PMC-91 PlasMarC systeM
Mechanized Plasma Cutting and Marking
with PT-600, PT-19XLS or PT-36
Instruction Manual
0558008059 05 / 2008
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ....................................................................................5
1.1 Safety - English .................................................................................5
1.2 Safety - Spanish.................................................................................9
1.3 Safety - French.................................................................................13
2.0 Introduction .........................................................................................17
2.1 General ........................................................................................17
2.2 Features .......................................................................................17
2.3 Component Description........................................................................18
3.0 Installation.......................................................................................... 25
3.1 System Component Locations.................................................................. 25
3.2 System Connections ........................................................................... 26
3.3 Torch Components ............................................................................ 34
3.4 Installing Air Curtain ........................................................................... 38
3.5 Water Muer Installation ...................................................................... 39
3.6 Air Curtain / Water Muer Control Box Installation.............................................. 40
4.0 Operation - Cutting ..................................................................................41
4.1 Controls and Indicators .........................................................................41
4.2 Pre-Operation Test / Checkout ................................................................. 46
4.3 Operating Techniques ......................................................................... 50
5.0 Operation - Marking..................................................................................55
5.1 Pre-Operation Test and Checkout ...............................................................55
5.2 Marking and Cutting Procedure ................................................................ 56
6.0 Troubleshooting .................................................................................... 57
6.1 Programmable Logic Controller (PLC)........................................................... 57
6.2 Sequence Description.......................................................................... 58
6.3 Operating Information .........................................................................60
6.4 Troubleshooting Guide .........................................................................61
WARNING
PLASMA CUTTING WITH GAS MIXTURES CONTAINING HYDROGEN (H) OR METHANE (CH4)
CAN RESULT IN AN EXPLOSION.
FAILURE TO COMPLY WITH THE INFORMATION LISTED BELOW CAN RESULT IN DEATH, SEVERE
PERSONAL INJURY OR SERIOUS EQUIPMENT DAMAGE.
HYDROGEN OR METHANE GAS MIXTURES SHOULD NEVER BE USED FOR PLASMA CUTTING
UNDERWATER.
CUTTING WITH COMBUSTIBLE GAS MIXTURES OVER A WATER TABLE CAN RESULT IN THE ACCUMULATION OF EXPLOSIVE GAS POCKETS BETWEEN THE CUTTING TABLE AND THE WORK
PIECE. THESE POCKETS WILL EXPLODE WHEN IGNITED BY SPARKS FROM THE PLASMA ARC.
TO REDUCE, BUT NOT ELIMINATE, THE POSSIBILITY OF AN EXPLOSION THE FOLLOWING PRECAUTIONS SHOULD BE TAKEN:
LOWER WATER LEVEL IN THE WATER TABLE 4 TO 6 INCHES (100 TO 150MM) BELOW THE •
WORK PIECE.
BEFORE CUTTING, BE AWARE OF POSSIBLE EXPLOSIVE GAS SOURCES IN THE WATER TA-•
BLE SUCH AS MOLTEN METAL REACTION, SLOW CHEMICAL REACTION AND SOME PLASMA GASES.
CLEAN SLAG (ESPECIALLY FINE PARTICLES) FROM BOTTOM OF TABLE FREQUENTLY. RE-•
FILL TABLE WITH CLEAN WATER.
DO NOT LEAVE WORK PIECE ON TABLE OVERNIGHT.•
IF WATER TABLE HAS NOT BEEN USED FOR SEVERAL HOURS, VIBRATE OR JOLT IT TO •
BREAK UP GAS POCKETS BEFORE LAYING WORK PIECE ON THE TABLE.
IF POSSIBLE, CHANGE WATER LEVEL BETWEEN CUTS TO BREAK UP GAS POCKETS.•
MAINTAIN WATER PH LEVEL NEAR 7 (NEUTRAL).•
PROGRAMMED PART SPACING SHOULD BE A MINIMUM OF TWICE THE KERF WIDTH TO •
ENSURE MATERIAL IS ALWAYS UNDER THE KERF.
FANS SHOULD BE USED TO CIRCULATE AIR BETWEEN WORK PIECE AND WATER SURFACE. •
A TABLE WATER AERATION SYSTEM SHOULD ALSO BE USED.
4
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
WARNING: These Safety Precautions are
for your protection. They summarize precautionary information from the references
listed in Additional Safety Information section. Before performing any installation or operating
procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, Thick long-
sleeve shirt, cuess 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 cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
1.1 Safety - English
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hidden smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a re hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
5
SECTION 1 SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic 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 eects 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 specic ventilation recommendations.
6
SECTION 1 SAFETY PRECAUTIONS
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
SECTION 1 SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used
throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
8
SECCION 1 SEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el ltro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chis-
pas calientes con una cortina adecuada no-amable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
SECCION 1 SEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas 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 especícas en la ventilación.
10
SECCION 1 SEGURIDAD
5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. Siempre tenga personal cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
SECCION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
SECTION 1 SÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans la-
téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres ltrants et de
plaques protectrices appropriées an 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 an 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 ininammable an 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 ininammable.
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.
L es p er so n ne s se tr o uv an t à p r ox im it é do ive nt é ga l ement 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 susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. 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 inammables 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 surchauer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
13
SECTION 1 SÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an 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 eectuer 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
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-
teur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A. Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 an
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 spéciques
concernant la ventilation.
14
SECTION 1 SÉCURITÉ
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
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'eectuez aucune modication.
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"
15
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
SECTION 2 INTRODUCTION
2.1 General
The PMC-91 Plasmarc System is a full capability plasmarc cutting and marking system that oers a wide variety of plasma
cutting and marking processes and applications. The system is designed specically for computer controlled mechanized
applications with expanded interfacing, exible conguration from a selection of packages and versatile ease of operation. By
selecting the components that best suit your needs the PMC-91 Plasmarc System can fully automate your cutting process.
2.2 Features
The system is capable of water injection cutting and gas shielded underwater cutting can be accomplished at most •
current levels with appropriate torch and accessories.
The PMC-91 Plasmarc System can accommodate all major cutting gases including; oxygen, air, nitrogen, methane (CH•
or argon/hydrogen mixture.
The separate component design, ow control, plumbing box, power source provides maximum exibility for system •
layout tailored to your needs.
Selection from a variety of power sources and the paralleling capability allows a wide range of available cutting power •
to meet virtually any cutting condition.
Patented ESAB technology allows underwater cutting and beveling with excellent results.•
The PMC-91 Plasmarc System uses simple switch settings to setup process parameters for ow control and cutting •
power eliminating the diculty of adjustment associated with needle valves.
The shielded construction of the plasma torches and versatility of component location minimizes electrical interference •
with surrounding equipment.
The PMC-91 Plasmarc System can have marking capabilities through the marking box.•
Marking and cutting can be alternated in real-time by controlling the mark mode signal.•
Dierent power supplies can be controlled through the marking box, such as current, range selection.•
The PMC-91 system uses advanced technology for high quality cutting for a variety of common metals while keeping •
the operating costs at a minimum.
Flow
Control
Plumbing
Box
4
)
Coolant
Circulator
Power Source
Torch (PT-600, PT-19XLS or PT-36)
Figure 2-1 Major Components
17
SECTION 2 INTRODUCTION
2.3 Component Description
The components that make up a PMC-91 Plasmarc System are designed specically for use in automated plasma cutting
and marking applications.
Refer to the specic equipment manual for detailed information.
The EPP power sources are designed for marking and high speed
plasma mechanized cutting applications. They can be used with
other ESAB products such as the
PT-15, PT-19XLS, PT-600 and PT-36
torches along with the Smart Flow
II, a computerized gas regulation
and switching system.
EPP-201 Power Source
10 to 36 amperes for marking•
25 to 200 amperes cutting current range•
EPP-401/450 Power Source EPP-601 Power Source
10 to 100 amperes for marking in low current range•
50 to 450 amperes cutting in high current range•
35 to 100 amperes cutting in low current range•
Forced air cooled•
Solid state DC power•
Input voltage protection•
Remote or local front panel control•
Thermal switch protection for main transformer and power semiconductor com-•
ponents
Top lifting eyes or base forklift clearance for transport•
Parallel supplemental power source capabilities to extend current output range.•
EPP-360 Power Source
10 to 36 amperes for marking•
30 to 360 amperes cutting current range•
10 to 100 amperes for marking in low current range•
50 to 600 amperes cutting in high current range•
35 to 100 amperes cutting in low current range•
Figure 2-2 EPP-201 Power Source Figure 2-3 EPP-360 Power Source
18
SECTION 2 INTRODUCTION
2.3 Component Description (con’t.)
Figure 2-4 EPP-401/450 Power Source
Flow Control
The Flow Control is a programmable Logic Control (PLC) based unit. This device provides all the necessary control functions
for various uids and signals to and from other components of the system. Control Inputs/Outputs are connected to the
power source, marking box, coolant circulator, air curtain and the cutting machine control.
Connections to the ow control are Oxygen In, Air In, Alternate Gas In, Nitrogen In, Start Gas Out, Cut Gas Out, Shield Gas
Out.
Figure 2-5 EPP-601 Power Source
Figure 2-6 Flow Control and PMC-91 Plasma Marking Control
19
SECTION 2 INTRODUCTION
2.3 Component Description (con’t.)
Plumbing Box
The Plumbing Box is an interconnecting device between the torch and other system components. It also contains the arc
starting high frequency generator. Connection of functions through the plumbing box include; cut gas, start gas, shield
gas, marking gas (argon), torch coolant, pilot arc, cutting current and height control.
Figure 2-7 Plumbing Box Assembly
Coolant Circulator
The CC-11 coolant circulator is a radiator type cooler for circulating a coolant uid through the plasma torch providing heat
exchanger action for the internal parts of the torch. Though the system refers to water, it is not recommended that water be
used. For the protection of internal parts and lines a specially formulated coolant liquid is available that prevents production
of corrosion and mineral buildup. Refer to the power source manual for installation instructions.
PT-19XLS Plasma Torch
The PT-19XLS Torch is designed with all the quality standards and feature characteristics of the PT-15XL. The dierences are
primarily in applications and conditions for which the PT-19XLS is to be used. The PT-19XLS is a mechanized torch designed
for high speed, high current cutting using gas shielding instead of water injection.
The PT-19XLS is intended for applications of dry cutting using air (clean & dry) for the cut gas at current levels up to 200
amps. Oxygen (to 360A) or H-35 (to 600A) can be used with the PT-19XLS, however these gases are not recommended for
some materials. Use of an air curtain kit permits the PT-19XLS to be used for underwater cutting. Refer to the torch manual
for further details.
20
SECTION 2 INTRODUCTION
November, 2005
Installation, Operation, and Maintenance for the
PT-600 Mechanized
Plasma Cutting Torch
2.3 Component Description (con’t.)
PT-600 Plasma Torch
The PT-600 torch is a PT-19XLS with reduced manufacturing tolerances. The result is improved torch component concentricity and cut accuracy.
PT-36 Plasma Torch
The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the eld.
Only the torch front-end has replaceable parts.
Figure 2-8 PT-19XLS and PT-600 Torches Figure 2-9 PT-36 Torch
21
SECTION 2 INTRODUCTION
Figure 1-11. Bubble Muffler Assembly
PT-19XLS
AIR CURTAIN
This device also allows above water cutting with re-
duced fume, noise and UV radiation from the arc by
the flow of water through the bubble muffler. A sepa-
rate water pump recycles filtered water from the water
cutting table through the bubble muffler.
PT-19XLS Water Muffler
The PT-19XLS water muffler works much as the bubble
muffler described above.
2.3 Component Description (con’t.)
Air Curtain
The Air Curtain assembly provides improved cutting performance of the plasma torches when cutting underwater. A source
of oil free air at 80 psig is required to the air curtain control box. A curtain (wall) of air is created around the plasma arc area
allowing operation in a relatively dry zone, even with the end of the torch submerged 2 - 3 inches.
Underwater cut quality and speed are enhanced when using the air curtain for all plasma torch cutting applications.
Water Muer
The Water Muer system creates a bubble of air surrounded by water that allows the torch to be used underwater with
oxygen cut gas and water injection cutting without signicant loss of cut quality.
This device also allows above water cutting with reduced fume, noise and UV radiation from the arc by the ow of water
through the water muer. A separate water pump recycles ltered water from the water cutting table through the water
muer.
Figure 2-10 Air Curtain Assembly Figure 2-11 Water Muer Assembly
22
SECTION 2 INTRODUCTION
2.3 Component Description (con’t.)
DESCRIPTION PART NUMBER
EPP-201
EPP-360
EPP-401/450
EPP-601
The basic torch body can be supplied in seven lead lengths between the plumbing box and torch.
The replaceable torch components are selected for the type of cut gas and current level used.
460 V, 3-Phase, 60 Hz 0558007801
575 V, 3-Phase, 60 Hz 0558007802
460 V, 3-Phase, 60 Hz 0558006832
575 V, 3-Phase, 60 Hz 0558006833
380/400V, 3-Phase, 50/60 Hz 0558007730
460 V, 3-Phase, 60 Hz 0558007731
575 V, 3-Phase, 60 Hz 0558007732
380/400V, 3-Phase, 50/60 Hz 0558007733
460 V, 3-Phase, 60 Hz 0558007734
575 V, 3-Phase, 60 Hz 0558007735
PT-19XLS - 4.5 ft. 37086
PT-19XLS - 6 ft. 37087
PT-19XLS - 12 ft. 37088
PT-19XLS - 15 ft. 37089
PT-19XLS - 17 ft. 37090
PT-19XLS - 20 ft. 37091
PT-19XLS - 25 ft. 37092
PT-600 - 4.5 ft. 0558001827
Plasma Torches:
Flow Control: Provides interface for gases and power 0558005760
PMC-91 Marking
Control:
Plumbing Box:
CC-11 Water
Recirculator:
Air Curtain:
Water Muer: PT-19XLS, PT-600 and PT-36 37439
Provides interface for gases and power
Provides interconnection between torch and
Circulates coolant for the torch 0558007515
PT-19XLS, PT-600 and PT-36 Beveling
PT-600 - 6 ft. 0558001828
PT-600 - 12 ft. 0558001829
PT-600 - 15 ft. 0558001830
PT-600 - 17 ft. 0558001831
PT-600 - 20 ft. 0558001832
PT-600 - 25 ft. 0558001833
PT-36 - 4.5 ft. 0558003849
PT-36 - 6 ft. 0558003850
PT-36 - 12 ft. 0558003852
PT-36 - 25 ft. 0558003856
Remote current control
Pilot arc Hi / Lo control
rest of system.
PT-19XLS, PT-600 and PT-36
0558007858
0558008045
37440
34752
23
SECTION 2 INTRODUCTION
24
SECTION 3 INSTALLATION
General
Proper installation substantially contributes to the satisfactory and trouble-free operation of the PMC-91 System components. Each step in this section should be studied carefully and followed as closely as possible. Immediately upon receipt
of the components, each should be inspected closely for damage which may have occurred in transit. Notify the carrier of
any damage or defects immediately. Instruction manuals for each component of the system are included in the package.
It is recommended that these manuals be collected and compiled in a common location.
Note
If the components are not to be immediately installed, store them in a clean, dry and well ventilated area.
3.1 System Component Locations
Power Source
When lifting the Power Source using the lifting lugs, ensure the lifting
CAUTION
The location of the Power Source should be carefully selected to ensure satisfactory and dependable service. The Power
Source components are maintained at the proper operating temperatures by forced air that is drawn through the cabinet by
the fan units. For this reason, it is important that the Power Source be located in an indoor-open area where air can circulate
freely at the front, bottom, and rear openings of the cabinet. If space is a premium, leave at least two feet of clearance at
the rear of the cabinet.
The location should be such that a minimum of dirt, dust, or moisture will be drawn into the air stream. It is desirable to
locate the unit so that the top and side panels can be removed for cleaning and troubleshooting. In relationship to a cutting
machine, the power source can be positioned virtually anywhere that will not interfere with machine travel. Accessories on
the cutting machine are available to carry hoses and cables without interference with machine travel.
Flow Control
The Flow Control can be placed on the Power Source or mounted onto the cutting machine. The Flow Control needs to
be accessible for setting various cutting parameters. After setting the cutting conditions, access to the Flow Control is not
required during the cutting operation.
means is securely connected to BOTH lifting lugs to prevent damage to the
unit or injury to personnel. DO NOT USE ANY LEVER DEVICE WHICH COULD
DAMAGE THE UNIT.
25
SECTION 3 INSTALLATION
3.1 System Component Locations (con’t.)
Marking Box
Marking Box provides marking capability for PMC-91 Plasmarc System. The marking box should be under the ow control
box. Connections between the two boxes should be made with the cables provided. A hose assembly should also be used
for shield gas connection. Access to marking box is not required during normal, standard operation after the current and
gases are set up.
Plumbing Box
The Plumbing Box is normally located on the cutting machine in close proximity to the torch station. Since the torch can
be equipped with various standard lengths of cable and hose, the exact location is determined by the conguration and
station load capacity of the machine.
Access to the Plumbing Box is not required during the standard operating procedures, location near the operator is not
required. Two important considerations pertain to the location of the plumbing box:
There should be space for the box door to be opened fully.1.
Sucient space should be provided on all sides to permit easy connection of gas/water hoses and electrical cables to the box.2.
3.2 System Connections
BEFORE MAKING ANY CONNECTIONS TO THE OUTPUT BUS BARS, MAKE SURE
WARNING
Input Power Connections
The power sources (EPP-201, EPP-360, EPP-401/450 or EPP-601) used with the system are 3-phase units and must be connected to a 3-phase power line. Although designed with line voltage compensation, it is suggested that the unit be operated
on a separate line to ensure the performance of the power source is not impaired due to an overloaded circuit.
A line (wall) disconnect switch, with fuses or circuit breakers, shall be used at the main power panel. The primary power input
must have four insulated power leads (three power leads and one ground wire). The wires may be a thick rubber covered
cable or may run in a solid or exible conduit.
The ground wire must be approximately six inches longer than the power leads. This is a safety measure to
ensure that in the event the power lines are accidently pulled out the ground wire will remain connected.
Input conductors must be terminated with ring terminals sized for 1/2 inch hardware before being connected.
Refer to the specic equipment manual for detailed installation instructions.
THE POWER SOURCE IS DEENERGIZED BY OPENING THE LINE WALL DIS
CONNECT SWITCH. TO BE DOUBLY SAFE, HAVE A QUALIFIED PERSON CHECK
THE OUTPUT BUS BARS WITH A VOLTMETER TO BE SURE ALL POWER IS OFF.
Note
Note
Flow Control Connections
The Flow Control serves as a form of interface between the various process utilities to enable a central location for setup
adjustments. Connections are made to receptacles on the rear panel and are grouped into two sections, the bottom row is
for gas connections while the top row is for electrical connections. The gas connections should be made rst.
26
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Fluid Hookups (See Table 3-1 for hose assemblies)
OXYGEN (O2) IN - This is a “B” size CGA oxygen tting. Connect the supply hose from the oxygen regulator to this 1.
point.
NITROGEN (N2) IN - This is a “B” size IAA tting. Connect the supply hose from the nitrogen regulator to this point.2.
AIR IN - This is a “B” size air tting. Connect the supply hose from the air regulator to this point.3.
ALTERNATE GAS IN - This is a “B” size CGA fuel gas tting. Connect the supply hose from the alternate gas regulator to 4.
this point.
START GAS OUT - This is a “B” size IAA tting. From this point connect the hose to Start Gas INPUT on the Plumbing 5.
Box.
CUT GAS OUT - This is a “B” size oxygen tting. The hose is connected from this point to the Cut Gas INPUT on the 6.
Plumbing Box.
SHIELD GAS OUT - This is a “B” size air / water tting. The hose is connected from this point to the shield gas input on 7.
the Plumbing Box. If the Marking Box is used, a tee hose assembly (0558008044) should be connected to Shield Gas
Out rst. The shield gas is then connected both to the Plumbing Box and the Marking Box.
Electrical Hookups (See Table 3-3 for cables)
POWER SOURCE - The power source plug should connect to Marking Box. Through Marking Box, Flow Control Box is 1.
powered and commanded.
PARALLELED POWER SOURCE - A cable from a second power source connects to this receptacle whenever two power 2.
sources are used in parallel. It parallels all control connections between the power source and ow control. The parallel
power supply is used only for cutting.
AIR CURTAIN - This is used to connect the coil of a solenoid valve in the air curtain control (when used) or to control a 3.
relay coil in the water muer pump unit.
WATER COOLER - This point is used to connect to the relay coil in the water cooler.4.
PLUMBING BOX - This cable connection goes to the Plumbing Box in the Marking Box, then through the Marking Box. 5.
It is connected to Plumbing Box.
CUTTING MACHINE NUMERICAL CONTROL (CNC) - This connection provides a current reference signal to the plasma 6.
power source and provides control signals to and from the ow control circuits, Start Process Command, Arc On, Process
Fault, and E-stop Interlock. This cable connection goes to the Marking Box CNC.
115 VAC AUXILIARY POWER - This optional connection allows the Flow Control to be energized without powering up 7.
the system. Disconnect after test function is completed.
27
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Argon
Gas Regulators
Air
Oxygen
Nitrogen
Alternate
Flow Control
Wall Box
Cooler and
Pump
Start Gas
Shield Gas
Power
Input
Cut Gas
Argon
Power Source
Coolant Return
Coolant to Torch
Plumbing Box
(+) Work
(-) Electrode
Pilot Arc
Shield Gas
Argon
Process OK
Interlocks
Current Ref.
Cutting Machine Control
Legend
Marking Box
E-Stop
Process O
Height
Reference
Electrical Connections
Fluid Lines
Voltage
Feedback
Interlocks
High Freq. On-O
Cut Gas Solenoid
Start Gas Solenoid
Height
Control
Torch
PT-19XLS,
PT-600 or
PT-36
Coolant to
Torch
Coolant Return
Shield Gas
Plasma Gas
Pilot Arc High Freq.
(-) Electrode
Workpiece
Figure 3-1 Interface Block Diagram
28
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
To Parallel Power Source If Needed
115 VAC Auxiliary Power
For Testing Only
(Disconnect During
Normal Operation)
Power Source On Marking Box
Cut Gas Out To Plumbing
Box And Marking Box
Air In From Regulator
Start Gas Out To Plumbing Box
In From Regulator
N
2
O2 In From Regulator
Alternate In From Regulator
Figure 3-2a Flow Control Connections With Marking Box
To Air Curtain
To Water Cooler
To Plumbing Box
On Marking Box
To Cutting
Machine CNC
On Marking Box
Tee
From Shield Gas On Marking Box
Shield Gas Out To
Plumbing Box
Power Supply On
CNC Control
Flow Control Box
CNC Control On
Flow Control Box
Power Supply
Figure 3-2b Connections For Marking Box
Plumbing Box
Shield Gas In
Shield Gas Out
Argon In
Argon Out
Plumbing Box On
Flow Control Box
29
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Table 3-1 Hose Assemblies
Cable Length Shield Gas Hose Cooling Water Start Gas Hose Cut Gas Hose Argon Gas Hose
25 FT. 33127 21588 33122 33117 0558002978
50 FT. 33128 21574 33123 33118 0558002979
75 FT. 33129 21575 33124 33119 0558002980
100 FT. 33130 21576 33125 33120 0558002981
125 FT. 33131 21577 33126 33121 0558002982
Table 3-2 Cooling Water Hose Assemblies
Cable Length Hose Assembly
25 FT. 33132
50 FT. 33133
75 FT. 33134
100 FT. 33135
125 FT. 33136
Table 3-3 Interconnection Cables
Marking Box
or
Cable Length
25 FT. 33219 33224 33253 33303 33253
50 FT. 33220 33225 33254 33304 33254
75 FT. 33221 33226 33255 33305 33255
100 FT. 33222 33227 33256 33306 33256
125 FT. 33223 33228 33257 33307 33257
Flow Control Plumbing Box
(Cable, 18 AWG,
8 Conductor)
Flow Control Remote Location - Flow Control to Power Source Cable:
Flow Control
- CNC
(Cable, 18
AWG,
14 Conductor)
30 Ft. - 34378
60 Ft. - 34377
Flow Control -
Water Cooler
(Cable, 18
AWG,
3 Conductor)
Power Source
- Plumbing
Box
(Cable, Pilot
Arc)
3 Conductor)
Air Curtain
(Cable, 18
AWG,
30
SECTION 3 INSTALLATION
GRN/YEL
3.2 System Connections (con’t.)
Table 3-4 Interconnection Cables
Marking Box - CNC
(Cable, 20 AWG, 24 Conductor)
Table 3-5 Recommended Regulators
Description Part Number
Station Regulator, O2, R-76-150-024* 19151
Station Regulator, N2, R-6703 22236
Two Stage Cylinder Regulator, O2, R-77-150-540** 998337
Two Stage Cylinder Regulator, N2, R-77-150-580** 998344
Two Stage Cylinder Regulator, H-35, R-77-150-350 998342
Liquid Cylinder Regulator, O2, R-76-150-540LC 19777
Liquid Cylinder Regulator, N2, R-76-150-580LC 19977
Station Regulator, Air 30338
* Station (line) regulators connect to station outlets of piping systems that transport
gas to welding or cutting stations. These regulators are intended for inlet pressures of
less than 200 psig. When used with plasma cutting systems, minimum inlet pressure
should be 120 psig.
** Two stage cylinder regulators provide a more constant delivery pressure than single
stage cylinder regulators. The delivery pressure of a single stage varies about 1 psig
per 10 psi of change in the inlet pressure as the cylinder empties.
31
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
MAKE SURE THAT ALL CONNECTIONS ARE PROPERLY MADE TO PREVENT
WARNING
To make the following connections, the door must be opened and the cover removed.
Plumbing Box Connections To Torch:
Connect the torch bundle to the plumbing box. Check that the box location permits torch movement as required.1.
Connect the cooling water (coolant) in and out (with the internal power cable) to the connectors on the main power A.
junction bus bar inside the plumbing box. One connection has right-hand threads and the other has left-hand
threads. Left-hand threads are indicated by a groove or notch on the hex of the tting.
Connect the Pilot Arc cable from the torch bundle to the stud marked PILOT ARC TORCH (TB1) located inside the B.
Plumbing Box.
Connect the Shield Gas Hose to the SHIELD GAS TO TORCH connector on the top section of the Plumbing Box.C.
Connect the Cut Gas hose to the GAS TO TORCH connector on top section of Plumbing Box.D.
ANY LEAKS. ANY LEAKAGE DURING ACTUAL OPERATION COULD LEAD TO
A HAZARDOUS SITUATION BECAUSE OF THE HIGH VOLTAGES INVOLVED.
Note
Cut Gas to Torch
Shield Gas
To Torch
Shield Gas
Marking Gas
Coolant In
Start Gas
Coolant Out
Cut Gas
Control Cable
(from Flow
Control)
Pilot Arc
(from Power
Source)
4/0 Power
Cables (from
Power Source)
To Height Control
Figure 3-3 Plumbing Box Connections
32
SECTION 3 INSTALLATION
3.2 System Connections (con’t.)
Plumbing Box Connections To Power Source
Connect the 4/0 power cable(s) to the studs on the main power bus bar TB3. The number of cables depends on the maxi-2.
mum cutting thickness capacity for the installation. Two cables must be connected to carry the full 600 amperes.
Select plasma cutting output cables on the basis of one 4/0 AWG, 600 volt insulated copper cable for each 400 amperes
of output current. Do not use ordinary 100 volt insulated welding cable.
Each 4/0 cable must be terminated with the correct lug prior to attempting connection to the bus bar. Each cable
goes through one of two strain reliefs on the box. Ensure neither lugs nor bare wires touch the sheet metal of the
box.
Connect the Pilot Arc cable from the power source through its strain relief (PILOT CURRENT) to the stud (TB2) on the 3.
side of the high frequency box inside the Plumbing Box. This cable runs uninterrupted from the power source to the
termination in the plumbing box, so it is essential that it be the proper length. Use # 6 AWG 600 volt wire with ring
terminals to t the 1/4-inch stud.
4. Connect coolant in / out to Plumbing Box. Connect Start Gas, Cut Gas / Shield Gas from Flow Control Box to Plumbing
Box. If marking is needed, connect Argon gas from the Marking Box directly. Connect Shield Gas with provided Tee
(0558008044) to Plumbing Box.
Torch Pilot Arc Cable Stud
Pilot Current Stud
(from Power Source)
Coolant In and Out
Connectors
4/0 Power Cable Connecting Studs
Figure 3-4 Plumbing Box Internal Connections
33
SECTION 3 INSTALLATION
3.3 Torch Components
Refer to your torch manual for detailed installation instructions.
ELECTRIC SHOCK CAN KILL! BEFORE TOUCHING THE TORCH, BE SURE THE
POWER SOURCE IS SHUT OFF BY TURNING OFF THE 3-PHASE POWER INPUT TO
THE POWER SOURCE.
WARNING
The PT-19XLS, PT-600 and PT-36 are water-cooled plasma arc torches designed for mechanized cutting at currents up to 350
amps with oxygen and up to 600 amps with nitrogen or H-35.
The PT-36 torch can also be used for marking. For details please see the enclosed cutting data.
CAUTION
NEVER USE OIL OR GREASE ON THIS TORCH. HANDLE PARTS ONLY WITH CLEAN
HANDS AND LAY PARTS ONLY ON A CLEAN SURFACE. OIL AND GREASE ARE
EASILY IGNITED AND BURN VIOLENTLY IN THE PRESENCE OF OXYGEN UNDER
PRESSURE. USE SILICONE LUBRICATE ONLY WHERE INDICATED.
Make sure that the heat shield, shield retainer, and other front end parts are
cool before handling.
34
SECTION 3 INSTALLATION
3.3 Torch Components (con’t.)
Electrode Holder
Contact Ring Assy.
Gas Bae
Electrode
Rear Main Body Assy.
Sleeve
O-Ring
Insulator Assy.
Shield Retainer
Nozzle Base
Nozzle Tip
Nozzle Retaining Cup
Diuser
Shield
Figure 3-5 PT-19XLS Torch Components
35
SECTION 3 INSTALLATION
3.3 Torch Components (con’t.)
Torch Sleeve
Torch Body
Gas Bae
O-ring (supplied with electrode holder)
Electrode Holder
O-ring (supplied with electrode)
Electrode
O-ring (supplied with nozzle)
Nozzle Assembly
O-ring (supplied with nozzle)
Nozzle Retainer Cup
Diuser
Shield
Figure 3-6 PT-600 Torch Components
36
Shield Retainer
SECTION 3 INSTALLATION
3.3 Torch Components (con’t.)
Torch Sleeve
Torch Body
2 ea. O-Rings
Gas Bae
O-Ring Supplied with Electrode Holder
Electrode Holder with O-Ring
O-Ring Supplied with Electrode
Electrode
O-Ring Supplied with Nozzle
Nozzle
O-Ring Supplied with Nozzle
Nozzle, Retaining Cup
Gas Diuser
Shield
Shield Retainer
Figure 3-7 PT-36 Torch Components
37
SECTION 3 INSTALLATION
3.4 Installing Air Curtain
The Air Curtain is a device used to improve performance of the plasma torches when cutting underwater. Cut quality and
cutting speed are enhanced when using the air curtain with plasma torches. The device mounts onto the torch and produces
a curtain of air around the cutting area producing a relatively dry area.
Installation procedures of the air curtain for the plasma torches are very similar with slight dierences in the nozzle clearance positioning.
Remove the torch nozzle retaining cup.1.
Slide the chrome plated Air Curtain Body.2.
Note
It will ease assembly if all o-rings in the air curtain body are lightly lubricated with silicone grease,
77500101 (5.3 oz.) or 17672 (1 oz.).
Replace the nozzle retaining cup and any front end parts that may have removed from the torch.3.
Install the air curtain sleeve over the assembled torch and snap it into place.4.
Secure the air curtain sleeve by installing the air curtain retainer. The Retainer rotates to lock in place with the locking 5.
pins.
Adjust the position of the air curtain on the torch until the nozzle extends 0.06 inch from the end of the air curtain 6.
sleeve.
Lock the air curtain into place by tightening the Allen screw on the air curtain body.7.
Note
The air curtain sleeve must remain completely bottomed in the air curtain body for the adjustment in
Step 6 to be correct.
After tightening the Allen screw, the gap between the sleeve and torch cup should be uniform all the way
around.
RetainerAir Inlet
Torch Body
Air Curtain Body
Figure 3-8 Air Curtain Installation
38
SECTION 3 INSTALLATION
3.5 Water Muer Installation
The water muer creates a bubble of air surrounded by water so that a plasma torch can be used underwater with oxygen/
water injection cutting without signicant sacrice of cut quality. This system also permits operation above water as the
ow through the muer reduces fumes, noise and arc UV radiation.
Installation and Adjustment
Remove the brass nozzle retaining cup from the torch.1.
Note
Lubrication of o-rings in the water muer is recommended for ease of installation.
Slide the chrome plated water muer clamp onto the torch about 1/2 inch up the torch sleeve (body).2.
Replace the nozzle retaining cup and any front end torch parts that may have removed from the torch.3.
Install the water muer sleeve in the water muer main body. Maker sure it bottoms completely.4.
Install the water muer main body (with sleeve) over the assembled torch and snap it into place on the water muer 5.
clamp.
Adjust the position of the water muer on the torch until a gap of .040 to .060 (use 1/16 inch Allen wrench for gapping) 6.
is obtained between the inside wall of the muer sleeve and the torch retaining cup.
Lock the water muer into position by tightening the Allen screw on the water muer clamp.7.
A helpful hint for adjusting the Air Curtain or Water Muer for proper location on the torch:
Mark the nozzle retaining cup and back it up 3/4 to 1 turn from fully tight.1.
Install the Air Curtain or Water Muer sleeve and push the assembly up the torch until the sleeve bottoms out against 2.
the nozzle retaining cup.
Lock into position with the allen screw.3.
Retighten the nozzle retaining cup.4.
The sleeve must remain completely bottomed in the Water Muer body for the adjustment in Step 6 to be correct.
After tightening the Allen screw, the gap between the sleeve and torch cup should be uniform all the way around.
Better centering of the water muer sleeve can be obtained by putting 3 evenly spaced (120° intervals) pads of tape of
electrical tape on the nozzle retaining cup.
39
SECTION 3 INSTALLATION
Figure 2-10. Bubble Muffler Assembly
ALLEN
SCREW
MAIN
BODY
SLEEVE
CLAMP
TORCH
RETAINING
CUP
.040 - .060
NOZZLE
RETAINING
CUP
2-3 LAYERS ELECTRICAL
TAPE AT 3 PLACES
SPACED 120
o
CLAMP
TORCH
RETAINING
CUP
.040 - .060
NOZZLE
RETAINING
CUP
2-3 LAYERS ELECTRICAL
TAPE AT 3 PLACES
SPACED 120
o
3.6 Air Curtain / Water Muer Control Box Installation
Clamp
Allen Screw
Figure 3-9 Water Muer Assembly Figure 3-10 Centering Tape On Retaining Cup
Main Body
Mount the Control Box at a convenient location and use the hose supplied to connect the box with the unit mounted 1.
on the torch.
Connect the Control Box to a source of oil free shop air capable of delivering at least 20 scfm at 80 psig. The hose used 2.
should be at least 3/8 inch inside diameter.
Use SJO wire to connect the control to the cutting machine control. If the ESP system is used, the connection may be 3.
made to the appropriate Amphenol connector on the back of the Flow Control. The connection of the control is made
at terminals marked FC. An appropriate cable may be selected from the table of optional accessories.
The user supplied 115 volt AC may be connected to the terminals so marked. This will allow manual operation of the 4.
air curtain control.
Connect a ground wire to the stud provided in the control box.5.
Provide air to the control box. Energize solenoid in control box and adjust regulator screw from 15 - 30 psig delivery. 6.
Adjust within range for best cut quality.
Place switch in AUTO. The system should turn on when the preow begins. The pump will recirculate approximately 7.
20 gpm from the water table.
Torch
Retaining
Sleeve
Cup
0.04” - 0.06”
Nozzle
Retaining
Cup
2 -3 Layers Electrical
Tape At 3 Places
Spaced 120°
Further details and replacements parts for the air curtain and water muer are depicted in the corresponding instruction
manuals.
40
SECTION 4 OPERATION CUTTING
General
Operating with a plasma system such as the PMC-91 Plasmarc System contains a great number of variables to achieve quality
cutting over a wide range of applications. The setup and operating characteristics for specic applications depend on type
of material, thickness of material, type of cut gas, dry cutting, water injection cutting or underwater cutting.
ELECTRIC SHOCK CAN KILL! DO NOT OPERATE THIS EQUIPMENT WITH ANY
COVERS REMOVED. TAKE ALL PRECAUTIONS TO REMOVE POWER BEFORE ATTEMPTING ANY SERVICE OR MAINTENANCE INSIDE CABINETS OR TORCH.
NEVER OPERATE THE POWER SOURCE WITH THE COVER REMOVED. IN ADDITION
TO THE SAFETY HAZARD, IMPROPER COOLING MAY CAUSE DAMAGE TO INTERNAL
COMPONENTS. KEEP SIDE PANELS CLOSED WHEN UNIT IS ENERGIZED. ALSO,
WARNING
MAKE SURE YOU ARE ADEQUATELY PROTECTED BEFORE YOU START TO CUT.
ENSURE THAT THE POWER CABLE CONNECTIONS ARE PROPERLY MADE TO PREVENT WATER LEAKS. ANY LEAKAGE DURING OPERATION COULD BE HAZARDOUS
BECAUSE OF HIGH VOLTAGE AND CURRENT.
ARC RAYS CAN BURN EYES AND SKIN, NOISE CAN DAMAGE HEARING! WEAR
WELDING HELMET WITH APPROPRIATE FILTER. WEAR EAR AND BODY PROTECTION.
4.1 Controls and Indicators
Flow Control
All controls for cutting function are located on the front of the Flow Control. The control panel is laid out in four sections,
Test / Run, Cut Gas, Primary Shield Gas . Shield Mix Gas plus, the Power Switch.
A. Test / Run
This area consists of a 5-position switch. The functions are:
CUT GAS position permits testing the cut gas ow or purging the system without actually cutting.1.
START GAS permits testing the start gas ow or purging the system without cutting.2.
RUN 1 position is used when cutting is to start with the start gas, and after arc transfer occurs to switch automatically to cut 3.
gas. This is one of two positions for actual cutting to occur. Oxygen cutting is normally performed in this position.
RUN 2 position is used when the start of the process is done with the same gas and ow as the cutting process. This 4.
position is normally used when Nitrogen and Argon-Hydrogen cutting is performed.
HF position permits testing of the high frequency without cutting.5.
Note
The test of the HF unit is made without activating the main contactor of the power source. Since shield
gas is tested at the same time, some of the tests are combined to reduce the number of positions on the
switch.
41
SECTION 4 OPERATION CUTTING
4.1 Controls and Indicators (con’t.)
Figure 4-1 Flow Control Front Panel
B. Cut Gas
This area includes the O2 / N2 switch, Flow Rate that is an 8-position switch, HI / LOW toggle switch, a pressure gauge and a
bypass pressure regulator. Refer to Table 4-1 for approximate ow rate for specic settings.
The O1.
/ N2 switch selects the type of cut gas being used for cutting.
2
FLOW RATE switches. The 8-position rotary switch and two position toggle switch are used to set the cut gas ow rate. 2.
The 8-position switch (0-7) is used for inputs within the ow control that determines the gas ow rates. The switch operates a combination of three of four solenoid valves in parallel. The fourth valve is operated by the HIGH / LOW switch.
The cut gas ows through measuring orices in each line of the four solenoid valves. The orices vary in size so that
each is capable of doubling the ow, the largest orice delivers eight times the ow as the smallest.
In the 0 / LOW setting a bypass solenoid is energized activating the bypass pressure regulator. In this position gas is controlled by pressure setting of the regulator with the gauge displaying the downstream pressure supply of the torch.
Position 1 energizes the solenoid valve in the smallest orice line.
Position 2 energizes the valve next in line of ow rate.
Position 3 energizes both of these valves.
The progression continues to provide more ow at each higher numbered position in equal increments. In combination
the four valves are capable of providing dierent ows but the switch limit is eight settings. The HIGH / LOW switch is
used to energize the solenoid with the largest orice that allows using the remainder of the ows.
42
SECTION 4 OPERATION CUTTING
4.1 Controls and Indicators (con’t.)
Table 4-1 Cut Gas Flow Rates
Switch Setting /
Flow Rate
0 / LOW 0
1 / LOW 20
2 / LOW 40
3 / LOW 60
4 / LOW 80
5 / LOW 100
6 / LOW 120
7 / LOW 140
0 / HIGH 160
1 / HIGH 180
2 / HIGH 200
3 / HIGH 220
4 / HIGH 240
5 / HIGH 260
6 / HIGH 280
7 / HIGH 300
Cut Gas (O2/N2)
SCFH
C. Primary Shield Gas
This area includes the N2 / Air switch, supply pressure gauge, ow adjustment valve and ow meter tube.
The N1.
/ Air switch selects the type of Primary Shield Gas being used for cutting.
2
The supply pressure gauge indicates the source pressure of the selected gas supplied to the ow meter tube. Supply 2.
pressure must be properly adjusted to insure accurate reading of ow meter tube.
The ow adjustment valve allows shield gas ow rates to be varied for optimizing cutting results.3.
The ow meter tube indicates the shield gas ow supplied to the torch.4.
D. Shield Mix Gas
This area includes the O2 / NONE / Alternate switch, supply pressure gauge, ow adjustment valve and ow meter tube.
The O1.
/ NONE / Alternate switch selects the type of shield mix gas being used for cutting. In the NONE position only
2
the Primary Shield Gas is used and no mix gas will be added to the shield gas.
The supply pressure gauge indicates the source pressure of the selected mix gas supplied to the ow meter tube. Sup-2.
ply pressure must be properly adjusted to insure accurate reading of ow meter tube.
The ow adjustment valve allows shield mix gas ow rates to be varied for optimizing cutting results.3.
The ow meter tube indicates the shield mix gas ow supplied to the torch.4.
43
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0
1.0
SCFH N
2
Figure 5. Flowmeter Calibration Curves
60 PSIG
80 PSIG
100 PSIG
SECTION 4 OPERATION CUTTING
4.1 Controls and
Indicators (con’t.)
100 psig
80 psig
60 psig
2
SCFH N
Pressures Shown Are Measured At Flowmeter Outlet
Figure 4-2a Primary Shield Gas Flowmeter Calibration Curves
Flowmeter Reading (Measured At Top Of Ball)
44
SECTION 4 OPERATION CUTTING
4.1 Controls and
Indicators (con’t.)
100 psi - Methane
Pressures Shown Are Measured At Flowmeter Outlet
SCFH
100 psi - O260 psi - Methane
Figure 4-2b Shield Mix Flowmeter Calibration Curves
45
Flowmeter Reading (Measured At Top Of Ball)
SECTION 4 OPERATION CUTTING
4.1 Controls and Indicators (con’t.)
Power Source (EPP-601)
All control functions are provided through one receptacle located on the front panel of the power source. A receptacle
allows plugging in the cable from the Marking Box. Adapter may be needed for this connection. All control signals are
routed through this connection.
A. The current control mode for the power source is set using the PANEL/REMOTE switch.
With the switch in the PANEL position, output current is controlled by setting the power source current control 1.
potentiometer (CCP).
With the switch in the REMOTE position, output current is controlled from a remote device such as a cutting ma-2.
chine CNC.
B. When using an EPP-601 power source, the LED indicator lights on the front panel are used to help check for proper operation of the unit.
OVER TEMP - illuminates should the power source become over heated.1.
CONTACTOR ON - This light indicates that the main power contactor has been energized and voltage is being ap-2.
plied to the cutting circuit.
FAULT INDICATOR - illuminates should abnormalities occur in the cutting process or if the input line voltage falls 3.
outside of the nominal value by +/- 10%.
POWER RESET FAULT - illuminates when a serious fault is detected. Input power must be disconnected far at least 4.
5 seconds and then reapplied.
C. MAIN POWER indicator illuminates when input power is applied to the Power Source.
D. PILOT ARC HIGH/LOW switch allows selection of the pilot arc range HIGH or LOW.
E. VOLTMETER displays the arc voltage value when cutting or marking.
F. AMMETER displays the arc current level when cutting or marking.
For control descriptions pertaining to the EPP-401/450 and EPP-201/360 refer to the appropriate instruction manual.
4.2 Pre-Operation Test / Checkout
The pre-operation testing and checking oers the advantage of having the parameters set and established in proper order
before starting to cut actual material.
A. Test Functions
The TEST / RUN portion of the Flow Control front panel allows the user to test parts of the system, purge gas, lines and to
select between two dierent RUN modes.
46
SECTION 4 OPERATION CUTTING
4.2 Pre-Operation Test / Checkout (con’t.)
B. Run Modes
The rst run mode (RUN 1) starts with start gas (at start gas ow) and switches over to cut gas when the arc transfers.
The start gas is taken from the N
or the O2 input on the back of the ow control box. The selection of the cut gas is accomplished with the O2 / N2 selector
switch on the front panel.
The second run mode (RUN 2) starts directly with cut gas ow. In this case the gas used for cutting must be connected to
the N2 input on the back of the ow control.
Purging of gas leads should be possible even if insucient gas pressure exists on incoming gas pressure
gas input on the back of the ow control box. The cut gas is taken either from the N2
2
Note
switches.
Table 4-2 Test / Run Selection Description
Activated Function
Positions
Cut Gas No Yes Yes No
Start Gas Yes No Yes No
Cut Gases
Test
Start Gas Cut Gas Shield Gas HF
HF Yes No No Yes
A. Set the delivery pressure of the gas supply regulators according to the Table 4-3 (with gas owing). For example, the
recommended delivery pressure for nitrogen cut gas and 50 feet of 1/4 inch ID hose is 104 psig. Delivery gauge mounted
on regulator must not read greater than 200 psig. Refer to Table 3-4 for recommended gas regulators.
Note
Do not use hoses less than 1/4 inch ID in the system.
Table 4-3 Recommended Regulator Pressure Settings ( psiG)
CUT
GAS
TYPE
O2 100 100 100 100 100 100 100 100 100 100 100 100
N2 100 103 104 105 100 100 100 102 100 100 100 100
H-35 138 139 141 144 135 135 137 138 135 135 135 135
Air 60 60 63 65 60 60 61 62 60 60 60 60
12.5 25 50 100 12.5 25 50 100 12.5 25 50 100
1/4-IN. ID HOSE
LENGTH IN FEET
5/16-IN. ID HOSE
LENGTH IN FEET
47
3/8-IN. ID HOSE
LENGTH IN FEET
SECTION 4 OPERATION CUTTING
4.2 Pre-Operation Test / Checkout (con’t.)
Coolant
Cooling of the plasma torch is usually accomplished with a coolant circulator. This circulator should be lled with plasma
torch coolant. Always use torch coolant, it lubricates the internal parts of the pump.
Settings over 150 psig will cause premature failure of the pump and/or motor-
CAUTION
to-pump coupling.
Check out the coolant ow with the power source ON, by observing the return water at the cooler. Coolant ow with N
consumables should be 1.4 to 1.6 gpm. Coolant ow with O2 consumables should be 1.25 gpm. Coolant can be conveniently
checked at the return line by using a suitable container.
Coolant Blowdown
If the equipment is to be exposed to freezing temperatures (while during non-operative time), coolant lines should be blown
out to prevent freeze damage to torch and equipment.
Note
Blowdown of the coolant system is not required if plasma torch coolant is used.
To blowdown the cooling system, disconnect the hose from the cooler or pump and connect it to nitrogen or clean air at 20
psig. The return hose should be connected to drain. Blow gas through the system until coolant no longer comes out the
drain line. Do Not operate the coolant circulator without using plasma coolant 156F05 . The coolant provides lubrication
of the internal pump parts. Algae growth and damage to the pump may occur if plain water is substituted.
Power Source
NEVER OPERATE THE POWER SOURCE WITH THE COVER REMOVED, IN ADDITION
TO THE SAFETY HAZARD, IMPROPER COOLING CAN CAUSE DAMAGE TO INTERNAL
WARNING
COMPONENTS. KEEP SIDE PANELS CLOSED WHEN UNIT IS ENERGIZED. ALSO, MAKE
SURE YOU ARE ADEQUATELY PROTECTED BEFORE YOU START TO CUT.
2
The Power Source controls and their functions are described in the following sequence.
Check the secondary output connections to the positive and negative output bus bar terminals.A.
Verify that the control connections have been properly made.B.
Determine the current control mode the power source is to be operated in and set the Control Switch in the desired C.
position. With this switch in the PANEL position, output current is controlled by setting the power source current
potentiometer. When the power source output current is controlled by a cutting machine control system, place this
switch in the REMOTE position.
If the primary electrical input connections to the power source have been installed correctly, close the main line (wall) D.
disconnect switch. Power will be applied and the Pilot Light on the front panel will be on. The cooling fans will come
on when cutting starts.
48
SECTION 4 OPERATION CUTTING
4.2 Pre-Operation Test / Checkout (con’t.)
Adjust the desired output current level at the power source or at the remote control location.E.
Operate the starting switches on the cutting control to energize the power source main contactor. Power will appear F.
at the power source output bus bar terminals.
After cutting has started, observe the ammeter, voltmeter and/or the cutting operation. If necessary readjust the cur-G.
rent control as required.
The cutting arc will extinguish and the power source will shut o automatically when the torch travels beyond the edge H.
of the work piece. The nozzle and electrode will experience excessive wear (especially with O2). Therefore, extinguishing
the arc with an Arc Stop Signal before running o the work piece is recommended.
A properly installed and operating power source should function as follows:
After energizing the power source (at the disconnect switch), the Main Power light (on the front panel) will illuminate A.
and the Fault Indicator light will ash and then go out.
When the contactor signal is received ( the “Contactor On” indicator will light) and power is applied to the main trans-B.
former, Open Circuit Voltage is available at the power source output terminals as indicated on the voltmeter.
Upon transfer of the main arc to the work, a current detector circuit senses the current and sends an “ARC ON” signal C.
to the Flow Control.
49
PLATE XR NOZZLE MAXIMUM
THICKNESS ASSEMBLY BEVEL ANGLE
(IN.) PART NO. (A)
1/4 2075691 (0.125) 35
o
3/4 2075611 (0.156) 40
o
1-1/2 2075612 (0.200) 45
o
2 2075613 (0.230) 40-45
o
PT-15XL Bevel Angles
The resulting bevel angle setting, particularly on thin
materials, may be 5 degrees greater than the torch
angle. The bevel retaining cup has smaller feet and
steeper sloped sides required to angle the torch with-
out hitting the work piece. The bevel retaining cup is
also usable for straight cutting required with an air cur-
tain or bubble muffler although there is less protection
than with the standard cup. Normally used with oxy-
gen.
Special nozzles for oxygen beveling are available. See
Form F-15-031 Instructions or PT-15XL Plasmarc torch.
Piercing
Piercing can be accomplished on plates up to about 1-
1/2 inches thick by delaying carriage movement until
the arc penetrates through the plate. The following are
typical delay timer settings:
PLATE SET CARRIAGE
THICKNESS DELAY TO
1/2 IN. 1/4 SEC.
1 IN. 3/4 SEC.
1-1/2 IN. 1-1/2 SEC.
When piercing plate 1-1/2 to 3 inches thick, allow the
A
ARC LENGTH
1/8"
SECTION 4 OPERATION CUTTING
4.3 Operating Techniques
Mirror Image Cutting
If desiring to cut with two torches simultaneously, with one moving in the mirror image of the other, the standard gas bae
can be replaced by their reverse swirl counterparts so that the right-edge remains square.
Bevel Cutting with Standard Parts
Bevel cutting requires the same setup considerations as standard straight cutting with a few exceptions. The thickness of
the cut is longer than the material thickness therefore the nozzle assembly and cutting speed must be selected accordingly.
Illustrated below are the maximum bevel angles that can provide good quality cuts with each nozzle based on 1/8 inch
clearance (not stando) between torch and work piece. Large bevel angles can be made by reducing the clearance and
increasing the arc length if cut quality can be sacriced.
1/8”
Arc Length
Torch Bevel Angles
Plate
Thickness
(IN.)
1/4 2075691 (0.125) 35º
XR Nozzle
Assembly
Part No.
Maximum
Bevel Angle
(A)
3/4 2075611 (0.156) 40º
1-1/2 2075612 (0.200) 45º
2 2075613 (0.230) 40-45º
Figure 4-4 Bevel Cutting Characteristics
The resulting bevel angle setting, particularly on thin materials, may be 5 degrees greater than the torch angle. The bevel
retaining cup has smaller feet and steeper sloped sides required to angle the torch without hitting the work piece. The
bevel retaining cup is also usable for straight cutting required with an air curtain or bubble muer although there is less
protection than with the standard cup. Normally used with oxygen.
Special nozzles for oxygen beveling are available. See instruction manual that came with torch.
50
SECTION 4 OPERATION CUTTING
4.3 Operating Techniques (con’t.)
Piercing
Piercing can be accomplished on plates up to about 1-1/2 inches thick by delaying carriage movement until the arc penetrates through the plate. The following are typical delay timer settings:
Plate Set
Thickness
1/2 In. 1/4 Sec.
1 In. 3/4 Sec.
1-1/2 In. 1-1/2 Sec.
When piercing plate 1-1/2 to 3 inches thick, allow the carriage to move (no delay) at about 1/2 the normal cutting speed.
Permit the arc to slice through the plate and produce a rooster-tail eect of molten spray. As soon as the arc penetrates
through the plate, adjust the carriage travel to the normal cutting speed. Piercing requires practice and skill. Piercing is
made at a higher stando than actual cutting. This helps prevent spatter from destroying the nozzle.
Noise, Fume and UV Radiation Considerations
The noise level of plasma cutting is greater than 110 db 6 ft. or 1.8 m from torch and depending on location of torch with
respect to sound reecting surfaces and the power level used for cutting. OSHA allows exposure to 95 db on a 50% duty
cycle (4 hours out of an 8 hour shift) and to 90 db on a 100% duty cycle.
There are currently several methods of attenuating noise, fumes and UV radiation of the plasma arc process; underwater
cutting, underwater cutting with bubble muer, underwater cutting with air curtain or cutting with a water muer.
Underwater Cutting1.
Carriage
Delay To
It has been found that an eective means of reducing the cutting noise level to 85 db or lower is by cutting under 2 to 3
inches of water. Fumes and UV radiation are substantially reduced. No plasma arc equipment change or accessory is required
for underwater cutting. However, an automatic cutting system requires controlling the initial stando when starting the
cut. In cutting materials up to 1-inch thick underwater, neither cutting speed nor cut surface appearance is appreciably
aected. Cutting speed and cut surface quality diminishes when cutting plates between 1 and 3 inches thick. Underwater
cutting of plates 3-inches or thicker is not recommended. Underwater cutting with oxygen requires the use of an air curtain
or bubble muer.
Note
When cutting underwater, care must be taken when a rust inhibitor is used in the water. Some inhibitors
contain enough conductive materials to prevent arc starting. CM-1000S (manufactured by Chemicals
Methods, Inc.) is one satisfactory inhibitor.
Air Curtain (Option)2.
The air curtain uses air to provide a “dry” area around the arc during underwater cutting. The air curtain is recommended
for use with oxygen cutting as the most economical approach to fume and noise control.
51
SECTION 4 OPERATION CUTTING
4.3 Operating Techniques (con’t.)
Water Muer (Option)3.
The water muer can be viewed as a combination air curtain and water muer. It is recommended for use with oxygen
when both underwater and above water cutting are to be used.
HYDROGEN EXPLOSION HAZARD! READ THE FOLLOWING BEFORE
WARNING
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.
ATTEMPTING TO CUT WITH A WATER TABLE.
The best available information indicates that three possible sources of hydrogen exists in water tables:
Molten Metal Reaction1.
Most of the hydrogen is liberated by a fast reaction of molten metal from the kerf in the water to form metallic oxides. This
reaction explains why reactive metals with greater anity 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.
Slow Chemical Reaction2.
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.
Plasma Gas3.
Hydrogen may come from the plasma gas. At currents over 750 amps, H-35 is used as cut gas. This gas is 35% hydrogen 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 hydro gen 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.
52
SECTION 4 OPERATION CUTTING
4.3 Operating Techniques (con’t.)
Follow these practices to reduce hydrogen generation and accumulation:4.
Clean the slag (especially ne particles) from the bottom of the table frequently. Rell the table with clean water.A.
Do not leave plates on the table overnight or a weekend.B.
If a water table has been unused for several hours, vibrate it in some way before the rst plate is laid in position. C.
This will allow accumulated hydrogen in the refuse to break loose and dissipate before it is conned 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.
If cutting above water, install fans to circulate air between the plate and the water surface.D.
If cutting underwater, agitate the water under the plate to prevent accumulation of hydrogen. This can be done E.
by aerating the water using compressed air.
If possible, change the level of the water between cuts to dissipate accumulated hydrogen.F.
Maintain pH level of the water near 7 (neutral). This reduces the rate of chemical reaction between water and G.
metals.
Programmed part spacing should be a minimum of twice the kerf width to ensure material is aluminum under the H.
arc.
POSSIBLE EXPLOSION HAZARD FROM PLASMA CUTTING ALUMINUM-
WARNING
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:
For additional details and information on the safe use from the hazards associated with these alloys, contact your aluminum
supplier.
LITHIUM ALLOYS!
Alithlite (Alcoa) X8192 (Alcoa)
Alithally (Alcoa) Navalite (U. S. Navy)
2090 Alloy (Alcoa) Lockalite (Lockhead)
X8090A (Alcoa) Kalite (Kaiser)
X8092 (Alcoa) 8091 (Alcan)
53
SECTION 4 OPERATION CUTTING
54
SECTION 5 OPERATION MARKING
5.0 Operation – Marking
PMC-91 Plasmarc system can have marking capability if the marking box (0558005878) is used. The marking box also
provides functions such as, remote control for dierent current scaling, control of pilot arc Hi/Low, mark mode selection,
welding current feedback.
The marking box has three cables connected to the ow control box.
5.1 Pre-Operation Test and Checkout
Mode Selection
Marking box has eight dierent working modes, depending on the power supply used. EPP-401/450 low current, EPP-401/450
high current. EPP-601 low current, EPP-601 high current, EPP-201/360 high current, EPP-201/360 low current, CNC control
and marking gas test.
Marking Gas Test
In marking gas test mode, the operator can set up and test pressure of marking gas (argon) and shield gas from the front
panel of marking box.
Marking Current and Cutting Current Pre-Set Up
If not CNC controlled, through marking box, the operator can pre-set the marking current and also the cutting current. This
will remotely control the marking current and cutting current. Note: Make sure cutting mode is selected before presetting
both marking and cutting currents.
To set up the currents, hold down the display switch on the front panel of the power supply. In that way the pre-set current
will be displayed. First, set cutting current to zero. Adjust marking current to the desired value. Then adjust the cutting
current to the desired value.
Main Power Light and Fault Light
After the marking box is energized, the main power light on the front panel will illuminate and the fault indicator light will
be on for 2 seconds. After 2 seconds, if the fault light is still on, a fault must exist. This fault could be a system fault, ow
switch fault or interlock switch fault. If the CNC sends plasma start command before the marking box is energized, the fault
light will also be on.
55
SECTION 5 OPERATION MARKING
5.2 Marking and Cutting Procedure
Connect the electrical cables described in Section 3.2.1.
Connect the gas and water hoses described in Section 3.2.2.
Switch on the power supply and marking box. Choose “remote” control.3.
Switch to gas test mode from marking box. Adjust the pressure and ow rate for shield gas and marking gas according 4.
to the cutting data.
Select the proper power supplies from EPP-201, 360, 450 or 601. 5.
Turn cutting current pot to zero. Hold the spring return switch on the power supply and at the same time adjust the 6.
marking current pot until a desired marking current is preset and displayed on the power supply.
If cutting operation is needed, hold the spring return switch again on the power supply. Adjust the cutting current to 7.
the desired value by adjusting the cutting current pot.
Follow the procedure to set up gas and ow control in the ow control box (PCC-91).8.
Provide plasma start signal and mark mode signal from the remote control device (CNC). By switching on and o the 9.
marking mode signal, marking and cutting operation can be alternated. Before switching, the plasma arc must be o,
then start the arc again after the marking mode signal is switched.
56
SECTION 6 TROUBLESHOOTING
TABLE 4-1 PLC INPUT/OUTPUT LEDs
INPUT OUTPUT
LED FUNCTION LED FUNCTION
0 Start/Stop 0 Process Running
1 Current Detector 1 Fault Signal
2 Nitrogen Pressure 2 Power Source On/Off
3 Oxygen Pressure 3 Cut Water On/Off
4 Interlock Plumb.Box 4
5 Cooling Water Flow 5
6 Cut Water Flow 6 Air Curtain
7 Cut Gas Pressure 7 Cut Gas Metering
8 Run 1 8 Cut Gas On/Off
9 O2/N2 Select 9 Start Gas On/Off
10 Emergency Stop 10 HF On/Off
11 Cut Water On/Off 11
12 Test Cut Gas
13 Test Start Gas
14 Run 2
15 Test HF
4.2 Sequence Description
The program controlling the plasma system sequence is
made with the help of a group of conditional states. Inputs
from sensors, and the cutting machine are continuously
evaluated by the PLC to determine whether the program
stays in its present state or makes a transition to another
state.
The different states are shown as rectangles in figure 4-
2. The function of the seven states are described in the
following paragraphs.
0 - Ready state
The "Ready" state is the normal state for the system to be
in when not executing the cutting process. In this state,
the system awaits the start signal from the cutting ma-
chine and monitors the selection keys and safety switches.
While in this state it is possible to activate the gas flows
and cut water flow for testing and purging the system.
1 - Preflow state
The "Preflow" state is a fixed duration and is reached only
from state "0". Nitrogen is always the preflow gas in RUN
1 position. Selected cut gas type and flow is the preflow
gas in RUN 2 position. Cut water flow during preflow
whenever a water injection torch is used and cut water is
switched on at the front panel. The air curtain output is
energized at this time also.
2 - Open Circuit Voltage State
6.1 Programmable Logic Controller (PLC)
The PLC is located in the top section of the Flow Control and is a device capable of providing predened outputs depending
on the state of the inputs. The precise conditions are programmed and permanently stored in the PLC. Because it is a solid
state device the PLC is inherently very reliable. It is also relatively compact.
The PLC will provide predened outputs in response to inputs from external devices. This exchange of signals can be conrmed by observing the LEDs on the top of the PLC while troubleshooting. These indications are useful in isolating a system
failure to the most likely device. They can be seen through window in the Flow Control top cover.
The LEDs are divided into two groups; Input (0-15) and Output (0-11). Input LEDs light when the corresponding signal is
detected by the PLC. Output LEDs light when the PLC issues a signal to an external device. The fault LED (output 1) indicates
the PLC has detected an error within the ESP and has caused the system to enter the not ready (fault) state.
LEDs are highly reliable indicators. It is not likely that one will burn out. However, if the technician is not condent that the
LEDs are working the presence of a signal can be conrmed by using a meter to measure the appropriate pin. Refer to the
schematic and wiring diagrams.
The signal exchange between the PLC and external devices are both time dependent and condition dependent. If a required
signal is not received in the proper sequence, the PLC will discontinue the process and generate a fault signal to the CNC.
Figure 6-1 PLC LED Panel (Partial View)
Table 6-1 PLC Input / Output LEDs
Input Output
LED Function LED Function
0 Start / Stop 0 Process Running
1 Current Detector 1 Fault Signal
2 Nitrogen Pressure 2 Power Source On/O
3 Oxygen Pressure 3 Shield Gas On / O
4 Interlock Plumb. Box 4
5 Cooling Water Flow 5
6 Shield Gas Flow 6 Air Curtain
7 Cut Gas Pressure 7 Cut Gas Metering
8 Run 1 8 Cut Gas On / O
9 O2 / N2 Select 9 Start Gas On / O
10 Emergency Stop 10 HF On/O
Shield Gas -
11
Enabled / Disabled
12 Test Cut Gas
13 Test Start Gas
14 Run 2
15 Test HF
57
11
SECTION 6 TROUBLESHOOTING
6.2 Sequence Description
The program controlling the plasma system sequence is made with the help of a group of conditional states. Inputs from
sensors, and the cutting machine are continuously evaluated by the PLC to determine whether the program stays in its
present state or makes a transition to another state.
The dierent states are shown as rectangles in Figure 6-2. The function of the seven states are described in the following
paragraphs.
0 - Ready State
The “Ready” state is the normal state for the system to be in when not executing the cutting process. In this state, the system
awaits the start signal from the cutting machine and monitors the selection keys and safety switches. While in this state it
is possible to activate the gas ows for testing and purging the system.
1 - Preow State
The “Preow” state is a xed duration and is reached only from state “0”. Nitrogen is always the preow gas in RUN 1 position. Selected cut gas type and ow is the preow gas in RUN 2 position. Shield Gas also ows during preow and the air
curtain output is energized at this time.
2 - Open Circuit Voltage State
The main contactor of the power source is activated after the preow, and a short time is allowed for the open circuit voltage to be reached.
3 - Pilot Arc State
The Pilot Arc State is started by activating the high frequency unit. The time allowed between this and the requirement of
a current ow signal from the power source is a xed time. If the signal from the power source is not received during this
time, the state is transferred to the Not Ready State 7.
4 - Cutting State
In the Cutting State, the cut gas is turned on and the start gas o if using RUN 1. A signal is sent to the cutting machine
control indicating that the process is running. This is the Normal State to be in during cutting.
5 - Priority Postow State
The Priority Postow State provides the minimum postow of nitrogen gas and shield gas ow necessary before a restart
is possible. The time is dierent depending upon whether cutting with nitrogen or oxygen. This state is reached when the
START / STOP goes low or current ow through the arc is lost.
6 - Final Postow State
The Final Postow State provides the time during which nitrogen gas and shield gas ow cools the torch. This state immediately follows the Priority Postow State, a restart is possible during postow.
When the time for postow has elapsed, the program transfers to the 0 Ready State. If a new start signal has been given
from the cutting machine control after it stopped the process, a fast restart will be executed directly from the Postow State
to State 2 that turns on the main contactor in the power source.
58
SECTION 6 TROUBLESHOOTING
6.2 Sequence Description (con’t.)
7 - Not Ready State
During the Not Ready State (fault state) the Programmable Logic Controller (PLC) is sending a fault signal to the cutting
machine.
It is possible to test gas ows in this state. The HF unit can be run for test purposes in this state.
3 Start Pilot Arc
Cut Current
Flows
4 Cutting
Time delay to HF done
Start
reset
Time out HF
Arc
Start signal o
or arc out
2 Turn power
source on
Start
reset
1 Preow
Start
reset
0 Ready
All OK
7 Not ready
(fault state)
Faults
detected
Startup
5 Priority
postow
Preow done
Start signal on
Postow done
Arc-out
no
Startup
reset
Priority postow
done
Restart
requested
6 Final
postow
Figure 6-2 Plasma Sequence Flow Diagram
59
SECTION 6 TROUBLESHOOTING
CLEANING OXYGEN NOZZLES
As the electrode wears considerable deposits of
hafnium oxide and silver can build up in the nozzle.
Calcium carbonate can also build up at he nozzle exit
if the cut water is not adequately treated. These de-
posits can sometimes cause substantial reductions in
cut quality, speed and consumable life.
Nozzle performance can be restored by removing these
deposits from the inside of the nozzle and the nozzle
exit. A twisted piece of very fine sandpaper or crocus
cloth usually cleans the nozzle well enough. Care must
be taken not to damage the thin copper edge at the
nozzle exit. The 340 amp nozzles have a heavier less
easily damaged exit as compared to the 260 and 300
amp nozzles.
Nozzle performance is also degraded by nicks and elon-
gation of the orifice due to double arcs or mechanical
damage. Cleaning will not restore a damaged nozzle.
Whenever a nozzle is removed for cleaning the elec-
trode should be inspected. If the wear is greater than
0.090 inch or very irregular, the electrode should be
replaced.
CUT QUALITY
Maximum attainable cut quality is highly dependent on
the material being cut. With the wide variety of com-
ELECTRODE LIFE
LINE
DURATION OF CUT
# OF STARTS
6.3 Operating Information
Maximizing Consumable Life
Plasma torch electrode and nozzle life is a function of many factors, some of which are under control of the operator. When
using oxygen as the plasma gas in a properly operating system, electrode wear and life is a function of the number of arc
starts, the total duration of the cutting time and the current level. The longer the cut time for a part being cut, the fewer the
number of arc starts on an oxygen electrode before it must be replaced. The graph below shows the relationship between
the two.
Electrode Life Line
Number Of Starts
Duration Of Cut
Figure 6-3 Oxygen Electrode Life Graph
Oxygen electrode and nozzle life are also aected by the current setting. If parts are operated above their recommended
current level, life deteriorates quickly. Improper cutting and parts programming can adversely eect oxygen consumable
life, so it is important that proper techniques be used. Oxygen plasma nozzles and electrodes are less forgiving of improper
operation than nitrogen nozzles and electrodes. When using nitrogen or argon/hydrogen as a plasma gas, nozzle and electrode life are primarily a function of current level. The higher the current the shorter the life.
Cleaning Oxygen Nozzles
As the electrode wears considerable deposits of hafnium oxide and silver can build up in the nozzle. Calcium carbonate can
also build up at the nozzle exit if the cut water is not adequately treated. These deposits can sometimes cause substantial
reductions in cut quality, speed and consumable life.
Nozzle performance can be restored by removing these deposits from the inside of the nozzle and the nozzle exit. A twisted
piece of very ne sandpaper or crocus cloth usually cleans the nozzle well enough. Care must be taken not to damage the
thin copper edge at the nozzle exit. The 340 amp nozzles have a heavier less easily damaged exit as compared to the 260
and 300 amp nozzles.
Nozzle performance is also degraded by nicks and elongation of the orice due to double arcs or mechanical damage.
Cleaning will not restore a damaged nozzle.
Whenever a nozzle is removed for cleaning the electrode should be inspected. If the wear is greater than 0.090 inch or very
irregular, the electrode should be replaced.
60
SECTION 6 TROUBLESHOOTING
6.3 Operating Information (con’t.)
Cut Quality
Maximum attainable cut quality is highly dependent on the material being cut. With the wide variety of commercial metals
and alloys being cut with plasma, optimum cut quality can vary widely from situation to situation. Suggested cut parameters given in this manual are starting points only for general cases. Fine tuning of the various parameters may be required
to get the best possible cut of a specic material. Some materials, including certain steels, are dicult, if not impossible to
cut dross free. Likewise, in carbon steels, variations in plate composition, treatment while rolling, contaminants and other
factors can cause the dross generated to vary from heat to heat, plate to plate and area to area on a plate. As a general rule,
using oxygen as a plasma gas produces less dross variation on carbon steel as a result of these factors, but is not a guarantee
that “dross free” cuts will be produced.
6.4 Troubleshooting Guide
The following troubleshooting guide is primarily an operationally oriented guide. If a problem exists in one of the system
components, the guide will direct you to that manual. When directed to another manual, be sure a qualied maintenance
technician is contacted.
61
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Problem
1. Reduced consumable
(electrode) life (O2 and N2
cutting)
Probable Cause
Excessive current.
Gas settings - inlet pressure.
Gas or water leak.
Inadequate cooling.
Single phasing of power
source.
Wrong gas bae (O2).
Moisture in system.
Process factors:
Running o work.
Remedy
Check power source ammeter (Refer to power source
manual).
Check that settings are in accordance with charts. Use
gas ow check kit.
Check for leaks.
Check water cooler for proper operation.
Refer to power source manual.
Install correct gas bae (O2).
Purge system of moisture for a minimum of 30 seconds
after long idle time.
Extinguish arc with Arc Stop signal prior to running o
work or use a waste plate to run o on. This is most
important with O2 cutting.
Flipping or twisted
parts hitting torch.
Skeleton cutting.
Change program or x table.
Cutting skeletons to facilitate their removal from the
table can adversely aect electrode life by:
A. Causing the torch to run o the work. (see above)
B. Causing multi-pop edge starts.
62
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Problem Probable Cause
1. Reduced consumable
(electrode) life (O
cutting) - (cont)
and N2
2
Remedy
C. Greatly increasing the frequency of starts. This is
mainly a problem for O2 cutting and can be alleviated
by choosing a path with a minimum number of starts
or by bridging gaps in the skeleton with water plates.
D. Increased likelihood that the plate will spring up
against the nozzle causing a double arc. This can be
mitigated by careful operator attention and by increasing stando and reducing cutting speeds.
Since many of these problems are most severe with O2
cutting consumables, consider when it may be practical to cut skeletons with N2 consumables:
A. When you will be changing to N2 consumables for
the next plate anyway.
B. When one plasma station on the machine is not
being used for part cutting and could be used for cutting skeletons with N2.
On machine with Oxweld or Purox torch, it may be
practical to use the gas torch for skeleton cutting.
Height control problems.
Piercing stando too low.
Starting on edges with
multi-pop starts.
Drawn arc from falling part.
Purity and dryness of gas.
Gas switching is not activating.
See crashing / diving.
Increase piercing stando.
Position torch more carefully or use a waster plate to
start on. This is most important for O2 cutting.
Change program.
Verify purity to be 99.55% O2 . Verify dew point. Verify
purity of N2 to be 99.995%.
This pertains to O2 cutting only. Check to make sure
that switch is in Run 1 mode so that the arc begins in
N2 and switches to O2. This may be checked by installing the gas test owmeter rst on the N2 line into the
ow control to see that N2 is owing during preow
and postow only. Then install it on the O2 line into
the ow control to check that O2 is owing only during
the cut. O2 should never ow when cutting with N2.
63
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Probable CauseProblem Remedy
1. Reduced consumable
(electrode) life (O
cutting) - (cont)
2. Reduced nozzle life
(N2, O2 and ArH2)
and N2
2
O2 present at start.
Using non-genuine consumables.
Improper pierce height.
Contacting work:
When O2 cutting, check above for gas switching.
When N2 cutting, any presence of O2 will result in
rapid electrode wear. Make sure system has been
purged in cut gas test.
Check for gas or water leaks in torch or hoses.
Check gas quality. Ensure that O2 OSV in ow control is not leaking by disconnecting O2 from the ow
control purging system.
N2 cutting is done with a tungsten electrode.
Tungsten will turn blue or yellow in the presence of
oxygen from any source.
Replace with genuine consumables.
Refer to appropriate application table for correct
setting.
Diving
Work ipping
Diving is usually caused by a change in arc voltage
when an automatic height control is in use. Diving
can result in loss of cut damage to the nozzle. Usually the voltage change is as the result of a change
of direction or speed to negotiate a corner or as
a result of plate falling away from the arc. These
problems can be dealt with by disabling the height
control in such situations and by extinguishing the
arc earlier when nishing the cut on falling plate.
Diving may also be caused by a problem with the
height control or the signals fed to it.
The nozzle may sometimes be damaged if the
torch hits a ipped up part. This is dicult to avoid
entirely but careful part programming can minimize
the problem.
64
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Probable CauseProblem Remedy
2. Reduced nozzle life (N2, O2
and ArH2) - (cont)
Catching on piece
Air curtain / water muer
alignment
Excessive speed
Excessive pilot arc on
time.
Process factors:
Inadequate initial delay.
Pierce not complete before
starting.
Excessive initial delay.
Improper torch assembly.
This refers to crashes or nozzle damaged caused
by the front end of the torch catching on top spatter after a pierce. Hold the torch at a high stando
for a longer lead-in to avoid this problem.
Refer to Subsection 3.6 to make necessary adjustments.
Reduce speed to prevent rooster tailing during cut.
Reduce speed corners if rooster tailing occurs only
coming out of corners.
Same as for electrode above.
Increase delay time.
Decrease initial delay.
Reassemble torch properly. Check for gas
and water leaks.
Improper piercing
technique.
Running pilot arc without
transfer.
Using non-genuine
consumables.
Improper connection or
inadvertent grounding of
pilot arc cable running from
power source to plumbing
box.
Worn feet on retaining
65
Refer to Subsections 4.3 and 4.5.
Running pilot arcs without transfer is very damaging to nozzles. Check stando and work connections.
Replace with genuine consumables.
Connect wire properly in the power source. Make
sure there are no breaks in the insulation.
Replace retaining cup.
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Problem Probable Cause Remedy
3. Poor cut quality. Dross and cut surface:
Varying characteristics
of material being cut.
Incorrect speed
Incorrect stando
Incorrect cut gas or shield
gas ow.
Incorrect alignment or
improper operation of
air curtain or bubble
muer.
Damaged or worn
consumables.
Using non-genuine
consumable part.
Gas selection.
No remedy.
Adjust to correct speed.
Refer to Subsections 4.3 and 4.5 for applicable
cutting techniques.
Refer to Subsections 4.1 and 4.2.
Refer to Subsections 3.4, 3.5 and 3.6.
Replace.
Replace with genuine consumable part.
N2 produces smoother surfaces on Al and SS
than O2. O2 sometimes produces less dross on
C.S. than N2.
Torch alignment to work.
Incorrect current.
Cutting over slats.
Cutting machine or torch
vibrates.
Mixing standard and
reverse swirl parts.
Bevel angle:
Verify and correct torch alignment.
Verify correct current. Refer to appropriate cutting tables after Subsection 4.4.
Cutting over slats will cause some bottom dross.
If the cut runs along the slat, it can produce other
cut quality problems. The only solution is to try
to avoid running along the slats.
Make sure brackets and height control are rigid
and properly adjusted.
Check to be sure swirl is in the same direction.
Remove swirl parts that are marked with an "R".
Same as dross and cut surface above
except varying characteristics of material being
cut and cutting machine or torch vibrations.
Stando and speed have considerable eect
on bevel angle.
66
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
RemedyProbable CauseProblem
3. Poor cut quality - (cont)
4. No pilot arc.
Damaged nozzle
Wrong travel direction
(good angle on scrap side)
Plate shifting while being
cut.
Slag buildup on cut table.
Contaminated electrode.
Insucient spark gap
setting (in plumbing box).
Pilot Arc Contactor (PAC)
malfunctioning.
Blown fuse in pilot arc or
starting circuit.
Plate not level - ensure work is level. Torch not perpendicular to work - ensure torch is plumb (perpendicular) to work.
With standard swirl parts the most square side of the
cut is on the right side of the direction of travel.
Small, thin, or light weight plates can shift while cutting. Clamp them down.
Clean slag from cut table.
Clean or replace electrode.
Set spark gap to 0.040” (+.004").
Refer to power source manual.
Refer to power source manual.
Improperly assembled torch
or broken torch pilot arc
cable.
Broken or improperly
connected pilot arc cable
between plumbing box and
power source.
Insucient Open Circuit
Voltage (OCV).
Gas ow improperly set.
Improper clamping of stainless steel torch body.
Conductive water muer
hoses.
Water leak in torch.
67
Reassemble torch properly or replace torch pilot arc
cable.
Replace or verify connections between
plumbing box and power source.
Refer to power source manual.
Refer to Subsections 4.1 and 4.2.
Clamp onto non-conductive sleeve above
indicated mark.
Replace with non-conductive hoses.
Determine cause of leak.
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Problem Probable Cause Remedy
4. No pilot arc - (cont)
5. No arc transfer.
Shield gas ow switch not
activated.
Blown fuse in pilot arc or
starting circuits.
Insucient Open Circuit
Voltage (OCV).
Gas ow improperly set.
Stando too high or torch
centered o edge of work.
Poor connection to workpiece.
Thick mill scale or non-conductive surface on work.
Power source current setting too low.
Defective power source.
Check for adequate shield gas ow. Check shield
gas ow switch.
Refer to power source manual.
Refer to power source manual.
Refer to Subsections 4.1 and 4.2.
Check cutting technique or position torch to be
over work.
Check connection.
Clean mill scale or ensure conductive surface
on work.
Refer to power source manual.
See power source manual.
6. No preow.
No start signal.
Emergency stop signal
open.
Door opened on plumbing
box allowing interlock to
open.
Shorted, closed or jumpered
out shield gas ow switch.
No cooling water.
N2 pressure switch not
activated.
O2 pressure switch not
activated when N2/O2 switch
is set to O2.
68
Check input 0 on PLC in ow control. Should
be lit when receiving start signal. Ensure
qualied technician performs this check.
Check input 10 on PLC in ow control. Should
be lit to enable operation. Ensure qualied
technician performs this check.
Close door.
Check input 6 on PLC. Should be o before
start signal applied. Should be on when in
test. Ensure qualied technician performs
this check.
Check ow switch.
100 psig N2 (gas owing) should be supplied to
the ow control.
100 psig O2 (gas owing) should be supplied to
the ow control.
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Problem Probable Cause Remedy
7. Arc extinguishes during a
cut or shuts down immediately after transfer.
8. Water muer air supply
does not come on.
9. Water muer under pump
does not come on.
Loss of start signal.
Interlock not satised - loss
of gas pressure or gas ow.
Running across very large
kerf or o plate.
Speed too low.
Switch on air curtain control
box in the OFF position.
Air curtain control box is not
receiving signal from ow
control.
Starting relay on water mufer is not receiving signal
from ow control.
Pump is not connected to
main power.
Check signal from cutting machine.
Check PLC inputs.
Check part program.
Increase speed as necessary.
Switch to AUTO.
Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of ow control. Check wiring.
Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of ow control. Check wiring.
Check wiring and fuses.
Pump is running backwards.
Check wiring.
69
SECTION 6 TROUBLESHOOTING
6.4 Troubleshooting Guide (con’t.)
Problem Probable Cause Remedy
10. Poor cut quality with
water muer or air curtain installed. (Cuts are good above
water with water muer or
air curtain turned o. Cuts are
bad under-water with device
operating.)
11. Shield gas ow inadequate. Cannot reach proper
ow setting.
Sleeve not bottomed out on
the main body.
O-rings missing or broken.
Air pressure set too high, or
air shut o.
Sleeve spacing between air
curtain or water muer and
torch retaining cup incorrect.
Sleeve not centered in reference to the torch retaining
cup.
Dirt in sleeve holes.
Holes in sleeve align with air
input port.
Internal gas supply lter (in
ow control) is clogged.
Reseat Sleeve.
Replace o-rings in main body.
Set air pressure between 15-30 psi. Some
trails should be made on scrap plate to nd
the optimum pressure for your conditions.
Adjust spacing. See Subsections 3.4, 3.5 and 3.6.
Center sleeve. Clamp may be cocked on
torch handle or o-rings may be damaged.
Remove sleeve and clean.
Rotate sleeve 5°.
Clean or replace internal lter of ow control.
70
05 / 2008 - Original release.
REVISION HISTORY
71
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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