ESAB m3 plasma m3 Integrated Gas Control (IGC) - Vision 5x Instruction manual

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m3 Integrated Gas Control (IGC) - Vision 5x

Instruction Manual

Date: Oct12 Part Number: 0558009696 Language: EN

m3 Integrated Gas Control (IGC) - Vision 5x

Revision History:

•2012 - 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 specic statement of ESAB’s responsibilities and limitations on liability.

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, 2012

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 congurations 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.

m3 Integrated Gas Control (IGC) - Vision 5x

ABBREVIATIONS:

IGC - INTEGRATED GAS CONTROL

ICH - INTERFACE CONTROL HUB

CGC - COMBINED GAS CONTROL

PDB - POWER DISTRIBUTION BOX

RAS - REMOTE ARC STARTER

AC - AIR CURTAIN

AHC - AUTOMATIC HEIGHT CONTROL

WIC - WATER INJECTION CONTROL

m3 Integrated Gas Control (IGC) - Vision 5x

Table of Contents

SAFETY

1.0 Safety .......................................................................................................................................................... 11

Introduction ........................................................................................................................................................................................ 11

Safety - English ................................................................................................................................................................................... 12

Safety - Spanish ..................................................................................................................................................................................16

Safety - French ....................................................................................................................................................................................20

Integrated Gas Control System Interconnect Diagram .................................................................................25

Combined Gas Control

2.0 Combined Gas Control (CGC) .....................................................................................................................29

Specications ...................................................................................................................................................................................... 29

Functions and Features.............................................................................................................................................................32

CGC Flow Diagram ......................................................................................................................................................................33

Combined Gas Control Plumbing Schematic ...................................................................................................................34

Combined Gas Control Electrical Schematic .....................................................................................................................35

Connections .................................................................................................................................................................................. 36

Troubleshooting .......................................................................................................................................................................... 36

CGC Mounting Dimensions ..................................................................................................................................................... 37

CGC Bottom View .......................................................................................................................................................................37

POWER DISTRIBUTION BOX

3.0 Power Distribution Box (PDB) ....................................................................................................................41

PDB Mounting Dimensions ..................................................................................................................................................... 41

PDB Mounting Plate Dimensions ..........................................................................................................................................42

PDB Schematic ............................................................................................................................................................................. 42

m3 Integrated Gas Control (IGC) - Vision 5x

Remote Arc Starter

4.0 Remote Arc Starter Box ..............................................................................................................................45

Power Source Connections ............................................................................................................................................................47

Power Source Connections (con’t.) ............................................................................................................................................ 48

Torch Connections ............................................................................................................................................................................ 49

Remote Arc Starter Box Mounting .............................................................................................................................................. 51

Typical / Recommended E-stop Connection ...........................................................................................................................52

PT-36 Torch

4.0 General ........................................................................................................................................................55

Scope ..................................................................................................................................................................................................... 55

Package Options Available ........................................................................................................................................................... 55

Optional Accessories: ....................................................................................................................................................................... 55

PT-36 Torch Consumable Kits .................................................................................................................................................56

PT-36 Technical Specications ...................................................................................................................................................... 59

Recommended Regulators ......................................................................................................................................................59

PT-36 Torch Technical Specications ...................................................................................................................................60

Connection of Torch To Plasma System .................................................................................................................................... 61

Connection to the Remote Arc Starter Box .......................................................................................................................61

Mounting Torch to Machine ........................................................................................................................................................ 62

Set Up .................................................................................................................................................................................................... 65

Mirror Cutting ..............................................................................................................................................................................65

Cut Quality ........................................................................................................................................................................................... 65

Cut Angle ....................................................................................................................................................................................... 66

Cut Flatness ................................................................................................................................................................................... 67

Surface Finish ...............................................................................................................................................................................68

Dross ................................................................................................................................................................................................ 68

Dimensional Accuracy ............................................................................................................................................................... 69

Torch Flow Passages ................................................................................................................................................................ 70

Torch Front End Disassembly ........................................................................................................................................................ 71

m3 Integrated Gas Control (IGC) - Vision 5x

Assembly of Torch Front End ........................................................................................................................................................74

Assembly of Torch Front End using the Speedloader .................................................................................................... 75

Torch Front End Disassembly (for Production Thick Plate) ................................................................................................. 76

Assembly of Torch Front End (for Production Thick Plate) .................................................................................................79

Torch Body Maintenance ............................................................................................................................................................. 81

Removal and Replacement of the Torch Body ........................................................................................................................ 82

Reduced Consumable Life .......................................................................................................................................................... 84

REPLACEMENT PARTS

6.0 Replacement Parts .....................................................................................................................................89

General ..................................................................................................................................................................................................89

Ordering ............................................................................................................................................................................................... 89

m3 Integrated Gas Control (IGC) - Vision 5x

SAFETY

Be sure this information reaches the operator.

You can get extra copies through your supplier.

SAFETY

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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

SAFETY

1.0 Safety

Introduction

ESAB cutting machines are designed to operate both safely and eectively. 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 specic safety information, obtain and read publications listed in Recommended References.

The following words and symbols are used throughout this manual to indicate dierent 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.

Safety - English

SAFETY

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

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

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

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

1. Always wear safety glasses with side shields in

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

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

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

3. Wear ameproof gauntlet type gloves, heavy

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

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

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

5. Protect other personnel from arc rays and hot

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

6. Use goggles over safety glasses when chipping

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

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

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

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

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

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

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

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

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

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

SAFETY

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

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

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

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

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

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

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

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

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

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

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

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

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

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

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

Therefore:

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

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

conductor causes localized Electric

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

machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

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

are unknown.

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

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

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

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

SAFETY

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

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

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

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

2. Always secure cylinders in an upright position by

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

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

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

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

Never strike an arc on a cylinder.

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

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

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

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

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

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

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

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

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

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

ADDITIONAL SAFETY INFORMATION -- For more

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

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

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

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

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

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

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

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

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

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

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

SAFETY

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

DANGER

CAUTION

WARNING

Enclosure Class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked 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

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

CAUTION

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

Maximum

Tilt Allowed

15°

SAFETY

Safety - Spanish

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

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

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

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

1. Utilice gafas de seguridad con protección a los lados

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

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

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

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

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

4. Chispas y partículas de metal caliente puede alojarse en

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

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

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

6. Use careta protectora además de sus gafas de seguridad

cuando esté removiendo escoria o puliendo.

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

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

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 inamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inamables.

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

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

6. Después de termirar la operación del 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 connado en lugares estrechos o si hay posibilidad de caer al suelo.

SAFETY

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

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

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

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

5. 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 especícas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

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

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

1. Soldadores u Operadores que use marca-pasos para

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

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

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

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

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

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

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

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

lo más cercano posible al área de la soldadura.

E. M antenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

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

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

1. Siempre provea ventilación adecuada en el área

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

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

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

3. Si momentáneamente desarrolla inrritación de

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

4. Haga referencia a la publicación ANSI/ASC Standard

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

SAFETY

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

§25249.5 et seq.)

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

Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

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

2. Asegure siempre los cilindros en posición vertical

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

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

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

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

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

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

INFORMACION ADICIONAL DE SEGURIDAD -- Para

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SAFETY

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

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

PELIGRO

mente en serio daño personal o la muerte.

ADVERTENCIA

CUIDADO

Clase de envolvente

El código IP indica la clase de envolvente, es decir, el grado de protección contra la penetración de objetos sólidos o agua. Se provee protección contra el toque con un dedo, penetración de objetos sólidos de un tamaño superior a 12 mm y contra rocío de agua de hasta 60 grados de la vertical. El equipo marcado IP23S se puede almacenar, pero no se debe usar en el exterior durante periodos de precipitaciones a menos que esté protegido.

ADVERTENCIA

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

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

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

ADVERTENCIA

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

ADVERTENCIA

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

Inclinación

máxima permitida

15°

SAFETY

Safety - French

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

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

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et

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

1. Portez des lunettes protectrices munies d'écrans latéraux

lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de plaques

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

3. Portez des gants ignifugiés à crispin, une chemise épaisse

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

4. Les étincelles et les projections de métal incandescent

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

5. Protégez toute personne se trouvant à proximité des étin-

celles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes de

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

INCENDIES ET EXPLOSIONS -- La

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

laitier incandescent ou les étincelles peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les 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 inammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'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 surchauer et provoquer un incendie.

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

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

02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces élec-

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

SAFETY

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

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

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

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

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

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

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

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

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

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

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — com-

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

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

1. Un soudeur ayant un stimulateur cardiaque doit

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

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

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

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

A. Acheminez l'électrode et les câbles de masse

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

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

autour de votre corps.

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

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

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

plus près possible de la section à souder.

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

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

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

l'asphyxie. Par conséquent :

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

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

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

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

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

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

SAFETY

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

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

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

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

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

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

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

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

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

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

4. Placez les cylindres à une distance appropriée de toute

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

5. Pour de l'information supplémentaire, consultez CGA

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

Highway, Arlington, VA 22202.

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

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

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

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

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

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

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

INFORMATIONS SUPPLÉMENTAIRES 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.

SAFETY

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

DANGER

AVERTISSEMENT

ATTENTION

Classe de protection de l’enveloppe

L’indice de protection (codication IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale. Les équipements portant la marque 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

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

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

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

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

AVERTISSEMENT

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

AVERTISSEMENT

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

Angle

d’inclinaison

maximal

15°

SAFETY

Vision

Lifter

PT-36

TORCH

Phone 1-843-664-5550

Email: oemplasma@esab.com

Interconnect Diagram

Integrated Gas Control System

AHC-VDR

RAS-VDR

RAS-E(

RAS-PSC

PS & CC Control Cable

Power Cable

AHC-AC IN

RAS-PA

Pilot Arc Cable

AHC-CAN

Work Table

POWER/COOLANT/PILOT ARC

RAS

(Remote Arc Starter)

RAS-TC IN

Coolant Supply Hose

RAS-ESTOP

RAS-TC OUT

Coolant Return Hose

RAS-CAN

CGC-PWR

PDB-PWR

PLASMA GAS HOSE

SHIELD GAS HOSE

CGC-Ar

CGC-N2/Air

CGC-O2/H35/F5

CAN-RAS

CGC-CAN

Air Curtain

CGC-N2/Air

CAN-AHC

CAN-CGC

CGC

(Combined Gas Control)

BOLD FONT = Cable Connection Label

Integrated Gas Control System Interconnect Diagram

PDB

(Power

Distribution Box)

PS-PSC

PS-EC(-)

PPS-PA

PS-W

(Power Supply)

PS-IC

CC-TC OUT

CC-IC

CC-TC IN

(Coolant

Circulator)

PWR-PDB

PWR-RB

PWR-AHC

Box

Relay

Customer

CNC-ESTOP

Supplied

CAN Hub

HUB-PWR

HUB-CAN

CNC-CAN

CNC-PWR

Vision

Optional

Customer Supplied

LIQUID

GAS

POWER

DATA

{

PHASE

POWER

THREE

PHASE

POWER

SINGLE

COMBINED GAS CONTROL

2.0 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.

Specications

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

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 0558010163

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

COMBINED GAS CONTROL

NOTE:

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

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

BOTH HOSES MUST BE ORDERED

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

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

PT-36

m3 G2

Plasma

Component Locator Designation

(See following component illustrations)

Torch

CNC or

Process

Controller

Control

Power Box

Customer

Supplied

Gases

Power

N2/Air

O2/H35

Air N2/Air

Argon CAN

Combined

Gas Control

E F

Combined Gas Control Component Locator Designations

Note:

Refer to enclosed tables for all available hoses and cables.

Shield Gas Hose

Plasma Gas Hose

Air Curtain Hose

COMBINED GAS CONTROL

C EFD

COMBINED GAS CONTROL

Functions and Features

The Combined Gas Control regulates the output of the plasma gas (PG) selected from the three plasma gas inlets (N2/Air, O2/H35 and Argon) and controls the ow of shield gas (SG). It is powered by 24 Volts (AC and DC) from the Control Power Box and receives commands via the CAN-bus directly from the CNC.

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

Note: For required gas specications see manual 0558008682, Subsection 8.1

* 6.25”

(158.8 mm)

CAN cable must be routed separate

NOTE:

from torch leads.

* 8.50” (215.9 mm)

including ttings on

front and back

Weight:

9.3 lbs. (4.2 kg)

4.75”

(120.7 mm)

4.50”

(114 .3 m m)

COMBINED GAS CONTROL

When connecting fuel gas lines to the oxygen plasma gas input, or re-

CAUTION

NOTE

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

COMBINED GAS CONTROL

Combined Gas Control Plumbing Schematic

PT1

PV1

O2/H35/F5

PT3

Plasma Gas

N2/Air

PT = Pressure Transducer

PV = Proportional Valve

PT2

∆P

PV2

Shield Gas

COMBINED GAS CONTROL

Combined Gas Control Electrical Schematic

Con 1

CAN H Out CAN L Out

CAN Gnd CAN H In

CAN L In NC NC NC

24VAC In 24VAC In

-24VDC In

+24VDC In

POWER

CAN

Con 2

CO 1

15 16

10 12

LED 1

LED 2

COMBINED GAS CONTROL

Connections

There are two cables connected to the Combined Gas Control: one is 24V power, the other is CAN. There are four gas inputs (N2/Air, O2/H35, Argon and SG) and two gas outputs (PG and SG). The gas ttings are listed below.

Note:

Chassis must be connected to the machine ground.

ESAB

P/N

20 64113

Inputs

Output

Gas Fitting

N2/Air 1/8” NPT x “A” Inert Gas RH Female 631475

O2/H35 1/4” NPT x “B” Fuel LH Male 83390

Argon 1/4” NPT x “B” Inert Gas RH Female 74S76

SG 1/4” NPT x “B” Oxygen RH Male 83389

Connection, Male

0.125NPT to "A" Size

Troubleshooting

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

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

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

LED Status Meaning

OFF Power OFF

10% ON, 90% OFF Boot loader is running

Green

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

Yellow ON Station is selected

CGC Mounting Dimensions

p/n 0558008459

 0.281

(7.1m m)

0.313”

(8.0mm)

COMBINED GAS CONTROL

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)

0.90”

2.52”

COMBINED GAS CONTROL

POWER DISTRIBUTION BOX

3.0 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 commands from the CNC or Process Controller 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 placing another power block and necessary connectors inside. Power block and connectors kit part number is 0558010247.

Specications

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)

.875”

(22.2 mm)

3.00”

(76.2 mm)

4.25”

(108.0 mm)

10.00”

(254.0 mm)

POWER DISTRIBUTION BOX

PDB Mounting Plate Dimensions

p/n 0558008794

 0.281

(7.1m m)

0.313”

(8.0mm)

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 dierent input voltage, then change the switch to 115 VAC.

P/N 0580038383

REMOTE ARC STARTER

4.0 Remote Arc Starter Box

p/n 05580 08150

Component Locator Designation

(See following component illustrations)

Power

Supply

CC-11

Coolant

Circulator

CGC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Coolant Return Hose

E-Stop

CAN

Vision 5x

CNC

Arc Starter

Assembly

Power, Pilot Arc, Coolant

VDR Cable

AHC / Lift

PT-36

Plasma

Torch

Cutting Machine

Relay Box

Remote Arc Starter Box Component Locator Designations

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

REMOTE ARC STARTER

The Remote Arc Starter Box is more commonly referred to as the RAS Box. The RAS Box serves as an interface between the CNC and the EPP family of Plasma Power Supplies, helping to deliver the plasma arc. The RAS 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 ACON module for communicating with the CNC, a High Frequency/Voltage Divider circuit board which functions to provide 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.

GND

B, C

Letter Description

A 24 Pin Amphenol Power Supply Connection B C D Coolant Inlet - Flowing To The Torch

F E-Stop G 8 Pin Can Bus Connection To The Cnc Or Interface H 3 Pin Voltage Divider Connection To The Lift

I Torch Shroud Connection

GND Machine Ground Connection

Coolant Return - Flowing Back To The Coolant

Strain Relief Fittings

Circulator From The Torch

Note:

Chassis must be connected to

the machine ground.

REMOTE ARC STARTER

Power Source Connections

1. To make the power supply connection to the RAS box, you must rst open the unit: remove or unlock the cover screws and lift the box cover o to expose internal components.

The cover is grounded to the Remote Arc Starter Box internally

CAUTION

2. To attach the Pilot Arc and Power cables to the RAS box, you must pass them through the strain relief ttings.

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

Strain Relief Fittings

Pilot Arc Cable

Power Source Cables

REMOTE ARC STARTER

Power Source Connections (con’t.)

Buss Bar / Block

Locking Screw

Nomex Insulation

Connection for Pilot Arc Cable

1. Strip back the insulation of the 4/0 (95 mm2) cable, approximately 38 mm.

2. Insert the 4/0 (95 mm2) cable in the buss bar / block hole until copper extends to the edge of the buss bar / block.

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

Refer to the following table to determine the number of 4/0 (95 mm2) conductors required for

your application.

Amperage Required # of 1/0 Cables

Up to 200 amps 1

Amperage Required # of 4/0 Cables

Up to 400 amps 1 Up to 800 amps 2

Up to 1000 amps 3

Careful attention while stripping the insulation of the 4/0 (95 mm2)

NOTICE

cable will make installation in the buss clamp easier. Do not spread or are the copper conductors.

Note:

Chassis must be connected to the machine ground.

REMOTE ARC STARTER

Torch Connections

Torch hook-up requires the connection of power cables / coolant hoses, pilot arc cable and chassis ground. On the PT36 torch, the coolant hoses from the RAS box to the torch also carry electrode power.

Ground

Lug

Pilot

Arc Cable

Chassis

Ground

Wire

Pilot Arc

Connection

Power Cable /

Coolant Connections

Power Cable /

Coolant

REMOTE ARC STARTER

* 8.75”

(222.3 mm)

7.5 0”

(190.5 mm)

* 9.75” (247.7 mm) including handle on top

Weight:

28.5 lbs. (12.9 kg)

17.0 0”

(431.8 mm)

REMOTE ARC STARTER

Remote Arc Starter Box Mounting

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

(127.0 0)

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.

7.5 0 "

(190. 5 mm)

(165.1 mm)

1.00

(2.54)

3.25"

(82.6 mm)

6.50"

2.75

(69.85)

13.75

(349.25)

Remote Arc Starter Box Mounting Hole Locations (Bottom View)

18. 50"

(469.9 mm)

17. 5 0"

8.75"

(222.3 mm)

(444.5 mm)

Remote Arc Starter Box Optional Mounting Plate (0558008461) Hole Locations

REMOTE ARC STARTER

Typical / Recommended E-stop Connection

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

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

Replacement parts may be ordered from your ESAB Distributor.

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

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

Note

Items listed in the assembly drawing Bill of Materials (included in the back

of this publication) that do not have a part number shown are not avail-

able from ESAB as a replaceable item and cannot be ordered. Descriptions

are shown for reference only. Please use local retail hardware outlets as a

source for these items.

PT36 TORCH

PT-36 TORCH

4.0 General

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

Scope

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

Package Options Available

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

DESCRIPTIONS FOR PT-36 TORCH ASSEMBLY'S PART NUMBER

PT-36 Torch Assembly 4.5 ft (1,4m) 0558008301 PT-36 Torch Assembly 6 ft (1,8m) 0558008302 PT-36 Torch Assembly 12 ft (3,6m) 0558008303 PT-36 Torch Assembly 14 ft Mini-Bevel (4,3m) 0558008308 PT-36 Torch Assembly 15 ft (4,6m) 0558008304 PT-36 Torch Assembly 17 ft (5,2m) 0558008305 PT-36 Torch Assembly 20 ft (6,1m) 0558008306 PT-36 Torch Assembly 25 ft (7,6m) 0558008307

Optional Accessories:

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

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

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

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

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

PT-36 TORCH

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

NOTE:

Cannot be used with vent hole nozzles.

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

PT-36 Torch Consumable Kits

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

Part Number Quantity Description

0558003804 1 Torch Body PT-36 w/o-rings

996528 10 O-ring 1.614" (41mm) ID x .07" (1.8mm) 0558002533 5 Bae, 4 Hole x .032" (0.81mm) 0558001625 5 Bae, 8 Hole x .047" (1.2mm) 0558002534 5 Bae, 4 x .032" (0.81mm) Reverse 0558002530 1 Bae, 8 x .047" (1.2mm) Reverse 0558005457 5 Bae, 4 Hole x .022" (0.6mm) 0558003924 3 Electrode Holder PT-36 w/o-ring

86W99 10 O-ring .364 ID x .07" (1.8mm) 0004470045 2 Nozzle Retaining Cup, Standard 0004470030 5 Shield Gas Diuser, Low Current 0004470031 5 Shield Gas Diuser, Standard 0004470115 1 Shield Gas Diuser, Reverse 0004470046 2 Shield Retainer, Standard 0558003858 2 Contact Ring w/screw

37073 6 Screw, Contact Ring

93750010 2 Hex Key Wrench .109" (2.8mm) 0004485649 1 Nut Driver 0.44" ( 11.1mm)(Electrode tool) 0558003918 1 Electrode Holder Tool PT-36

77500101 1 Silicon Grease DC-111 5.3oz (150g)

PT-36 TORCH

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

0558005224

600 amp

10 10 10 0558003914 Electrode O2 UltraLife, Standard

5 5 5 0558003928 Electrode N2/H35, Standard 5 5 5 0558005459 Electrode O2/N2, Low Current 5 5 5 0558006908 Nozzle PT-36 0.8mm (.030") 5 5 5 0558006010 Nozzle PT-36 1.0mm (.040") 5 5 5 0558008010 Nozzle PT-36 1.0mm (.040") PR 5 5 5 0558006014 Nozzle PT-36 1.4mm (.055") 5 5 5 0558006018 Nozzle PT-36 1.8mm (.070") 5 5 5 0558006020 Nozzle PT-36 2.0mm (.080") 5 5 5 0558006023 Nozzle PT-36 2.3mm (.090") 5 5 - 0558006025 Nozzle PT-36 2.5mm (.099") 5 5 - 0558006030 Nozzle PT-36 3.0mm (.120") 5 5 - 0558006036 Nozzle PT-36 3.6mm (.141") 5 - - 0558006041 Shield PT-36 4.1mm (.161") 5 5 5 0558007624 Shield PT-36 2.4mm (.095") 5 5 5 0558006130 Shield PT-36 3.0mm (.120") 5 5 5 0558006141 Shield PT-36 4.1mm (.160") 5 5 5 0558006166 Shield PT-36 6.6mm (.259") 5 - - 0558006199 Shield PT-36 9.9mm (.390")

0558005223

360-450 amp

0558005222

200 amp

Part Number Description

PT-36 TORCH

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

Part Number Quantity Description

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

PT-36 TORCH

PT-36 Technical Specications

7.5 4"

(191. 5mm)

6.17"

(156.7mm)

NOTE:

Clamp only on insulated torch sleeve not less than

1.25" (31.7mm) from the torch end of sleeve.

2.00"

(50.8mm)

9.13"

(231.9mm)

10.50" (266.7mm) Length of Sleeve

Recommended Regulators

Liquid Cylinder Service:

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

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

High Pressure Cylinder Service:

O2 : R-77-150-540 .................................................................................................................. P/N 998337

Ar & N2 : R-77-150-580 .......................................................................................................... P/N 998344

H2 & CH4 : R-77-150-350 ..................................................................................................... P/N 998342

Industrial Air : R-77-150-590 ............................................................................................ P/N 998348

Station/Pipeline Service:

O2 : R-76-150-024 ..................................................................................................................... P/N 19151

Ar & N2 : R-76-150-034 ............................................................................................................. P/N 19155

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

PT-36 TORCH

PT-36 Torch Technical Specications

Type: Water cooled, Dual gas, mechanized plasmarc cutting torch

Current Rating: 1000 Amps @ 100% duty cycle

Mounting Diameter: 2 inches (50.8 mm)

Length of Torch without leads: 16.7 inches (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 bars)

Maximum Coolant Pressure at Inlet: 200 psig (13.8 bars)

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 bars)

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.

PT-36 TORCH

Connection of Torch To Plasma System

Refer to system manual and the Plasma/Shield Gas Box manual.

DANGER

Electric Shock Can Kill!

• Disconnect primary power source before making any adjustments.

• Disconnect primary source before doing maintenance on system

components.

• Do not touch front-end torch parts (nozzle, retaining cup, etc.) without turning primary power o.

Power Cables

Connection to the Remote Arc Starter Box

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

The pilot arc cable is connected to the arc stater box (see Plasma/Shield Gas Box manual). The pilot arc cable also has a green/yellow wire that is connected to a grounding stud.

Mounting Torch to Machine

Refer to machine manual.

Mount torch on insulated sleeve here

DO NOT mount on steel torch body here

PT-36 TORCH

Clamping on Torch Body May Cause Dangerous Current To Flow 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 machine.

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

replacement.

•Damage to machine components may result.

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

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

PT-36 TORCH

DANGER

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

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

1. Molten Metal Reaction

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

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

2. Slow Chemical Reaction

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

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

3. Plasma Gas

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

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

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

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

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

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

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

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

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

metals.

PT-36 TORCH

WARNING

Possible explosion hazard from plasma cutting aluminum-lithium alloys!

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

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

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

WARNING

Oil And Grease Can Burn Violently!

• Never use oil or grease on this torch.

• Handle torch clean hands only on clean surface.

• Use silicone lubricant only where directed.

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

WARNING

Hydrogen explosion hazard.

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

Spark hazard.

Heat, spatter, and sparks cause ﬁre and burns.

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

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

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

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

process.

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

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

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

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

WARNING

PT-36 TORCH

Set Up

•Select an appropriate condition from the process data (SDP File) and install recommended torch front-end

parts (nozzle, electrode, etc.) See process data to identify parts and settings.

•Position torch over material at desired start location.

•See Power Source Manual for proper settings.

•See Flow Control Manual for gas control procedures.

•See Control and Machine Manuals for startup procedures.

Mirror Cutting

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

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

Reverse Diuser P/N 0004470115

Cut Quality

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

•Cut Angle, negative or positive

•Cut Flatness

•Surface nish

•Dross

•Dimensional Accuracy

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

•Make small incremental adjustments when making corrections.

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

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

Before attempting ANY corrections, check cutting variables with the

CAUTION

Cut Angle

Negative Cut Angle

Top dimension is greater than the bottom.

factory recommended settings/consumable part numbers listed in Process Data.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• Stando low (arc voltage)

• Cutting speed slow (machine travel rate)

PT-36 TORCH

Part

Positive Cut Angle

Top dimension is less than the bottom dimension.

•Misaligned torch

•Bent or warped material

•Worn or damaged consumables

•High stando High (arc voltage)

•Cutting speed fast

•Current high or low. (See Process Data for

recommended current level for specic nozzles).

Drop

Part

PT-36 TORCH

Cut Flatness

Top And Bottom Rounded. Condition usually occurs when material is .25" thick (6,4mm) or less.

•High current for given material thickness (See

Process Data for proper settings).

Top Edge Undercut

•Stando low (Arc Voltage)

Drop

Part

Surface Finish

PT-36 TORCH

Process Induced Roughness

Cut face is consistently rough. May or may not be conned to one axis.

 •IncorrectShieldGasmixture(SeeProcessData).  •Wornordamagedconsumables.

Machine Induced Roughness

Can be dicult to distinguish from Process Induced Roughness. Often conned to only one axis. Roughness is inconsistent.

 •Dirtyrails,wheelsand/ordriverack/pinion.

(Refer to Maintenance Section in machine operation manual).

 •Carriagewheeladjustment.

Dross

Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.

Top View

Process Induced Roughness

Lag Lines

Cut Face

Machine Induced Roughness

Cut Face

Rollover

High Speed Dross

Material weld or rollover on bottom surface along kerf. Dicult to remove. May require grinding or chipping. “S” shaped lag lines.

 •Standohigh(arcvoltage)  •Cuttingspeedfast

Slow Speed Dross

Forms as globules on bottom along kerf. Removes easily.

 •Cuttingspeedslow

Side View

Cut Face

Lag Lines

Globules

Side View

PT-36 TORCH

Recommended cutting speed and arc voltage will give optimal cutting performance in most cases. Small incremental adjustments may

CAUTION

Top Dross

Appears as splatter on top of material. Usually removes easily.

 •Cuttingspeedfast  •Standohigh(arcvoltage)

Intermittent Dross

Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross.

 •Possiblewornconsumables

Other Factors Aecting Dross;

 •Materialtemperature  •Heavymillscaleorrust  •Highcarbonalloys

be needed due to material quality, material temperature and specic alloy. The operator should remember that all cutting variables are interdependent. Changing one setting aects all others and cut quality could deteriorate. Always start at the recommended settings.

Side View

Splatter

Cut Face

Before attempting ANY corrections, check cutting variables with the

CAUTION

factory recommended settings/consumable part numbers listed in the Process Data.

Dimensional Accuracy

Generally using the slowest possible speed (within approved levels) will optimize part accuracy. Select consumables to allow a lower arc voltage and slower cutting speed.

NOTICE

Recommended cutting speed and arc voltage will give optimal cutting performance.

Small incremental adjustments may be needed due to material quality, material temperature and specic alloy. The operator should remember that all cutting variables are interdependent. Changing one setting aects all others and cut quality could deteriorate. Always start at the recommended settings. Before attempting ANY corrections, check cutting variables with the factory recommended settings/ consumable part numbers listed in the process data.

Torch Flow Passages

Pilot Arc

PT-36 TORCH

Shield Gas In

Plasma Gas In

Water Out

Pilot Arc

Water In

PT-36 TORCH

Torch Front End Disassembly

Wear on torch parts is a normal occurrence to plasma cutting. Starting a plasma arc is an erosive process to both the electrode and nozzle. Regularly scheduled inspection and replacement of PT-36 parts must take place to maintain cut quality and consistent part size.

DANGER

1. Remove the Shield Cup Retainer.

HOT TORCH WILL BURN SKIN! ALLOW TORCH TO COOL BEFORE SERVICING.

NOTE:

If the shield cup retainer is dicult to remove, try to screw the nozzle retaining cup tighter to

relieve pressure on the shield cup retainer.

2. Inspect mating metal surface of shield cup and shield cup retainer for nicks or dirt that might prevent these two parts from forming a metal to metal seal. Look for pitting or signs of arcing inside the shield cup. Look for melting of the shield tip. Replace if damaged.

3. Inspect diuser for debris and clean as necessary. Wear on the top notches does occur, eecting gas volume. Replace this part every other shield replacement. Heat from cutting many small parts in a concentrated area or when cutting material greater than 0.75" (19.1mm) may require more frequent replacement.

Incorrect assembly of the diuser in the shield will prevent the torch

CAUTION

from working properly. Diuser notches must be mounted away from the shield as illustrated.

Shield Cup

Shield Cup Retainer

Diuser

Torch Body

Electrode

Nozzle

Nozzle Retaining Cup

PT-36 TORCH

4. Unscrew nozzle retainer and pull nozzle straight out of torch body. Inspect insulator portion of the nozzle retainer for cracks or chipping. Replace if damaged.

Inspect nozzle for:

• melting or excessive current transfer.

• gouges from internal arcing.

• nicks or deep scratches on the O-ring seating surfaces .

• O-ring cuts, nicks, or wear.

Remove hafnium particles (from the nozzle) with steel wool. Replace if any damage is found.

NOTE:

Discoloration of internal surfaces and small black starting marks are normal and do not eect

cutting performance.

If the holder was tightened suciently, the electrode may unscrew without being attached to the electrode

holder. When installing the electrode, use only sucient force to adequately secure the electrode.

5. Remove electrode using electrode removal tool.

6. Disassemble electrode from electrode holder. Insert ats on the holder into a 5/16" wrench. Using the electrode tool, rotate electrode counter-clockwise to remove. Replace electrode if center insert is pitted more than 0.09" (3/32").

Torch Body

Electrode Removal Tool

Electrode

Replace electrode if center insert is

pitted more than 0.09" (3/32")

PT-36 TORCH

7. Remove the electrode holder from the torch body. The hex head on the end of the electrode holder removal tool will engage in a hex socket in the electrode holder.

Gas Bae

Removal Tool

Electrode Holder Assembly

Electrode

NOTE:

The electrode holder is manufactured in two pieces. Do not disassemble. If the holder is dam-

aged, replace the electrode holder assembly.

8. Disassemble the electrode holder and gas bae. Carefully remove the O-ring from electrode holder and

slide bae from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not attempt to clear holes. Replace bae if damaged.

NOTE:

Check all O-rings for nicks or other damage that might prevent the O-ring from forming a gas/

water tight seal.

Gas Bae

Electrode Holder Assembly

O-ring

NOTE:

Discoloration of these surfaces with use is normal. It is caused by galvanic corrosion.

PT-36 TORCH

Assembly of Torch Front End

Over tightened Parts Will Be Dicult To Disassemble And May Dam-

CAUTION

age Torch. Do not over tighten parts during reassembly. Threaded parts are designed to work properly when hand tightened, approximately 40 to 60 inch/pounds.

•Reverse order of disassembly.

•Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates easy

future assembly and disassembly for service.

•Installing the electrode requires only moderate tightening. If the electrode holder is made tighter than the

electrode, it is possible to change worn electrodes without removing the electrode holder.

NOTE:

When assembling, place the nozzle inside the nozzle retaining cup and thread the nozzle retaining cup/nozzle combination on the torch body. This will help align the nozzle with the assembly. The shield cup and shield cup retainer should be installed only after installing the nozzle retain-

ing cup and nozzle.

Otherwise the parts will not seat properly and leaks may occur.

Shield Cup Retainer

Diuser

Torch Body

Nozzle

Electrode

Nozzle Retaining Cup

Shield Cup

PT-36 TORCH

Assembly of Torch Front End using the Speedloader

Use of a speedloader, p/n 0558006164, will ease assembly of the torch front end parts.

step 1. To use the speedloader, rst insert the nozzle into the

nozzle retaining cup.

step 2. Screw the speedloader into the nozzle retaining cup

to secure the nozzle.

Nozzle

Nozzle Retaining Cup

step 3. Secure retaining nut on nozzle with preassembly tool,

p/n 0558005917 included with the speedloader.

step 4. Remove the speedloader. It is very important to

remove the speedloader to ensure proper seating of the remaining parts.

step 5. Insert the diuser into the shield cup.

Diuser

step 6. Insert the nozzle retaining cup assembly into the

shield cup retainer.

Nozzle retaining cup assembly

Preassembly tool

Retaining nut p/n 0558005916

Shield Cup

Shield cup retainer

Shield cup retainer assembly

step 7. Screw shield cup retainer assembly onto nozzle re-

taining cup assembly.

PT-36 TORCH

Torch Front End Disassembly (for Production Thick Plate)

DANGER

CAUTION

1. Remove the High Current Nozzle Retaining Cup assembly. Unless one of these components requires replacement, they can remain assembled to each other. Inspect for signs of melting on the shield cup and check the insulator portion of the nozzle retaining cup for wear or damage.

Torch Body

HOT TORCH WILL BURN SKIN! ALLOW TORCH TO COOL BEFORE SERVICING.

Incorrect assembly of the diuser in the shield will prevent the torch from working properly. Diuser notches must be mounted away from the shield as illustrated.

Nozzle

High Current Nozzle Retaining Cup Assembly

High Current Shield

2. Pull nozzle straight out of torch body.

Inspect nozzle for:

• melting or excessive current

transfer.

• gouges from internal arcing.

• nicks or deep scratches on the

O-ring seating surfaces.

• O-ring cuts, nicks, or wear.

Remove tungsten particles (from the nozzle) with steel wool. Replace if any damage is found.

PT-36 TORCH

Torch Body

Nozzle

Nozzle Retaining Cup

NOTE:

Discoloration of internal surfaces and small black starting marks are normal and do not eect

cutting performance.

3. Remove electrode using electrode removal tool.

4. Disassemble electrode from electrode holder. Insert ats on the holder into a 5/16" wrench. Using the electrode tool, rotate the collet body counter-clockwise to remove. Replace electrode if center is pitted more than 0.06" (1/16") or if the at has become irregular in shape or is worn to a larger diameter. Use only sucient force to adequately secure the electrode.

Note:

The electrode has two usable ends. When one end is worn, ip electrode to

other end for continued use.

Torch Body

Electrode

Electrode Removal Tool

Collet

Collet Body

Electrode, Tungsten

PT-36 TORCH

5. If the electrode holder did not come out in step 3, remove the electrode holder from torch body using the Electrode Holder Removal Tool. The hex head on the end of the electrode holder removal tool will engage in a hex socket in the electrode holder.

Torch Body

Electrode Holder

Electrode Holder Removal Tool

8. Disassemble electrode holder and gas bae. Carefully remove O-ring from electrode holder and slide bae

from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not attempt to clear holes. Replace bae if damaged.

NOTE:

Check all O-rings for nicks or other damage that might prevent O-ring from forming a gas/water

tight seal.

Electrode Holder

O-ring (located behind bae)

Gas Bae

PT-36 TORCH

Assembly of Torch Front End (for Production Thick Plate)

Over tightened parts will be dicult to disassemble and may dam-

CAUTION

age torch. Do not over tighten parts during reassembly. Threaded parts are designed to work properly when hand tightened, approximately 40 to 60 inch/pounds.

•Reverse order of disassembly.

•Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates easy

future assembly and disassembly for service.

•Installing the electrode requires only moderate tightening.

Torch Body

1. Replace electrode holder in torch body. Hex on the end of the electrode holder removal tool will engage in a hex in the holder.

Collet

Collet Body

Electrode, Tungsten

2. To replace the electrode, assemble collet, collet body and electrode. Insert electrode assembly into the electrode removal tool and ensure electrode makes contact with bottom of tool hole (electrode will fall into place).

PT-36 TORCH

3. Screw electrode assembly in a clockwise direction to torch body. Electrode will tighten in the correct position when collet closes. When using the high current nozzle retaining cup, remove o-ring indicated and replace it with o-ring, p/n 488158 as shown.

Remove this O-ring

Place O-ring, p/n 488158 here

Nozzle Retaining Cup

Torch Body

Nozzle

NOTE:

When assembling, place the nozzle inside the high current nozzle retaining cup and thread the high current nozzle retaining cup/nozzle combination on the torch body. This will help align the nozzle with the assembly. The high current shield cup can be assembled onto the high current

nozzle retaining cup at any time.

PT-36 TORCH

Torch Body Maintenance

•Inspect O-rings daily and replace if damaged or worn.

•Apply a thin coat of silicone grease to O-rings before assembling torch. This facilitates easy future assembly

and disassembly for service.

•O-ring (1.61" (41mm) I.D. x .07" (1.8mm) BUNA-70A) p/n 996528.

ElectricShockCanKill!Beforeperformingtorchmaintenance:

WARNING

•Turn power switch of the power source console to the OFF position

•Disconnect primary input power.

•Keep electrical contract ring contact points free of grease and dirt.

•Inspect ring when changing nozzle.

•Clean with cotton swab dipped in isopropyl alcohol.

O-Ring locations

Contact Ring Points

Contact Ring Screw

Contact Ring Points

Contact Ring

PT-36 TORCH

Removal and Replacement of the Torch Body

ElectricShockCanKill!Beforeperformingtorchmaintenance:

WARNING

•Turn power switch of the power source console to the OFF position

•Disconnect primary input power.

1. Loosen the worm gear hose clamp so that the torch sleeving can be freed and pulled back up the cable bundle. Approximately 7 inches should be far enough. Unscrew the torch sleeve and slide it back until the pilot arc connection is exposed.

Handle

Torch Body

2. Disconnect the power cables which are threaded onto the shorter stems at the back of the torch. Note that

one of these connections is left-handed. Unscrew the gas hoses from the torch head assembly by using a 7/16" (11.1mm) and a 1/2" (12.7mm) wrench. Removal of the gas hoses is easier if the power cables are removed rst.

1/2" power cable

connections

1/2" shield gas

connection

7/16" plasma gas

connection

PT-36 TORCH

3. Unwrap the electrical tape at the back of the gray plastic insulator over the pilot arc connection. Slide the insulator back and undo the knife connectors.

Pilot Arc Cable

Wire splice

Electrical Tape

(shown removed)

Knife-splice connection

4. To install the new torch head assembly - Connect the pilot arc cable and the main power cable by reversing the steps taken to disconnect them. Be sure the gas and water ttings are tight enough to prevent leaks, but do not use any kind of sealant on them. If the knife connection seems loose, tighten the connection by pressing on the parts with needle-nosed pliers after they are assembled. Secure the gray pilot arc insulator with 10 turns of electrical tape.

New Torch Head Assembly

5. Slide the handle forward and thread it rmly onto the torch body.

PT-36 TORCH

Reduced Consumable Life

1. Cutting Up Skeletons

Cutting skeletons (discarded material left after all pieces have been removed from a plate). Their removal from the table can adversely aect electrode life by:

•Causing the torch to run o the work.

•Greatly increasing the start frequency. This is mainly a problem for O

by choosing a path with a minimum number of starts.

cutting and can be alleviated

•Increasing likelihood that the plate will spring up against the nozzle causing a double arc. This can

be mitigated by careful operator attention and by increasing stando and reducing cutting speeds.

If possible, use an OXWELD torch for skeleton cutting or operate the PT-36 at a high stando.

2. Height Control Problems

•Torch diving is usually caused by a change in arc voltage when an automatic height control is used. The

voltage change is usually the result of plate falling away from the arc. Disabling the height control and extinguishing the arc earlier when nishing the cut on a falling plate can eectively eliminate these problems.

•Diving can also occur at the start if travel delay is excessive. This is more likely to occur with thin material.

Reduce delay or disable the height control.

•Diving can also be caused by a faulty height control.

3. Piercing Stando Too Low Increase pierce stando

4. Starting on edges with continuous pilot arc Position torch more carefully or start on adjacent scrap material.

5. Work Flipping The nozzle may be damaged if the torch hits a ipped up part.

6. Catching on Pierce Spatter Increase stando or start with longer lead-in.

7. Pierce not complete before starting Increase initial delay time.

8. Coolant ow rate low, Correct settings Plasma gas ow rate high, Current set too high

9. Coolant leaks in torch Repair leaks

PT-36 TORCH

Checking for Coolant Leaks:

Coolant leaks can originate from seals on the electrode, electrode holder, nozzle, and torch body. Leaks could also originate from a crack in the insulating material of the torch or nozzle retaining cup or from a power cable.

To check for leaks from any source remove the shield cup, clean o the torch, purge it, and place it over a clean dry plate. With the gases o, run the watercooler for several minutes and watch for leaks. Turn on the plasma gas and watch for any mist from the nozzle exit. If there isn’t any, turn o the plasma gas, turn on the shield gas, and watch for any mist from the shield gas passages in the nozzle retaining cup.

If a leak appears to be coming from the nozzle orice, remove and inspect the o-rings on the nozzle, electrode, and electrode holder. Check the sealing surfaces on the electrode holder and stainless steel torch liner.

If you suspect that a leak is coming from the electrode itself, you can install a PT-19XL 100 to 200 amp 2-piece nozzle base without a nozzle tip. After purging, run the water cooler with the gas o and observe the end of the electrode. If water is seen to collect there, make sure it is not running down the side of the electrode from a leak at an o-ring seal.

If it is necessary to supply power to the power source to run the wa-

WARNING

ter cooler, it is possible to have high voltages at the torch with no arc present. Never touch the torch with the power source energized.

PT-36 TORCH

REPLACEMENT PARTS

6.0 Replacement Parts

General

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

Ordering

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

Replacement parts may be ordered from your ESAB Distributor.

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

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

Note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

REPLACEMENT PARTS

PT-36

Mechanized Plasmarc Cutting Torch

for Production Thick Plate

Use:

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

Item No. Part Number Quantity Description

1 0558003963 1 Electrode, Tungsten 3/16"D

2 0558003965 1 Nozzle H35 .198" Divergent

3 0558003964 1 Collet 3/16"D Electrode

4 0558005689 1 Electrode/Collet Holder PT-36R

5 0558003967 1 Collet Body

6 0558002532 1 Bae, 32 Hole x .023

7 0558006688 1 Shield High Current

8 0558003918 1 Electrode Holder Tool PT-36R

9 0558003962 1 Tungsten Electrode Tool

10 0558008737 1 Nozzle Retaining Cup assy High Current

NOTE:

These are the only items that are

181W89

488158

P/N 0558003965 is supplied with (2) p/n 181W89

installed & (1) p/n 488158 loose in the box.

When using the high current nozzle retaining

cup and high current shield, as recommended,

remove and discard the o-ring nearest the ori-

ce and install p/n 488158 on the step originally

dierent for Production Thick

Plate. Refer to the Cut Data man-

ual (0558008434/0558008435) for

complete setup and parameters.

NOTE:

intended for the diuser.

REPLACEMENT PARTS

* bill of materials listed on 11 x 17 fold-out pages (0558008300)

O-rings supplied with Torch Body, P/N 996528

O-ring supplied with Electrode Holder assembly, P/N 86W99

O-ring supplied with Electrode

O-rings, p/n 181W89 supplied with Nozzle

NOTE:

Items 8, 15, 18 & 33 are supplied in a

bag with the torch.

REPLACEMENT PARTS

PT-36 Torch Lead Sets

Item No. Part Number Description

1 0558007031 Lead Set PT-36 4.5' (1.4m) 2 0558007032 Lead Set PT-36 6' (1.8m) 3 0558007034 Lead Set PT-36 12' (3.6m) 4 0558007035 Lead Set Beveling PT-36 14' (4.3m) 5 0558007036 Lead Set PT-36 15' (4.6m) 6 0558007037 Lead Set PT-36 17' (5.2m) 7 0558007038 Lead Set PT-36 20' (6.1m) 8 0558007039 Lead Set PT-36 25' (7.6m)

1. Originally released - 10/2012.

REVISION HISTORY

ESAB Welding & Cutting Products, Florence, SC

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM EST

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

ESAB m3 plasma m3 Integrated Gas Control (IGC) - Vision 5x Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

1.0 Safety

Introduction

Safety - English

Safety - Spanish

Safety - French

Integrated Gas Control System Interconnect Diagram

COMBINED GAS CONTROL

2.0 Combined Gas Control (CGC)

Functions and Features

CGC Flow Diagram

Combined Gas Control Plumbing Schematic

Combined Gas Control Electrical Schematic

Connections

Troubleshooting

CGC Mounting Dimensions

CGC Bottom View

POWER DISTRIBUTION BOX

3.0 Power Distribution Box (PDB)

PDB Mounting Dimensions

PDB Mounting Plate Dimensions

PDB Schematic

REMOTE ARC STARTER

4.0 Remote Arc Starter Box

Power Source Connections

Power Source Connections (con’t.)

Torch Connections

Remote Arc Starter Box Mounting

Typical / Recommended E-stop Connection

4.0 General

Scope

Package Options Available

Optional Accessories:

PT-36 Torch Consumable Kits

Recommended Regulators

Connection of Torch To Plasma System

Connection to the Remote Arc Starter Box

Mounting Torch to Machine

Set Up

Mirror Cutting

Cut Quality

Cut Angle

Cut Flatness

Surface Finish

Dross

Dimensional Accuracy

Torch Flow Passages

Torch Front End Disassembly

Assembly of Torch Front End

Assembly of Torch Front End using the Speedloader

Torch Front End Disassembly (for Production Thick Plate)

Assembly of Torch Front End (for Production Thick Plate)

Torch Body Maintenance

Removal and Replacement of the Torch Body

Reduced Consumable Life

REPLACEMENT PARTS

6.0 Replacement Parts

General

Ordering