure provisions are made during the installation for each of these elements for creating a complete ground system.

Plasma Current Return Path

The return path ground cable is the most important element of the ground system. It completes the path for the plasma current. Solid, low impedance, well maintained electrical connections are a necessity.

The plasma cutting current is generated by the plasma power supply . A welding cable carries this current from the negative (-) connection in the plasma power supply through the x axis cable chain to the torch. The current then arcs to the work piece on the cutting table. The current path must be closed so that the current can easily return to its source. This is done by connecting the cutting table to the positive (+) connection on the plasma power supply. If the return path ground cable is not connected, the plasma system will not work. There will be no way for the arc to establish between the torch and the work piece. If the cable is connected, but the connections have a very high resistance, it will limit the current of the arc, and cause dangerous voltage levels between system components.

InstallatIon

The only way to ensure that all components are at the same voltage level (same potential), and thus eliminate the possibility of being shocked, is to ensure that all interconnections are making good electrical contact. Good electrical contact requires that connections are made with bare metal to metal contact, the connections are very tight, and are protected from rust and corrosion. Use a grinder or wire wheel to clean all paint, rust, and dirt from the surface when connecting cable lugs to any metal surface. Use an electrical joint compound between cable lugs and metal surfaces to prevent future rust and corrosion. Use the largest size bolts, nuts, and washers possible, and tighten fully. Use lock washers to ensure that connections stay tight.

Plasma System Safety Ground

The plasma system safety ground (or ground rod) serves several important purposes. It provides:

•Frame voltage for personnel safety by ensuring

that there are no potential dierences between system components and building components.

•A stable signal reference for all digital and analog

electrical signals on the cutting machine.

•Helps control electromagnetic Interference (or

EMI).

•Provides a discharge path for short circuits and

high voltage spikes, such as those caused by lightening strikes.

InstallatIon

There are many misconceptions about the ground rod, and the role it plays in reducing electromagnetic interference. In theory, the ground rod is present to eliminate possible potential dierences between equipment and building structures. However many people believe that the ground rod allows all radio frequency noise to be absorbed and disappear into the Earth. Experience has shown that a good ground rod will eliminate radio frequency noise problems.

Misconception about Earth ground rods.

InstallatIon

In reality the ground rod is providing a low impedance path by which noise currents may return to their source .

Earth ground rod reality.

InstallatIon

Rail System Safety Ground

The rail system safety ground makes sure that the entire rail is at ground potential, eliminating any possible shock hazard, and providing backup for the machine chassis ground in case of a plasma current short circuit. All four corners of the rail system should be connected to the cutting table.

InstallatIon

Earth Ground Rod

The best way to make sure that your Earth ground connection is optimized is to enlist the services of a professional. There are a number of engineering rms which specializes in designing and installing Earth grounding systems. However, if this option cannot be used, then there are several things which can be done to ensure that your Earth ground connection is good:

Ground Rod

The ground rod itself can be optimized in two ways: length and diameter. The longer the grounding rod, the better the connection. The same is true for diameter: the larger the diameter, the better the connection. However, if the soil resistance is very low, then a ground rod longer than 3m [10 feet] does not make a signicant dierence. Since soil resistivity is rarely as good as it could be, a standard grounding rod should be 25mm [1 inch] in diameter and 6m [20 feet] long.

Soil Resistivity

Soil resistivity can be changed in two ways: by altering the mineral content, the moisture content, or both. The ideal solution to poor soil resistivity is to excavate the immediate area and backll with conditioned soil additives. In extremely dry areas, the moisture content can be improved by installing a drip system which continually moisturizes the soil surrounding the ground rod. A crude way of aecting soil moisture and content is to use salt water, or rock salt to condition the surrounding soil.

InstallatIon

Utility Power Electrical Ground

The utility power electrical ground must accompany all 3 phase and single phase power feeds. This electrical ground provides the proper reference for all incoming power. Failure to provide this ground is a violation of most electrical codes, and a serious safety hazard.

Depending on the 3 phase power arrangement (either a “Delta” or a “Y”), the line to ground voltage may be equal to, or less than the line to line voltage. A problem exists any time the line to ground voltage exceeds any individual line to line voltage (dierence in potential). Contact your local utility company if you are not sure that your 3 phase power has a proper electrical ground. Make sure that your electrical contractor properly installs the electrical ground wire with all 3 phase and single phase power feeds.

The electrical ground must be connected to the appropriate terminal inside of the plasma power supply. Size wire according to local electrical codes.

Utility Power Electrical Ground

3 Phase Electrical Supply

Plasma Power Supply

InstallatIon

Multiple Ground Rods

There are a number of reasons why multiple ground rods should not be used. While installing multiple rods may improve a safety ground or lightening ground, it oers no advantage for electromagnetic interference reduction, and can cause more problems than it is worth.

The problem with multiple ground rods is that each rod uses an “interfacing Electromagnetic Interference

1.1

Multiple ground points can also create undetectable “sneak” pathways for radio frequency noise currents, actually causing more interference! Instead of considering multiple ground rods, take steps to make the single ground rod as good a ground connection as possible.

sphere” of earth, having a radius of 1.1 times the length of the rod. Overlapping of these Electromagnetic Interference spheres causes a loss in grounding eectiveness proportional to the amount of overlap.

Multiple ground rods should be avoided if possible. However, if all other avenues have been explored to lessen your systems’ electronic interferences, multiple ground rods are an option.

Such a system should be installed by a professional and the distance between the rods should exceed

2.5 l

2.5 times the length of the rods.

InstallatIon

Machine Grounding Schematic

Main Control Enclosure

Component Enclosures

Main Star Ground

Rails

Cutting Table

System Star Ground (on Table)

Earth Ground Rod

Plasma Power Supply

Plasma Power Supply Ground (required by EU

Standards)

Electrical System Ground

(+)

•All electrical enclosures bolted to the

machine chassis

•Machine chassis grounded to star point on

cutting table.

•Rails grounded to cutting table

•Plasma ground connected to star point on

cutting table

•Earth ground rod connected to star point on

cutting table.

•A separate ground rod is required for the

plasma power supply by some regulations and directives. Check with local regulations to determine if this additional ground rod is required.

InstallatIon

Check upon receipt

1. Verify all the system components on your order have been received.

2. Inspect the system components for any physical damage that may have occurred during shipping. If

there is evidence of damage, please contact your supplier with the model number and serial number from the nameplate.

Before Installation

All installation and service of the electrical and plumbing systems

WARNING

Locate the major components to the right position prior to making electrical, gas, and interface connections. Refer to the system interconnection diagrams for major components placement. Ground all major components to earth at one point. To prevent leaks, make sure to tighten all gas and water connections with specic torque.

must conform to national and local electrical and plumbing codes. Installation should be performed only by qualied, licensed personnel. Consult your local authorities for any regulation issues.

Placement of Power Supply

Failure to follow instructions could lead to death, injury or

WARNING

damaged property. Follow these instructions to prevent injury or property damage. You must comply with local, state and national electrical and safety codes.

•A minimum of 1 meter (3 ft.) clearance on front and back for cooling air ow.

•Plan for top panel and side panels having to be removed for maintenance, cleaning and inspection.

•Locate the power supply relatively close to a properly fused electrical power supply.

•Keep area beneath power supply clear for cooling air ow.

•Environment should be relatively free of dust, fumes and excessive heat. These factors will aect cooling

eciency.

Input Power Connection

Electric shock can kill! Provide maximum protection against

WARNING

Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

electrical shock. Before any connections are made inside the machine, open the line wall disconnect switch to turn power o.

Input Conductors

•Customer needs to supply the input conductors, which may consist either of heavy rubber covered copper

conductors (three power and one ground) or run in solid or exible conduit.

•Size of input conductors is dependent on the current. Please refer to the specic power supply manual for

the size on input conductors.

InstallatIon

Input Connection Procedure

Power Input Cable Access Opening (Rear Panel)

Primary Terminals

Chassis Ground

1. Remove small rear panel of the plasma unit.

2. Thread cables through the access opening in the rear panel.

3. Secure cables with strain relief at the access opening.

4. Connect the ground lead to the stud on the chassis.

5. Connect the power leads to the primary terminals.

6. Connect the input conductors to the line (wall) disconnect.

7. Before applying power, replace the rear cover panel.

Electric shock can kill! Dangerous voltage and current may be present any time working around a plasma power source with covers removed:

WARNING

•DISCONNECT POWER SOURCE AT THE LINE (WALL) DISCONNECT.

•HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSITIVE

AND NEGATIVE) WITH A VOLTMETER.

InstallatIon

Output Connection Procedure

1. Open access panel on the lower front of the power source by removing four M6 screws.

2. Thread output cables through the openings at the bottom of the power source immediately behind the front panel.

3. Connect cables to designated terminals mounted inside the power source using UL listed pressure wire connectors.

4. Close front access panel.

Front Access

Panel Closed

Remove four M6

Front Access

Panel Opened

screws to open

Access Panel

To ease connections,

thread cables/hoses

through these 3 access holes

The plasma unit does not have an ON/OFF switch. The main power is controlled through the line (wall) disconnect switch. Optionally, an input power disconnect box (ESAB p/n 0558011541) can be used.

InstallatIon

Interface Cables/Connections

CAN Connector

This is the CAN communication bus connector. The cable from this connector is tied to the ICH/process controller.

J1 (RAS)

This is a connector for interfacing with Remote Arc Starter (RAS) unit. The cable from this connector carries signals such as: Mark Mode and Hi-Frequency ON.

Interface Cable Connectors Panel (bottom side of front panel)

Analog

Interface

CAN

J1 (RAS)

InstallatIon

Placement of RAS Box

Connections on the RAS Box

1. Remove or unlock the cover screws and lift the box cover o to expose internal components.

The cover is grounded to the Remote Arc Starter Box internally with

WARNING

2. Power cables pass through the strain relief ttings. To make the power supply connection to the RAS box,

you must rst open the unit: remove or unlock the cover screws and lift the box cover o to expose internal components.

a short ground wire. Remove cover carefully to avoid damage to the wire or loosening of the ground wire.

Pilot Arc Cable enters through strain relief tting

to Voltage Divider (VDR)

Coolant IN to Power Supply Enable

to Power Supply

Coolant OUT

Strain Relief Fittings

Power Source Cables enter through strain relief ttings

InstallatIon

Buss Bar / Block

Locking Screw

3. Strip back the insulation of the 4/0 (95 mm

4. Insert the 4/0 (95 mm block.

5. Tighten the locking screw(s) down on the cable.

) cable in the buss bar/block hole until copper extends to the edge of the buss bar /

Nomex Insulation

) cable, approximately 38 mm.

Connection for Pilot Arc Cable

NOTICE

Amperage Required # of 1/0 Cables

Up to 200 amps 1

Amperage Required # of 4/0 Cables

Up to 400 amps 1 Up to 800 amps 2

Up to 1000 amps 3

Careful attention while stripping the insulation of the 4/0 (95 mm2) cable will make installation in the buss clamp easier. Do not spread or are the copper conductors.

Note:

Chassis must be connected to the machine ground.

InstallatIon

Standard VDR Cable

VDR Cable (with free end)

6. If a non-ESAB lifter is to be used with a system the supplied VDR cable will only have a connector on

one end. The other end of the cable will have no connector. The end with the supplied connector is to be connected to the RAS box to its corresponding socket which is labeled “Voltage Divider.”

The free end of the VDR cable will be connected to the lifter. Although this is a three conductor cable, only two of the wires are used, BRN (VDR - ) and BLU (WORK). The black wire is a spare and is to be terminated and capped inside of the lifter. The corresponding pin at the RAS box comes terminated from the factory. The RAS box is not to be modied.

It is imperative that the BLUE wire be connected to ground. The BROWN wire is the VDR(-) output.

Customer

Supplied

Lifter

Ground

in Lifter is

VDR (Voltage Divider Cable)

required for

reference

InstallatIon

Torch Connections

Torch hook-up requires the connection of power cables / coolant hoses, pilot arc cable and chassis ground. On the PT-36 torch, the coolant hoses from the RAS box to the torch also carry electrode power.

The pilot arc cable is connected inside the arc starter box. The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.

Power Cable /

Coolant Connections

Pilot Arc Connection

Ground

Stud

Pilot

Arc Cable

Power Cable /

Coolant

Chassis

Ground

Wire

PG Hose

SG Hose

InstallatIon

Connection of Torch to Plasma System

DANGER

Electric Shock Can Kill!

• Disconnect primary powersourcebefore making anyadjustments.

• Disconnectprimarysourcebeforedoingmaintenanceonsystem

components.

• Donottouchfront-endtorchparts(nozzle,retainingcup,etc.)

without turning primary power o.

Ground Stud

Ground cable

Power cables

Pilot Arc cable

Connection to the Remote Arc Starter Box

The PT-36 has two water cooled power cables which must be connected to the negative output from the power supply. The right handed 7/16-20 tting is on the cable supplying coolant to the torch. The left handed 7/16-20 tting is on the cable returning coolant from the torch. Both of these cables have a green/yellow wire to be connected to the ground stud shown above.

The pilot arc cable is connected to the arc starter box (see Installation section). The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.

InstallatIon

Mounting Torch to Machine

DANGER

CLAMPING ON TORCH BODY MAY CAUSE DANGEROUS CURRENT TO FLOW THROUGH MACHINE CHASSIS.

Mount torch on insulated sleeve here

•Do not mount on stainless steel torch body.

•Torch body is electrically insulated, however high frequency

start current may arc through to nd a ground.

•Clamping near torch body may result in arcing between body

and machine.

•When this arcing occurs, torch body may require non-warranty

DO NOT mount on steel torch body here

replacement.

•Damage to machine components may result.

•Clamp only on insulated torch sleeve (directly above label) not

less than 1.25" (31.75mm) from the torch end of the sleeve.

InstallatIon

DANGER

Hydrogen explosion hazard! Read the following before attempting to cut with a water table.

A hazard exists whenever a water table is used for plasma arc cutting. Severe explosions have resulted from the accumulation of hydrogen beneath the plate being cut. Thousands of dollars in property damage has been caused by these explosions. Personal injury or death could result from such an explosion. The best available information indicates that three possible sources of hydrogen exists in water tables:

1. Molten Metal Reaction

Most of the hydrogen is liberated by a fast reaction of molten metal from the kerf in the water to form metallic ox-

ides. This reaction explains why reactive metals with greater anity for oxygen, such as aluminum and magnesium, release greater volumes of hydrogen during the cut than does iron or steel. Most of this hydrogen will come to the surface immediately, but some will cling to small metallic particles. These particles will settle to the bottom of the water table and the hydrogen will gradually bubble to the surface.

2. Slow Chemical Reaction

Hydrogen may also result from the slower chemical reactions of cold metal particles with the water, dissimilar metals,

or chemicals in the water. The hydrogen gradually bubbles to the surface.

3. Plasma Gas

Hydrogen may come from the plasma gas. At currents over 750 amps, H-35 is used as cut gas. This gas is 35% hydro-

gen by volume and a total of about 125 cfh of hydrogen will be released.

Regardless of the source, the hydrogen gas can collect in pockets formed by the plate being cut and slats on the

table, or pockets from warped plate. There can also be accumulation of hydrogen under the slag tray or even in the air reservoir, if these are part of the table design. The hydrogen, in the presence of oxygen or air, can then be ignited by the plasma arc or a spark from any source.

4. Follow these practices to reduce hydrogen generation and accumulation:

A. Clean the slag (especially ne particles) from the bottom of the table frequently. Rell the table with clean water. B. Do not leave plates on the table overnight or a weekend. C. If a water table has been unused for several hours, vibrate it in some way before the rst plate is laid in position.

This will allow accumulated hydrogen in the refuse to break loose and dissipate before it is conned by a plate on the table. This might be accomplished by laying the rst plate onto the table with a slight jolt, then raising

the plate to permit hydrogen to escape before it is nally set down for cutting. D. If cutting above water, install fans to circulate air between the plate and the water surface. E. If cutting underwater, agitate the water under the plate to prevent accumulation of hydrogen. This can be done

by aerating the water using compressed air. F. If possible, change the level of the water between cuts to dissipate accumulated hydrogen. G. Maintain pH level of the water near 7 (neutral). This reduces the rate of chemical reaction between water and

metals.

InstallatIon

WARNING

Possible explosion hazard from plasma cutting aluminum-lithium alloys!

Aluminum-Lithium (Al-Li) alloys are used in the aerospace industry because of 10% weight savings over conventional aluminum alloys. It has been reported that molten Al-Li alloys can cause explosions when they come into contact with water. Therefore, plasma cutting of these alloys should not be attempted in the presence of water. These alloys should only be dry cut on a dry table. Alcoa has determined that "dry" cutting on a dry table is safe and gives good cutting results. DO NOT dry cut over water. DO NOT water injection cut.

The following are some of the Al-Li alloys currently available: Alithlite (Alcoa) X8192 (Alcoa) Alithally (Alcoa) Navalite (U. S. Navy) 2090 Alloy (Alcoa) Lockalite (Lockheed) X8090A (Alcoa) Kalite (Kaiser) X8092 (Alcoa) 8091 (Alcan)

For additional details and information on the safe use from the hazards associated with these alloys, contact your aluminum supplier.

WARNING

Oil And Grease Can Burn Violently!

• Neveruseoilorgreaseonthistorch.

• Handletorchcleanhandsonlyoncleansurface.

• Usesiliconelubricantonlywheredirected.

• Oilandgreaseareeasilyignitedandburnviolentlyinthepresenceofoxygenunderpressure.

WARNING

Hydrogen explosion hazard.

Do Not Cut Underwater With H-35! Dangerous buildup of hydrogen gas is possible in the water table. Hydrogen gas is extremely explosive. Reduce the water level to 4 inches minimum below the workpiece. Vibrate plate, stir air and water frequently to prevent hydrogen gas buildup.

Spark hazard.

Heat, spatter, and sparks cause re and burns.

• Donotcutnearcombustiblematerial.

• Donotcutcontainersthathaveheldcombustibles.

• Donothaveonyourpersonanycombustibles(e.g.butanelighter).

• Pilotarccancauseburns.Keeptorchnozzleawayfromyourselfandotherswhenactivatingplasmaprocess.

• Wearcorrecteyeandbodyprotection.

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

• Wearame-retardantclothingthatcoversallexposedareas.

• Wearcuesstrouserstoprevententryofsparksandslag.

WARNING

InstallatIon

Preparing to Cut

•Select an appropriate condition from the Cut Data manual (SDP File) and install recommended torch

front-end parts (nozzle, electrode, etc.) See Cut Data manual to identify parts and settings.

•Position torch over material at desired start location.

•See Power Source Manual for proper settings.

•See Description and Installation sections for gas control and startup procedures.

Mirror Cutting

When mirror cutting, a reverse swirl gas bae and reverse diuser are required. These reverse parts will “spin” the gas in the opposite direction, reversing the “good” side of the cut.

Reverse 4 x .032 Bae P/N 0558002534 Reverse 8 x .047 Bae P/N 0558002530

Reverse Diuser P/N 0004470115

Cut Quality

Causes aecting cut quality are interdependent. Changing one variable aects all others. Determining a solution may be dicult. The following guide oers possible solutions to dierent undesirable cutting results. To begin select the most prominent condition:

•Cut Angle, negative or positive

•Cut Flatness

•Surface Finish

•Dross

•Dimensional Accuracy

Usually the recommended cutting parameters will give optimal cut quality, occasionally conditions may vary enough that slight adjustments will be required. If so:

•Make small incremental adjustments when making corrections.

•Adjust Arc Voltage in 5 volt increments, up or down as required.

•Adjust cutting speed 5% or less as required until conditions improve.

Before attempting ANY corrections, check cutting variables with the

CAUTION

Cut Angle

Negative Cut Angle

Top dimension is greater than the bottom.

factory recommended settings/consumable part numbers listed in Cut Data manual.

•Misaligned torch

InstallatIon

•Bent or warped material

•Worn or damaged consumables

•Stando low (arc voltage)

•Cutting speed slow (machine travel rate)

Positive Cut Angle

Top dimension is less than the bottom dimension.

•Misaligned torch

•Bent or warped material

•Worn or damaged consumables

•High stando High (arc voltage)

•Cutting speed fast

•Current high or low. (See Cut Data manual for

recommended current level for specic nozzles).

Drop

Part

100

Drop

Part

ESAB M3 Plasma G2 Plasma System - ICH Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety

Safety - English

Safety - Spanish

Safety - French

System Diagrams

system diagrams

G2 Plasma System - ICH EPP-202/362 Interconnect Diagram

Descriptions

Power Supplies

380/400V Power Supplies 460/575V Power Supplies

380/400V Power Supplies 460/575V Power Supplies

Interface Control Hub (ICH)

ICH Mounting Dimensions

CNC Direct Board

Shield Gas Box

Plumbing Schematic

Electrical Schematic

Connections

Troubleshooting

Replacement Parts

Plasma Gas Box

Plumbing Schematic

Electrical Schematic

Connections

Troubleshooting

Replacement Parts

Remote Arc Starter (RAS)

Remote Arc Starter Connections

RAS Box Mounting Dimensions

RAS Box Mounting Plate Dimensions

Air Curtain (A/C)

Water Injection Control (WIC)

Automatic Height Control (AHC)

B4 Mounting Dimensions

Hoses and Cables

PT-36 Mechanized Plasmarc Cutting Torch

Package Options Available

Optional Accessories

PT-36 Torch Consumable Kits

Recommended Regulators

Replacement Parts

Installation

Grounding

Introduction

Grounding Overview

Basic Layout

Elements of a Ground System

Plasma Current Return Path

Plasma System Safety Ground

Rail System Safety Ground

Earth Ground Rod

Ground Rod

Soil Resistivity

Utility Power Electrical Ground

Multiple Ground Rods

Machine Grounding Schematic

Check upon receipt

Before Installation

Placement of Power Supply

Input Power Connection

Input Conductors

Input Connection Procedure

Output Connection Procedure

Interface Cables/Connections

Placement of RAS Box

Connections on the RAS Box

Torch Connections

Connection of Torch to Plasma System

Connection to the Remote Arc Starter Box

Mounting Torch to Machine

Preparing to Cut