Integrated Gas Control (IGC) System
®
Instruction Manual
Date: Oct12
Part Number: 0558010296
Language: EN
Integrated Gas Control (IGC) System
Revision History:
•2011 - Original Release
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating, and maintaining this equipment.
The purchaser is responsible for the safe
operation and use of all products purchased,
including compliance with all applicable
standards in the country of use. See standard
ESAB terms and conditions of sale for a specic
statement of ESAB’s responsibilities and
limitations on liability.
This manual is ESAB part number 0558010296.
Information in this document is subject to change
without notice. This manual is for the convenience
and use of the cutting machine purchaser. It is not a
contract or any obligation on the part of ESAB Global
Cutting Technology.
ESAB Global Cutting Technology, 2011
Preface
This product was designed to provide years of
dependable, accurate, repeatable part cutting, with
a high degree of reliability and ease of operation.
There are optional features and congurations
available which may or may not be included in this
manual. In addition, more capabilities and features
may be added in the future, which are not covered
in this manual. ESAB Global Cutting Technology
reserves the right to change or add features and
capabilities without notice. Before operating the
machine, one should become familiar with this
manual in its entirety, with special attention to the
SAFETY section.
2
Integrated Gas Control (IGC) System
Table of Contents
SAFETY
1.0 Safety .......................................................................................................................................................... 11
Introduction ........................................................................................................................................................................................ 11
Safety - English ................................................................................................................................................................................... 12
Safety - Spanish ..................................................................................................................................................................................16
Safety - French ....................................................................................................................................................................................20
DESCRIPTION
2.0 System Diagrams ........................................................................................................................................27
Base System .........................................................................................................................................................................................28
Base System + AHC ........................................................................................................................................................................... 29
Base System + ACC ...........................................................................................................................................................................30
Base System + WIC ............................................................................................................................................................................31
Base System + AHC + WIC .............................................................................................................................................................. 32
Base System + AHC + ACC ..............................................................................................................................................................33
Base System + WIC + ACC ..............................................................................................................................................................34
Base System + AHC + WIC + ACC .................................................................................................................................................35
2.1 Power Supply ..............................................................................................................................................36
380/400V Power Supplies ............................................................................................................................................................... 36
460/575V Power Supplies ............................................................................................................................................................... 37
2.2 Coolant Circulator (CC-11) �������������������������������������������������������������������������������������������������������������������������38
Specications ...................................................................................................................................................................................... 38
2.3 Interface Control Hub (ICH) .......................................................................................................................39
Specications ...................................................................................................................................................................................... 39
ICH Mounting Dimensions .............................................................................................................................................................39
CNC Direct Board ..............................................................................................................................................................................40
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Integrated Gas Control (IGC) System
2.4 Combined Gas Control (CGC) .....................................................................................................................41
Specications ...................................................................................................................................................................................... 41
CGC Flow Diagram ............................................................................................................................................................................ 42
CGC Mounting Dimensions ........................................................................................................................................................... 43
CGC Bottom View ..............................................................................................................................................................................43
2.5 Power Distribution Box (PDB) .................................................................................................................. 44
Specications ......................................................................................................................................................................................44
PDB Mounting Dimensions............................................................................................................................................................44
PDB Mounting Plate Dimensions .................................................................................................................................................45
PDB Schematic ................................................................................................................................................................................... 45
2.6 Remote Arc Starter (RAS) .......................................................................................................................... 46
Specications ......................................................................................................................................................................................46
Remote Arc Starter Connections .................................................................................................................................................46
RAS Box Mounting Dimensions ...................................................................................................................................................47
RAS Box Mounting Plate Dimensions ........................................................................................................................................ 47
2.7 PT-36 Plasma Torch ................................................................................................................................... 48
Specications ......................................................................................................................................................................................48
2.8 Air Curtain Control (ACC) ...........................................................................................................................49
Specications ...................................................................................................................................................................................... 49
ACC Mounting Dimensions ............................................................................................................................................................50
ACC Component Connections ......................................................................................................................................................50
2.9 Water Injection Control (WIC) ...................................................................................................................51
Specications ...................................................................................................................................................................................... 51
2.10 Automatic Height Control (AHC) .............................................................................................................52
Specications ...................................................................................................................................................................................... 52
B4 Mounting Dimensions ............................................................................................................................................................... 53
4
Integrated Gas Control (IGC) System
INSTALLATION
3.0 Grounding ...................................................................................................................................................57
Introduction ........................................................................................................................................................................................ 57
Grounding Overview ....................................................................................................................................................................... 58
Basic Layout ........................................................................................................................................................................................59
Elements of a Ground System .......................................................................................................................................................60
Plasma Current Return Path ..........................................................................................................................................................60
Plasma System Safety Ground ...................................................................................................................................................... 61
Rail System Safety Ground ............................................................................................................................................................. 64
Earth Ground Rod ............................................................................................................................................................................. 65
Ground Rod ......................................................................................................................................................................................... 65
Soil Resistivity ..................................................................................................................................................................................... 65
Utility Power Electrical Ground ....................................................................................................................................................66
Multiple Ground Rods .....................................................................................................................................................................67
Machine Grounding Schematic....................................................................................................................................................68
3.1 Placement of Power Supply .......................................................................................................................69
Input Power Connection ................................................................................................................................................................69
Input Conductors .............................................................................................................................................................................. 69
Input Connection Procedure ........................................................................................................................................................70
Output Connection Procedure .....................................................................................................................................................70
Interface Cables/Connections.......................................................................................................................................................71
3.2 Placement of CC-11 Coolant Circulator .....................................................................................................72
Input Power Connection ................................................................................................................................................................72
Coolant Connections and Optional Equipment ..................................................................................................................... 73
3.3 Placement of RAS Box ................................................................................................................................ 74
Connections on the RAS Box ........................................................................................................................................................74
3.4 Torch Connections ...................................................................................................................................... 76
3.5 Mounting Torch to Machine .....................................................................................................................77
3.6 Placement of ICH ........................................................................................................................................78
5
Integrated Gas Control (IGC) System
3.7 Placement of PDB .......................................................................................................................................78
3.8 Placement of CGC .......................................................................................................................................78
Individual Component Connections .......................................................................................................................................... 79
ACC Component Connections ......................................................................................................................................................80
Component Placement Example .................................................................................................................................................81
OPERATION
4.0 Interface Control Hub ................................................................................................................................85
4.1 Operation ....................................................................................................................................................87
ICH Connectors .................................................................................................................................................................................. 87
Display Screens .................................................................................................................................................................................. 88
Editing a Parameter on the Display ............................................................................................................................................88
Setup Descriptions............................................................................................................................................................................ 91
Communication Options ................................................................................................................................................................ 92
Station Options .................................................................................................................................................................................. 93
Digital I/O ............................................................................................................................................................................................. 95
Digital Inputs ...................................................................................................................................................................................... 95
Digital Outputs...................................................................................................................................................................................95
4.2 Modes of Operation: ................................................................................................................................. 96
Remote Interface without Serial Communication ................................................................................................................. 96
Operation sequence with ESAB supplied plasma lifter: ......................................................................................................98
Operation sequence with customer supplied plasma lifter: ............................................................................................100
Remote Interface with Serial Communication ...................................................................................................................... 101
Local Interface - Diagnostics Only ............................................................................................................................................. 102
Operation sequence: ......................................................................................................................................................................103
Interface Wiring Descriptions .....................................................................................................................................................105
Interface Wiring ...............................................................................................................................................................................105
4.3 Maintenance/Troubleshooting ...............................................................................................................109
Communication Problems ...........................................................................................................................................................109
Digital Input Problems ..................................................................................................................................................................109
Digital Output Problems ...............................................................................................................................................................109
6
Integrated Gas Control (IGC) System
Gas Problems ....................................................................................................................................................................................109
Power Supply Problems ................................................................................................................................................................ 109
Error Messages on the ICH Display ........................................................................................................................................... 110
Process Errors .....................................................................................................................................................................................111
Communication Errors .................................................................................................................................................................. 112
APPENDIX
ESAB Serial Communication Interface .......................................................................................................... 117
Introduction ...................................................................................................................................................................................... 117
System Requirements .................................................................................................................................................................... 117
Installation ......................................................................................................................................................................................... 118
Operation ........................................................................................................................................................................................... 121
ICH Serial Communication Protocol ..............................................................................................................132
Commands ........................................................................................................................................................................................132
ICH Communication Errors ..........................................................................................................................................................139
ICH Login Sequence .......................................................................................................................................................................139
ICH Communication Error Messages ........................................................................................................................................140
ICH Parameter Loading ................................................................................................................................................................. 143
PT-36 Mechanized Plasmarc Cutting Torch ..................................................................................................144
Package Options Available .........................................................................................................................................................14 4
Optional Accessories ...................................................................................................................................................................... 144
PT-36 Torch Consumable Kits ......................................................................................................................................................145
Recommended Regulators ..........................................................................................................................................................148
Connection of Torch to Plasma System ...................................................................................................................................149
Connection to the Remote Arc Starter Box ............................................................................................................................ 149
Mounting Torch to Machine ...................................................................................................................................................... 150
Preparing to Cut...............................................................................................................................................................................153
Torch Front End Disassembly ......................................................................................................................................................159
Assembly of Torch Front End ......................................................................................................................................................162
Assembly of Torch Front End using the Speedloader ........................................................................................................163
Torch Front End Disassembly (for Production Thick Plate) ...............................................................................................164
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Integrated Gas Control (IGC) System
Assembly of Torch Front End (for Production Thick Plate) ...............................................................................................167
Torch Body Maintenance ...........................................................................................................................................................169
Removal and Replacement of the Torch Body ......................................................................................................................170
Reduced Consumable Life ........................................................................................................................................................ 172
Checking for Coolant Leaks ......................................................................................................................................................... 173
8
SAFETY
SAFETY
DESCRIPTION INSTALLATION OPERATION APPENDIX
Be sure this information reaches the operator.
SAFETY
SAFETY
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
10
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
SAFETY
SAFETY
1.0 Safety
Introduction
ESAB cutting machines are designed to operate
both safely and eectively. Sensible attention
to operating procedures, precautions, and safe
practices is required to achieve a full measure of
usefulness. Whether an individual is involved with
operation, servicing, or as an observer, compliance
with established precautions is mandatory. Failure
to observe precautions could result in equipment
damage, serious injury, or death. The following
precautions are guidelines when working with
cutting machines and associated equipment. More
explicit precautions are found within the instruction
literature. For specic safety information, obtain and
read publications listed in Recommended References.
The following words and symbols are used
throughout this manual to indicate dierent levels of
required safety involvement:
DANGER
WARNING
CAUTION
Used to call attention to high risk hazards,
which if not avoided, will result in death or
serious injury.
Used to call attention to medium risk
hazards, which if not avoided, could result
in death or serious injury.
Used to call attention to low risk hazards,
which if not avoided, could result in minor
or moderate injury.
Used to call attention to important
information not directly related to
safety hazards or could potentially cause
equipment damage.
11
SAFETY
SAFETY
Safety - English
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, cuess 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 me tal can lodge in rolled up sleeves,
trouser cus, 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 conned, or if there is
danger of falling.
12
SAFETY
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 everything dr y, 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 conned 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 specic 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 eects 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 specic ventilation recommendations.
13
SAFETY
5. WARNING: This product, when used for welding
SAFETY
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 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause
injury or death. Therefore:
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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.
14
SAFETY
MEANING OF SYMBOLS - As used throughout this manual: Means Attention! Be Alert! Your
safety is involved.
SAFETY
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 IP23S 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
CAUTION
If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or signicant damage to equipment is possible.
CAUTION
CAUTION
To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.
Maximum
Tilt Allowed
15°
15
SAFETY
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:
1. Remueva todo material combustible lejos del área de
trabajo o cubra los materiales con una cobija a prueba de
fuego. Materiales combustibles incluyen madera, ropa,
líquidos y gases amables, solventes, pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en las
grietas y agujeros de pisos y paredes causando fuegos
escondidos en otros niveles o espacios. Asegúrese de
que toda grieta y agujero esté cubierto para proteger
lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado
hasta que la pieza de trabajo esté totalmente limpia y
libre de substancias que puedan producir gases inamables o vapores tóxicos. No trabaje dentro o fuera de
contenedores o tanques cerrados. Estos pueden explotar
si contienen vapores inamables.
4. Tenga siempre a la mano equipo extintor de fuego para
uso instantáneo, como por ejemplo una manguera con
agua, cubeta con agua, cubeta con arena, o extintor
portátil. Asegúrese que usted esta entrenado para su
uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en los
cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione
el área de trabajo para cerciorarse de que las chispas o
metal caliente ocasionen un fuego más tarde. Tenga
personal asignado para vigilar si es necesario.
7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of
Cutting and Welding Processes", disponible a través de la
National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo
o muerte. NO use so ldadura de corriente
alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos
o si hay posibilidad de caer al suelo.
16
SAFETY
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. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas 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 especícas en la ventilación.
17
SAFETY
5. ADVERTENCIA-- Este producto cuando se utiliza
SAFETY
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 modique 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 cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.
18
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
Signican ¡Atención! ¡Esté Alerta! Se trata de su seguridad.
Signica riesgo inmediato que, de no ser evadido, puede resultar inmediata-
PELIGRO
mente en serio daño personal o la muerte.
SAFETY
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 IP23S se puede
almacenar, pero no se debe usar en el exterior durante periodos de precipitaciones a menos que esté protegido.
ADVERTENCIA
Signica el riesgo de un peligro potencial que puede resultar en serio daño
personal o la muerte.
Signica 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 supercie 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°
19
SAFETY
Safety - French
SAFETY
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.
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 an 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 an 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
ininammable an 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 ininammable.
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.
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de précaution provenant des références dans
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.
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 susamment tous les matériaux combustibles
de l'aire de travail et recouvrez les matériaux avec un
revêtement protecteur ininammable. Les matériaux
combustibles incluent le bois, les vêtements, la sciure, le
gaz et les liquides combustibles, les solvants, les peintures
et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent
peuvent tomber dans les ssures dans les planchers ou
dans les ouvertures des murs et déclencher un incendie
couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal
incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à
chaud avant d'avoir complètement nettoyé la surface de
la pièce à traiter de façon à ce qu'il n'ait aucune substance
présente qui pourrait produire des vapeurs inammables
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'extinction 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 surchauer 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.
20
SAFETY
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 an 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 eectuer 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
spéciques 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 eets 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'eectuez 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 ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 an
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 spéciques
concernant la ventilation.
21
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 Jeerson Davis
Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
SAFETY
1. Eorcez-vous de toujours coner les tâches d'installation,
de dépannage et d'entretien à un personnel qualié.
N'eectuez aucune réparation électrique à moins d'être
qualié à cet eet.
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'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA
SÉCURITÉ -- Pour obtenir de l'information
supplémentaire sur les règles de sécurité à
observer pour l'équipement de soudage à
l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for
Arc Welding, Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc
Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc
Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon
Arc Gouging and Cutting”.
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.
22
SAFETY
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel, signie "Attention" ! Soyez vigilant ! Votre sécurité
est en jeu.
SAFETY
DANGER
AVERTISSEMENT
ATTENTION
Classe de protection de l’enveloppe
L’indice de protection (codication 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 IP23S 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
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
Signie 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 an d’éviter de vous blesser ou
d’endommager l’équipement.
Angle
d’inclinaison
maximal
15°
23
SAFETY
SAFETY
24
DESCRIPTION
SAFETY
DESCRIPTION
INSTALLATION OPERATION APPENDIX
DESCRIPTION
Below are some abbreviations used throughout this manual.
ABBREVIATIONS:
A/C - Air Curtain
ACC - AIR Curtain Control
AHC - Automatic Height Control
DESCRIPTION
CGC - Combined Gas Control
ICH - Interface Control Hub
IGC - Integrated Gas Control
PDB - Power Distribution Box
RAS - Remote Arc Starter
WIC - Water Injection Control
26
2.0 System Diagrams
DESCRIPTION
The following pages illustrate dierent system congurations available on the Integrated Gas Control (IGC) System. With this system, ESAB oers 8 dierent congurations to meet customer’s requirements. Below are the
descriptions of each conguration.
1. Base System
This system is the basic conguration for the IGC Plasma System. It contains the major components, such as the
Power Supply (EPP201/360/450/601), Coolant Circulator, PT-36 Torch, Remote Arc Starter (RAS), Combined Gas
Control (CGC), Power Distribution Box (PDB), 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 conguration, 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 + ACC
This system includes the above Base System and ESAB Air Curtain Control (ACC). 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 congured to introduce the Water Injection Control (WIC), a module used to regulate cut water ow
to shield the cutting process. This conguration 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 dierent 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 + ACC
This system gives the customer the ability to cut under water with ESAB Automatic Height Control (AHC).
7. Base System + WIC + ACC
This system is the Base System adding Water Injection Control (WIC) and Air Curtain Control (ACC). Customer needs
to provide their own Height Control and control its sequence.
8. Base System + AHC + WIC + ACC
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 Control (ACC).
DESCRIPTION
27
Base
System
R
0558010538-OR
PT-36 Torch
Shield Gas Hose
DESCRIPTION
CGC-SG
Plasma Gas Hose
CGC-PG
Phone 1-843-664-5550
Email: oemplasma@esab.com
AHC
(Automatic Height Control)
AHC-VDR
RAS-VDR
Power, Pilot Arc, Coolant
CGC-PWR
PDB-PWR1
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
PDB
CGC-N2/Air
(Power
Distribution Box)
CGC
(Combined Gas Control)
CGC-CAN
RAS
Interconnect Diagram
Integrated Gas Control System
R
RAS-E(-)
RAS-PSC
RAS-PA
RAS-TC IN
RAS-TC OUT
(Remote Arc Starter)
RAS-CAN
RAS-ESTOP
PDB-AC IN
ICH-GAS-PWR
ICH-RAS-CAN
ICH-CGC-CAN
BOLD FONT = Cable Connection Label
ICH
(Interface Control Hub)
28
Base System
Power Cable
Pilot Arc Cable
Work Table
PS & CC Control Cable
PS-PSC
PS(-)
PS-PA
PS-W
PS
R
(Power Supply)
{
THREE
PHASE
POWER
Coolant Return Hose
Coolant Supply Hose
PS-IC
CC-IC
CC-TC OUT
CC-TC IN
CC
(Coolant Circulator)
{
PHASE
SINGLE
CNC-ESTOP
POWER
ICH-CNC
CNC-IO
CNC
ICH-PWR IN
CNC-PWR
Customer Supplied
LIQUID
GAS
POWER
DATA
AHC
R
0558010536-OR
PT-36 Torch
DESCRIPTION
Interconnect Diagram
Integrated Gas Control System
R
AHC-VDR
RAS-VDR
RAS-E(-)
RAS-PSC
AHC
(Automatic
Height Control)
AHC-AC IN
RAS-PA
AHC-CAN
RAS-TC IN
RAS-TC OUT
Power, Pilot Arc, Coolant
RAS
AHC Input Power
(Remote Arc Starter)
RAS-CAN
RAS-ESTOP
CAN BUS
CGC-PWR
PDB-PWR1
PDB-
PDB-AC IN
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
PDB
A/C
CTRL
ICH-AUX
ICH-GAS-PWR
ICH-AHC-CAN
ICH-AHC-PWR
ICH-RAS-CAN
Shield Gas Hose
CGC-SG
CGC-N2/Air
(Power
Distribution Box)
Plasma Gas Hose
CGC-PG
CGC
(Combined Gas Control)
CGC-CAN
ICH-CGC-CAN
ICH
(Interface Control Hub)
Phone 1-843-664-5550
Email: oemplasma@esab.com
BOLD FONT = Cable Connection Label
Base System + AHC
Power Cable
Pilot Arc Cable
Work Table
PS & CC Control Cable
PS-PSC
PS(-)
PS-PA
PS-W
PS
R
(Power Supply)
{
THREE
PHASE
POWER
Coolant Return Hose
Coolant Supply Hose
PS-IC
CC-IC
CC-TC OUT
CC-TC IN
CC
(Coolant Circulator)
{
PHASE
SINGLE
CNC-ESTOP
POWER
ICH-CNC
CNC-IO
CNC
ICH-PWR IN
CNC-PWR
Customer Supplied
LIQUID
GAS
POWER
DATA
29
R
0558010537-OR
ACC
-PWR
-PWR1
Air Curtain Hose
CGC-A/C OUT
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
Shield Gas Hose
CGC-SG
CGC-N2/Air
ACC
CGC
-A/C
DESCRIPTION
AHC
(Automatic Height Control)
Power, Pilot Arc, Coolant
AHC-VDR
CGC
PDB
RAS-VDR
Air Curtain
PT-36 Torch
CGC-PG
CGC
(Combined Gas Control)
-A/C IN
OUT
Phone 1-843-664-5550
Email: oemplasma@esab.com
Plasma Gas Hose
CGC-CAN
Interconnect Diagram
Integrated Gas Control System
R
R
RAS-E(-)
RAS-PSC
Power Cable
PS & CC Control Cable
PS-PSC
PS(-)
PS
(Power Supply)
RAS-PA
Pilot Arc Cable
PS-PA
Work Table
PS-W
RAS
(Remote Arc Starter)
RAS-TC IN
Coolant Supply Hose
RAS-CAN
RAS-ESTOP
RAS-TC OUT
Coolant Return Hose
PS-IC
CC-IC
CC-TC OUT
CC-TC IN
CC
(Coolant Circulator)
PDB-AC IN
(Power
PDB
Distribution Box)
PDB-
A/C
CTRL
PDB-A/C1
ICH-AUX
ICH-GAS-PWR
ICH-RAS-CAN
CNC-ESTOP
ACC-IN
ACC
ACC-AIR
ICH-CNC
CNC-IO
CNC
(Air Curtain Control)
ICH-CGC-CAN
BOLD FONT = Cable Connection Label
ICH
(Interface Control Hub)
Customer Supplied
ICH-PWR IN
LIQUID
CNC-PWR
POWER
GAS
DATA
30
Base System + ACC
THREE
PHASE
{
POWER
{
PHASE
SINGLE
POWER
R
0558010535-OR
WIC
AHC
(Automatic
AHC-VDR
RAS-VDR
Height Control)
BPR
BPR-H2O
(Back
Pressure
BPR-SG
BPR-SG/H2O
Regulator)
OUT
WIC-H2O
CGC-SG
Shield Gas Hose
CGC-PWR
CGC-N2/Air
PDB-PWR1
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
PT-36 Torch
Plasma Gas Hose
CGC-PG
CGC
(Combined Gas Control)
CGC-CAN
DESCRIPTION
Phone 1-843-664-5550
Email: oemplasma@esab.com
Interconnect Diagram
Integrated Gas Control System
R
R
RAS-E(-)
RAS-PSC
Power Cable
PS & CC Control Cable
PS-PSC
PS(-)
PS
(Power Supply)
RAS-PA
Pilot Arc Cable
PS-PA
Work Table
PS-W
RAS
(Remote Arc Starter)
RAS-TC IN
Coolant Supply Hose
RAS-CAN
RAS-ESTOP
RAS-TC OUT
Coolant Return Hose
PS-IC
CC-IC
WIC-AC-IN
CC-TC OUT
CC-TC IN
CC
(Coolant Circulator)
WIC
(Water Injection Control)
WIC-CAN
WIC-AIR IN
WIC-H2O IN
PDB-AC IN
(Power
PDB
ICH-GAS-PWR
ICH-GAS-PWR
ICH-WIC-CAN
ICH-RAS-CAN
CNC-ESTOP
Distribution Box)
ICH-CGC-CAN
ICH-CNC
CNC-IO
CNC-WIC PWR
CNC
BOLD FONT = Cable Connection Label
ICH
(Interface Control Hub)
Customer Supplied
ICH-PWR IN
LIQUID
CNC-PWR
POWER
GAS
DATA
Base System + WIC
THREE
PHASE
{
POWER
PHASE
SINGLE
POWER
31
R
0558010532-OR
WIC
AHC
BPR
BPR-H2O
(Back
DESCRIPTION
AHC
(Automatic
Height Control)
AHC-VDR
AHC-AC IN
RAS-VDR
AHC-CAN
Power, Pilot Arc, Coolant
Pressure
Regulator)
BPR-SG
OUT
WIC-H2O
BPR-SG/H2O
CGC-SG
Shield Gas Hose
CGC
-PWR
PDB
-PWR1
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
PT-36 Torch
CGC-PG
CGC
(Combined Gas Control)
CGC-CAN
CGC-N2/Air
Plasma Gas Hose
Phone 1-843-664-5550
Email: oemplasma@esab.com
Interconnect Diagram
Integrated Gas Control System
R
R
RAS-E(-)
RAS-PSC
Power Cable
PS & CC Control Cable
PS-PSC
PS(-)
PS
(Power Supply)
RAS-PA
Pilot Arc Cable
PS-PA
Work Table
PS-W
RAS
(Remote Arc Starter)
RAS-TC IN
Coolant Supply Hose
RAS-CAN
RAS-ESTOP
RAS-TC OUT
Coolant Return Hose
AHC Input Power
PS-IC
CC-IC
CAN BUS
CC-TC OUT
CC-TC IN
WIC
(Water Injection Control)
WIC-CAN
WIC-AC-IN
WIC-AIR IN
WIC-H2O IN
CC
(Coolant Circulator)
PDB
-AC IN
(Power
PDB
Distribution Box)
ICH-GAS-PWR
ICH-WIC-CAN
ICH-AHC-CAN
ICH-AHC-PWR
ICH-RAS-CAN
CNC-ESTOP
ICH-CGC-CAN
ICH-CNC
CNC-IO
CNC-WIC PWR
CNC
BOLD FONT = Cable Connection Label
ICH
(Interface Control Hub)
ICH-PWR IN
CNC-PWR
Customer Supplied
LIQUID
POWER
GAS
DATA
32
Base System + AHC + WIC
THREE
PHASE
{
POWER
{
PHASE
POWER
SINGLE
R
0558010533-OR
ACC
AHC
AHC
(Automatic
AHC-VDR
AHC-AC IN
RAS-VDR
Height Control)
AHC-CAN
Power, Pilot Arc, Coolant
CGC
PDB
-PWR
-PWR1
Air Curtain Hose
CGC-A/C OUT
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
Shield Gas Hose
CGC-SG
CGC-N2/Air
ACC
CGC
(Combined Gas Control)
CGC
-A/C IN
-A/C
OUT
Air Curtain
PT-36 Torch
Plasma Gas Hose
CGC-PG
CGC-CAN
DESCRIPTION
Phone 1-843-664-5550
Email: oemplasma@esab.com
Interconnect Diagram
Integrated Gas Control System
R
R
RAS-E(-)
RAS-PSC
Power Cable
PS & CC Control Cable
PS-PSC
PS(-)
PS
(Power Supply)
RAS-PA
Pilot Arc Cable
PS-PA
Work Table
PS-W
RAS
(Remote Arc Starter)
RAS-TC IN
Coolant Supply Hose
RAS-CAN
RAS-ESTOP
RAS-TC OUT
Coolant Return Hose
AHC Input Power
PS-IC
CC-IC
Can Bus
CC-TC OUT
CC-TC IN
CC
PDB-AC IN
(Coolant Circulator)
(Power
PDB
Distribution Box)
PDB-
A/C
CTRL
PDB-A/C1
ACC-IN
ICH-AUX
ICH-GAS-PWR
ICH-AHC-CAN
ICH-AHC-PWR
ICH-RAS-CAN
CNC-ESTOP
ACC
ACC-AIR
ICH-CNC
CNC-IO
CNC
(Air Curtain Control)
ICH-CGC-CAN
BOLD FONT = Cable Connection Label
ICH
(Interface Control Hub)
Customer Supplied
ICH-PWR IN
LIQUID
CNC-PWR
POWER
GAS
DATA
Base System + AHC + ACC
THREE
PHASE
{
POWER
{
PHASE
POWER
SINGLE
33
R
0558010534-OR
WIC
ACC
BPR-A/C
(Back
BPR
Pressure
Regulator)
BPR
DESCRIPTION
BPR-A/C
BPR-H2O
BPR-SG
-SG/H2O
Air Curtain Hose
Shield Gas Hose
Air Curtain
PT-36 Torch
Phone 1-843-664-5550
Email: oemplasma@esab.com
Interconnect Diagram
Integrated Gas Control System
R
AHC
(Automatic Height Control)
AHC-VDR
RAS-VDR
RAS-PA
RAS-E(-)
RAS-PSC
Power, Pilot Arc, Coolant
RAS
(Remote Arc Starter)
RAS-TC IN
RAS-ESTOP
RAS-TC OUT
OUT
WIC-H2O
RAS-CAN
WIC-AC-IN
WIC-CAN
WIC-H2O IN
CGC-SG
CGC-A/C OUT
CGC
-PWR
WIC
(Water Injection Control)
PDB
-PWR1
WIC-AIR IN
PDB-AC IN
CGC-N2/Air
CGC-O2/H35/F5
(Power
PDB
Distribution Box)
PDB-
A/C
CTRL
CGC-Ar
CGC-N2/Air
PDB-A/C1
ICH-AUX
ICH-GAS-PWR
ICH-WIC-CAN
ICH-RAS-CAN
CGC
(Combined Gas Control)
CGC
-A/C IN
ACC
(Air Curtain Control)
ACC-IN
ACC-AIR
Plasma
Gas Hose
CGC
-PG
CGC-CAN
ICH-CGC-CAN
ICH
(Interface Control Hub)
BOLD FONT = Cable Connection Label
34
Base System + WIC + ACC
Power Cable
Pilot Arc Cable
Work Table
PS & CC Control Cable
PS-PSC
PS(-)
PS-PA
PS-W
PS
R
(Power Supply)
{
THREE
PHASE
POWER
Coolant Return Hose
Coolant Supply Hose
PS-IC
CC-IC
CC-TC OUT
CC-TC IN
CC
(Coolant Circulator)
{
PHASE
POWER
SINGLE
CNC-ESTOP
ICH-CNC
CNC-IO
CNC-WIC PWR
CNC
ICH-PWR IN
CNC-PWR
Customer Supplied
LIQUID
GAS
POWER
DATA
WIC
AHC
ACC
R
AHC
(Automatic
Height Control)
BPR-A/C
BPR
BPR-A/C
BPR-H2O
(Back
Pressure
BPR-SG
Regulator)
BPR-SG/H2O
Air Curtain Hose
Shield Gas Hose
Air Curtain
PT-36 Torch
CGC
-PG
0558010531-OR
Phone 1-843-664-5550
Email: oemplasma@esab.com
Plasma
Gas Hose
DESCRIPTION
Interconnect Diagram
Integrated Gas Control System
R
AHC-VDR
RAS-VDR
RAS-E(-)
RAS-PSC
Power Cable
PS & CC Control Cable
AHC-CAN
AHC-AC IN
RAS-PA
Pilot Arc Cable
RAS-TC IN
RAS-TC OUT
Work Table
Coolant Return Hose
Coolant Supply Hose
Power, Pilot Arc, Coolant
RAS
AHC Input Power
(Remote Arc Starter)
RAS-CAN
RAS-ESTOP
WIC-H2O
CAN BUS
OUT
WIC-CAN
WIC-AC-IN
CGC-SG
CGC-A/C OUT
CGC-PWR
PDB-PWR1
WIC
(Water Injection Control)
WIC-AIR IN
WIC-H2O IN
PDB-
PDB-AC IN
CGC-Ar
CGC-N2/Air
CGC-O2/H35/F5
(Power
PDB
Distribution Box)
A/C
CTRL
ICH-AUX
ICH-GAS-PWR
ICH-WIC-CAN
ICH-AHC-CAN
ICH-AHC-PWR
ICH-RAS-CAN
CGC-N2/Air
PDB-A/C1
CGC
(Combined Gas Control)
IN
CGC
-A/C
ACC
-A/C
OUT
ACC
(Air Curtain Control)
ACC-IN
ACC-AIR
ICH-CNC
CGC-CAN
ICH-CGC-CAN
BOLD FONT = Cable Connection Label
ICH
(Interface Control Hub)
Customer Supplied
ICH-PWR IN
Base System + AHC + WIC + ACC
CC-TC OUT
PS-PSC
PS(-)
PS-PA
PS-W
PS
R
(Power Supply)
PS-IC
{
THREE
PHASE
POWER
CC-TC IN
CC-IC
CC
(Coolant Circulator)
{
PHASE
SINGLE
POWER
CNC-WIC PWR
CNC-ESTOP
CNC-IO
CNC
CNC-PWR
LIQUID
GAS
POWER
DATA
35
DESCRIPTION
400V
m3 601
50/60HZ
380V
m3 601
50/60HZ
DESCRIPTION
40 0V TAPS
380V
m3 601
50/60HZ
380V TAPS
400V
m3 450
50/60HZ
380V
m3 450
50/60HZ
40 0V TAPS
380V
m3 450
50/60HZ
380V TAPS
m3 Plasma Power Supply Input/Output Information
m3 360,
50 / 60Hz
380 / 400V,
m3 201,
50 / 60Hz
380 / 400V,
2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 4/0 AWG 4/0 AWG 4/0 AWG
360 VDC 360 VDC 430VDC 406VDC 427VDC 430VDC 406VDC 427VDC
10A to 36A 10A to 36A 10A to 100A 10A to 100A
30A to 200A 30A to 360A 35A to 450A 35A to 600A
36
2.1 Power Supply
380/400V Power Supplies
The IGC system can use dierent plasma power supplies. ESAB provides the EPP-201/360/450/601, with various input voltages and current output
for your requirements. For details about our power supplies, please refer to the power supply’s specic manual.
Input Voltage (3-Phase) 380 / 400V 380 / 400V 380VAC 380VAC 400VAC 380VAC 380VAC 400VAC
Input Current (3-Phase) 60 / 57A RMS 140 / 132A RMS 167A R MS 167A R MS 159A RMS 217A RMS 217A RMS 206A RMS
Input Frequency 50 / 60 HZ 50 / 60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ 50/60 HZ
Input KVA 39.5 KVA 91.6 KVA 109.9 K VA 109.9 KVA 11 0. 2 K VA 142.8 KVA 142.8 KVA 142.7 KVA
Input Power 35.5 K W 82.5 KW 98.9 KW 98.9 KW 99.1 KW 128 .5 KW 128 .5 KW 128. 4 KW
Input Power Factor 90.0 % 90.0 % 90% 90% 90% 90% 90% 90%
Recommended Input
Power Cable
Input Fuse (Recommended) 100A 200A 200A 200A 200A 250A 250A 250A
Output Open Circuit Voltage
(OCV) (High Range Cutting)
Output Cutting Range
(100% Duty)
Output Marking Range
(100% Duty)
Output Power (100% Duty) 32 KW 72 KW 90 KW 120 KW
Protection Class IP 21 IP 21 IP 21 IP 21
Dimensions 585 x 1040 x 1195 mm 585 x 1040 x 1195 mm 950 x 1050 x 1150 mm 950 x 1050 x 1150 mm
Input
Output
Weight 493 kg 493 kg 850 kg 850 kg
DESCRIPTION
m3 601
575V, 60HZ
m3 601
460V, 60HZ
m3 450
575V, 60HZ
m3 450
460V, 60HZ
DESCRIPTION
m3 360
575V, 60Hz
m3 Plasma Power Supply Input/Output Information
m3 360
460V, 60Hz
m3 201
575V, 60Hz
360 VDC 360 VDC 431VDC 431VDC
m3 201
460V, 60Hz
2/0 AWG 2/0 AWG 2/0 AWG 2/0 AWG 1/0 AWG 2/0 AWG 1/0 AWG 1/0 AWG
10A to 36A 10A to 36A 10A to 100A 10A to 100A
30A to 200A 30A to 360A 35A to 450A 35A to 600A
460/575V Power Supplies
Input Voltage (3-Phase) 460V 575V 460V 575V 460VAC 575VAC 460VAC 575VAC
Input Current (3-Phase) 51A RMS 41A RMS 115 A RMS 92A RMS 138A RMS 110 A RMS 179A R MS 143A R MS
Input Frequency 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ 60 HZ
Input KVA 40.6 KVA 40.6 KVA 91.6 KVA 91.6 KVA 110.0 KVA 109.6 KVA 142.6 KVA 142.4 K VA
Input Power 35.5 K W 35.5 K W 82.5 KW 82.5 KW 99.0 KW 98.6 KW 128 .4 K W 128.2 K W
Input Power Factor 90.0 % 90.0 % 90.0 % 90.0 % 90% 90% 90% 90%
Recommended Input
Power Cable
Input Fuse (Recommended) 100A 60A 150A 125A 200A 150A 250A 200A
Output Open Circuit Voltage
(OCV) (High Range Cutting)
Output Cutting Range
(100% Duty)
Output Marking Range
(100% Duty)
Output Power (100% Duty) 32 KW 72 KW 90 KW 120 KW
Protection Class IP 21 IP 21 IP 21 IP 21
Dimensions 585 x 1040 x 1195 mm 585 x 1040 x 1195 mm 950 x 1050 x 1150 mm 950 x 1050 x 1150 mm
Input
Output
Weight 493 kg 493 kg 850 kg 850 kg
37
2.2 Coolant Circulator (CC-11)
p/n 0558007515
The Coolant Circulator (CC-11) recirculates coolant to
cool the torch, electrode and nozzle. For more specific details, please refer to the CC-11 Instruction manual.
DESCRIPTION
DESCRIPTION
Specications
Dimensions: 34.00" (864 mm) high x 21.75" (552 mm) wide x 28.00 (711 mm) deep
Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg)
Pump Type:
Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.),
CW rotation as viewed from nameplate.
Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.
AC Input Voltages
AC Input Amperage 9 / 8 / 5 / 4 / 3 Amperes
Pump Capacity
Cooling Capacity @ 1.60 gpm
(6.0 l/min)
at 45° F (25° C) temperature dierence between high coolant temperature and ambient air temperature using ESAB coolant p/n 0558004297 (25% propylene glycol / 75% distilled water).
Max. Delivery Pressure 175 psig (12 bars)
Reservoir Capacity 4 gallons (15.2 liters)
50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power
200 / 230 / 400 / 460 / 575 V, + / - 10%
1.60 gpm at 175 psi
(6.0 l/min at 12 bars)
16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts)
1.60 gpm at 175 psi
(6.0 l/min at 12 bars)
38
DESCRIPTION
2.3 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 IGC plasma system. At the
same time, it functions as a hub for CAN communication.
DESCRIPTION
Specications
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 mm)
3.00”
(76.2 mm)
230 VAC, 5 Amps
120 VAC, 3 Amps
11. 50 ”
(292.1 mm)
39
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.
DESCRIPTION
40
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
X9 ASIOB1 Communication V41 IC for ASIOB1
XS1 Switches: Plasma Start, Gas Test J1
XS2
Switches: Local/Remote, Station Select and
Screen Select
EEPROM, Save data for system conguration,
error history, etc.
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
2.4 Combined Gas Control (CGC)
p/n 0558010241
The Combined Gas Control (CGC) regulates the output of the
plasma gas (PG) selected from the three plasma gas inlets (N2/
Air, O2/H35/F5 and Argon) and controls the ow of shield gas
(SG). It is powered by 24 Volts (AC and DC) from the Power Distribution Box and receives commands via the CAN-bus.
There are four gas inputs (three plasma gases, one shield gas),
two gas outputs (SG, PG), and one outboard connection (air curtain). The four inputs are tted with porous
bronze lters and "G-1/4" (BSPP) female right hand thread. Either of two adaptor tting kits are available to adapt
standard metric or CGA hose connections. The gas ttings and adaptors are listed in the following tables.
Specications
Dimensions: 8.5” (215.9 mm) long x 6.0” (152.4 mm) wide x 4.5” (114. 3 mm) high
Weight: 8.65 lbs. (3.9 kg)
Power Input: 24 VAC/DC
DESCRIPTION
Metric
Input
Adaptors
CGA
Input
Adaptors
Gas Fitting
Argon G-1/4” right hand male x G-1/4” right hand male 0558010163
Plasma
Shield N2/Air G-1/4” right hand male x G-1/4” right hand male 0558010163
Air Curtain Air G-1/4” right hand male x “B” Air/Water right hand male 0558010165
Plasma
Shield N2/Air G-1/4” right hand male x “B” Air/Water right hand male 0558010165
Air Curtain Air G-1/4” right hand male x “B” Air/Water right hand male 0558010165
Outputs
N2/Air G-1/4” right hand male x G-1/4” right hand male 0558 010163
O2/H35/F5* G-1/4” right hand male x G-1/4” right hand male 0558010163
* Another adapator is required when connecting H35/F5.
Part Number - 0558010246 (G-1/4” right hand female x G-1/4” left hand male)
Argon G-1/4” right hand male x “B” Inert Gas right hand female 0558010166
N2/Air G-1/4” right hand male x “B” Inert Gas right hand female 0558010166
O2/H35/F5* G-1/4” right hand male x “B” Oxygen right hand male 0558010167
* Another adapator is required when connecting H35/F5.
Part Number - 0558010245 (“B” Oxygen right hand female x “B” Fuel Gas left hand male)
SG 1/4” NPT x 5/8"-18 LH male 10Z30
PG 1/4” NPT x “B” Inert Gas right hand female 2064113
Air Curtain 1/8” NPT x “B” Inert Gas left hand female 08030280
ESAB
P/N
ESAB Kit p/n
0558000254
ESAB Kit p/n
0558000253
41
DESCRIPTION
When connecting fuel gas lines to the oxygen plasma gas input, or re-
CAUTION
NOTE
DESCRIPTION
Each gas has a requirement for maximum ow and pressure as shown in chart below:
Gas Pressure
Argon 125 psi (8.6 bar), 200 SCFH (5.7 SCMH)
Plasma
Shield N2/Air 125 psi (8.6 bar), 353 SCFH (10.0 SCMH)
Air Curtain Air 80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)
O2/H35/F5 125 psi (8.6 bar) for O2, 75 psi (5.2 bar) for H35/F5, 255 SCFH (7.2 SCMH)
N2/Air 125 psi (8.6 bar), 255 SCFH (7.2 SCMH)
connecting oxygen after fuel gas use, extra care must be taken to assure that all lines from input through the torch are completely purged.
It is recommended to purge the system and torch lines with nitrogen
for 60 seconds prior to reconnection, then purge the nitrogen for 60
seconds with the new supply gas before cutting.
CGC Flow Diagram
42
CGC Mounting Dimensions
p/n 0558008459
0.281
(7.1mm)
0.313”
(8.0mm)
DESCRIPTION
DESCRIPTION
4.00”
(101.6mm)
0.37”
(9.5mm)
CGC Bottom View
7.5 0 ”
(190.5mm)
4.72”
(120.0mm)
0.37”
(9.5mm)
(22.9mm)
(64.0mm)
M6
0.90”
2.52”
43
DESCRIPTION
2.5 Power Distribution Box (PDB)
p/n 0558010242
The Power Distribution Box (PDB) takes 230 VAC or
115 VAC depending on the switch setup. Outputs of
24 VDC and 24 VAC are to supply power to the Combined Gas Control (CGC). The PDB also recieves com-
DESCRIPTION
mands from the ICH via the A/C CTRL port. This is for
controlling the air curtain outputs. By default, the
PDB can control one CGC and one air curtain. If needed, a second CGC and air curtain can be controlled after putting another power block and necessary connectors inside. Power block and connectors kit part
number is 0558010247.
Specications
Dimensions: 10” (254 mm) long x 9.5” (241.3 mm) wide x 4.25” (108 mm) high
Weight: 9.0 lbs. (4.1 kg)
Input Power
Output Power 24 V AC/DC
PDB Mounting Dimensions
230 VAC, 2 Amps
115 VAC, 3 Amps
8.00”
(203.2 mm)
6.50”
(165.1 mm)
M6
44
.875”
(22.2 mm)
3.00”
(76.2 mm)
4.25”
(108.0 mm)
10.00”
(254.0 mm)
PDB Mounting Plate Dimensions
p/n 0558008794
0.281
(7.1mm)
0.313”
(8.0mm)
DESCRIPTION
DESCRIPTION
5.75”
(146.0mm)
0.50”
(12.7mm)
9.50”
(241.3mm)
PDB Schematic
From the factory, the PDB’s 230/115VAC switch is set to 230VAC. If the customer requires a dierent input voltage, then change the switch to 115 VAC.
45
DESCRIPTION
2.6 Remote Arc Starter (RAS)
p/n 0558008150
The Remote Arc Starter is more commonly referred to as
the RAS Box. The RAS box serves as an interface between
the plasma controller and the EPP family of plasma power
supplies, helping to deliver a stable plasma arc. The RAS
DESCRIPTION
box also 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 an I/O module for communicating with the plasma controller, 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.
Specications
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)
Remote Arc Starter Connections
A
B
G, H
C
D
EF
Chassis must be connected to
the machine ground.
Letter Description
A 3 Pin Voltage Divider Connection to the Lift
B 8 Pin Can Bus Connection to the CNC or Interface
C 24 Pin Amphenol Power Supply Connection
D E-Stop
E Coolant Inlet - Flowing to the Torch
Coolant Return - Flowing back to the Coolant Circu-
F
G, H Strain Relief Fittings
J
I Torch Shroud Connection
J Machine Ground Connection
Note:
lator from the Torch
46
I
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.
DESCRIPTION
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 mm)
13.75”
(349.25 mm)
18. 50"
(469.9 mm)
17. 50"
(444.5 mm)
47
2.7 PT-36 Plasma 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.
DESCRIPTION
7.54"
(191. 5 mm)
DESCRIPTION
(50.8 mm)
9.13"
(231.9 mm)
6.17"
(156.7 mm)
10.50" (266.7 mm)
Length of Sleeve
Specications
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.
2.00"
48
DESCRIPTION
2.8 Air Curtain Control (ACC)
p/n 374 4 0
DESCRIPTION
p/n 0558010243
Specications
Dimensions: 6.00” high (152.4 mm) x 9.56” wide (242.8 mm) x 2.50” deep (63.5 mm)
Weight: 4.00 lbs. (1.81 kg)
Input Power: 24 VAC
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).
49
ACC Mounting Dimensions
DESCRIPTION
9.31”
(236.5 mm)
DESCRIPTION
5.81”
(147. 6 mm)
2.91”
(74.0 mm)
1.16”
(29.5 mm)
.312” x .500”
slots
7.00”
(17 7.8 mm)
ACC Component Connections
NOTE:
Cables “A” and “B” are listed in the ACC
Component Connections, INSTALLATION
section of this manual.
A
Compressed Air
50
B
DESCRIPTION
2.9 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 CNC. 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.
Specications
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: 150o F (66o C)
1/2 HP, 230 VAC single phase, 60 Hz, 1725 RPM, 3.6A current,
Temperature rating: 150o F (66o C)
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: -40o - 257o F (-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: Orice size: 3/32”, Cv:0.14 (fully open)
Operating dierential pressure: 115 psi (8.0 bar) ; Max. ow 1.5 gpm
Maximum uid temperature: 150o F (66o C)
Maximum operating pressure: 200 psi (13.8 bar),
Operating temperature: -4o - 212o F (-20o - 100o C), Input power: 5 - 24 VDC @ 50 mA maximum, 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: 32o - 77o F (0 - 25o C)
o
- 125o C)
DESCRIPTION
51
DESCRIPTION
2.10 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 conguration. 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
DESCRIPTION
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.
Specications
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
52
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 specic details, please refer to the B4 Lift manual.
DESCRIPTION
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 Monting Bracket/Nut Plate
53
DESCRIPTION
DESCRIPTION
54
INSTALLATION
SAFETY DESCRIPTION
INSTALLATION
OPERATION APPENDIX
INSTALLATION
INSTALLATION
56
INSTALLATION
3.0 Grounding
Introduction
Machine grounding is an important part of the installation process, which can be greatly simplied if prepared
in advance. The most dicult 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.
INSTALLATION
The cutting table must be connected to
machine earth grounding rod.
57
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
A common symbol used to identify
a chassis ground on drawings.
INSTALLATION
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).
58
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 . Specication 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
7
1
5
9
4
3
INSTALLATION
Note: The three phase electrical input
to the plasma power supply must include
an electrical ground.
2
8
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.
8
59
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.
INSTALLATION
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.
1
5
3
2
2
4
4
1
3
60
5
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 dierences between
system components and building components.
INSTALLATION
•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.
61
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 dierences 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
1
1
62
INSTALLATION
In reality the ground rod is providing a low impedance path by which noise currents may return to their
source .
2
Earth ground rod reality.
1
INSTALLATION
2
1
63
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
64
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
signicant dierence. 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 backll 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 aecting soil moisture and content
is to use salt water, or rock salt to condition the surrounding soil.
INSTALLATION
65
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 (dierence 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.
INSTALLATION
2
1
1
Utility Power Electrical Ground
2
3 Phase Electrical Supply
3
Plasma Power Supply
3
66
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 oers 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
1
2
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.
l
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 eectiveness proportional to the amount of overlap.
INSTALLATION
l
1
2
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.
67
INSTALLATION
Machine Grounding Schematic
2
1
3
4
8
10
INSTALLATION
5
(+)
6
1
Main Control Enclosure
2
Component Enclosures
3
Main Star Ground
Rails
4
9
7
•All electrical enclosures bolted to the
machine chassis
•Machine chassis grounded to star point on
cutting table.
•Rails grounded to cutting table
Cutting Table
5
•Plasma ground connected to star point on
System Star Ground (on Table)
6
Earth Ground Rod
7
Plasma Power Supply
8
Plasma Power Supply Ground (required by EU
9
Standards)
Electrical System Ground
10
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.
68
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 specic torque.
must conform to national and local electrical and plumbing codes.
Installation should be performed only by qualified, licensed
personnel. Consult your local authorities for any regulation issues.
3.1 Placement of Power Supply
INSTALLATION
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 aect cooling
eciency.
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 off.
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 specic power supply manual for
the size on input conductors.
69
INSTALLATION
Input Connection Procedure
1. Remove cover panel.
2. Thread cables through the access opening.
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 cover panel.
INSTALLATION
Electric shock can kill! Dangerous voltage and current may be
present any time working around a plasma power source with
covers removed:
Connection example of EPP-360
Chassis Ground
Primary Terminals
WARNING
•DISCONNECT POWER SOURCE AT THE LINE (WALL) DISCONNECT.
•HAVE A QUALIFIED PERSON CHECK THE OUTPUT BUS BARS (POSITIVE
AND NEGATIVE) WITH A VOLTMETER.
Output Connection Procedure
1. Open access panel on the lower front of the
power source.
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.
Workpiece connection
Connection example of EPP-360
70
Pilot Arc connection
Electrode connection
INSTALLATION
Interface Cables/Connections
Connection example of EPP-360
INSTALLATION
CNC Interface Cable
RAS Box front view
CNC Interface Cables
Part Number Length Part Number Length
0558004651 7.6m 0558004654 30.5m
0558004652 15.0 m 0558003978 38.1m
0558004653 22.8m 0558004655 45.7m
Water Cooler Interface Cable
CC-11 rear view
Water Cooler Interface Cables
Part Number Length
0558004837 5.0m
0558004838 10.0m
0558004839 20.0m
71
INSTALLATION
3.2 Placement of CC-11 Coolant Circulator
Install the CC-11 in an appropriate location so as to maintain adequate and unrestricted airow into and out of
the cabinetry.
Input Power Connection
A 3-conductor power cable suitable to meet the required input power must be installed. The cable must have
0.25” (6.4 mm) ring lugs installed on the machine end. Connect the power leads to the L1 and L2 terminals and
the ground lead to the ground lug located on the base near the rear panel. A strain relief tting is provided to
feed a power cable through the rear panel of the cabinet. Please refer to the CC-11 Instruction manual for details.
Electrical installation must be in accordance with local electrical codes for this type of equipment.
Voltage link MUST be moved if equipment is operated at any voltage
CAUTION
INSTALLATION
other than 575V. Failure to move voltage link to location that matches input voltage can result in damage to equipment.
NOTE:
Voltage link is shipped in
this location which is for
575 volt operation.
Input Power Cable
L1 and L2 terminals
72
Typical connection for 460 VAC input
INSTALLATION
Coolant Connections and Optional Equipment
Connect the hoses to the CC-11 accordingly.
When the CC-11 unit is installed above
the plasma torch location, Shut-o
Valve (p/n 0558008364) should be or-
dered and installed. It is connected to
the CC-11 using the “Coolant Supply To
Torch” tting located on the rear panel.
The shut-o valve closes when delivery
pressure falls below approximately 25
psig (1.7 bar). This will insure that wa-
ter does not drain from the unit when
changing consumables.
Shut-o Valve
p/n 0558008364
CC-11 rear view
Coolant Connections Control Cable
INSTALLATION
An 8-pin receptacle J1 is provided on the rear panel to supply the CC-11 with 115 VAC
control voltage for pump motor contactor control. The CC-11 is normally supplied
with this control voltage in order for the pump and fan to operate. J1 also provides
contact closure signals for a satised 1.00 gpm (3.8 l/min) ow switch (pins D and C)
and coolant level switch satised (pins E and H).
RAS Box front view
Connection example of EPP-360
73
INSTALLATION
These connectors are located on the back of the unit. Connect the hoses to the CC-11 accordingly. The torch
hose ends should be tted with one 5/8"-18 male left-hand air / water hose and one 5/8"-18 female right-hand
air / water hose connector.
With the torch and the CC-11 connected, ll the reservoir with the specially formulated torch coolant.
Do not use regular anti-freeze solutions, such as for
an automobile, as the additives will harm the pump
and torch. ESAB P/N 0558004297 is recommended
for service down to 12° F (-11° C). ESAB P/N 156F05 is
recommended for service below 12° F (-11° C) to -34°
F (-36° C).
After lling the reservoir, run the pump with its cap
INSTALLATION
removed in order to purge air from the radiator, hoses, and torch. Re-check coolant level to ensure reservoir is lled. Replace reservoir cap after purging and
checking coolant level.
Coolant Connections
3.3 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.
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)
to CAN
74
to PS Control
Coolant IN
to E-Stop
Coolant OUT
Power Source Cables enter through strain relief ttings
INSTALLATION
Buss Bar / Block
Nomex Insulation
Locking Screw
3. Strip back the insulation of the 4/0 (95 mm
4. Insert the 4/0 (95 mm
2
) cable in the buss bar/block hole until copper extends to the edge of the buss bar /
2
block.
5. Tighten the locking screw(s) down on the cable.
Connection for Pilot Arc Cable
) cable, approximately 38 mm.
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 modied.
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
75
INSTALLATION
3.4 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
INSTALLATION
Power Cable /
Ground
Stud
Chassis
Ground
Wire
Pilot
Arc Cable
Coolant
76
PG Hose
SG Hose
INSTALLATION
3.5 Mounting Torch to Machine
Clamping on Torch body may cause dangerous current to flow
WARNING
Mount torch on insulated sleeve here.
through machine chassis.
•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
DO NOT mount
on steel torch
body here.
machine.
•When this arcing occurs, torch body may require non-warranty
replacement.
•Damage to machine components may result.
INSTALLATION
•Clamp only on insulated torch sleeve (directly above label) not less
than 1.25" (31.75 mm) from the torch end of the sleeve.
•PT-36 Torch has an outside diameter of 50mm for standard
mounting.
77
INSTALLATION
3.6 Placement of ICH
The ICH should be located close to the operator for easy access.
Connect required CAN cables between ICH and other CAN nodes,
such as Remote Arc Starter (RAS), B4 lifter, if applicable. CAN connection is always made from left to right, if one node is removed
from CAN bus, all nodes on the right need to be shifted to left. After
connecting all CAN nodes, a terminator is required. Leave all unused
CAN ports open.
Connect DB37 cable to port “CNC” on ICH. The other side of DB37,
is connected to the customer’s CNC via a male DB37 connector. An
optional breakout board may be used.
INSTALLATION
Connect power from ICH to PDB and B4 lifter, if applicable. Make sure the power switch on ICH is o.
Connect power to ICH box.
3.7 Placement of PDB
The PDB should be placed on the deck as it is used for
supplying power to the CGC.
3.8 Placement of CGC
The CGC regulates the plasma gas and shield gas. For optimum
performance, it should always be placed close to torch. According to the material being cut, the customer needs to select and
connect the correct inlet gases. Inline lters are embedded into
the inlet ttings. Please make sure all inlet gases meet the pressure and ow requirements.
Connect 24V AC/DC power from PDB, then connect CAN cable
to ICH.
78
INSTALLATION
Individual Component Connections
Part numbers and lengths for the cables shown below are provided on the following page.
PDB front
ICH back
A
INSTALLATION
B
CGC front
C
“A” - Power cable from ICH to PDB (115/230V)
Part Number Length Part Number Length
0560947962 1m (3. 3’) 0560947088 5m (16’)
0560946776 2m (6.4’) 0560947089 6m (19 ’)
0560947964 3m (10’) 0560947090 7m (23’)
0560947087 4m (13’)
“C” - Power cable PDB to CGC (24 VAC/DC)
Part Number Length Part Number Length
0560947079 1.5m (5’ ) 056094706 4 8m (26’)
0560947080 3m (10’) 0560947065 9m (30’)
0560947061 4m (13’ ) 0560947082 10m (33’)
0560947081 5m (16’) 0560946780 12.8m (42')
0560947062 6m (19’) 0560947066 15m (49’)
0560947063 7m (23’) 0560947083 20m (66’)
PDB back
“B” - CAN cable from ICH to CGC
Part Number Length Part Number Length
0558008464 1m (3. 3’) 0558008473 10 m (33’)
0558008465 2m (6.5’) 0558008474 11m (3 6’)
0558008466 3m (10 ’) 0558008475 12m (39 ’)
0558008467 4m (13’) 0558008476 13m (43’ )
0558008468 5m (16’) 0558008477 14m (46’)
0558008469 6m (19’) 0558008478 15 m (49 ’)
0558008470 7m (23’) 0558008479 20m (66’)
0558008471 8m (26’) 0558008809 25m (82')
0558008472 9m (30’) 0558008480 36m (118')
79
INSTALLATION
ACC Component Connections
A
INSTALLATION
B
Compressed Air
“A” - Cable from ACC to PDB
Part Number Length Part Number Length
0560947067 0.5m (1.7’) 0560947070 7m (23’)
0560947075 1.5m (5’) 0560947071 8m (26’)
0560947076 3m (10’) 0560947072 9m (30’)
0560947068 4m (13’) 0560947078 10m (33’)
0560947077 5m (16’) 0560947073 15m (49’)
0560947069 6m (19’) 0560947074 20m (66’)
0560946782 6.1m (20') 0560946758 25m (82')
“B” - Air Curtain hose from ACC to CGC
Part Number Length Part Number Length
0558004841 1.4m (4.75’) 0558004846 7.6m (25’)
0558004842 1.8m (6’) 0558008503 8.0m (26.25’)
0558004843 3.7m (12’) 0558008504 9.1m (30’)
0558004844 4.6m (15.25’) 0558008505 10.1m (33')
0558004845 5. 3 m (17. 2 5’ ) 0558008506 11. 0 m ( 3 6 .25’)
0558006865 6.1m (20’) 0558008507 11.9m (39.5’)
0558008502 7. 0 m (23 ’ )
80
INSTALLATION
Component Placement Example
6
5
7
2
1
alternative mounting location
8
6
INSTALLATION
4
3
Components
1 CNC
2
3 PT-36 Torch
4 B4 Lift
5
6 Remote Arc Starter Box (RAS)
7 Power Supply
8 Power Distribution Box (PDB)
Interface Control Hub (ICH)
Combined Gas Control (CGC)
81
INSTALLATION
INSTALLATION
82
SAFETY DESCRIPTION INSTALLATION
OPERATION
OPERATION
APPENDIX
OPERATION
OPERATION
84
OPERATION
4.0 Interface Control Hub
The ICH (Interface Control Hub) is used to interface the ESAB m3 Process Control with the customer CNC using
RS232/RS422/RS485 and digital I/O.
Operation of the m3 IGC system can be made via the ICH (Interface Control Hub) in the following modes.
1. Remote mode without serial communications. (Default)
2. Remote mode with serial communications.
3. Local mode - diagnostics only.
The following pages describe how to operate the ICH.
OPERATION
85
OPERATION
7
6
OPERATION
1 2 3 4 5
ICH front view
8 9 10 11
16
15
GND
12
13
14
Note:
Chassis must be connected
to the machine ground.
86
ICH back view
OPERATION
4.1 Operation
ICH Connectors
Item Number Item Description
In Local mode, this switch will start the plasma process. If the Gas Test switch
1 Plasma Start
2 Gas Te st
3 Local/Remote
4 Station Select
5 Screen Select This switch will allow the user to select dierent screens.
6
7 Power Switch This switch will turn on the Interface Control Hub.
8 Input Power
9 AHC Power Power connection for an ESAB lift (B4 or A6).
10 Gas Power
11 RS232 RS232 protocol for remote control if needed.
12 ASIOB1 ASIOB1 protocol for retrotting older ESAB systems.
13 CNC
14 AUX Control DB25 connector for auxiliary options such as Air Curtain.
15 CAN Vision 5x Not used.
16 Fuses Replace fuses with same type and size.
Encoder Wheel
with Push Button
is set to on, then the process will go into TEST Mode. In TEST Mode the power
supply faults, errors, and warnings are ignored while at the same time the steps
for starting the power supply and turning HF on are skipped.
In Local mode, this switch will start the plasma gas and shield gas at their start
values. If the plasma start switch is turned on after this one, the plasma process
will start in TEST mode.
This switch will change the ICH system from being remotely controlled, via the
serial communications and digital inputs from the CNC, to locally controlled via
the switches on the Interface Control Hub.
This switch is a momentary switch which will change the station of which the
information on the screen is displaying. If the system is in local mode, then the
station selected will change to only the station displayed.
This only has an eect in local mode under normal operation, when communication is set to none, and in the set up mode. This wheel will allow you to
change the parameter the cursor is currently on. The button will also allow you
to see a more detailed error message when on the error log screen.
To work the wheel for editing a parameter, push the wheel, move the wheel to
change the value, and then press the wheel again to lock in the value.
Customer supplied input power to ICH. See specications for power requirements.
Power connection to the Power Distribution Box (PDB), which provides 24 VAC/
DC to the Combined Gas Control (CGC).
DB37 connector to interface to customer I/O. This also has the RS422/485 connections.
OPERATION
87
OPERATION
Display Screens
Startup Screen
On powerup the ICH screen displays the following information for 3 seconds:
Software version
OPERATION
Editing a Parameter on the Display
Only available when communication is set to none or Local/Remote switch is set to Local.
1. Use the encoder wheel to scroll to the parameter.
2. Push the wheel.
3. Turn the wheel to edit the value.
4. Push the wheel again to lock the value.
Gas Selection Screen
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
Current Output (Amp)
Gas Select Table
Plasma Shield
GS
Start Cut Start Cut
1 N2 O2 N2 N2
2 Air O2 Air Air
3 N2 N2 N2 N2
4 N2 H35 Air Air
5 N2 H35 N2 N2
6 Ar Ar Air Air
7 Ar Ar N2 N2
8 Air Air Air Air
9 N2 O2 Air Air
10 N2 N2 Air Air
11 Ar O2 N2 N2
12 Ar O2 Air Air
13 Ar Ar H2O H2O
14 N2 N2 H2O H2O
88
Timers Screen
OPERATION
Timers
Current Ramp Up Time (seconds)
Piercing Time (seconds)
Second Ramp for Thick Plate (seconds)
Current Ramp Down Time (seconds)
Time to delay gas o from the time plasma start is removed. (seconds)
Time to raise torch when cutting is complete (Height Control option required) (seconds)
OPERATION
Height Control Screen (Height Control option required)
Height Settings
Initial/Ignition Height (mm)
Piercing Height (mm)
Cutting Height (mm)
Plate Thickness (mm)
Arc Voltage (volts)
Encoder Height (mm)
Arc Voltage Output (volts)
89
CNC Input Screen
OPERATION
Inputs
Plasma Start 0 0
Corner 0 0
Block AHC 0 0
Plasma Test 0 0
Mark Mode 0 0
Stat 1 ON 0 0
Stat 2 ON 0 0
Stat 1 UP** 0** 0**
Stat 1 Down** 0** 0**
Stat 2 UP** 0** 0**
Stat 2 Down** 0** 0**
CNC’s Direct
Input
ACT
(selection program
is currently
running)
OPERATION
CNC Output Screen
**only present when the Height Control option is present
Outputs
Dened by motion signal
System has faulted
Arc was lost during cut/mark
System is not ready to cut/mark
Station 1 is on Upper Limit Switch
Station 2 is on Upper Limit Switch
Motion Signal options:
Arc On - Motion Enable only goes high when arc is
on. Normally used when no torch lifter is supplied
with plasma system.
90
Motion - Motion Enable only goes high when motion
is allowed. Normally used when a torch lifter is supplied with plasma system.
OPERATION
Setup Descriptions
Setup - The “setup screen” on the Interface Control Hub is accessed by having “Plasma Start” set to “ON” and “Remote/
Local” set to “L O CAL” when powering up the box. It is exited by turning the power o and then back on. Make sure to
reset the switches back to the original state for parameter display. The encoder wheel with pushbutton, is used to select an
item and change the values or to select a sub-menu.
An example shown here, is for setting up a Plasma
System congured for the following:
1� m3 Integrated Gas Control System
2� EPP-360 Plasma Power Supply
3� Supplied with ESAB Lifter
4� No Water Injection option
Long Preow Timer (seconds)
Short Preow Timer (seconds)
Gas purge before Intial Height sensing (seconds)
Power Supply type
ESAB lifter installed
ESAB Water Injection Module installed
Motion Enable Signal meaning
Gas Control type
Gas Test timeout (seconds)
Error Log
Communication Options
Station 1 Lift Options
Station 2 Lift Options
Save Constants
Reload Constants
OPERATION
If the ESAB lifter has not been supplied with the system, the ICH setup screen for the above conguration would
be as shown below:
Long Preow Timer (seconds)
Short Preow Timer (seconds)
Gas purge before Intial Height sensing (seconds)
Power Supply type
ESAB lifter installed
ESAB Water Injection Module installed
Motion Enable Signal meaning
Gas Control type
Gas Test timeout (seconds)
Error Log
Communication Options
Save Constants
Reload Constants
91
OPERATION
Described below are the various options to be modied before setting up the plasma system for operation:
Long Preow The long preow is the time, in milliseconds, the system will wait for the gases to ow before starting the power supply. This
Short Preow The short preow is the time, in milliseconds, the system will wait for the gases to ow before starting the power supply. This
Power Supply The power supply option is where the power supply attached to the system is specied. The EPP-201, EPP-360, EPP-450 and the
ESAB Lifter The ESAB Lifter option is set to “YES” if an ESAB lifter was purchased for use with this system.
ESAB Injection The ESAB Injection option species that the ESAB water injection module was purchased for use with this system.
Motion Signal Arc On - Motion Enable only goes high when arc is on. Normally used when no torch lifter is supplied with plasma system.
Gas Control This option species which type of Gas Control is to be used. The options are: (1) Water - Water Injection is the only shield avail-
Gas Timeout This species the maximum time, in seconds, which gases will be allow to ow during a gas test before they are automatically
Error Log The error log stores up to 13 errors at a time reported by the ICH in the order they are detected. These errors are only cleared by
Communication The communication section is used to change the serial communications between the ICH and the CNC.
OPERATION
time is only used for each start until there is a successful start (after power-up) or when the gas being used is not compatible
with the previous gas being used.
time is only used for when it can be asserted that the last gas used and the current gas are compatible.
EPP-601 are the available choices.
Motion - Motion Enable only goes high when motion is allowed. Normally used when a torch lifter is supplied with plasma
system.
able, (2) CGC - Combined Gas Control in use, (3) Full - The fully automatic gas control system is in use.
shut o.
selecting “CLEAR”. Select the error, by pushing the pushbutton part of the encoder wheel, to see more details about the error.
Protocol - There are four options: None, RS-232, RS-422, and RS-485. Serial communications is disabled when none is selected.
The RS-422 protocol uses four wire while the RS-485 uses two wire.
Baud Rate - The baud rate must be set to the same rate as the CNC’s serial communication transfer rate. Available options are:
300, 1200, 2400, 9600, 19200.
Parity - The parity needs to match the CNC’s serial communication parity. Available options are: None, Even, and Odd.
Stop Bits - The stop bits needs to match the CNC’s serial communication stop bits. Available options are: 1 or 2.
Communication Options
Communication Options
Protocol
Baud Rate
Parity
Stop Bits
Previous Screen
92
OPERATION
Station Options
The following are the options listed under station 1 and station 2:
Li ft Type The lifter type species which lift is being used. Available options are: A6 or B4.
Arc Volt Cut The arc voltage calibration used when in CUTTING mode. Using a calibrated voltmeter, measure the voltage from the bus bar in
Arc Volt Mark The arc voltage calibration used when in marking mode. Using a calibrated voltmeter, measure the voltage from the bus bar in
ULS to Table The distance from the torch tip, when on the upper limit switch, to the top of the table slats. This is in micrometers.
the Remote Arc Starter Box to ground, while the process is active in cut mode. If that is higher than the arc voltage requested,
then raise this number. If it is lower, then low this number.
the Remote Arc Star ter Box to ground, while the process is active in MARK mode. If that is higher than the arc voltage requested,
then raise this number. If it is lower, then lower this number. The result should be around half of the “Arc Volt Cut” option.
Fast Speed This is the speed at which the lifter will move when not in the slowdown zone, when using height control, or when moving up.
The slowdown zone is the plate thickness, plus 25 millimeter, above the table slats.
Slow Speed This is the speed at which the lifter will m ove when in the slowdown zone or using height control. The slowdown zone is the plate
thickness, plus 25 millimeter, above the table slats.
Station 1 Lift Options
Lif t Type
Arc Voltage for Cutting
Arc Voltage for Marking
Upper Limit Switch to Table (µm)
Fast Speed (Relative speed 0-500)
Slow Speed (Relative speed 0-500)
Previous Screen
OPERATION
Station 2 Lift Options
Lif t Type
Arc Voltage for Cutting
Arc Voltage for Marking
Upper Limit Switch to Table (µm)
Fast Speed (Relative speed 0-500)
Slow Speed (Relative speed 0-500)
Previous Screen
93
OPERATION
Once the setup is complete, make sure to save the constants by selecting the “Save Constants” tab. The following screen will be displayed for a couple of seconds to conrm that your changes have been taken.
Save Complete
If you do not want to keep the changes you have made and would like to revert back to the last saved settings
OPERATION
then select the “Reload Constants” tab. The following screen will be displayed for a couple of seconds to con-
rm that your changes have been taken.
Load Complete
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OPERATION
Digital I/O
Digital Inputs
Digital inputs are to be only turned on with 24 VDC. Any other voltage may damage the board or cause unpredictable results. The best method is to send the 24 VDC from the DB37 connector back on the input, via a relay
or opto-isolator chip.
Signal Name Description
Corner
Block AHC Block height control
Plasma Test
Plasma Start Start the plasma process
Mark Switch to marking mode and use the last loaded marking data
Station 1 Up Move the station 1 lifter up (if installed)
Station 1 Down Move the station 1 lifter down (if installed)
Station 2 Up Move the station 2 lifter up (if installed)
Station 2 Down Move the station 2 lifter down (if installed)
Station 2 On Turn on station 2.
Station 1 On Turn on station 1.
Informs the ICH to reduce the current to the corner current and block height
control (if enabled)
Prevents the ICH from sending the start signal to the high frequency unit and
power supply during a plasma start. Power supply faults are ignored.
OPERATION
Digital Outputs
Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement.
Signal Name Description
This signal is high when the arc is on or the process is o, when motion signal
Motion Enable/Arc On
System Fault
Arc Lost
Not Ready
Station 1 ULS Station 1 is on the upper limit switch.
Station 2 ULS Station 2 is on the upper limit switch.
is set to Motion in the setup screen. This signal is high when the arc is on, when
motion signal is set to Arc On in the setup screen.
The ICH has detected a problem which required the process to stop. Send message 003 or check the error log to get the exact set of errors. These are reset
with a 000 command, but will remain in the error log.
The arc was lost during a cut/mark operation. This is reset on the next plasma
start.
The ICH is not ready to start the process. Possible causes: no Station selected,
not in Remote Mode, Plasma Start was high on boot up and is still high, Gas
settings missing, Start Current missing, Cut Current missing, Timers missing,
Height Control settings missing (if a lifter is installed).
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OPERATION
4.2 Modes of Operation:
Remote Interface without Serial Communication
This mode describes the instance when the CNC controls everything except parameter selection via the digital
inputs and outputs. To operate in this mode, go to the setup screen and change the “Protocol” to “None” under “Communications”.
•The process parameters need to be modied on the ICH screen every time the CNC needs to change the
cutting or marking parameters. The ICH system supports a cutting parameter set and a marking parameter
set. The last used set will be available upon restarting the ICH. This requires starting the process at least
once with the set.
•The cutting parameters and marking parameters can be loaded into dierent tables in the ICH. After all the
parameters are loaded, switching can be done by pressing the push button on the parameter line in the
Gas Selection screen.
•Gas Test - The gas test function is designed to allow diagnostics of the gas control system. The gas test
feature can be enabled by turning on the “Plasma Test” digital input and issuing a “Plasma Start”. The
gases owing in each test and the pressure/ow at which they are set to, is based on the currently loaded
parameters on the ICH display.
•The ICH system has two possible sequences it can be running. One with the lifter height controlled by the
ICH system and another with the lifter height controlled by the CNC.
OPERATION
Described below are examples for cutting a part from the CNC. The parameters from the cut data manual used
for the setup below are detailed on the following page.
Material Type Carbon Steel
Material Thickness 12 mm
Cut Quality Production
Current 200 Amps
Start Gas N2
Cut Gas O2
Shield Gas Air
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OPERATION
OPERATION
P MS 100A GS9 ncode112 pic2
OPERATION
9 9 9 9
1.7 1.7 1.7 1.7
2.8 2.8 2.8 2.8
3(0.125) 6(0.250) 10(0.375) 12(0.500)
4.1 4.1 4.1 4.1
PRODUCTION
Material Carbon Steel
Gas Select 9
Cut Gas O2
Start Gas N2/AI R
Amperes 100
Shield Gas N2 /AIR
Code Description Material Thickness - mm (inch)
Gas Parameters:
P1 Gas Select
P2 Plasma Start - Bar
P3 Shield Start - CMH
P4 Plasma Cut - Bar
2.8 2.8 2.8 2.8
100 100 100 100
P5 Shield Cut - CMH
P6 Cut Current - Amps
50 50 50 50
P7 Start Current - Amps
Timers: (sec)
0.6 0.6 0.6 0.6
0.1 0.1 0.2 0.4
T1 Ramp Up
T2 Pierce
0.0 0.0 0.0 0.0
T3 Thick Plate
0.6 0.6 0.6 0.6
T4 Ramp Down
0.35 0.35 0.35 0.35
T5 Gas O
1.0 1.0 1.0 1.0
T6 Raise Lift
(inch)
Height Parameters: mm
(0.160) 4(0.160) 4(0.160) 4(0.160)
4
H1 Ignition
6(0.250) 6(0.250) 6(0.250) 6(0.250)
H2 Pierce
3(0.125) 3(0.125) 3(0.125) 3(0.125)
H3 Cutting
3(0.125) 6(0.250) 10(0.375) 12(0.500)
H4 Thickness
142 149 153 155
H5 Arc Voltage - Volts
Machine Parameters:
(225) 3556(140) 1905(75) 1524(60)
1.7(0.065) 2.0(0.080) 2.5(0.100) 2.5(0.100)
5715
(in/min)
Speed - mm/min
Kerf - mm (inch)
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OPERATION
Operation sequence with ESAB supplied plasma lifter:
1. Setup the part program that needs to be cut from the CNC.
2. Go to the ICH screen for “C:Cutting Parameters” and setup the parameters according to the cut data manual:
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table under DISPLAY SCREENS section)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
OPERATION
Current Output (Amp)
3. Next, go to the ICH screen for Timers and setup the timer values according to the cut data manual:
Timers
Current Ramp Up Time (seconds)
Piercing Time (seconds)
Second Ramp for Thick Plate (seconds)
Current Ramp Down Time (seconds)
Time to delay gas o from the time plasma start is removed. (seconds)
Time to raise torch when cutting is complete (Height Control option required) (seconds)
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OPERATION
4. Next, go to the ICH screen for Height Settings and setup the height parameters according to the cut data
manual:
Height Settings
Initial/Ignition Height (mm)
Piercing Height (mm)
Cutting Height (mm)
Plate Thickness (mm)
Arc Voltage (volts)
Encoder Height (mm)
Arc Voltage Output (volts)
OPERATION
5. Once all of the setups have been completed on the ICH, refer to the cut data manual for the Speed and Kerf
inputs to be made on the CNC part program.
6. Execute the program from the CNC and send a “Plasma Start” signal to the ICH.
7. The following happens while the CNC waits for motion enable.
a. The ICH starts the purge before initial height sensing.
b. The torch comes down, does the initial height sensing and nishes the preow.
c. The ICH starts the power supply.
d. The ICH waits for the arc to transfer and the main current to start, turning the high frequency generator
o once the arc has transferred. If the motion signal constant is set to “Arc On”, this is when the
“Motion Enable” signal is returned to the CNC.
e. The gas switches from start to cut values and gas.
f. The ICH ramps the current up to the desired cutting/marking current.
g. The ICH raises to the piercing height.
h. The ICH waits a time, from the parameters, for the current to pierce the plate.
i. The ICH lowers down to the cutting height. If the motion signal constant is set to “Motion”, this is
when the “Motion Enable” signal is returned to the CNC.
8. Start moving the machine in the shape desired, turning the corner signal on when not going at full speed for
the parameters sent.
9. Remove the “Plasma Start” signal to the ICH at the end of cut.
10. The following happens while the CNC waits for “Motion Enable” to be removed and come back (if the motion signal constant is set to “Motion”).
a. “Motion Enable” is removed, if the motion signal constant is set to “Motion”.
b. The current ramps down.
c. The power supply is turned o and, after a time specied in the parameters, the gas stop owing.
If the motion signal constant is set to “Arc On”, this is when the “Motion Enable” signal is removed.
d. The lift raises for an amount of time specied in the process parameters.
e. If the motion signal constant is set to “Motion”, then this is when “Motion Enable” is returned.
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OPERATION
Operation sequence with customer supplied plasma lifter:
1. Setup the part program that needs to be cut from the CNC.
2. Go to the ICH screen for “C:Cutting Parameters” and setup the parameters according to the cut data man-
ual:
L = Local
C = Cutting
M = Marking
Parameter Set Type
Gas Selection (see table under DISPLAY SCREENS section)
Plasma Start (Bar)
Shield Start (CMH)
Plasma Cut (Bar)
Shield Cut (CMH)
Cut Current (Amp)
Start Current (Amp)
Plasma Output (Bar)
Shield Output (CMH)
OPERATION
Current Output (Amp)
3. Next go to the ICH screen for Timers and setup the timer values according to the cut data manual:
Timers
Current Ramp Up Time (seconds)
Piercing Time (seconds)
Second Ramp for Thick Plate (seconds)
Current Ramp Down Time (seconds)
Time to delay gas o from the time plasma start is removed. (seconds)
Time to raise torch when cutting is complete (Height Control option required) (seconds)
100
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