ESAB m3 plasma PT-36 Integrated Gas Control (IGC) System - Vision 5x Instruction manual

Integrated Gas Control (IGC) System - Vision 5x

Instruction Manual

(use with EPP-202/362 Power Sources)

for cut data see manual: 0558011611

0558012268 09/2014

Integrated Gas Control (IGC) System - Vision 5x

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Integrated Gas Control (IGC) System - Vision 5x

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!

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Integrated Gas Control (IGC) System - Vision 5x

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Integrated Gas Control (IGC) System - Vision 5x

Table of Contents

Safety

Safety - English ................................................................................................................................................. 11

Safety - Spanish ..................................................................................................................................................................................15

Safety - French ....................................................................................................................................................................................19

System Diagram

System Diagrams ..............................................................................................................................................25

Base System + WIC + ACC (all options) ..................................................................................................................................... 26

Descriptions

Power Supplies .................................................................................................................................................29

380/400V Power Supplies ............................................................................................................................................................... 29

460/575V Power Supplies ............................................................................................................................................................... 29

380/400V Power Supplies ............................................................................................................................................................... 30

460/575V Power Supplies ............................................................................................................................................................... 30

Combined Gas Control (CGC) ...........................................................................................................................31

Specications ...................................................................................................................................................................................... 31

Connections ........................................................................................................................................................................................ 32

CGC Flow Diagram ............................................................................................................................................................................ 35

Combined Gas Control Plumbing Schematic ..........................................................................................................................36

Combined Gas Control Electrical Schematic ........................................................................................................................... 37

CGC Mounting Dimensions ...........................................................................................................................................................38

CGC Bottom View .............................................................................................................................................................................. 38

Troubleshooting ................................................................................................................................................................................ 39

Replacement Parts ............................................................................................................................................................................ 39

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Integrated Gas Control (IGC) System - Vision 5x

Remote Arc Starter (RAS) ................................................................................................................................ 40

Specications ......................................................................................................................................................................................40

Remote Arc Starter Connections ................................................................................................................................................. 41

RAS Box Mounting Dimensions ...................................................................................................................................................43

RAS Box Mounting Plate Dimensions ........................................................................................................................................43

Typical / Recommended E-stop Connection ........................................................................................................................... 44

Replacement Parts ............................................................................................................................................................................44

Air Curtain Control (ACC) .................................................................................................................................45

Specications ...................................................................................................................................................................................... 45

ACC Mounting Dimensions ............................................................................................................................................................46

ACC Component Connections ......................................................................................................................................................46

Water Injection Control (WIC) ..........................................................................................................................47

Specications ...................................................................................................................................................................................... 47

Automatic Height Control (AHC) .................................................................................................................... 48

Specications ......................................................................................................................................................................................48

B4 Mounting Dimensions ............................................................................................................................................................... 49

Hoses and Cables ..............................................................................................................................................50

Specications ...................................................................................................................................................................................... 55

PT-36 Mechanized Plasmarc Cutting Torch ....................................................................................................55

Package Options Available ...........................................................................................................................................................56

Optional Accessories ........................................................................................................................................................................ 56

PT-36 Torch Consumable Kits ........................................................................................................................................................57

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

Replacement Parts ............................................................................................................................................................................ 59

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Integrated Gas Control (IGC) System - Vision 5x

Installation

Grounding .........................................................................................................................................................63

Introduction ........................................................................................................................................................................................ 63

Grounding Overview .......................................................................................................................................................................64

Basic Layout ........................................................................................................................................................................................65

Elements of a Ground System .......................................................................................................................................................66

Plasma Current Return Path ..........................................................................................................................................................66

Plasma System Safety Ground ...................................................................................................................................................... 67

Rail System Safety Ground .............................................................................................................................................................70

Earth Ground Rod ............................................................................................................................................................................. 71

Ground Rod ......................................................................................................................................................................................... 71

Soil Resistivity ..................................................................................................................................................................................... 71

Utility Power Electrical Ground ....................................................................................................................................................72

Multiple Ground Rods .....................................................................................................................................................................73

Machine Grounding Schematic....................................................................................................................................................74

Check upon receipt .......................................................................................................................................................................... 75

Before Installation ............................................................................................................................................................................. 75

Placement of Power Supply .............................................................................................................................75

Connection Procedures .................................................................................................................................................................. 75

Placement of RAS Box ......................................................................................................................................76

Connections on the RAS Box ........................................................................................................................................................76

Torch Connections ............................................................................................................................................79

Connection of Torch to Plasma System ..................................................................................................................................... 80

Connection to the Remote Arc Starter Box ..............................................................................................................................80

Mounting Torch to Machine ........................................................................................................................................................ 81

Preparing to Cut.................................................................................................................................................................................84

Placement of CGC ............................................................................................................................................ 90

Individual Component Connections ..........................................................................................................................................90

ACC Component Connections ......................................................................................................................................................91

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Integrated Gas Control (IGC) System - Vision 5x

Maintenance/Troubleshooting

Torch Front End Disassembly ........................................................................................................................................................ 95

Torch Front End Assembly .............................................................................................................................................................98

Torch Front End Assembly using the Speedloader ............................................................................................................... 99

Torch Front End Disassembly (for Production Thick Plate) ...............................................................................................100

Torch Front End Assembly (for Production Thick Plate) .....................................................................................................103

Torch Body Maintenance ...........................................................................................................................................................105

Torch Body Removal and Replacement ..................................................................................................................................106

Reduced Consumable Life ........................................................................................................................................................108

Checking for Coolant Leaks ......................................................................................................................................................... 109

Replacement Parts

General ................................................................................................................................................................................................ 113

Ordering ............................................................................................................................................................................................. 113

8

Safety

Safety - English

SAFETY

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

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

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

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

1. Always wear safety glasses with side shields in

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

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

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

3. Wear ameproof gauntlet type gloves, heavy

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

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

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

5. Protect other personnel from arc rays and hot

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

6. Use goggles over safety glasses when chipping

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

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

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

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

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

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

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

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

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

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

11

SAFETY

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

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

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

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

5 . Keep everything dry, including clothing, work area,

cables, torch/electrode holder, and power source.

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

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

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

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

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

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

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

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

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

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

Therefore:

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

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

conductor causes localized Electric

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

machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with
some pacemakers.

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

are unknown.

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

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

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

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

12

SAFETY

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

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

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

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

2. Always secure cylinders in an upright position by

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

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

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

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

Never strike an arc on a cylinder.

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

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

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

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

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

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

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

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

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

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

ADDITIONAL SAFETY INFORMATION -- For more

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

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

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

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

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

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

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

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

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

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

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

13

SAFETY

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

DANGER

CAUTION

WARNING

Enclosure Class

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

CAUTION

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

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

Means hazards which could result in minor personal injury.

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

CAUTION

CAUTION

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

CAUTION

CAUTION

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

14

Maximum

Tilt Allowed

15°

SAFETY

Safety - Spanish

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

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

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

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

1. Utilice gafas de seguridad con protección a los lados

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

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

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

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

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

4. Chispas y partículas de metal caliente puede alojarse en

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

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

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

6. Use careta protectora además de sus gafas de seguridad

cuando esté removiendo escoria o puliendo.

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

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

1

. Remueva todo material combustible lejos del área de

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

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

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

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

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

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

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

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

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

15

SAFETY

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

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

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

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

5 . Mantenga todo seco, incluyendo su ropa, el área de

trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

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

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

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

9. Apage el equipo antes de quitarse sus guantes.

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

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

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

1. Soldadores u Operadores que use marca-pasos para

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

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

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

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

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

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

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

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

lo más cercano posible al área de la soldadura.

E. 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.

16

SAFETY

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

§25249.5 et seq.)

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

Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

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

2. Asegure siempre los cilindros en posición vertical

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

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

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

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

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

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

INFORMACION ADICIONAL DE SEGURIDAD -- Para

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

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

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

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

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

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

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

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

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

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

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

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

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

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

17

SAFETY

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

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

PELIGRO

mente en serio daño personal o la muerte.

ADVERTENCIA

CUIDADO

Clase de envolvente

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

ADVERTENCIA

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

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

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

ADVERTENCIA

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

ADVERTENCIA

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

18

Inclinación

máxima permitida

15°

SAFETY

Safety - French

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

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

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

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

1. Portez des lunettes protectrices munies d'écrans latéraux

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

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

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

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

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

4. Les étincelles et les projections de métal incandescent

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

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

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

6. Portez des lunettes étanches par dessus vos lunettes de

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

INCENDIES ET EXPLOSIONS -- La

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

laitier incandescent ou les étincelles
peuvent également provoquer un

incendie ou une explosion. Par conséquent :

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

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

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

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

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

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

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

02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces élec-

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

19

SAFETY

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

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

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

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

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

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

7 . Si vous devez eectuer votre travail dans un espace

restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

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

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

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

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — com-

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

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

1. Un soudeur ayant un stimulateur cardiaque doit

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

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

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

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

A. Acheminez l'électrode et les câbles de masse

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

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

autour de votre corps.

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

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

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

plus près possible de la section à souder.

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

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

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

l'asphyxie. Par conséquent :

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

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

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

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

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

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

20

SAFETY

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

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

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

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

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

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

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

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

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

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

4. Placez les cylindres à une distance appropriée de toute

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

5. Pour de l'information supplémentaire, consultez CGA

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

Highway, Arlington, VA 22202.

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

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

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

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

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

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

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

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA

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

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

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

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

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

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

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

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

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

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

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

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

21

SAFETY

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

DANGER

AVERTISSEMENT

ATTENTION

Classe de protection de l’enveloppe

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

AVERTISSEMENT

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

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

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

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

AVERTISSEMENT

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

AVERTISSEMENT

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

22

Angle

d’inclinaison

maximal

15°

System Diagram

SyStem Diagram

Below are some abbreviations used throughout this manual.

ABBREVIATIONS:
A/C - Air Curtain

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

24

SyStem Diagram

System Diagrams

The following illustration shows congurations available on the Integrated Gas Control (IGC) System. With this
system, ESAB oers a variety of congurations to meet customer’s requirements. Below are the descriptions of
each conguration.

1. Base System

This system is the basic conguration for the IGC Plasma System. It contains major components, such as the Power
Supply, PT-36 Torch, Remote Arc Starter (RAS), Combined Gas Control (CGC), Automatic Height Control (AHC) and
Vision CNC. This system will meet most customers’ needs in cutting carbon steel, stainless steel, and aluminum. It
also has the functionality of marking on carbon steel and stainless steel with the same torch and the same consum­ables. By simply alternating cutting and marking mode on the go, this system is capable of cutting and marking in
the same part program without changing the consumables.

2. Base System + ACC

This system includes the above Base System and ESAB Air Curtain Control (ACC). Air Curtain is a device used to
improve the performance of plasma arc when cutting underwater. The Air Curtain output is triggered from the AHC
electrical cabinet.

3. Base System + WIC

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

4. Base System + WIC + ACC (diagram shows all options)

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

25

R

Vision 5X

(EPP-202/362)

IGC Base System

Height

AHC

(Automatic

Control)

Air Curtain

Hose

Air Curtain

CGC-SG or BPR-SG/H2O

PT-36 Torch

Shield Gas Hose

Plasma Gas Hose

CGC-PG

Interconnect Diagram

Power, Pilot Arc, Coolant

RAS-PA

RAS-E(-)

RAS-PSC

Power Cable

Pilot Arc Cable

PS & CC Control Cable

AHC-VDR

RAS-VDR

PDM-PWR

RAS

(Remote Arc Starter)

RAS-TC IN

RAS-ESTOP

RAS-TC OUT

Coolant Return Hose

Coolant Supply Hose

AHC-CAN

AHC-AC IN

AHC-ACC OUT

CAN BUS

AHC Input Power

WIC-AC-IN

BPR

Regulator)

(Back Pressure

BPR-H2O

WIC-H2O OUT

WIC

(Water Injection Control)

WIC-CAN

WIC-AIR IN

WIC-H2O IN

CGC-PWR

ACC-AIR OUT

ACC-IN

CAN-WIC-CAN

CAN-AHC-CAN

CGC-N2/Air

CGC-AIR IN

CGC-O2/H35/F5

ACC

(Air Curtain Control)

ACC-AIR

CGC-Ar

CGC-N2/Air

CGC

CGC-CAN

CGC-CAN

(Combined Gas Control)

BOLD FONT = Cable Connection Label

Optional

Customer Supplied

CAN Hub

PS-PSC

PS-PA

PS(-)

CNC-CAN

CNC-WIC PWR

AHC-PWR

PS-W

Integrated Gas Control Machine Version

R

Base System + WIC + ACC (all options)

PS

(Power Supply)

{

THREE

PHASE

POWER

P/S-CAN

Table

Work

Vision

CNC-ESTOP

CNC

P/S-CAN

Control Box

LIQUID

GAS

POWER

DATA

Descriptions

Description

28

Description

Power Supplies

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

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

EPP-202,

Part Number

Voltage 160 VDC

Output

(100 %

duty cycle)

Input

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

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

200/230/460V,

60Hz,

0558 011310

EPP-202,

380/400V CCC,

50Hz,

0558 011311

EPP-202,

400V CE,

50Hz,

0558011312

EPP-202,

575V,
60Hz,

0558011313

29

Description

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

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

EPP-362,

Part Number

460V,
60Hz,

0558011314

Voltage 200 VDC

Output

(100 %

duty cycle)

Input

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

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

EPP-362,

380V CCC,

50Hz,

0558 011315

EPP-362,
400V CE,

50Hz,

0558 011316

EPP-362,

575V,
60Hz,

0558 011317

30

Description

Combined Gas Control (CGC)

p/n 0558010241

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

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

There are four gas inputs (three plasma gases, one shield gas), two gas outputs (SG, PG), and one outboard con­nection (air curtain). The four inputs are tted with porous bronze lters and "G-1/4" (BSPP) female right-hand
thread. Either of two adaptor tting kits are available to adapt standard metric or CGA hose connections. The gas
ttings and adaptors are listed in the following tables.

Specications

Dimensions: 8.5” (215.9 mm) long x 6.0” (152.4 mm) wide x 4.5” (114. 3 mm) high
Weight: 8.65 lbs. (3.9 kg)
Power Input: 24 VAC/DC

* 6.25”

(158.8 mm)

NOTE:

CAN cable must be routed separate

from torch leads.

4.50”

(114. 3 mm)

* 8.50” (215.9 mm)

including ttings on

front and back

4.75”

(120.7 mm)

31

CNC or

Process

Controller

Customer

Supplied

Gases

Description

Component Locator Designation

(See following component illustrations)

RAS Box

Power

N2/Air

O2/H35
Air

N2/Air

Argon
CAN

B

C

D

J
F
E

A

Combined

Gas Control

PT-36

Plasma

Torch

Shield Gas Hose

Plasma Gas Hose

G

H

J

Air Curtain Hose

Combined Gas Control Component Locator Designations

Note:

Refer to enclosed tables for all available hoses and cables.

Connections

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

Note:

Chassis must be connected to the machine ground.

ESAB

P/N

206 4113

Inputs

Output

Gas Fitting

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

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

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

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

PG

SG

Connection, Male

0.125NPT to "A" Size

32

Description

BA

C E FD

J

J

H

G

33

CAUTION

Description

When connecting fuel gas lines to the oxygen plasma gas input, or re­connecting oxygen after fuel gas use, extra care must be taken to as­sure that all lines from input through the torch are completely purged.
It is recommended to purge the system and torch lines with nitrogen
for 60 seconds prior to reconnection, then purge the nitrogen for 60
seconds with the new supply gas before cutting.

Metric

Input

Adaptors

CGA

Input

Adaptors

Gas Fitting

Argon G-1/4” right hand male x G-1/4” right hand male 0558010163

Plasma

Shield N2/Air G-1/4” right hand male x G-1/4” right hand male 0558010163

Air Curtain Air G-1/4” right hand male x “B” Air/Water right hand male 0558010165

Plasma

Shield N2/Air G-1/4” right hand male x “B” Air/Water right hand male 0558010165

Air Curtain Air G-1/4” right hand male x “B” Air/Water right hand male 0558010165

Outputs

N2/Air G-1/4” right hand male x G-1/4” right hand male 0558010163

O2/H35/F5* G-1/4” right hand male x G-1/4” right hand male 0558010163

* Another adapator is required when connecting H35/F5.

Part Number - 0558010246 (G-1/4” right hand female x G-1/4” left hand male)

Argon G-1/4” right hand male x “B” Inert Gas right hand female 0558010166

N2/Air G-1/4” right hand male x “B” Inert Gas right hand female 0558010166

O2/H35/F5* G-1/4” right hand male x “B” Oxygen right hand male 0558010167

* Another adapator is required when connecting H35/F5.

Part Number - 0558010245 (“B” Oxygen right hand female x “B” Fuel Gas left hand male)

SG 1/4” NPT x 5/8"-18 LH male 10Z30

PG 1/4” NPT x “B” Inert Gas right hand female 2064113

Air Curtain 1/8” NPT x “B” Inert Gas left hand female 08030280

Note:

ESAB

P/N

ESAB Kit p/n

0558000254

ESAB Kit p/n

0558000253

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

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

BOTH HOSES MUST BE ORDERED

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

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

34

Description

Each gas has a requirement for maximum ow and pressure as shown in chart below:

Gas

Argon 125 psi (8.6 bar), 200 SCFH (5.7 SCMH)

Plasma

O2/H35/F5 125 psi (8.6 bar) for O2, 75 psi (5.2 bar) for H35/F5, 255 SCFH (7.2 SCMH)

N2/Air 125 psi (8.6 bar), 255 SCFH (7.2 SCMH)

Shield

Air Curtain Air

N2/Air 125 psi (8.6 bar), 353 SCFH (10.0 SCMH)

Gas &

Pressure

Air (85psi / 5.9bar)

Process

Nitrogen

(125psi / 8.6bar)

Oxygen

(125psi / 8.6bar)

CGC Flow Diagram

Pressure

80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)

Maximum Gas Flow Rates - CFH (CMH)

With PT-36 Torch

269

(7.6)

385

(10.9)

66

(1.9)

Gas Purity

Clean, Dry, Oil Free

Filtered to 25 microns

99.99%, Filtered to 25 microns

99.5%, Filtered to 25 microns

35

Description

Combined Gas Control Plumbing Schematic

V1

Ar

PT1

V2

PV1

O2/H35/F5

PT3

Plasma Gas

N2/Air

N2/Air

V3

PT = Pressure Transducer
PV = Proportional Valve

PT2

∆P

P

P

1

2

PV2

Shield Gas

36

Description

Combined Gas Control Electrical Schematic

Con 1

CAN H Out
CAN L Out

CAN Gnd
CAN H In

CAN L In
NC
NC

NC

CAN

1

2

3

4

5

6

7

8

Con 2

1

2

3

POWER

4

24VAC In
24VAC In

-24VDC In

+24VDC In

CO 1

1

3

5

7

9

11

13

15 16

LED 2

2

4

6

8

10
12

14

LED 1

37

CGC Mounting Dimensions

p/n 0558008459

 0.281

(7.1mm)

0.313”

(8.0mm)

Description

4.00”

(101.6mm)

0.37”

(9.5mm)

CGC Bottom View

7.5 0 ”

(190. 5mm)

4.72”

(120.0mm)

0.37”

(9.5mm)

M6

0.90”

(22.9mm)

2.52”

(64.0mm)

38

Description

Troubleshooting

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

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

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

LED Status Meaning

OFF Power OFF

Green

Yellow ON Station is selected

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

Replacement Parts

NOTE:

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

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

39

Description

Remote Arc Starter (RAS)

p/n 0558012260

The Remote Arc Starter is more commonly referred to as the RAS
Box. The RAS box serves as an interface between the plasma con­troller and the EPP family of plasma power supplies, helping to de­liver a stable plasma arc. The RAS box also provides a voltage feed­back to the plasma torch lift. This voltage is used to regulate the
torch height while cutting, maintaining the proper height of the
torch above the work piece.

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

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

Specications

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

8.75”

(222.3 mm)

17.0 0”

(431. 8 mm)

40

7.5 0 ”

(190. 5 mm)

Remote Arc Starter Connections

A

Description

Note:

Chassis must be connected to the

machine ground.

G, H

Letter Description

D

C

EF

J

I

A 3 Pin Voltage Divider Connection to the Lift

C 14 Pin Amphenol Power Supply Connection

D Power Supply Enable

E Coolant Inlet - Flowing to the Torch

Coolant Return - Flowing back to the Coolant Circu-

F

G, H Strain Relief Fittings

I Torch Shroud Connection

J Machine Ground Connection

lator from the Torch

41

Description

Component Locator Designation

(See following component illustrations)

Power

Supply

Control

Box

PS & CC Control Cable

Power Cable

Pilot Arc Cable

Coolant Supply Hose
Coolant Return Hose

Power Supply Enable

C

G

H

E

Assembly

F

D

Arc

Starter

Power, Pilot Arc, Coolant

I

VDR Cable

A

AHC / Lift

( Optional )

Remote Arc Starter Box Component Locator Designations

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

PT-36

Plasma

Torch

42

Description

RAS Box Mounting Dimensions

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

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

CAUTION

5.00”

(12 7.0 0 mm)

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

1.00”

(2.54 mm)

2.75”

(69.85 mm)

RAS Box Mounting Plate Dimensions

p/n 0558008461

8.75"

(222.3 mm)

3.25"

7.50"

(190 .5 mm)

(82.6 mm)

6.50"

(165.1 m m)

13.75”

(349.25 mm)

18. 50"

(469.9 mm)

17. 50"

(444.5 mm)

43

Description

Typical / Recommended E-stop Connection

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

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

Replacement parts may be ordered from your ESAB Distributor.

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

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

Replacement Parts

NOTE:

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

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

44

Air Curtain Control (ACC)

Description

p/n 37440

p/n 0558010243

Specications

Dimensions: 6.00” high (152.4 mm) x 9.56” wide (242.8 mm) x 2.50” deep (63.5 mm)
Weight: 4.00 lbs. (1.81 kg)

Input Power: 24 VAC

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

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

45

ACC Mounting Dimensions

Description

9.31”

(236.5 mm)

5.81”

(147. 6 mm)

2.91”

(74.0 mm)

1.16”

(29.5 mm)

ACC Component Connections

.312” x .500”

slots

7.00”

(17 7.8 mm)

NOTE:

Cables “A” and “B” are listed in the ACC
Component Connections, INSTALLATION

section of this manual.

A

Compressed Air

46

B

Description

Water Injection Control (WIC)

p/n 0558009370

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

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

Specications

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

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

Water Requirements

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

Pump

Motor

Pressure Regulator

Pressure Transducer

Proportional Valve

Flow Sensor

Air Solenoid

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

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

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

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

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

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

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

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

o

- 77o F (0 - 25o C)

o

F (66o C)

o

- 257o F (-40

o

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

o

- 125o C)

o

F (66o C)

o

F (66o C)

47

Description

Automatic Height Control (AHC)

p/n 0560947166

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

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

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

Specications

Dimensions:

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

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

IHS Accuracy: ± 0.5 mm

Component Tolerances

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

48

Description

B4 Mounting Dimensions

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

2.50”
[63.5mm]

4.47”

[113.5mm]

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

4.13” [104.9mm]

3.64” [92.4mm]

0.49” [12.4mm]

0.53”
[13.5mm]

x6 M8x1.25 - 6H
THRU HOLES

5.00”

[127.0mm]

Recommended Mounting Bracket/Nut Plate

49

Hoses and Cables

Description

Cable / Hose

Description

CAN Bus Cable

Available

Lengths

m ( ft. )

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

3m (10’) 0558008466
4m (13’) 0558008467
5m (16’) 0558008468
6m (19 ’ ) 0558008469
7m (23’) 0558008470
8m (26’) 0558008471

9m (30’) 0558008472
10m (33’) 0558008473
11m (36’ ) 0558008474
12m (39’) 0558008475
13m (43’ ) 0558008476
14m (46’) 0558008477
15m (49’ ) 0558008478
20m (66’) 0558008479
25m (82') 0558008809

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

60m (200') 0558008486

ESAB

Part Number

50

Description

Cable / Hose

Description

E-Stop Cable

Cable / Hose

Description

VDR Cable

Available

Lengths

m ( ft. )

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

Available

Lengths

m ( ft. )

0.5m (1.7’) 0560947067

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

6.1m (20') 0560946782
7m (23’) 0560947070
8m (26’) 0560947071
9m (30’) 0560947072

10m (33’) 0560947078
15m (49’ ) 0560947073
20m (66’) 0560947074
25m (82') 0560946758

ESAB

Part Number

ESAB

Part Number

Cable / Hose

Description

Pilot Arc Cable

Available

Lengths

m ( ft. )

1.4m (4.5’) 0558008310

1.8m (6’) 0558008311

3.6m (12’) 0558008312

4.6m (15’) 0558008313

5. 2m (17 ’) 0558008314

6.1m (20’) 0558008315

7.6m (25’) 0558008316

4.5m (14.5’) 0558008317

ESAB

Part Number

51

Description

Cable / Hose

Description

Coolant Hose

Available

Lengths

m ( ft. )

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

45m (115 ' ) 0558005566

50m (164') 0558005567

5m (16') 0558005246

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

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

Plasma Gas Control to Air Curtain Hoses

Cable / Hose

Description

Air Curtain Hose

Available

Lengths

m ( ft. )

2. 3m ( 7. 5’ ) 0558010204

3.4m (11’) 0558010206

ESAB

Part Number

ESAB

Part Number

52

NOTE:

Description

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

Cable / Hose

Description

Plasma Gas Control Power Cable

Basic Flex Cable

Available

Lengths

m ( ft. )

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

10m (33’) 0560947082

12.8m (42') 0560946780
15m (49’ ) 0560947066

20m (66’) 0560947083

4.6m (15’) 0560936665

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

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

ESAB

Part Number

53

Description

Torch

Description

PT-36 m3 CAN

Plasma Torch

Cable / Hose

Description

PS & CC Control Cable

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

0558011630

Available

Lengths

m ( ft. )

1.4m (4.5’) 0558008301

1.8m (6’) 0558008302

3.6m (12’) 0558008303

4. 3m (14’) 0558008308

4.6m (15’) 0558008304

5. 2m (17 ’) 0558008305

6.1m (20’) 0558008306

7.6m (25’) 0558008307

Available

Lengths

m ( ft. )

2.9m (9.5’) 0558011840

7.6m (25’) 0558011631
10m (33’) 0558011632
15m (50’) 0558011633

20m (66’) 0558011634
23m (75’) 0558011635
25m (82’) 0558011636

30m (100’) 0558011637

35m (115’ ) 0558011963
40m (131’ ) 0558011638
45m (150’) 0558011964
50m (164’) 0558011639
55m (180’) 0558011965

60m (200’) 0558011640

ESAB

Part Number

ESAB

Part Number

54

Description

PT-36 Mechanized Plasmarc Cutting Torch

p/n 0558008300

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

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

Specications

TYPE: WATER COOLED, DUAL GAS, MECHANIZED PLASMARC CUTTING TORCH
CURRENT RATING: 1000 AMPS  100% DUTY CYCLE
MOUNTING DIAMETER: 2 “ 50.8 MM 
LENGTH OF TORCH WITHOUT LEADS: 16.7 “42 C M
IEC 609747 VOLTAGE RATING: 500 VOLTS PEAK
STRIKING VOLTAGE MAXIMUM VALUE OF HIFREQUENCY VOLTAGE: 8000 VAC
MINIMUM COOLANT FLOWRATE: 1.3 GPM 5.9 L/MIN
MINIMUM COOLANT PRESSURE AT INLET: 175 PSIG 12.1 BAR
MAXIMUM COOLANT PRESSURE AT INLET: 200 PSIG 13.8 BAR
MINIMUM ACCEPTABLE RATING OF COOLANT RECIRCULATOR: 16,830 BTU/HR 4.9 KW AT HIGH COOLANT

TEMPERATURE  AMBIENT = 45°F 25°C AND 1.6 USGPM 6 L/MIN

MAXIMUM SAFE GAS PRESSURES AT INLETS TO TORCH: 125 PSIG 8.6 BAR
SAFETY INTERLOCKS: THIS TORCH IS INTENDED FOR USE WITH ESAB PLASMARC CUTTING SYSTEMS AND CONTROLS

EMPLOYING A WATER FLOW SWITCH ON THE COOLANT RETURN LINE FROM THE TORCH. REMOVAL OF THE
NOZZLE RETAINING CUP TO SERVICE THE TORCH BREAKS THE COOLANT RETURN PATH.

55

7.54"

(191. 5 mm)

Description

2.00"

(50.8 mm)

9.13"

(231.9 mm)

6.17"

(156.7 mm)

10.50" (266.7 mm)
Length of Sleeve

Package Options Available

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

Optional Accessories

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

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

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

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

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

56

Description

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

NOTE:

Cannot be used with vent hole nozzles.

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

PT-36 Torch Consumable Kits

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

Part Number Quantity Description

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

57

Description

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

0558010625

600 AMP

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

0558010624

450 AMP

0558010623

360 AMP

0558010622

200 AMP

Part No Description

58

Description

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

Part Number Quantity Description

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

Recommended Regulators

LIQUID CYLINDER SERVICE:

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

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

HIGH PRESSURE CYLINDER SERVICE:

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

AR & N2 : R77150580 .............................................................................................. P/N 0558010682

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

INDUSTRIAL AIR : R77150590 ......................................................................... P/N 0558010684

STATION/PIPELINE SERVICE:

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

AR & N2 : R76150034 .............................................................................................. P/N 0558010658

AIR, H2, & CH4 : R6703 ...........................................................................................................P/N 22236

Replacement Parts

NOTE:

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

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

59

Description

60

Installation

InstallatIon

62

InstallatIon

Installation

General

FAILURE TO FOLLOW INSTRUCTIONS COULD LEAD TO DEATH, IN

WARNING

Unpacking

• Inspect for transit damage immediately upon receipt.

• Remove all components from shipping container and check for loose parts in container.

• Inspect louvers for air obstructions.

Check upon receipt

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

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

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

JURY OR DAMAGED PROPERTY. FOLLOW THESE INSTRUCTIONS TO
PREVENT INJURY OR PROPERTY DAMAGE. YOU MUST COMPLY WITH
LOCAL, STATE AND NATIONAL ELECTRICAL AND SAFETY CODES.

Before Installation

ALL INSTALLATION AND SERVICE OF THE ELECTRICAL AND PLUMB
ING SYSTEMS MUST CONFORM TO NATIONAL AND LOCAL ELEC

WARNING

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

TRICAL AND PLUMBING CODES. INSTALLATION SHOULD BE PER
FORMED ONLY BY QUALIFIED, LICENSED PERSONNEL. CONSULT
YOUR LOCAL AUTHORITIES FOR ANY REGULATION ISSUES.

63

InstallatIon

Grounding

Introduction

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

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

WARNING

ELECTRIC SHOCK HAZARD.

IMPROPER GROUNDING CAN CAUSE SEVERE
INJURY OR DEATH.
IMPROPER GROUNDING CAN DAMAGE MA
CHINE ELECTRICAL COMPONENTS.
MACHINE MUST BE PROPERLY GROUNDED
BEFORE PUTTING IT INTO SERVICE.
THE CUTTING TABLE MUST BE CONNECTED
TO MACHINE EARTH GROUNDING ROD.

64

InstallatIon

Grounding Overview

There are three parts to a ground system;

• Component or "chassis" ground

• Earth ground

• Protective Earth ground

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

A common symbol used to identify

a chassis ground on drawings.

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

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

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

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

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

65

Basic Layout

InstallatIon

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

6 8

7

1

5

9

4

3

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

an electrical ground.

66

2

8

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

8

InstallatIon

Elements of a Ground System

The ground system consists of ve main components:

• plasma current return path

• plasma system safety ground

• utility power electrical ground

• cutting machine chassis ground

• rail system safety ground.

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

Plasma Current Return Path

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

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

1

5

3

2

2

4

4

1

3

5

67

InstallatIon

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

Plasma System Safety Ground

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

• Frame voltage for personnel safety by en­suring that there are no potential dier­ences between system components and
building components.

• A stable signal reference for all digital and
analog electrical signals on the cutting
machine.

• Helps control electromagnetic Interfer­ence (or EMI).

• Provides a discharge path for short cir­cuits and high voltage spikes, such as
those caused by lightening strikes.

68

InstallatIon

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

Misconception about Earth ground rods.

1

1

69

InstallatIon

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

2

Earth ground rod reality.

1

2

1

70

InstallatIon

Rail System Safety Ground

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

71

InstallatIon

Earth Ground Rod

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

Ground Rod

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

Soil Resistivity

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

72

InstallatIon

Utility Power Electrical Ground

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

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

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

2

1

1

Utility Power Electrical Ground

2

3 Phase Electrical Supply

3

Plasma Power Supply

3

73

InstallatIon

Multiple Ground Rods

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

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

1.1

1

2

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

l

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

l

1

2

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

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

2.5 l

2.5 times the length of the rods.

74

InstallatIon

Machine Grounding Schematic

8

10

9

1

Main Control Enclosure

2

Component Enclosures

3

Main Star Ground

Rails

4

Cutting Table

5

System Star Ground (on Table)

6

Earth Ground Rod

7

Plasma Power Supply

8

Plasma Power Supply Ground (required by EU

9

Standards)

Electrical System Ground

10

2

1

3

4

5

(+)

6

7

• All electrical enclosures bolted to the
machine chassis

• Machine chassis grounded to star
point on cutting table.

• Rails grounded to cutting table

• Plasma ground connected to star point

on cutting table

• Earth ground rod connected to star
point on cutting table.

• A separate ground rod is required for
the plasma power supply by some reg­ulations and directives. Check with lo­cal regulations to determine if this ad­ditional ground rod is required.

75

Placement of Power Supply

FAILURE TO FOLLOW INSTRUCTIONS COULD LEAD TO DEATH, IN
JURY OR DAMAGED PROPERTY. FOLLOW THESE INSTRUCTIONS TO

WARNING

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

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

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

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

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

PREVENT INJURY OR PROPERTY DAMAGE. YOU MUST COMPLY WITH
LOCAL, STATE AND NATIONAL ELECTRICAL AND SAFETY CODES.

InstallatIon

Connection Procedures

ELECTRIC SHOCK CAN KILL! PROVIDE MAXIMUM PROTECTION

WARNING

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

WARNING

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

CONDUCTIVE DUST AND DIRT INSIDE POWER SUPPLY MAY CAUSE
ARC FLASHOVER. EQUIPMENT DAMAGE MAY OCCUR. ELECTRICAL
SHORTING MAY OCCUR IF DUST IS ALLOWED TO BUILDUP INSIDE
POWER SUPPLY.
SEE MAINTENANCE SECTION.

76

InstallatIon

Placement of RAS Box

THE COVER IS GROUNDED TO THE REMOTE ARC STARTER BOX IN

WARNING

Connections on the RAS Box

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

2. Power cables pass through the strain relief ttings. To make the power supply connection to the RAS box,
you must rst open the unit: remove or unlock the cover screws and lift the box cover o to expose internal
components.

TERNALLY WITH A SHORT GROUND WIRE. REMOVE COVER CARE
FULLY TO AVOID DAMAGE TO THE WIRE OR LOOSENING OF THE
GROUND WIRE.

Pilot Arc Cable enters through strain relief tting

to Voltage Divider (VDR)

Coolant IN
to Power Supply Enable

to Power Supply

Coolant OUT

Strain Relief Fittings

Power Source Cables enter
through strain relief ttings

77

InstallatIon

Buss Bar / Block

Locking Screw

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

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

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

Nomex Insulation

Connection for Pilot Arc Cable

NOTICE

Amperage Required # of 1/0 Cables

Up to 200 amps 1

Amperage Required # of 4/0 Cables

Up to 400 amps 1
Up to 800 amps 2

Up to 1000 amps 3

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

Note:

Chassis must be connected to the machine ground.

78

InstallatIon

Standard VDR Cable

VDR Cable (with free end)

6. If a non-ESAB lifter is to be used with a system the supplied VDR cable will only have a connector on one
end. The other end of the cable will have no connector. The end with the supplied connector is to be con­nected to the RAS box to its corresponding socket which is labeled “Voltage Divider.”

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

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

Customer

Supplied

Lifter

Ground

in Lifter is

VDR (Voltage Divider Cable)

required for

reference

79

InstallatIon

Torch Connections

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

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

Power Cable /

Coolant Connections

Pilot Arc Connection

Ground

Stud

Pilot

Arc Cable

Power Cable /

Coolant

Chassis

Ground

Wire

80

PG Hose

SG Hose

InstallatIon

Connection of Torch to Plasma System

DANGER

Electric Shock Can Kill!

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

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

components.

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

without turning primary power o.

Ground Stud

Ground cable

Power cables

Pilot Arc cable

Connection to the Remote Arc Starter Box

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

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

81

Mounting Torch to Machine

InstallatIon

DANGER

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

Mount torch on insulated sleeve here

• Do not mount on stainless steel torch body.

• Torch body is electrically insulated, however high fre-

quency start current may arc through to nd a ground.

• Clamping near torch body may result in arcing between
body and machine.

• When this arcing occurs, torch body may require non­warranty replacement.

DO NOT mount
on steel torch
body here

• Damage to machine components may result.

• Clamp only on insulated torch sleeve (directly above la-

bel) not less than 1.25" (31.75mm) from the torch end of
the sleeve.

82

InstallatIon

Placement of CGC

The CGC regulates the plasma gas and shield gas. For optimum
performance, it should always be placed close to torch. Accord­ing to the material being cut, the customer needs to select and
connect the correct inlet gases. Inline lters are embedded into
the inlet ttings. Please make sure all inlet gases meet the pres­sure and ow requirements.

Connect 24V AC/DC power from PDB, then connect CAN cable
to ICH.

Gas

Argon 125 psi (8.6 bar), 200 SCFH (5.7 SCMH)

Plasma

O2/H35/F5 125 psi (8.6 bar) for O2, 75 psi (5.2 bar) for H35/F5, 255 SCFH (7.2 SCMH)

N2/Air 125 psi (8.6 bar), 255 SCFH (7.2 SCMH)

Shield

Air Curtain Air

N2/Air 125 psi (8.6 bar), 353 SCFH (10.0 SCMH)

Gas &

Pressure

Air (85psi / 5.9bar)

Process

Nitrogen

(125psi / 8.6bar)

Oxygen

(125psi / 8.6bar)

Pressure

80 psi (5.5 bar), 1200 SCFH (34.0 SCMH)

Maximum Gas Flow Rates - CFH (CMH)

With PT-36 Torch

269

(7.6)

385

(10.9)

66

(1.9)

Gas Purity

Clean, Dry, Oil Free

Filtered to 25 microns

99.99%, Filtered to 25 microns

99.5%, Filtered to 25 microns

83

InstallatIon

Component Connections

Part numbers and lengths for the cables shown below are provided on the following page.

CGC front

C

B

PDB back

Compressed Air

A

84

InstallatIon

“A” - Cable from ACC to Lifter

Part Number Length Part Number Length

0560947067 0.5m (20") 0560947070 7m (23')
0560947075 1.5m (5') 0560947071 8m (26')
0560947076 3m (10') 0560947072 9m (30')
0560947068 4m (13') 0560947078 10m (33')
0560947077 5m (16') 0560947073 15m (50')
0560947069 6m (20') 0560947074 20m (66')

“B” - Air Curtain Hose from ACC to CGC

Part Number Length Part Number Length

0558006217 1.5m (5’) 0558006226 13m (43’)
0558007316 2.3m (7.5’) 0558006227 14m (46')
0558006218 5m (16') 0558006228 15m (50')
0558006219 6m (20') 0558006229 16m (52')
0558006220 7m (23') 0558006230 17m (56')
0558006221 8m (126') 0558006231 18m (59')
0558006222 9m (30') 0558006232 19m (62')
0558006224 11m (30’) 0558006233 20m (66')
0558006225 12m (39')

“C” - Power cable PDB to CGC (24 VAC/DC)

Part Number Length Part Number Length

0560947079 1.5m (5’) 0560947064 8m (26’)
0560947080 3m (10’) 0560947065 9m (30’)
0560947061 4m (13’) 0560947082 10m (33’)
0560947081 5m (16’) 0560946780 12.8m (42')
0560947062 6m (19’) 0560947066 15m (49 ’ )
0560947063 7m (23’) 0560947083 20m (66’)

85

InstallatIon

DANGER

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

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

1. Molten Metal Reaction

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

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

2. Slow Chemical Reaction

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

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

3. Plasma Gas

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

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

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

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

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

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

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

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

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

metals.

86

InstallatIon

WARNING

Possible explosion hazard from plasma cutting aluminum-lithium alloys!

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

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

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

WARNING

Oil And Grease Can Burn Violently!

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

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

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

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

WARNING

Hydrogen explosion hazard.

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

WARNING

Spark hazard.

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

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

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

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

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

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

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

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

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

87

InstallatIon

Preparing to Cut

• Select an appropriate condition from the Cut Data manual (SDP File) and install recommended torch
front-end parts (nozzle, electrode, etc.) See Cut Data manual to identify parts and settings.

• Position torch over material at desired start location.

• See Power Source Manual for proper settings.

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

Mirror Cutting

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

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

Reverse Diuser P/N 0004470115

Cut Quality

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

• Cut Angle, negative or positive

• Cut Flatness

• Surface Finish

• Dross

• Dimensional Accuracy

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

• Make small incremental adjustments when making corrections.

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

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

88

Before attempting ANY corrections, check cutting variables with the

CAUTION

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

Cut Angle

Negative Cut Angle

Top dimension is greater than the bottom.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• Stando low (arc voltage)

• Cutting speed slow (machine travel rate)

InstallatIon

Part

Positive Cut Angle

Top dimension is less than the bottom dimension.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• High stando High (arc voltage)

• Cutting speed fast

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

recommended current level for specic noz­zles).

Drop

Drop

Part

Part

Part

89

InstallatIon

Cut Flatness

Top And Bottom Rounded. Condition usually occurs when
material is .25" thick (6.4mm) or less.

• High current for given material thickness.
(See Cut Data manual for proper settings).

Top Edge Undercut

• Stando low (Arc Voltage).

Drop

Drop

Part

Part

90

InstallatIon

Surface Finish

Process Induced Roughness

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

• Incorrect Shield Gas mixture (See Cut Data
manual).

• Worn or damaged consumables.

Machine Induced Roughness

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

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

• Carriage wheel adjustment.

Top View

Process
Induced
Roughness

or

Cut Face

Machine
Induced
Roughness

Dross

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

High Speed Dross

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

• Stando high (arc voltage).

• Cutting speed fast.

Slow Speed Dross

Forms as globules on bottom along kerf. Removes easily.

• Cutting speed slow.

Cut Face

Lag Lines

Rollover

Side View

Cut Face

Lag Lines

Globules

Side View

91

InstallatIon

Recommended cutting speed and arc voltage will give optimal cut­ting performance in most cases. Small incremental adjustments may
be needed due to material quality, material temperature and specic

CAUTION

Top Dross

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

• Cutting speed fast

• Stando high (arc voltage)

Intermittent Dross

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

• Possible worn consumables

alloy. The operator should remember that all cutting variables are in­terdependent. Changing one setting aects all others and cut quality
could deteriorate. Always start at the recommended settings.

Side View

Splatter

Other Factors Aecting Dross;

• Material temperature

• Heavy mill scale or rust

• High carbon alloys

Cut Face

Before attempting ANY corrections, check cutting variables with the

CAUTION

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

Dimensional Accuracy

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

NOTICE

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

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

92

Torch Flow Passages

InstallatIon

Water OUT & Power

Pilot Arc

Water IN (L.H.)

Plasma Gas IN

Shield Gas IN

93

InstallatIon

94

Maintenance/Troubleshooting

Maintenance/troubleshooting

96

Maintenance/troubleshooting

Torch Front End Disassembly

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

DANGER

1. Remove the Shield Cup Retainer.

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

NOTE:

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

relieve pressure on the shield cup retainer.

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

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

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

CAUTION

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

Shield Cup

Shield Cup Retainer

Diuser

Torch Body

Electrode

Nozzle

Nozzle Retaining Cup

97

Maintenance/troubleshooting

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

Inspect nozzle for:

• melting or excessive current transfer.

• gouges from internal arcing.

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

• O-ring cuts, nicks, or wear.

• Remove hafnium particles (from the nozzle) with steel wool.

Replace if any damage is found.

NOTE:

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

cutting performance.

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

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

5. Remove electrode using electrode removal tool.

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

Torch Body

Electrode Removal Tool

Electrode

Replace electrode if center insert is

pitted more than 0.09" (3/32")

98

Maintenance/troubleshooting

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

Removal
Tool

Electrode

Gas Bae

Electrode Holder Assembly

NOTE:

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

aged, replace the electrode holder assembly.

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

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

NOTE:

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

tight seal.

Gas Bae

Electrode Holder Assembly

O-ring

NOTE:

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

99

Maintenance/troubleshooting

Torch Front End Assembly

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

CAUTION

• Reverse order of disassembly.

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

easy future assembly and disassembly for service.

• Installing the electrode requires only moderate tightening. If the electrode holder is made tighter
than the electrode, it is possible to change worn electrodes without removing the electrode holder.

• Turn on the coolant circulator and purge the gases through the torch.

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

NOTE:

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

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

Diuser

Torch

Nozzle

Electrode

Nozzle Retaining
Cup

Shield
Cup

Shield Cup Retainer

body

100