ESAB m3 Plasma Manual Gas Control Plasma System Instruction manual

Manual Gas Control Plasma System

PCC-14 Plumbing Box

Plasma Control Interface

Instruction Manual

This documentation is for ESAB equipment:

PCC-14 Plumbing Box part number 0558005840 Plasma Control Interface part number 0560948696 (serial #’s AA-K004001,002,003,004,005)

0558009614 05/2011

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

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

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!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.0 ESAB m3 Manual Gas Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

PCC-14 Plumbing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Plumbing Box Spark Gap Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.3 Plumbing Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.4 EPP-201 / EPP-360 Torch Connections to Plumbing Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.5 PCC-14 Plumbing Box Mounting Hole Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Plasma Control Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

3.6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

3.7 Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.8 Plasma Control Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3.9 Typical / Recommended E-stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

3.10 Control Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.11 Plasma Control Interface Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

3.12 Plasma Control Interface STATUS Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

4.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.0 Marking Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

5.1 Marking Module Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

6.0 PT-36R Plasma Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

6.1 PT-36R Technical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

6.2 Gas Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

6.3 Recommended Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

6.4 PT-36R Torch Technical Specications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.0 Coolant Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

7.1 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

7.2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.3 Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

8.0 EPP-201 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

8.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

8.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

9.0 EPP-360 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

9.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

9.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

TABLE OF CONTENTS

10.0 HOSES AND CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

10.1 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

10.2 Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

11.0 Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

11.2 Ordering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Diagrams and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . attached packet

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references

listed in Additional Safety Information section. Before performing 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, emits

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 ameproof apron may also be desirable as protection against radiated heat and sparks.

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

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

5. Protect other personnel from arc rays and hot

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

6. Use goggles over safety glasses when chipping slag

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

1.1 Safety - English

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 workpiece has been completely cleaned so that there are no substances on the workpiece 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, Batterymarch 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.

SECTION 1 SAFETY PRECAUTIONS

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

2. Connect the workpiece to a good electrical ground.

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

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

5. Keep everything 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.

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 workpiece 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:

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

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.

SECTION 1 SAFETY PRECAUTIONS

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.

1. Always have qualied personnel perform the installation, 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.

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:

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"

SECTION 1 SAFETY PRECAUTIONS

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."

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

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.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad 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 precauciones 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 del 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 chis-

pas calientes con una cortina adecuada no-amable como división.

6. Use careta protectora además de sus gafas de segu-

ridad 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 soldadura de corri-

ente alterna (AC) en áreas húmedas, de movimiento connado en lugares estrechos o si hay posibilidad de caer al suelo.

SECCION 1 SEGURIDAD

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. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios

sin ventilación. No inhale el humo

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

1. Siempre provea ventilación adecuada en el área

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

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

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

3. Si momentáneamente desarrolla inrritación de

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

4. Haga referencia a la publicación ANSI/ASC Standard

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

SECCION 1 SEGURIDAD

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.

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

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.

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:

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

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

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

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

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

SECCION 1 SEGURIDAD

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 inmediatamente en serio daño personal o la muerte.

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.

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution

provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, 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 la-

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

2. Portez un écran facial muni de verres ltrants et de

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

3. Portez des gants ignifugiés à crispin, une chemise

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

4. Les étincelles et les projections de métal incandescent

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

5. Protégez toute personne se trouvant à proximité des

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

6. Portez des lunettes étanches par dessus vos lunettes

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

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les 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 électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

SECTION 1 SÉCURITÉ

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 — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conduc-

teur produit des champs électriques et magnétiques 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'effectuez 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.

SECTION 1 SÉCURITÉ

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 équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier 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"

SECTION 1 SÉCURITÉ

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

DANGER

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

AVERTISSEMENT

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

ATTENTION

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

SECTION 2 INTERCONNECT DIAGRAM

Customer CNC

Torch

Bubble Muffler

Plasma Gas

Shield Gas

Air Curtain

Power, Pilot Arc, Coolant

Bubble Muffler / Air Curtain Control

PCI-VDR

PCI

PCI-EP

PCI-CI

PCC-14 Control

PCI-CTL

PCI-ES

PCI-CC

VDR

PCI-AS

(optional)

Argon Select

PCC-VDR

PCC-CTL

PCC-14

(optional)

PCC-STG

PCC-PWR

PCC-SHG

PT-36R

PCC-OUT

PCC-IN

PCC-PA

2.0 ESAB m3 Manual Gas Control System

The Manual Gas Control System consists of several components: Plasma Control Interface (PCI), PCC-14 Plumbing Box, Power Supply (PS), Coolant Circulator (CC), Torch and customer CNC.

Dotted line denotes optional

Ext. 115/230VAC

Control Interface

PS Contol Cable

E-Stop

PS-ES

PS-CC

PS-PWR

SM-AS

PS-PA

(optional)

Module

Switching

Mark / Cut

PCC-AR

PCC-CG

Cut Gas

REG-AR

REG-CG

(optional)

CC-11 Control Cable

PS-IC

Start Gas

Shield Gas

REG-STG

Gas Supply

Regulated

Power Cable

REG-SHG

CC-IC

Pilot Arc Cable

Coolant Supply Hose

Coolant Return Hose

CC-IN

CC-OUT

LIQUID Optional

GAS

DATA

POWER

SECTION 2 INTERCONNECT DIAGRAM

PCC-14 Plumbing Box

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

3.0 General

The PCC-14 Plumbing Box is a Plasmarc Cutting Control used to connect the PT-36R Plasma Torch to a remotely located EPP-201 or EPP-360 power supply system. The PCC-14 includes high frequency starting circuits to eliminate starting problems with long torches and to minimize high frequency interference with other customer systems.

3.1 Scope

The purpose of this manual is to provide the operator with all the information required to install and operate the Plumbing Box & Plasma Control Interface. Technical reference material is also provided to assist in troubleshooting.

Specications: PCC-14 Plumbing Box

Weight: 41lbs. (18.6 kg)

Plasma and Start Gases:

The PCC-14 may be used with O2, N2, Air, or Ar/H2 with a maximum input pressure of 110 psig (7.6 bar). ***These are maximum input pressures and do not reect actual cutting pressures.***

It is recommended, but not required, that N2 be used as the start gas when using Ar/H2. The ow rate of gas will depend on the pressure set, the torch connected to the plumbing box, and the parts installed in the torch. Without a torch attached, the maximum ow rate for these gases at 100 psig (6.9 bar) is about 1000 scfh (28.3 cu-m/h). The minimum acceptable pressure for the start gas is 19 psig (1.3 bar); for the plasma gas it is 24 psig (1.7 bar). Below these pressures the pressure switches may not be satised.

Shield Gases: The PCC-14 may be used with Air, N2, Ar, or CO2. The maximum pressure is 110 psig (7.6 bar). This will result in a ow of 250 scfh (7.1 cu-m/h) N2. See Graph 3-1. There is no pressure interlock on the shield gas.

Coolant: The PCC-14 is designed for use with plasma torch coolant (ESAB P/N’s 156F05 or 0558004297). Maximum design pressure is 200 psig (13.8 bar). Flow rates depend on the torch but typically vary from 0.9 to 2 gpm (4.1 to 9.1 l/m).

THIS EQUIPMENT CAN BE HAZARDOUS IF NOT PROPERLY OPERATED AND MAINTAINED. READ AND UNDERSTAND ALL EQUIPMENT LITERATURE AND WARNING LABELS BEFORE OPERATING THIS EQUIPMENT.

WARNING

FOLLOW THESE INSTRUCTIONS TO PREVENT INJURY OR PROPERTY DAMAGE. YOU MUST COMPLY WITH LOCAL, STATE AND NATIONAL ELECTRICAL AND SAFETY CODES. ONLY TRAINED PERSONNEL SHOULD PERFORM MAINTENANCE OR REPAIRS ON THIS EQUIPMENT.

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Flashback arrestors are required to prevent re from propagating back to the gas supply through lines carrying oxygen or fuel gases. Use AWG 2/0 power cable to carry electrode current from the power source to the PCC-14. See section 9.0 for additional cables.

CAUTION

Gas Purging:

When switching between Ar/H2 and an oxidizing gas (air or oxygen) it is recommended that the following procedure be followed:

1. Turn o the gas.

2. Put the system into plasma gas test until line pressure is exhausted. If the start gas is being switched to or from Ar/ H2, switch to start gas test until that line is exhausted as well.

3. Disconnect the old gas and connect a relatively inert gas such as nitrogen, argon, carbon dioxide, C-25, etc. Set the pressure to 50 psig (3.5 bar) and purge each aected line for 60 seconds.

4. Then shut o the gas and exhaust each line per Step 2.

5. Connect the gas to be used. Set the pressure to recommended values for the cutting condition to be used, and purge each aected line for 15 seconds per 25 ft. (7.6 m) of line.

Avoid using the same supply lines for both oxygen and air if oil may be mixed with the air. Oil in the presence of 100% oxygen can be highly ammable. Failure to observe above cautions may result in personal injury and / or damage to the equipment.

Note:

The expected life of the internal exible hoses is 10 years. Replace them earlier if cracking or brittleness is noted.

Marking option

With the optional Marking Module installed, the PCC-14 will allow you to switch the cut gas to Argon for plate marking. With the Marking Module installed, Argon gas input to the Marking Module is 125 psig (8.6 Bar).

Note:

When marking, ensure the start gas line is pressurized to avoid pressure switch errors.

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

250 (7.1)

240 (6.8)

230 (6.5)

220 (6.2)

210 (5.9)

200 (5.7)

190 (5.4)

180 (5.1)

170 (4.8)

160 (4.5)

150 (4.2)

Graph 3-1 - Gas Pressure / Flow

140 (4.0)

130 (3.7)

120 (3.4)

110 (3.1)

100 (2.8)

Shield Gas Flow SCFH (CU-M/H) N

90 (2.5)

80 (2.3)

70 (2.0)

60 (1.7)

50 (1.4)

40 (1.1)

30 (0.8)

20 (0.6)

10 (0.3)

0 10 20 30 40 50 60 70 80 90 100 110 120 130

(0.7) (1.4) (2.1) (2.8) (3.5) (4.1) (4.8) (5.5) (6.2) (6.9) (7.6) (8.3) (9.0)

PSIG (BAR) Pressure Setting to 0.052 in. (1.32 mm) Diameter Orice

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

3.2 Plumbing Box Spark Gap Adjustment

ELECTRICITY CAN KILL! HIGH VOLTAGE CAN BE PRESENT BEHIND COVER PLATE. DO NOT OP ERATE WITHOUT COVER PLATE IN PLACE. BEFORE REMOVING COVER

WARNING

CAUTION

WARNING

PLATE OR PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS EQUIPMENT, ENSURE THE POWER SOURCE IS TURNED OFF AND DIS CONNECTED.

Only qualied maintenance personnel should repair and maintain this equipment. Unit is NOT designed for use in rain or snow. Damage to equipment may result. Unit is to be lifted only by the handle provided . Failure to do so may result in damage to the equipment.

ELECTRIC SHOCK CAN KILL! TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX BEFORE MAKING ANY CONNECTIONS TO THE PCC14.

Spark Gap

1. Disconnect input power to power source.

2. Remove access cover from spark gap opening.

3. Check / set to recommended spark gap of 0.040” (1 mm).

4. Replace cover.

Spark Gap

Access Cover

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

3.3 Plumbing Box Connections

Connection Locations

Inside Plumbing Box

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

ELECTRIC SHOCK CAN KILL! TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX BEFORE MAKING ANY CONNECTIONS TO THE POWER SUPPLY. DISCONNECT CURRENT SUPPLY AT WALL DISCONNECT BEFORE SERVICING

WARNING

PLUMBING BOX.

• DO NOT OPERATE PLUMBING BOX WITH ANY COVERS REMOVED / OPEN.

• DO NOT TOUCH ANY TORCH FRONTEND PARTS WITH POWER ON.

• DO NOT ATTEMPT TO SERVICE UNLESS POWER HAS BEEN DISCONNECTED AT THE WALL.

Pilot Arc Cable From Power Supply

Shield Gas Hose From Torch

Plasma Gas Hose From Torch

Pilot Arc Cable From Torch

Power / Coolant Supply Hose From Torch

Power / Coolant Return Hose From Torch

Coolant Supply Hose

Power Cables

Coolant Return Hose

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

ELECTRIC SHOCK CAN KILL!

WARNING

3.4 EPP-201 / EPP-360 Torch Connections to Plumbing Box

1. Torch connections are rst made in the PCC-14 plumbing box. Remove the cover of the plumbing box to access input

and output connections . For both manual and mechanized torch applications, pass the torch lines through the openings in the front of plumbing box and make connections as shown.

Lines from torch

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX BEFORE MAKING ANY CONNECTIONS TO THE PCC14.

1 Shield Gas Hose 2 Electrode Cable / Coolant Return Hose 3 Plasma Gas Hose 4 Electrode Cable / Coolant Supply Hose 5 Pilot Arc Cable

Shield Gas

Coolant Return

(Electrode Cable)

Plasma Gas

Coolant Supply

(Electrode Cable)

Pilot Arc

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Electrode (-)

Pilot Arc (+)

Chassis Ground

Pilot Arc (+)

Electrode (-)

Interconnection Diagram - EPP-201/360

Note:

Chassis ground to be connected from PCC-14 Plumbing Box to either the cutting machine or to the chassis

of the power supply using the supplied ground wire.

(Ensure star washer is installed on the ground stud for the PCC-14 connections).

Hose connections should be wrench-tight.

Ensure plug of the switch lead is rmly locked in place. Then close hinged cover.

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Connections to the Power Supply

1. A power output cable attaches to a large bolted connection labeled “Electrode”.

2. The Pilot Arc cable connects to a small threaded stud labeled “Pilot Arc”.

3. The Plasma Control Interface connects to the power supply. The PCC-14 Plumbing Box control cable connects to the Plasma Control Interface.

4. A work cable connects to the "Work" terminal on the front-lower-left of the console. The other end is attached to the cutting table or work piece.

Connections to the rear of the Plumbing Box

1. The Start, Cut & Shield gas hoses from the regulator panel attach to the rear of the plumbing box.

2. The Plumbing Box Control cable from the Plasma Control Interface connects to the amphenol receptacle labeled “CONTROL CABLE FROM POWER SOURCE”.

Both power cables, the pilot arc cable and both coolant hoses enter the plumbing box from the rear and are connected

internally.

Connections to the Coolant Circulator

1. The coolant supply and return lines connect to the supply and return ttings on the coolant circulator.

3.5 PCC-14 Plumbing Box Mounting Hole Locations

Install the PCC-14 Plumbing Box in an appropriate location so as to maintain adequate and unrestricted airow into and out of the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions in the base of this unit.

16.625"

(422.28 mm)

12.500"

(317.5 mm)

2.125"

(53.98 mm)

(26.92 mm)

4.500"

(114.3 mm)

1.060"

6.875"

(174.63 mm)

Plasma Control Interface

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

CNC PCC-14

E-STOP

3.6 General

This unit is an integral component of the m3 Manual Gas Control Plasma system used by an external controller (e.g. CNC) to interface with the PCC14 Plumbing Box. It controls all the sequencing required for handling the plasma cutting/marking operation leaving the external controller with a simple interface to the Plasma Control Interface (PCI).

3.7 Scope

Specications: Plasma Control Interface

Weight : 17.0 lbs. (7.7 kg)

13.67”

(347.2 mm)

6.59”

(167.4 mm)

15.50”

(393.7 mm)

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

CNC PCC-14

E-STOP

3.8 Plasma Control Interface Connections

FRONT VIEW

A C D

Note:

Chassis must be connected to

the machine ground.

WARNING

ITEM Description

A ON/OFF SWITCH

B POWER INPUT C MODE SELECT D READY/FAULT INDICATOR E PILOT ARC F ARGON SELECT OUTPUT G CAN INPUT H VDR INPUT

J GROUND STUD

ELECTRIC SHOCK CAN KILL! SHUT OFF POWER AT THE POWER SUPPLY BEFORE ATTEMPTING ANY MAINTENANCE.

A. On/O Switch – This switch controls the input power on/o to the PCI. B. Power Input – Connect the 120/230VAC supply to this connector. C. Mode Select - The PCI can be operated in four dierent modes which can be set using the “MODE SELECT” switch.

1. Operate – Used for normal cutting/marking operation.

2. Start Gas Test – Used for testing and setting the start gas pressure. The pressure value can be monitored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value can be monitored on the “Shield Gas” gauge display.

3. Cut Gas Test - Used for testing and setting the cutting gas pressure. The pressure value can be monitored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value can be monitored on the “Shield Gas” gauge display.

4. Mark Gas Test (Optional) - Used for testing and setting the argon gas pressure. The pressure value can be monitored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value can be monitored on the “Shield Gas” gauge display.

D. Ready/Fault Indicator – This LED indicates the dierent fault modes encountered by the PCI. Refer to “Plasma Con-

trol Interface STATUS Codes” section for more details.

E. Pilot Arc - The Pilot Arc High/Low switch on the unit is set based on the type of material being cut. Depending on

the material to be cut, the position of this switch is obtained from the PCC-14 Cut Data manual provided with the plasma system.

F. Argon Select Output – This connector is used to select the argon solenoid for plasma gas when marking. G. Can Input – Not used H. VDR Input – Supplies the arc voltage value divided with a ratio of 25:1 for cutting and 12.5:1 for marking to the PCI.

From the PCI this value is supplied to the external controller for torch height control.

J. Ground Stud – Connect the machine chassis to this stud.

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

REAR VIEW

CNC PCC-14

E-STOP

ITEM Description

A PS

B E-STOP C FUSE 1A D AIR CURTAIN/BUBBLE MUFFLER E PCC-14 F CNC

A. PS – Connects directly to the EPP-201/360 power supply. It carries all the control signals for the power supply.

B. E-STOP – Provides interconnection between the E-STOP actuator on the power supply and the customer’s E-STOP

control circuit. See section 3.9 Typical / Recommended ESTOP Connection for typical wiring schematic.

C. Fuse 1A – This fuse is rated at 1 Amp and is for protecting the internal transformer in the PCI.

D. Air curtain/Bubble Muer (Optional) – Connects with an ESAB supplied Air Curtain or Bubble Muer unit.

E. PCC-14 – Connects with the PCC-14 Plumbing Box.

F. CNC – Connects to the external CNC.

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

PIN Function

A Not Used B Coolant Flow SW C Mark Mode D Chassis E E-Stop to PS– 24vac F E-Stop to PS– 24vac G 24 VDC to PS H Master Select

J Current Ref Common K Coolant Level SW L Current Reference

M Plasma Start

N Pilot Ref Common P Main Arc On Q Pilot Arc Select Bit 1 R 120 VAC from PS S Pilot Arc Select Bit 0 T Current Range Select V Upslope Select

W Power Supply Fault

Y Main Arc Actual Current Z 120 VAC Common

CNC PCC-14

E-STOPPS

PIN Function

A E-Stop to CNC B E-Stop to CNC

E-STOP

PCC-14

PIN Function

A 24 VDC to Pressure SW

B Pressure SW Input C Not Used D Not Used

E Start Gas ON

F Solenoid Common G Cut Gas ON H Shield Gas ON

J Solenoid 2 Common M Plasma HF ON N HF Common

Not Used Not Used Not Used Not Used Not Used Not Used Not Used Not Used

CNC

PIN Function

A Cycle Start B Mark Mode C 24 VDC to CNC D Fault E Motion Enable F CNC Common G Remote Current Ref H Remote Current COM

J E-stop to PS K E-stop to PS L VDR -

M VDR + N E-stop to CNC

P E-stop to CNC R Preow

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

The external controller/CNC connector pin out is described below:

CNC:

A) Cycle Start - Digital input to the PCI which starts the cutting operation when the mode select is in Operate setting.

B) Mark Mode - Digital input to the PCI which enables marking mode on the PCI and the Power Supply.

C) 24VDC to CNC – Supplied to the CNC for Cycle Start and Mark Mode inputs.

D) Fault - Digital output to the CNC reporting a fault with the plasma system.

E) Motion Enable - Digital output to the CNC conrming arc transfer.

F) CNC Common - Voltage supplied from the CNC for fault and motion enable.

G) Remote Current Ref - 0-10 VDC Analog voltage input to PCI which corresponds to 0-360 Amps on the Power Supply.

H) Remote Current Com - DC common for analog voltage.

J) ESTOP to PS - 24 VAC supply to dry contact on emergency stop circuit on CNC. Used to report emergency stop on

external controller or machine to the Power Supply.

K) ESTOP to PS - 24 VAC return on dry contact on emergency stop circuit on CNC. Used to report emergency stop on

external controller to the Power Supply.

L) VDR(-) - Arc voltage feedback to the torch height control circuit on CNC.

M) VDR(+) - Arc voltage common to the torch height control circuit on CNC.

N) ESTOP to CNC - Dry contact from Power Supply. Used to report emergency stop on Power Supply to external con-

troller.

P) ESTOP to CNC - Dry contact from Power Supply. Used to report emergency stop on Power Supply to external con-

troller.

R) Preow - Unit is switched to preow to purge gas lines.

3.9 Typical / Recommended ESTOP Connection

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon























3.10 Control Sequence

  

      

  

      

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

3.11 Plasma Control Interface Mounting Hole Locations

Install the Plasma Control Interface in an appropriate location so as to maintain adequate and unrestricted airow into and out of the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions in the base of this unit.

15.50"

(393.7 mm)

14.50"

7.25"

(184.2 mm)

1.75"

(44.5 mm)

6.50"

(165.1 mm)

3.50"

(88.9 mm)

(368.3 mm)

4 X Ø 0.28” (7.1 mm)

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

WHEN SUPPLYING POWER TO THE PLASMA CONTROL INTERFACE

WARNING

3.12 Plasma Control Interface STATUS Codes

STATUS Code Label List:

BOX, FOR SAFE OPERATION, IT IS STRONGLY ADVISED TO TURN OFF POWER TO THE PLASMA CONTROL INTERFACE BOX WHENEVER AN EMERGENCY STOP IS ENCOUNTERED ON THE SYSTEM.

Ready/Fault LED

The STATUS code is determined by counting the number of intermittent “ON” ashes of the Ready/Fault LED on the Plasma Control Interface.

# of LED

ashes

1 Power Supply Fault Fault from power supply, check the power supply front panel for details. 2 Pressure Switch Fault Pressure switch inside PCC-14 is not closed, either due to low gas pres-

3 Coolant Flow Fault No coolant ow. Check CC-11. 4 Coolant Level Fault Need to rell coolant to CC-11. 5 Ignition Fault Arc was not able to transfer. 6 Arc On Lost Fault Arc is lost while cutting.

Fault Description/Solution

sure or a bad pressure switch. There are two pressure switches for start and cut gas which are in series. Both lines must be at the recommended PS-1 for the switches to stay closed.

SECTION 4 MAINTENANCE

ELECTRIC SHOCK CAN KILL! ENSURE THE LINE WALL DIS CONNECT SWITCH OR CIRCUIT BREAKER IS OPEN BEFORE AT

WARNING

4.0 Maintenance

4.1 General

Maintenance work must be performed by an experienced person. Do not permit untrained persons to inspect, clean, or lubricate this equipment.

On a regular basis, check cylinder valves, regulators, hoses, and gas connections for leaks using a soap solution or a leak test solution.

Keep the equipment dry, free of oil and grease, and protected at all times from damage by hot metal and sparks.

TEMPTING ANY INSPECTION OR WORK ON THE INSIDE OF THE PLUMBING BOX. ALWAYS WEAR SAFETY GOGGLES WITH SIDE SHIELDS WHEN BLOWING OUT THE EQUIPMENT WITH LOW PRESSURE AIR.

4.2 Cleaning

Periodically, remove the covers from the equipment and, wearing proper eye protection, blow accumulated dust and dirt from the air passages and the interior components using clean low-pressure air. It is imperative that the air passages to the interior of the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air.

The length of time between cleaning will depend on the location of the unit and the amount of dust in the atmosphere.

After cleaning with low-pressure air, check for and tighten any loose hardware, including all electrical connections. Check for frayed and/or cracked insulation on all power cables and replace if necessary.

ELECTRIC SHOCK CAN KILL! FAILURE TO REPLACE WORN OR DAMAGED CABLES MAY RESULT IN A BARE CABLE TOUCHING A GROUNDED SURFACE. THE RESULTING ELECTRICAL ARC MAY

WARNING

DAMAGE THE UNPROTECTED EYES AND WILL PRESENT A SE RIOUS FIRE HAZARD. BODILY CONTACT WITH A BARE CABLE, CONNECTOR, OR CONDUCTOR MAY RESULT IN SEVERE ELEC TRICAL SHOCK, CAUSING SERIOUS BURNS OR DEATH.

SECTION 4 MAINTENANCE

SECTION 5 MARKING MODULE

5.0 Marking Module

The Marking Module option is installed external to the PCC-14 Plumbing box and is controlled from the PCI Plasma Control Interface. This module will route the normal cut gas to the Plumbing Box until the operator selects a Marking operation. When this happens, the PCI Interface will switch the cut gas sent to the torch to Argon for marking operations. The module is supplied with 24 VAC from the PCI for operation

Gas connection:

Cut gas and Argon are connected as in the photo below. The gas output is sent to the Plumbing Box.

Electrical connection:

A three pin cable is connected from the Marking Module to the PCI to switch the gas supplied to the torch. By default the Marking Module will pass the cut gas to the Plumbing Box. This cable is supplied with the module at installation. This cable routes 24VAC to the Marking Module from the PCI during marking operations.

Cut Gas

Argon

Gas out to PCC-14

PCI connection

SECTION 5 MARKING MODULE

5.1 Marking Module Mounting Hole Locations

Install the Marking Module in an appropriate location so as to maintain adequate and unrestricted airow into and out of the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions in the base of this unit.

2.87

.25

1.50

.50

(4) PLCS

.25 TYP

TYP

SECTION 6 PT36R PLASMA TORCH

6.0 PT-36R Plasma Torch

Note:

See appropriate PT-36R Plasma Torch equipment literature (0558006829) for operating conditions and instruc-

tion information.

Torch

Description

PT-36R m3

Plasma Torch

Available

Lengths

m ( ft. )

1.4m (4.5’) 0558006811

1.8m (6’) 0558006812

2.2m (7.2’) 0558006781

3.6m (12’) 0558006813

4.3m (14’)

mini-bevel

4.6m (15’) 0558006815

5.2m (17’) 0558006816

6.1m (20’) 0558006782

7.6m (25’) 0558006817

ESAB

Part Number

0558006814

SECTION 6 PT36R PLASMA TORCH

6.1 PT-36R Technical Specications

7.54"

(191.5mm)

6.17"

(156.7mm)

Clamp only on insulated torch sleeve not less than

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

(231.9mm)

10.50" (266.7mm) Length of Sleeve

NOTE:

2.00"

(50.8mm)

9.13"

6.2 Gas Specications

Argon 125 PSI (8,6 bar) with 0.25” NPT, 99.995% purity, Filtered to 25 microns

Nitrogen 125 PSI (8,6 bar) with 0.25” NPT, 99.99% purity, Filtered to 25 microns

Oxygen 125 PSI (8,6 bar) with 0.25” NPT, 99.5% purity, Filtered to 25 microns

Ar/H2 (Argon/Hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns

Compressed Air

(Clean, dry & oil-free shop

air)

Typical requirements for ow delivered at 125 psig: Maximum Plasma Gas: 300 scfh Maximum Shield Gas: 350 scfh

80 PSI @ 1200cfh (5,5 bar @ 35 m

h), Filtered to 25 microns

Note:

These do not represent actual ows used in any condition, but are the design maximums of the system.

SECTION 6 PT36R PLASMA TORCH

6.3 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

6.4 PT-36R Torch Technical Specications

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

Current Rating: 750 Amps @ 100% duty cycle

Mounting Diameter: 2 inches (50.8 mm)

Length of Torch without leads: 18.5 inches (47 cm)

IEC 60974-7 Voltage Rating: 500 volts peak

Striking Voltage (maximum value of HI-FREQUENCY voltage): 8000 vac

Minimum Coolant Flowrate: 1.0 USGPM (3.8 L/min)

Minimum Operating Coolant Pressure at Inlet: 175 psig (12.1 bars)

Maximum Operating 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) Recommended Input Pressure: 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.

SECTION 6 PT36R PLASMA TORCH

SECTION 7 COOLANT CIRCULATOR

7.0 Coolant Circulator

Note:

See appropriate Coolant Circulator equipment literature (0558007523) for operating conditions and instruction

information.

SECTION 7 COOLANT CIRCULATOR

7.1 Specications

Dimensions: 34.00” high (864 mm) x 21.75” wide (552 mm) x 28.00 deep (711 mm)

Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg)

Pump Type: Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.),

CW rotation as viewed from nameplate.

Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.

AC Input Voltages

AC Input Amperage 9 / 8 / 5 / 4 / 3 Amperes

Pump Capacity

Cooling Capacity @ 1.60 gpm (6.0 l/min) 16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts)

at 45° F (25° C) temperature dierence between high coolant temperature and ambient air temperature using ESAB cool-

ant P/N 0558004297 (25% propylene glycol / 75% distilled water).

Max. Delivery Pressure 175 psig (12 bars)

Reservoir Capacity 4 gallons (15.2 liters)

50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power

200 / 230 / 400 / 460 / 575 V., + / - 10%

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

SECTION 7 COOLANT CIRCULATOR

7.2 Installation

Install the CC-11 in an appropriate location so as to maintain adequate and unrestricted airow into and out of the cabinetry. For permanent mounting refer to Figure 6.1 for mounting hole dimensions in the base of this unit.

0.531” (13.5 mm) diameter hole, typical, 8 places

19.50”

(495 mm)

1.69”

(43 mm)

3.42”

(87 mm)

17.78”

(452 mm)

Figure 6.1 Mounting Dimensions

3.42”

(87 mm)

SECTION 7 COOLANT CIRCULATOR

7.3 Input Power Connections

A 3-conductor power cable suitable to meet the required input power must be installed. The cable must have 0.25" (6.4 mm) ring lugs installed on the machine end. Connect the power leads to the L1 and L2 terminals on TB1 Input Power Terminal Board and the ground lead to the ground lug on the back of the fan support panel. A strain relief tting is provided to feed a power cable through the rear panel of the cabinet. Refer to Figure 6.2 for proper Input Voltage Link placement, Figure 6.2 shows link in place for 460 volt input. Electrical installation must be in accordance with local electrical codes for

this type of equipment.

Voltage link MUST be moved if equipment is operated at any volt-

CAUTION

age other than 575V. Failure to move voltage link to location that matches input voltage can result in damage to equipment.

NOTE:

Voltage link is shipped in

this location which is for

575 volt operation.

Figure 6.2 Voltage Links

SECTION 7 COOLANT CIRCULATOR

WARNING

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT PROCEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH IN THE OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT TRIPPING. IF THE CONNECTION IS MADE FROM A FUSE BOX, REMOVE THE CORRESPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS NOT POSSIBLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE DISCONNECT SWITCH OR FUSE BOX WARNING OTHERS THAT THE CIRCUIT IS BEING WORKED ON.

Typical Installation - User-supplied single phase fused power disconnect box with receptacle and plug

Input Power Cable

Figure 6.3 Input Connection Diagram

SECTION 7 COOLANT CIRCULATOR

SECTION 8 POWER SUPPLIES

8.0 EPP-201 Power Supply

Note:

See appropriate EPP-201 Power Supply equipment literature (0558007900) for operating conditions and instruc-

tion information.

SECTION 8 POWER SUPPLIES

8.1 Dimensions and Weight

40.75”

(1035 mm)

23.75”

(603.25 mm)

47.25”

(1200 mm)

Weight = 492 kg (1085 lbs.)

SECTION 8 POWER SUPPLIES

8.2 Input Power Connection

ELECTRIC SHOCK CAN KILL! PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK.

WARNING

Primary Power

EPP-201 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

BEFORE ANY CONNECTIONS ARE MADE INSIDE THE MACHINE, OPEN THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.

Recommended input conductor and line fuse sizes:

Input at Rated Load Input and Ground

Volts Amperes

380 60 35 (2/0)* 100 400 57 35 (2/0)* 100 460 51 35 (2/0)* 100

575 41 35 (2/0)* 60

Rated load is output of 200A at 160V

* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

To estimate the input current for a wide range of output conditions, use the formula below.

Input current =

NOTICE

Dedicated power line may be necessary. EPP-201 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.

(V arc) x (I arc) x 0.73

(V line)

conductor* CU/

mm2 (AWG)

Time delay

Fuse size

(amperes)

SECTION 8 POWER SUPPLIES

SECTION 9 POWER SUPPLIES

9.0 EPP-360 Power Supply

Note:

See appropriate EPP-360 Power Supply equipment literature (0558007676) for operating conditions and instruc-

tion information.

SECTION 9 POWER SUPPLIES

9.1 Dimensions and Weight

40.75”

(1035 mm)

23.75”

(603.25 mm)

47.25”

(1200 mm)

Weight = 492 kg (1085 lbs.)

SECTION 9 POWER SUPPLIES

9.2 Input Power Connection

ELECTRIC SHOCK CAN KILL! PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK.

WARNING

Primary Power

EPP-360 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations.

BEFORE ANY CONNECTIONS ARE MADE INSIDE THE MACHINE, OPEN THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.

Recommended input conductor and line fuse sizes:

Input at Rated Load Input and Ground

Volts Amperes

380 140 95 (4/0)* 200 400 132 95 (4/0)* 200 460 115 35 (2)* 150

575 92 35 (2)* 125

Rated load is output of 360A at 200V

To estimate the input current for a wide range of output conditions, use the formula below.

Input current =

NOTICE

Dedicated power line may be necessary. EPP-360 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required.

(V arc) x (I arc) x 0.73

(V line)

conductor* CU/

mm2 (AWG)

Time delay

Fuse size

(amperes)

SECTION 9 POWER SUPPLIES

SECTION 10 HOSES AND CABLES

10.0 HOSES AND CABLES

10.1 Hoses

Hose

Description

Air / Shield Gas Hose

Available

Lengths

m ( ft. )

1.5m (5’) 0558006200 5m (16’) 0558006201 6m (19’) 0558006202 7m (23’) 0558006203 8m (26’) 0558006204 9m (30’) 0558006205

10m (33’) 0558006206

11m (36’) 0558006207 12m (39’) 0558006208 13m (43’) 0558006209 14m (46’) 0558006210 15m (49’) 0558006211 16m (52’) 0558006212 17m (56’) 0558006213 18m (59’) 0558006214 19m (62’) 0558006215 20m (66’) 0558006216 30m (98') 0558008813

2.3m (7.5’) 0558007315 4m (13’) 0558008359

0.5m (1.7’) 0558008447

1m (3.3’) 0558008448

3m (10’) 0558008449

ESAB

Part Number

SECTION 10 HOSES AND CABLES

Hose

Description

N2 / PG-1 Hose

Available

Lengths

m ( ft. )

1.5m (5’) 0558006089 5m (16’) 0558006090 6m (19’) 0558006091 7m (23’) 0558006092 8m (26’) 0558006093

9m (30’) 0558006094 10m (33’) 0558006095 11m (36’) 0558006096 12m (39’) 0558006097 13m (43’) 0558006098 14m (46’) 0558006099 15m (49’) 0558006100 16m (52’) 0558006101 17m (56’) 0558006102 18m (59’) 0558006103 19m (62’) 0558006104

20m (66’) 0558006105 30m (98') 0558008814

2.3m (7.5’) 0558007313 4m (13’) 0558008357

0.5m (1.7’) 0558008441

1m (3.3’) 0558008442

3m (10’) 0558008443

ESAB

Part Number

SECTION 10 HOSES AND CABLES

Hose

Description

O2 / PG-2 Hose

Available

Lengths

m ( ft. )

1.5m (5’) 0558006106 5m (16’) 0558006107 6m (19’) 0558006108

7m (23’) 0558006109 8m (26’) 0558006110 9m (30’) 0558006111

10m (33’) 0558006112

11m (36’) 0558006113 12m (39’) 0558006114 13m (43’) 0558006115 14m (46’) 0558006116 15m (49’) 0558006117 16m (52’) 0558006118 17m (56’) 0558006119 18m (59’) 0558006120 19m (62’) 0558006121

20m (66’) 0558006122 30m (98') 0558008815

2.3m (7.5’) 0558007314 4m (13’) 0558008358

0.5m (1.7’) 0558008444 1m (3.3’) 0558008445

3m (10’) 0558008446

ESAB

Part Number

SECTION 10 HOSES AND CABLES

Hose

Description

H35 / CH4 Hose

Argon Hose

Available

Lengths

m ( ft. )

0.5m (1.7’) 0558008371 1m (3.3’) 0558008372

2.3m (7.5’) 0558008373

3m (10’) 0558008374

4m (13’) 0558008375

5m (16’) 0558008376 6m (19’) 0558008377 7m (23’) 0558008378 8m (26’) 0558008379 9m (30’) 0558008380

10m (33’) 0558008381

11m (36’) 0558008382 12m (39’) 0558008383 13m (43’) 0558008384

14m (46’) 0558008385

15m (49’) 0558008386

16m (52’) 0558008387

17m (56’) 0558008388

5m (16’) 0558008390 6m (19’) 0558008391 7m (23’) 0558008392 8m (26’) 0558008393 9m (30’) 0558008394

10m (33’) 0558008395

11m (36’) 0558008396 12m (39’) 0558008397 13m (43’) 0558008398

14m (46’) 0558008399

15m (49’) 0558008400

16m (52’) 0558008401

17m (56’) 0558008402

40m (132’) 0558008816

ESAB

Part Number

SECTION 10 HOSES AND CABLES

Hose

Description

Coolant Hose

Air Curtain Hose

Available

Lengths

m ( ft. )

10.1m (33’) 0558005563

15.2m (50’) 0558005564

20.1m (66’) 0558005565

35.1m (115’) 0558005566

50.3m (165’) 0558005567

4.9m (16’) 0558005246

29.9m (98’) 0558005247

39.9m (131’) 0558005248

59.7m (196’) 0558005249

1.4m (4.5’) 0558004841

1.8m (6’) 0558004842

3.6m (12’) 0558004843

4.6m (15’) 0558004844

5.2m (17’) 0558004845

7.6m (25’) 0558004846 6m (20’) 0558006865

7m (23’) 0558008502 8m (26’) 0558008503

9m (30’) 0558008504

10m (33’) 0558008505

11m (36’) 0558008506

12m (40’) 0558008507

ESAB

Part Number

SECTION 10 HOSES AND CABLES

10.2 Cables

Cable

Description

E-Stop Cable

( E-Stop )

Air Curtain / Bubble Muer

Control Cable ( optional )

VDR Cable ( VDR )

Mark Solenoid Cable ( ARG )

Available

Lengths

m ( ft. )

7.6m (25’) 0558009621 10m (33’) 0558009622 15m (50’) 0558009623 22m (75’) 0558009624

30m (100’) 0558009625

40m (131’) 0558009626

45m (150’) 0558009627 50m (164’) 0558009628 60m (200’) 0558009629

2.1m (6.75’) 0558009771

5m (16.5’) 0558009772

10m (33') 0558009773

0.5m (1.7’) 0560947067

1.5m (5’) 0560947075

3m (10’) 0560947076

4m (13’) 0560947068

5m (16’) 0560947077

6m (19’) 0560947069

6.1m (20') 0560946782

7m (23’) 0560947070

8m (26’) 0560947071

9m (30’) 0560947072

10m (33’) 0560947078

15m (49’) 0560947073

20m (66’) 0560947074

25m (82') 0560946758

ESAB

Part Number

SECTION 10 HOSES AND CABLES

Cable

Description

PCC-14 Interface Cable

( PCC-14 )

115 / 230 VAC Input Power Cable

( POWER )

CNC Cable

( CNC )

EPP Control Cable

( PS-1 )

Available

Lengths

m ( ft. )

0.9m (3’) 2238279

1.8m (6’) 2237958

3.0m (10’) 0558009510

4.0m (13’) 0558009511

4.9m (16’) 0558009512

6.1m (20’) 0558009513

7.0m (23’) 0558009514

7.9m (26’) 0558009515

9.1m (30’) 0558009516

10.1m (33’) 0558009517

15.2m (50’) 2237959

22.9m (75’) 2237960

30.5m (100’) 2237934

38.1m (125’) 2237935

45.7m (150’) 2237936

53.3m (175’) 2237937

61.0m (200’) 2237938 5m (16’) 0558008261

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

4.6m (15’) 0560936665

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

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

7.6m (25’) 0558004651 10m (33’) 0558008360 15m (50’) 0558004652

22.8m (75’) 0558004653

30.5m (100’) 0558004654 40m (131’) 0558003978

45.7m (150’) 0558004655 50m (164’) 0558008355

60m (200’) 0558008356

ESAB

Part Number

SECTION 10 HOSES AND CABLES

SECTION 11 REPLACEMENT PARTS

11.0 Replacement Parts

11.1 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.

11.2 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.

Note

Replacement Parts, Schematics and Wiring Diagrams are

printed on 279.4mm x 431.8mm (11” x 17”) paper and are

included inside the back cover of this manual.

NOTES

REVISION HISTORY

1. Original release - 03/2010

2. Revision 07/2010 - corrected serial #’s on front cover.

3. Revision 05/2011 - minor changes to chart on page 35 and 68.

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

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ESAB m3 Plasma Manual Gas Control Plasma System Instruction manual

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User Manual

1.1 Safety - English

1.2 Safety - Spanish

1.3 Safety - French