ESAB M3 Plasma Smart Voltage Height Control (SVHC-2) System Instruction manual

Smart Voltage Height Control (SVHC-2) System

®

Instruction Manual

Date: 03Nov11
Part Number: 0558011505
Language: EN

m3 Smart Voltage Height Control

Revision History:

• 2011 - Original Release

The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating, and maintaining this equipment.

The purchaser is responsible for the safe
operation and use of all products purchased,
including compliance with all applicable
standards in the country of use. See standard
ESAB terms and conditions of sale for a specic
statement of ESAB’s responsibilities and
limitations on liability.

This manual is ESAB part number 0558011505.

Information in this document is subject to change
without notice. This manual is for the convenience
and use of the cutting machine purchaser. It is not a
contract or any obligation on the part of ESAB Global
Cutting Technology.

ESAB Global Cutting Technology, 2011

Preface

This product was designed to provide years of
dependable, accurate, repeatable part cutting, with
a high degree of reliability and ease of operation.
There are optional features and congurations
available which may or may not be included in this
manual. In addition, more capabilities and features
may be added in the future, which are not covered
in this manual. ESAB Global Cutting Technology
reserves the right to change or add features and
capabilities without notice. Before operating the
machine, one should become familiar with this
manual in its entirety, with special attention to the
SAFETY section.

2

m3 Smart Voltage Height Control

Table of Contents

SAFETY

1.0 Safety ............................................................................................................................................................7

Introduction .......................................................................................................................................................................................... 7

Safety - English ..................................................................................................................................................................................... 8

Safety - Spanish .................................................................................................................................................................................. 12

Safety - French .................................................................................................................................................................................... 16

DESCRIPTION

2.0 Lift Control Interface (LCI) .........................................................................................................................23

Specications ......................................................................................................................................................................................23

LCI Mounting Dimensions ..............................................................................................................................................................23

CNC Direct Board ..............................................................................................................................................................................24

2.1 Automatic Height Control (AHC) ...............................................................................................................25

Specications ......................................................................................................................................................................................25

B4 Mounting Dimensions ...............................................................................................................................................................26

INSTALLATION

3.0 Grounding ...................................................................................................................................................29

Introduction ........................................................................................................................................................................................29

Grounding Overview .......................................................................................................................................................................30

Basic Layout ........................................................................................................................................................................................ 31

Elements of a Ground System ....................................................................................................................................................... 32

Plasma Current Return Path ..........................................................................................................................................................32

Plasma System Safety Ground ......................................................................................................................................................33

Rail System Safety Ground .............................................................................................................................................................36

Earth Ground Rod .............................................................................................................................................................................37

Ground Rod .........................................................................................................................................................................................37

3

m3 Smart Voltage Height Control

Soil Resistivity .....................................................................................................................................................................................37

Utility Power Electrical Ground ....................................................................................................................................................38

Multiple Ground Rods ..................................................................................................................................................................... 39

Machine Grounding Schematic....................................................................................................................................................40

3.1 Placement of LCI .........................................................................................................................................42

OPERATION

4.0 Lift Control Interface ..................................................................................................................................45

4.1 Operation ................................................................................................................................................... 46

LCI Connectors ...................................................................................................................................................................................46

Setup Descriptions............................................................................................................................................................................ 47

Digital I/O .............................................................................................................................................................................................49

Digital Inputs ......................................................................................................................................................................................49

Digital Outputs...................................................................................................................................................................................49

Display Screens ..................................................................................................................................................................................50

Editing a Parameter on the Display ............................................................................................................................................50

4.2 Modes of Operation: ..................................................................................................................................52

Remote Interface ...............................................................................................................................................................................52

Local Interface - Diagnostics Only ...............................................................................................................................................53

Operation sequence: ........................................................................................................................................................................53

Interface Wiring Descriptions .......................................................................................................................................................54

Interface Wiring ................................................................................................................................................................................. 54

4.3 Maintenance/Troubleshooting .................................................................................................................58

Error Messages on the LCI Display ..............................................................................................................................................58

Process Errors ...................................................................................................................................................................................... 59

Communication Errors ....................................................................................................................................................................60

4

SAFETY

SAFETY

DESCRIPTION INSTALLATION OPERATION

Be sure this information reaches the operator.

SAFETY

SAFETY

You can get extra copies through your supplier.

CAUTION

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

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompa­nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme­diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser­vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

6

SAFETY

SAFETY

1.0 Safety

Introduction

ESAB cutting machines are designed to operate
both safely and eectively. Sensible attention
to operating procedures, precautions, and safe
practices is required to achieve a full measure of
usefulness. Whether an individual is involved with
operation, servicing, or as an observer, compliance
with established precautions is mandatory. Failure
to observe precautions could result in equipment
damage, serious injury, or death. The following
precautions are guidelines when working with
cutting machines and associated equipment. More
explicit precautions are found within the instruction
literature. For specic safety information, obtain and
read publications listed in Recommended References.

The following words and symbols are used
throughout this manual to indicate dierent levels of
required safety involvement:

DANGER

WARNING

CAUTION

Used to call attention to high risk hazards,
which if not avoided, will result in death or
serious injury.

Used to call attention to medium risk
hazards, which if not avoided, could result
in death or serious injury.

Used to call attention to low risk hazards,
which if not avoided, could result in minor
or moderate injury.

Used to call attention to important
information not directly related to
safety hazards or could potentially cause
equipment damage.

7

Safety - English

SAFETY

SAFETY

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

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

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

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

1. Always wear safety glasses with side shields in

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

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

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

3. Wear ameproof gauntlet type gloves, heavy

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

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

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

5. Protect other personnel from arc rays and hot

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

6. Use goggles over safety glasses when chipping

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

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, Battery 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.

8

SAFETY

SAFETY

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

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

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

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

5. Keep everything 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.

9

SAFETY

5. WARNING: This product, when used for welding

SAFETY

or cutting, produces fumes or gases which con­tain chemicals known to the State of California
to cause birth defects and, in some cases, can­cer. (California Health & Safety Code §25249.5
et seq.)

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

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

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

2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar­riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 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 instal­lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.

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

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

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

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

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

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.

10

SAFETY

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

SAFETY

DANGER

CAUTION

WARNING

Enclosure Class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not
intended to be used outside during precipitation unless sheltered.

CAUTION

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

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

Means hazards which could result in minor personal injury.

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

CAUTION

CAUTION

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

Maximum

Tilt Allowed

15°

11

SAFETY

Safety - Spanish

SAFETY

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 precaucio­nes de seguridad listadas a continuación así como
también todo manual, hoja de datos de seguridad
del material, calcomanias, etc. El no observar las
Precauciones de Seguridad puede resultar en daño
a la persona o muerte.

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

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

1. Utilice gafas de seguridad con protección a los lados

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

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

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

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

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

4. Chispas y partículas de metal caliente puede alojarse en

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

5. Proteja a otras personas de los rayos del arco y 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 soldadura de corriente
alterna (AC) en áreas húmedas, de mov­imiento connado en lugares estrechos
o si hay posibilidad de caer al suelo.

12

SAFETY

SAFETY

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

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

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

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

5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

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

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

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

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones 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.

13

SAFETY

5. ADVERTENCIA-- Este producto cuando se utiliza

SAFETY

para soldaduras o cortes, produce humos o
gases, los cuales contienen químicos cono­cidos por el Estado de California de causar
defectos en el nacimiento, o en algunos ca­sos, Cancer. (California Health & Safety Code

§25249.5 et seq.)

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

Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

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

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

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

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

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

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

6. Use el equipo sólo para el propósito que fue
diseñado. No 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.

14

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

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

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

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

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

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

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

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

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

SAFETY

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

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

PELIGRO

mente en serio daño personal o la muerte.

SAFETY

ADVERTENCIA

CUIDADO

Clase de envolvente

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

ADVERTENCIA

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

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

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

ADVERTENCIA

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

ADVERTENCIA

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

Inclinación

máxima permitida

15°

15

SAFETY

Safety - French

SAFETY

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

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

1. Portez des lunettes protectrices munies d'écrans latéraux
lorsque vous êtes dans l'aire de travail, même si vous de­vez porter un casque de soudeur, un écran facial ou des
lunettes étanches.

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

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

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

5. Protégez toute personne se trouvant à proximité des étin­celles et des rayons de l'arc à l'aide d'un rideau ou d'une
cloison ininammable.

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

AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de pré­caution provenant des références dans

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive.

INCENDIES ET EXPLOSIONS -- La

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

laitier incandescent ou les étincelles
peuvent également provoquer un

incendie ou une explosion. Par conséquent :

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

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

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

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

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

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

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

02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces élec-

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

16

SAFETY

SAFETY

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

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

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion 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.

17

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 :

SAFETY

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.

18

SAFETY

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

SAFETY

DANGER

AVERTISSEMENT

ATTENTION

Classe de protection de l’enveloppe

L’indice de protection (codication IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de
protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration
d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de
la verticale. Les équipements portant la marque IP23S peuvent être entreposés à l’extérieur, mais ne sont pas
conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

AVERTISSEMENT

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

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

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

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

AVERTISSEMENT

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

AVERTISSEMENT

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

Angle

d’inclinaison

maximal

15°

19

SAFETY

SAFETY

20

DESCRIPTION

SAFETY

DESCRIPTION

INSTALLATION OPERATION

DESCRIPTION

Below are some abbreviations used throughout this manual.

ABBREVIATIONS:
AHC - Automatic Height Control

LCI - Lift Control Interface

DESCRIPTION

22

DESCRIPTION

2.0 Lift Control Interface (LCI)

p/n 0558009610

The Lift Control Interface (LCI) provides the plasma process control including current, gas and torch height (if
applicable). It also serves as the interface between the customer CNC and the ESAB SVHC-2 System. At the same
time, it functions as a hub for CAN communication.

DESCRIPTION

Specications

Dimensions: 7.50” (190.5 mm) high x 10.125” (257.2 mm) wide x 6.50” (165.1 mm) deep
Weight: 8.5 lbs. (3.9 kg)

Operating Temperature 5-40°C (41-104°F)
Max Humidity 95% non-condensing
Enclosure Degree of Protection IP54
Input Power Reduction 230 VAC, 5 Amps

LCI Mounting Dimensions

11.50”

 0.28”

(7.1 mm)

3.00”

(76.2 mm)

(292.1 mm)

23

DESCRIPTION

CNC Direct Board

p/n 0558011504

The CNC Direct board is the control and interface board inside the LCI. It provides the process control, interface
to customer CNC, system setup, panel interface, etc. Below is a skeleton of this CNC board. It shows the major
components and the major connectors on the board. The table below gives the functions of these connections.

DESCRIPTION

24

Port Function Port Function

X1 CNC Control, DB37
X2 RS232
X3 CAN1 and 24VDC input XP1 Programming port 1
X4 CAN2 XP2 Programming port 2
X6 Spare I/O S2, S3 ID switches, by default S2=1, S3=4
X7 Reserved V12 IC, Main processor

X8 Aux Control, DB25 V13

X9 ASIOB1 Communication V41 IC for ASIOB1

XS1 Switches: Plasma Start, Gas Test J1

XS2

Switches: Local/Remote, Station Select and
Screen Select

EEPROM, Save data for system conguration,
error history, etc.

DIP switches:
1- 120R for CAN1, 2- 120R for CAN2,
3- VCC to ASIOB1, 4- GND to ASIOB1
Default: 1 - ON, 2 - ON, 3 - OFF, 4 - OFF

DESCRIPTION

2.1 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.

DESCRIPTION

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

25

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.

DESCRIPTION

2.50”
[63.5mm]

4.47”

[113.5mm]

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

4.13” [104.9mm]

3.64” [92.4mm]

0.49” [12.4mm]

0.53”
[13.5mm]

x6 M8x1.25 - 6H
THRU HOLES

5.00”

[127.0mm]

26

Recommended Monting Bracket/Nut Plate

INSTALLATION

SAFETY

DESCRIPTION

INSTALLATION

OPERATION

INSTALLATION

INSTALLATION

28

INSTALLATION

3.0 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 machine
electrical components.

Machine must be properly grounded
before putting it into service.

INSTALLATION

The cutting table must be connected to
machine earth grounding rod.

29

INSTALLATION

Grounding Overview

There are three parts to a ground system;

• Component or "chassis" ground

• Earth ground

• Protective Earth ground

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

A common symbol used to identify

a chassis ground on drawings.

INSTALLATION

interference (EMI) from the enclosure to ground.

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

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

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

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

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

30

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

INSTALLATION

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

2

8

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

8

31

INSTALLATION

Elements of a Ground System

The ground system consists of ve main components:

• plasma current return path

• plasma system safety ground

• utility power electrical ground

• cutting machine chassis ground

• rail system safety ground.

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

INSTALLATION

Plasma Current Return Path

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

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

1

5

3

2

2

4

4

1

3

32

5

INSTALLATION

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

Plasma System Safety Ground

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

• Frame voltage for personnel safety by ensuring

that there are no potential dierences between
system components and building components.

INSTALLATION

• A stable signal reference for all digital and analog

electrical signals on the cutting machine.

• Helps control electromagnetic Interference (or

EMI).

• Provides a discharge path for short circuits and

high voltage spikes, such as those caused by
lightening strikes.

33

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.

INSTALLATION

1

1

34

INSTALLATION

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

2

Earth ground rod reality.

1

INSTALLATION

2

1

35

INSTALLATION

Rail System Safety Ground

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

INSTALLATION

36

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.

INSTALLATION

37

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.

INSTALLATION

2

1

1

Utility Power Electrical Ground

2

3 Phase Electrical Supply

3

Plasma Power Supply

3

38

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.

INSTALLATION

l

1

2

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

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

2.5 l

2.5 times the length of the rods.

39

INSTALLATION

Machine Grounding Schematic

INSTALLATION

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

10

9

2

1

3

4

8

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.

40

INSTALLATION

Check upon receipt

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

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

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

Before Installation

All installation and service of the electrical and plumbing systems

WARNING

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

must conform to national and local electrical and plumbing codes.
Installation should be performed only by qualified, licensed
personnel. Consult your local authorities for any regulation issues.

INSTALLATION

41

INSTALLATION

3.1 Placement of LCI

The LCI should be located close to the operator for easy access.

Connect required CAN cables between LCI and other CAN nodes,
such as the B4 lifter. CAN connection is always made from left to
right, if one node is removed from CAN bus, all nodes on the right
need to be shifted to left. After connecting all CAN nodes, a termi­nator is required. Leave all unused CAN ports open.

Connect DB37 cable to port “CNC” on LCI. The other side of DB37,
is connected to the customer’s CNC via a male DB37 connector. An
optional breakout board may be used.

Connect power from LCI to B4 lifter, if applicable. Make sure the power switch on LCI is o.

INSTALLATION

Connect power to LCI box.

42

SAFETY

DESCRIPTION INSTALLATION

OPERATION

OPERATION

OPERATION

OPERATION

44

OPERATION

4.0 Lift Control Interface

The LCI (Lift Control Interface) is used to interface the ESAB SVHC-2 with the customer CNC using digital I/O.

7

6

OPERATION

16

15

GND

Note:

Chassis must be connected

to the machine ground.

1 2 3 4 5

LCI front view

8 9 10 11

12

13

14

LCI back view

45

OPERATION

4.1 Operation

LCI Connectors

Item Number Item Description

1 AHC Test Only functional in Local mode. Starts automatic height control sequence.
2 IHS Test Only functional in Local mode. Starts initial height sensing test.

This switch will change the LCI system from being remotely controlled, via the

3 Local/Remote

4 Up/Down This switch is a momentary switch which will move the station up or down.
5 Screen Select This switch will allow the user to select dierent screens.

6

7 Power Switch This switch will turn on the Lift Control Interface.

OPERATION

8 Input Power

9 AHC Power Power connection for an ESAB lift (B4 or A6).
10 Gas Power Not used.
11 RS232 Not used.
12 ASIOB1 Not used.
13 CNC DB37 connector to interface to customer I/O.
14 AUX Control Not used.
15 CAN Vision 5x Not used.
16 Fuses Replace fuses with same type and size.

Encoder Wheel

with Push Button

digital inputs from the CNC, to locally controlled via the switches on the Lift
Control Interface.

This only has an eect in local mode under normal operation and in the set up
mode. This wheel will allow you to change the parameter the cursor is currently
on. The button will also allow you to see a more detailed error message when
on the error log screen.
To work the wheel for editing a parameter, push the wheel, move the wheel to
change the value, and then press the wheel again to lock in the value.

Customer supplied input power to LCI. See specications for power require­ments.

46

OPERATION

Setup Descriptions

Setup - The “setup screen” on the Lift Control Interface is accessed by having “AHC Test” set to “ON” and “Remote/Lo-

cal” set to “LOCAL” when powering up the box. It is exited by turning the power o and then back on. Make sure to reset

the switches back to the original state for parameter display. The encoder wheel with pushbutton, is used to select an item
and change the values or to select a sub-menu.

An example shown here, is for setting up a Plasma
System congured for the following:

Motion Enable Signal meaning
Lift Type
VDR Ratio
Upper Limit Switch to Table (µm)

Fast Speed (Relative speed 0-500)
Slow Speed (Relative speed 0-500)
Error Log

OPERATION

Save Constants

Reload Constants

Described below are the various options to be modied before setting up the plasma system for operation:

Motion Signal Motion - Motion Enable only goes high when motion is allowed.

Error Log The error log stores up to 13 errors at a time reported by the LCI in the order they are detected. These errors are only cleared by

Lift Type The lifter type species which lift is being used. Available options are: A6 or B4.

VDR Ratio Set to the Voltage Divider Ratio being used.

ULS to Table The distance from the torch tip, when on the upper limit switch, to the top of the table slats. This is in micrometers.

Fast Speed This is the speed at which the lifter will move when not in the slowdown zone, when using height control, or when moving up.

Slow Speed This is the speed at which the lifter will move when in the slowdown zone or using height control. The slowdown zone is the

IHS - Motion Enable goes high when IHS is complete and resets when cycle start goes low.

selecting “CLEAR”. Select the error, by pushing the pushbutton part of the encoder wheel, to see more details about the error.

The slowdown zone is the plate thickness, plus 25 millimeter, above the table slats.

plate thickness, plus 25 millimeter, above the table slats.

47

OPERATION

Once the setup is complete, make sure to save the constants by selecting the “Save Constants” tab. The follow-
ing screen will be displayed for a couple of seconds to conrm that your changes have been taken.

Save Complete

If you do not want to keep the changes you have made and would like to revert back to the last saved settings

OPERATION

then select the “Reload Constants” tab. The following screen will be displayed for a couple of seconds to con­rm that your changes have been taken.

Load Complete

48

OPERATION

Digital I/O

Digital Inputs

Digital inputs are to be only turned on with 24 VDC. Any other voltage may damage the board or cause unpre­dictable results. The best method is to send the 24 VDC from the DB37 connector back on the input, via a relay
or opto-isolator chip.

Signal Name Description

Corner Informs the LCI to block height control.
Cycle Start Start the Height Control Sequence.
Station Up Move the station lifter up.

Station Down Move the station lifter down.

Station On Turn on the station.

Arc on from the power source. Used when motion signal is set to motion in

Arc On

the setups screen. This causes the lift to go to piercing height and wait for the
piercing timer to expire before going to cutting height and sending Motion
Enable.

OPERATION

Digital Outputs

Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement.

Signal Name Description

This signal is high when the arc is on or the process is o, when motion signal

Motion Enable/IHS

Fault

Plasma Start

Station ULS Station is on the upper limit switch.

is set to Motion in the setup screen. This signal is high when IHS is complete
and resets when cycle start is low, when motion signal is set to IHS in the setup
screen.

The LCI has detected a problem which required the lifter to stop. Check the
error log for details.

Sent after IHS is complete, when motion signal is set to motion in the setup
screen. It is reset when cycle start goes low.

49

OPERATION

Display Screens

Startup Screen

On powerup the LCI screen displays the following information for 3 seconds:

Software version

OPERATION

Editing a Parameter on the Display

Only available when communication is set to none or Local/Remote switch is set to Local.

Use the encoder wheel to scroll to the parameter.

1.

2. Push the wheel.

3. Turn the wheel to edit the value.

4. Push the wheel again to lock the value.

Height Control Screen

Height Settings
Ignition (mm)

Pierce (mm)
Cutting (mm)
Thickness (mm)
Arc Voltage (volts)

Pierce (seconds)

50

CNC Input Screen

OPERATION

Inputs

Station 1 ON 0 0

Cycle Start 0 0

Corner 0 0

Arc ON 0 0

Station UP 0 0

Station DOWN 0 0

CNC’s Direct

Input

ACT

(selection program

is currently

running)

OPERATION

CNC Output Screen

Outputs
Dened by motion signal
System has faulted
Plasma Start for simple plasma
Station is on Upper Limit Switch

Motion Signal options:

IHS - Motion Enable only goes high when IHS is com-

plete and resets when cycle start goes low.

Motion - Motion Enable only goes high when motion
is allowed.

51

4.2 Modes of Operation:

Remote Interface

Operation sequence with Motion Signal set to “Motion”:

1. Setup the part program that needs to be cut from the CNC.

2. Go to the LCI screen and setup the parameters according to the cut data manual for height and piercing timer.

3. Once all of the setups have been completed on the LCI, refer to the cut data manual for setting up parameters on
the CNC.

4. Execute the program from the CNC.

5. The CNC does a purge before Initial Height Sensing, if required.

6. The CNC send a “Cycle Start” signal to the LCI.

7. The following happens while the CNC waits for motion enable.

a. The torch comes down and does the initial height sensing unless the “Corner” signal is high.
b. The LCI sets the “Plasma Start” signal high.
c. The LCI waits for the “Plasma Arc On” signal to go high.
d. The LCI raises to the piercing height unless the “Corner” signal is high.
e. The LCI waits a time, from the parameters, for the current to pierce the plate.
f. The LCI lowers down to the cutting height unless the “Corner” signal is high.
g. The “Motion Enable” signal is returned to the CNC.

8. Start moving the machine in the shape desired, turning the corner signal on when not going at full speed for the
parameters.

9. Remove the “Cycle Start” signal to the LCI at the end of cut.

OPERATION

10. The following happens while the CNC waits for “Motion Enable” to be removed and come back.

a. The “Motion Enable” is removed.
b. The “Plasma Start” is removed.
c. The “Motion Enable” is returned.

OPERATION

Operation sequence with Motion Signal set to “IHS”:

1. Setup the part program that needs to be cut from the CNC.

2. Go to the LCI screen and setup the parameters according to the cut data manual for height and piercing timer.

3. Once all of the setups have been completed on the LCI, refer to the cut data manual for setting up parameters on
the CNC.

4. Execute the program from the CNC.

5. The CNC does a purge before Initial Height Sensing, if required.

6. The CNC send a “Cycle Start” signal to the LCI.

7. The torch comes down and does the initial height sensing unless the “Corner” signal is high.

8. The “Motion Enable” signal is returned to the CNC.

9. The LCI waits for the “Plasma Arc On” signal to go high.

10. The LCI raises to the piercing height unless the “Corner” signal is high.

11. The LCI waits a time, from the parameters, for the current to pierce the plate.

12. The LCI lowers down to the cutting height unless the “Corner” signal is high.

13. Start moving the machine in the shape desired, turning the corner signal on when not going at full speed for the
parameters.

14. Remove the “Cycle Start” signal to the LCI at the end of cut.

15. The “Motion Enable” signal is removed.

52

OPERATION

Local Interface - Diagnostics Only

The local interface is used to test the SVHC-2 system for diagnostic purposes. This allows limited use of the sys­tem and is normally used for troubleshooting. This will disable the CNC’s ability to control the system.

Note:

The actual operation of cutting should not be performed while in this mode as the CNC is not in

control of the process.

Height Settings
Ignition (mm)

Pierce (mm)
Cutting (mm)
Thickness (mm)
Arc Voltage (volts)

Pierce (seconds)

OPERATION

Operation sequence:

1. To enable the local interface, the “Local/Remote” switch needs to be in the “Local” position.

2. Parameters can be setup on the screen.

3. Use “IHS Test” to test initail height sensing.

4. Use “AHC Test” to test the sequence.

5. With both “AHC Test” and “IHS Test” o, use station up/down to move the station manually.

53

OPERATION

Interface Wiring Descriptions

Interface Wiring

DB37 Connector

This cable should be a twisted pair cable with an overall shield attached to the shell on both ends of the cable.
It has a DB37 male connector on each end.

Wire No. Signal Name Function

1 RS422 RX- Not used

2 RS422/485 TX- Not used

3 RS422/485 GND Not used

4 Digital Output 1 (-) Motion Enable Emitter

5 Digital Output 2 (-) Fault Emitter

6 Digital Output 3 (-) Plasma Start Emitter

7 Digital Output 4 (-) ULS Emitter

8 Digital Output 5 (-) Spare Output Emitter

9 Digital Output 6 (-) Spare Output Emitter

10 Digital Output 7 (-) Spare Output Emitter

11 Digital Output 8 (-) Spare Output Emitter

OPERATION

12 Digital Input 1 Corner

13 Digital Input 2 Spare Input

14 Digital Input 3 Plasma Start On

15 Digital Input 4 Cycle Start

16 Digital Input 10 Spare Input

17 24VDC 24 VDC Power

18 GND Ground

19 Digital Input 5 Spare Input

20 RS422 RX+ Not used

21 RS422/485 TX+ Not used

22 GND Ground

23 Digital Output 1 (+) Motion Enable Collector

24 Digital Output 2 (+) Fault Collector

25 Digital Output 3 (+) Plasma Start Collector

26 Digital Output 4 (+) ULS Collector

27 Digital Output 5 (+) Spare Output Emitter

28 Digital Output 6 (+) Spare Output Emitter

29 Digital Output 7 (+) Spare Output Collector

30 Digital Output 8 (+) Spare Output Collector

31 Digital Input 6 Station Up

32 Digital Input 7 Station Down

33 Digital Input 8 Spare Input

34 Digital Input 9 Spare Input

35 Digital Input 11 Station On

36 GND Ground

37 24VDC 24 VDC Power

FG Field Ground Cable Shield Ground (Connected via the connector shell)

54

OPERATION

DB37 Connector

The customer has two options available for wiring to the DB37 connector shown below:

Connection assemblies for LCI and CNC interface.

Option 1:

ESAB provided DB37 cable (Male-free) and customer wires directly to their connection. Not all functions are avail­able with this option.

DB37 Cable

Part Number Length

0558010157 5 M (16’)

To Customer

DB37 Cable

LCI Box

provided

DB37 Interface

OPERATION

Shown below are two typical ways to use this option, with customer supplied 24 VDC and without.

55

OPERATION

Option 2:

ESAB provided DB37 cable (Male-Male) and customer provided DB37 (Female) connector. Customer builds their
own DB37 Interface for connection to CNC.

To Customer

DB37 Cable

LCI Box

DB37 Cable

Part Number Length Part Number Length

0558010071 2 M 0558010076 7 M
0558010072 3 M 0558010077 10 M

OPERATION

0558010073 4 M 0558010078 15 M
0558010074 5 M 0558010079 20 M
0558010075 6 M 0558010080 25 M

provided

DB37 Interface

Option 3:

ESAB provided DB37 cable (Male-Male) and terminal block assembly for connection to CNC.

DB37 Cable

Example DB37 Breakout boards:

LCI Box

56

Manufacturer Part Number

Sea Level TB02KT

Winford BRK37F series

Advantech * ADAM3937

*ESAB recommended part available as ESAB part number

0558009990.

DB37 Terminal

Block Assembly

OPERATION

DO+ 1

24V

B

A

coil

DO- 1

Power Connector

Wire No. Signal Name Function

1 Line 1 Line 1 of 230 VAC or Line of 115 VAC (No Height Control)
2 Line 2 Line 2 of 230VAC or Neutral of 115 VAC (No Height Control)
3 NC No Connect
4 GND Ground

Digital Output Wiring Examples

Digital outputs should only be 24 VDC with less than 80 milli-amperes current requirement. There are two good
methods for doing this. There is a small voltage drop across the opto-isolator in the Lift Control Interface, so it
is recommended that a voltage of at least 12 VDC be used in order to protect against noise generated by the
plasma system’s starting circuit.

24V

Method 1: Using the 24 VDC to drive a digital input circuit on the
CNC’s input.

DO+ 1

R1

10K

R3

2.74K

R2

5VDO- 1

1M

OPERATION

Method 2: Using the 24 VDC to drive a relay coil and using the con­tact on the coil however the CNC needs it.

DO+ 1

DO- 1

24V

B

A

coil

57

OPERATION

4.3 Maintenance/Troubleshooting

Error Messages on the LCI Display

Error Log Screen

Last received error always shown at top.

Clear all errors on screen.

OPERATION

This screen can be accessed by using “Switch Screen” on the LCI and displays a log of the last 13 errors received
by the LCI. By moving the cursor to the error and pressing the hand wheel, more details of the error are displayed.

Error Screen

Station number
Type of Error
Error ID

Error details

58

This screen can be accessed by scrolling down to the
“fault” text and pressing the hand wheel or through
the error log screen.

OPERATION

Process Errors

Process Errors from System Modules

ID Description

D Arc Voltage is too high. Check that the torch did not fall into a hole and that the arc voltage calibration is correct.

Arc Volt is too low. Check that the torch did not crash into the plate or ground and that the arc voltage calibration is

E

correct.

11 The torch has crashed. Please remove obstruction and reset the torch in the torch holder.

Initial Height Sensor (IHS) did not complete in the allowed time. Make sure the torch is over a plate and the amplier is

13

not faulted.
18 The lifter is missing. Please make sure the CAN cable is securely plugged into both the lifter and the LCI Box.
1D The lower limit switch on the lifter has been tripped.

1E-24 Contact service. This is not an error a customer can x.

The display has reset. This can happen during the plasma start sequence. Try moving DB37 cable further away from the
29

torch and power cables away from the power supply.

The module’s telegram counters did not match the ICH’s telegram counters. This happens when the ICH misses a telegram, the mod-

FF

ule misses a telegram, or the module resets unexpectedly.

OPERATION

59

OPERATION

Communication Errors

Communication Errors from System Modules

ID Description

3 Wrong ID or wrong CRC checksum.
9 CRC error during transfer of the station constants.

B Watchdog error.
11 CRC checksum is wrong.
12 Module carried out a reset.

1A Watchdog counter has been exceeded.

1B Output driver has a short circuit.

1C Wrong or no expansion board.
1D CRC error during transfer of the station constants.

1E Send buer overow CAN.
1F Receive buer overow CAN.

22 Dierence between set value and actual value of the digital outputs.
23 CRC error in the calibration data.
2B Junma amplier reports "Alarm".

OPERATION

2C CRC error in the calibration data.
2D Varying signal statuses on the relay outputs.

2E Over temperature at the heat sink.
2F No motor voltage.

30 CRC checksum of the PLC is not correct.

31 Short circuit on the motor supply cable.

34 Cable fault.

35 Wrong CRC checksum from the printer.
53 CRC checksum of the PLC is not correct.

54 Varying signal statuses on the relay outputs .

59 CRC error during transfer of the station constants.

5A Module carried out a reset.
5B Wrong position sensor.
5C No servo amplier.
5D Limit switch has been reached.

5E Over current in the servo amplier.
5F Watchdog counter has been exceeded.

60

NOTES

61

NOTES

62

original release - 03Nov11

REVISION HISTORY

63

ESAB Welding & Cutting Products, Florence, SC

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