Precision Plasmarc
Plasma Gas Box & Shield Gas Box
Plasma Gas Box
Shield Gas Box
Instruction Manual (EN)
0558007535
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!
114
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ..................................................................................117
2.0 Description...........................................................................................11 9
2.1 System Introduction ...........................................................................11 9
2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36 ...................................11 9
2.3 System Gas Requirements..................................................................... 120
2.4 Plasma Gas Box Water Supply Requirements ................................................... 12 0
2.5 Plasma Gas Box Electrical Input Requirements ................................................. 12 0
2.6 Shield Gas Box Electrical Input Requirements .................................................. 12 0
2.7 System Accessories ........................................................................... 12 0
2.8 Plasma Gas Box Dimensions....................................................................121
2.9 Shield Gas Box Dimensions.................................................................... 12 2
3.0 Installation .......................................................................................... 12 3
3.1 Plasma Gas Box Introduction ..................................................................12 3
3.2 Plasma Gas Box Mounting (Bottom View) ...................................................... 12 3
3.3 Plasma Gas Box Connections .................................................................. 12 4
3.4 Plasma Gas Box Nomex Insulation ............................................................ 13 0
3.5 Plasma Gas Box Gas Connections...............................................................131
3.6 Shield Gas Box Introduction ................................................................... 133
3.7 Shield Gas Box Mounting (Bottom View)....................................................... 13 3
3.8 Shield Gas Box Connections................................................................... 13 4
3.9 Component Relationship Block Diagram....................................................... 13 6
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 3
4.1 Plasma Gas Box Operation .................................................................... 143
4.2 Plasma Gas Box Pressure Gauges .............................................................. 143
4.3 Plasma Gas Box Pressure Switches ............................................................. 14 4
4.4 Shield Gas Box Operation ..................................................................... 14 5
4.5 Shield Gas Box Air Regulator for Air Curtain .................................................... 14 6
4.6 Shield Gas Box Check Valves .................................................................. 147
115
TABLE OF CONTENTS
116
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone
who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet
the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations
should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
117
SECTION 1 SAFETY PRECAUTIONS
WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
118
SECTION 2 DESCRIPTION
2.0 Description
2.1 System Introduction
The m3 Plasma System is a streamlined, high performance-cutting package designed for use exclusively with the
ESAB CNC. This advanced technology integrates gas and water control into the machine CNC.
Using a system of electronic valves driven by CNC outputs, this system:
dramatically reduces the amount of Plasma Gas hardware necessary to control the plasma torch.•
reduced purge time/increased part throughput .•
simplied operation with gas and water ow rates are controlled by the ESAB CNC process parameter •
screen.
allows for programmed/automated control of uid and water ow rates using SDP Files (SchneidDaten-•
Paket = Cutting Data Package, see Vision control and programming manuals for details on SDP Files.
Data used to generate SDP les can be found in your model specic torch manual.) SDP les can also
be referred to as TDF les (Technology Data Files).
to be used with the PT-36 cutting torch. •
Plasma Gas Box
Shield Gas Box
2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36
The complete m3 cutting system requires a variety of components. See section 3.9, Component Relationship
Block Diagram for components and hook-up.
119
SECTION 2 DESCRIPTION
2.3 System Gas Requirements
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
H-35 (Argon/Hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns
Methane 75 PSI (5,2 bar) with 0.25” NPT, 93% purity, Filtered to 25 microns
Compressed Air
(Air Curtain )
Compressed Air
(Pro cess)
2.4 Plasma Gas Box Water Supply Requirements
Cooling Water ......................................................................................175 PSI (12,1 bar), 1.5 gallons per minute (5.68 liters/minute)
2.5 Plasma Gas Box Electrical Input Requirements
80 PSI (5,5 bar) with 0.25” NPT, clean, dry, oil-free and ltered to 25 microns
80 PSI @ 1200cfh (5,5 bar @ 35 m3h) ltered to 25 microns
DIN Quality ISO 8573-1
Oil quality mg/m3 = 0.1 class 2
Particle Size 0.1um class 1
Temparature +3 C class 4
Voltage Supply +24 VDC for proportional valves, mfc
+15 VDC for pressure switch
Voltage Signals 24 VAC input to start gas solenoid valve
120 VAC input to arc starter
0-10 VDC input to proportional valves
0-10 VDC for mass ow valve
2.6 Shield Gas Box Electrical Input Requirements
Voltage Supply +24 VDC for 120/230 transformer and I/O board
+24 VDC for proportional valves and mfc’s
2.7 System Accessories
Coolant Hose Adaptor Kit ............................................................................................ 0558006698
Adapter Coolant EPP-200 ..............................................................................................0 55800 6162
120
SECTION 2 DESCRIPTION
2.8 Plasma Gas Box Dimensions
11 . 2 8 ”
286.5 mm
17.1 3 ”
435.1 mm
7. 2 5 ”
184.2 mm
121
SECTION 2 DESCRIPTION
2.9 Shield Gas Box Dimensions
12 .0 0 ”
304.8 mm
8.00”
203.2 mm
20.00”
508.0 mm
122
SECTION 3 INSTALLATION
2.00”
50.8 mm
3.0 Installation
ELECTRICITY CAN KILL!
BEFORE PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS
WARNING
3.1 Plasma Gas Box Introduction
The m3 Plasma System Plasma Gas Box interfaces with the ESAB Vision machine controls and the EPP product
line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control
electronic valves. The result is CNC management of gas or shield gas delivery to the plasma torch. Analog signal
feedback is sent back to the CNC, creating a control loop.
3.2 Plasma Gas Box Mounting (Bottom View)
EQUIPMENT, ENSURE THE POWER SOURCE EPP IS TURNED OFF AND
DISCONNECTED.
If mounting the box is required:
The box has four (1.10”) 28 mm threaded mounting holes in a pattern oset from longitudinal center. Note relationship of hole pattern to gauges and cable clamp.
.75”
19.1 mm
4.50”
114.3 mm
back
front
4.13”
104.9 mm
11. 0 0 ”
279.4 mm
2.00”
50.8 mm
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