ESAB Precision Etch-Arc Plasma Marking System Instruction manual

Download

Precision Etch-Arc®

Plasma Marking System

Instruction Manual

0558004910 02 / 2009

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

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.

TABLE OF CONTENTS

SECTION TITLE................................................................................................................................................ PAGE

SECTION 1 SAFETY PRECAUTIONS .........................................................................................................................................................5

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

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

1.2 La seguridad - español.............................................................................................................................................................9

1.3 La sûreté - français ..................................................................................................................................................................13

SECTION 2 DESCRIPTION .........................................................................................................................................................................17

2.1 Introduction .............................................................................................................................................................................17

2.2 System Description ................................................................................................................................................................ 19

SECTION 3 INSTALLATION .......................................................................................................................................................................23

3.1 Interface ..................................................................................................................................................................................... 23

3.2 Requirements ...........................................................................................................................................................................24

3.3 Connections to the Precision Etch-Arc ...........................................................................................................................25

3.4 PT-24 Installation .................................................................................................................................................................... 29

SECTION 4 OPERATION .............................................................................................................................................................................31

4.1 Precision Etch-Arc Setup ......................................................................................................................................................31

4.2 Gas Setup ..................................................................................................................................................................................32

4.3 CNC Setup .................................................................................................................................................................................33

4.4 Process Data .............................................................................................................................................................................33

SECTION 5 MAINTENANCE ......................................................................................................................................................................37

5.1 Routine Maintenance ............................................................................................................................................................37

5.2 Flow Switch ...............................................................................................................................................................................38

SECTION 6 TROUBLESHOOTING ........................................................................................................................................................... 39

6.1 Troubleshooting Guide ........................................................................................................................................................39

SECTION 7 REPLACEMENT PARTS ........................................................................................................................................................45

7.1 General .......................................................................................................................................................................................45

7.2 Ordering .....................................................................................................................................................................................45

7.3 Precision Etch-Arc -- Front and Rear View all models ............................................................................................... 46

7.4 Precision Etch-Arc Inside Right View –208/230v P/N 0588000967 ....................................................................... 47

7.5 Precision Etch-Arc Inside Left View –208/230v- P/N 0588000967 ....................................................................... 48

7.6 Precision Etch-Arc Inside Top View (cover removed) –208/230v -- P/N 0588000967 ....................................50

7.7 Precision Etch-Arc Inside Top View Cross Section 1 –208/230v -- P/N 0588000967 ......................................51

7.8 Precision Etch-Arc Inside Top View Cross Section 2–208/230v -- P/N 0588000967 ........................................52

7.9 Precision Etch-Arc Inside Right View – 460v P/N 0588000949 & 575v P/N 0588000966 ............................. 53

7.10 Precision Etch-Arc Inside Left View –460v P/N 0588000949 & 575v P/N 0588000966 ................................. 54

7.11 Precision Etch-Arc Inside Top View – 460v P/N 0588000949 & 575v P/N 0588000966 .................................56

7.12 Precision Etch-Arc Inside Top View Cross 1 – 460v P/N 0588000949 & 575v P/N 0588000966 .................. 57

7.13 Precision Etch-Arc Inside Top View Cross 2 – 460v P/N 0588000949 & 575v P/N 0588000966 ................. 58

7.14 Argon Gas Circuit (cut gas) ..................................................................................................................................................59

7.15 Auxiliary Solenoid Parts .......................................................................................................................................................60

7.16 PT-24 Marking Torch ..............................................................................................................................................................61

7.17 Torch Bundles and Other System Parts ..........................................................................................................................63

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references

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

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits

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

1. Always wear safety glasses with side shields in any

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

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

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

3. Wear ameproof gauntlet type gloves, heavy long-

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

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

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

5. Protect other personnel from arc rays and hot

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

6. Use goggles over safety glasses when chipping slag

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

1.1 Safety - English

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

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

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

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

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

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

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

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

02269.

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

SECTION 1 SAFETY PRECAUTIONS

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

2. Connect the workpiece to a good electrical ground.

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

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

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

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

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

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

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

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

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

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

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

Therefore:

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

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

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current owing through any conductor causes localized Electric and

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

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with some pacemakers.

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

are unknown.

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

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

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

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

SECTION 1 SAFETY PRECAUTIONS

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

§25249.5 et seq.)

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

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

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

1. Always have qualied personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualied to perform such work.

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

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

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

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

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

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

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

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

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

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

ADDITIONAL SAFETY INFORMATION -- For

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

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

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

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

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

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

SECTION 1 SAFETY PRECAUTIONS

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

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

7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.

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

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

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

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

Means hazards which could result in minor personal injury.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

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

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco,

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

1. Utilice gafas de seguridad con protección a los lados

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

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

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

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

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

4. Chispas y partículas de metal caliente puede alojarse

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

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

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

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

ridad cuando esté removiendo escoria o puliendo.

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

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

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases amables, solventes, pinturas, papel, etc.

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

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

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

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

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

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

CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corri-

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

SECCION 1 SEGURIDAD

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

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

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

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

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

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

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

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

9. Apage el equipo antes de quitarse sus guantes.

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

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

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

1. Soldadores u Operadores que use marca-pasos para

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

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

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

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

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

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

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

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

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

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

sin ventilación. No inhale el humo

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

1. Siempre provea ventilación adecuada en el área

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

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

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

3. Si momentáneamente desarrolla inrritación de

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

4. Haga referencia a la publicación ANSI/ASC Standard

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

SECCION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

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

2. Asegure siempre los cilindros en posición vertical

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

3. Cuando el cilindro no está en uso, mantenga la

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

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

Signica riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

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

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

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

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

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

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage

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

1. Portez des lunettes protectrices munies d'écrans la-

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

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

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

3. Portez des gants ignifugiés à crispin, une chemise

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

4. Les étincelles et les projections de métal incandescent

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

5. Protégez toute personne se trouvant à proximité des

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

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. L es p er so n ne s se tr o uv an t à p rox i mi té d oi ve n t é ga le ment porter des lunettes étanches par dessus leur lunettes de sécurité.

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

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

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

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

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

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

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

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

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-

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

SECTION 1 SÉCURITÉ

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

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

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

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

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

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

7. Si vous devez eectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

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

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

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

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel con-

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

1. Un soudeur ayant un stimulateur cardiaque doit

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

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

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

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

A. Acheminez l'électrode et les câbles de masse

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

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

autour de votre corps.

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

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

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

plus près possible de la section à souder.

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

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

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages

corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent :

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

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

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

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

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

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

SECTION 1 SÉCURITÉ

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

MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un

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

1. Utilisez toujours le gaz prévu pour une opération

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

2. Fixez les cylindres dans une position verticale, à

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

3. Lorsque les cylindres ne servent pas, gardez les

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

4. Placez les cylindres à une distance appropriée

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

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jeerson Davis Highway, Arlington, VA 22202.

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

1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualié. N'eectuez aucune réparation électrique à moins d'être qualié à cet eet.

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

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

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

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

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

INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529.

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

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

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

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

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

SECTION 1 SÉCURITÉ

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

DANGER

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

AVERTISSEMENT

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

ATTENTION

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

SECTION 2 DESCRIPTION

2.1 Introduction

The Precision Etch-Arc Plasma Marker is a constricted arc low amperage plasma marking system. It marks at speeds between 100 and 600 ipm. The plasma marking process is similar to the plasma cutting process. However, rather than piercing through the plate, the low amperage plasma arc merely cuts the surface of the plate material between .00020" and .0050" deep. Voltage height control maintains a constant torch stando for consistent, high speed, accurate pattern layout. When the Precision Etch-Arc Plasma Marker is used in conjunction with ESAB’s Vision CNC, Dynamic Current Control is used to precisely control width and depth of marks by proportionally ramping current up and down as the machine accelerates and decelerates. This minimizes pitting at the beginning, corners, and end of the mark. Accurate positioning of the layout lines and marks depends on using the automatic marker osets executed by the CNC during Automatic Mode. However, the marker can be used manually for testing and setup.

In automatic operation, the part program controls: machine motion• osets torch• turns on automatic height control• res the torch and begins marking.•

Torch leads

All of these steps can be performed by the operator for manual operation.

The Precision Etch-Arc Plasma Marking

Motorized vertical lift

Power Supply consists of a modied PCM1125 capable of supplying up to 35 amperes. Modications include an added argon solenoid, pressure switch, gas connections,

Torch body

marker control board and cable connection. Unused manual controls were removed or

Adaptor

disconnected from the PCM-1125.

The marking torch has only three consumable parts: the electrode, nozzle and shield cup. Argon cut gas provides long electrode and nozzle life.

Handle

SECTION 2 DESCRIPTION

2.1.1 Interconnection Diagram

131214

Precision Etch-Arc

Front Connections 1 Vision CNC (relay box) 9 Air Regulator 2 CNC Control Cable 10 Air Supply Hose 3 Argon Gas Hose to torch 11 Argon Supply Hose 4 Work Cable 12 Primary Power Cable 5 Torch Bundle 13 Argon Gas Supply 6 Marking Torch 14 Compressed Air Supply 7 Work Piece 15 Fused Disconnect (mounted on machine, used when 8 Earth Ground

Precision Etch-Archas been mounted on the machine)

16 Wall disconnect

Precision Etch-Arc Back Connections

SECTION 2 DESCRIPTION

2.2 System Description

2.2.1 Precision Etch-Arc Systems

Includes power supply, torch and necessary cables and hoses.

Marker Module ..............................................................................................P/N 0560938439

2.2.2 Precision Etch-Arc Power Supply

208/230 V, 50/60Hz, 1 or 3 phase............................................................P/N 0588000967

460 V, 50/60 Hz, 3 phase ............................................................................P/N 0588000949

575 V, 60 Hz, 3 phase ...................................................................................P/N 0588000966

Rated Inputs Rated Outputs

Phases Volts Amps Power Factor Duty Cycle

208 6455 73% 100% 35* 280 VDC

230 5855 73% 100% 35* 270 VDC 230 28 100% 100% 35* 285 VDC 208 25 100% 100% 35* 275 VDC

460 14 100% 100% 35* 285 VDC 575 11 100% 100% 35* 260 VDC

Output Amps* @ 120 VDC

* Output amperage is limited by the marker control board (P/N 38214) to 35 amperes.

Open Circuit Voltage

SECTION 2 DESCRIPTION

2.2.3 PT-24 Plasma Marker Torch Body, P/N 21758, Torch Handle, P/N 22568

Gas - Dual (Argon and Air)• AIr Cooled• Amperes, Variable -- 35 Amperes Maximum•

2.2.4 PT-24 Torch Lead Assembly

19 ft. (5.8 m)• .............................................................................................................................................................P/N 0560938411

25 ft. (7.6 m)• ............................................................................................................................................................ P/N 0560938412

32 ft. (9.8m)• ............................................................................................................................................................. P/N 0560938413

40 ft. (12.2 m)• .........................................................................................................................................................P/N 0560938414

50 ft. (15.2 m)• ..........................................................................................................................................................P/N 0560938415

2.2.5 Options

Remote Arc Starter, P/N 0558002819 (Required if torch lead to exceed 50 ft. (15.2 m))

SECTION 2 DESCRIPTION

2.2.6 Accessories

The following parts kits are available for maintaining the PT-24 torch with minimum downtime.

PT-24 Plasma Marker Starter / Repair Kit, P/N 0560943843 - Kit includes the following:

Part No. Qt y. Description

215 43 5 Nozzle, "D" Size

0558005309 2 Insulated Shield Assembly, One Piece

21692 2 Bae, Swirl 50/70/100 Amp 2153 9 5 Electrode, Oxygen 22007 2 Nozzle Retainer and Diuser 217 65 1 Tool, Nozzle and Electrode PT-24 217 25 1 Bae, Water

638797 2 O-Ring, Water Bae

86W62 2 O-Ring, Nozzle Retainer 1.239 ID

95 0714 2 O-Ring, Insulated Shield Assy 1.489 ID

98 W18 2 O-Ring, Electrode 0.364 ID

73585064 1 Dupont Kyrtox, 2 oz. Tube

77500101 1 Grease, Silicon Dow DC-111

0560942655 1 Plasma Marker Alignment Tool

215 40 5 Nozzle "A" Size 215 41 5 Nozzle "B" Size 21852 5 Bae, Swirl 15A 2153 6 5 Bae, Swirl 30A

SECTION 2 DESCRIPTION

SECTION 3 INSTALLATION

ELECTRIC SHOCK CAN KILL!

WARNING

CAUTION

3.1 Interface

The Precision Etch-Arc Marker system interfaces with any cutting machine controller via the standard ESP open interface. This interface provides an amphenol connector for linking the appropriate control wiring. The schematic below illustrates interfacing with an Precision Etch-Arc and ESAB Vision or ESAB Series 2000 CNC. The customer must provide the external requirements shown below when interfacing with a control other than these types.

ENSURE PRIMARY POWER SOURCE IS OFF AND DISCONNECTED BE FORE MAKING ANY ELECTRICAL CONNECTIONS. ONLY A QUALIFIED TECHNICIAN SHOULD INSTALL AND SERVICE THIS EQUIPMENT.

ENSURE YOUR PRECISION ETCHARC IS BEING SUPPLIED WITH THE AP PROPRIATE POWER. THIS EQUIPMENT COMES IN 208/230 VAC 1PHASE, 208/230 VAC 3PHASE, 460 VAC 3PHASE AND 575 VAC 3PHASE. CON NECTING TO INCORRECT POWER COULD DAMAGE YOUR MACHINE.

External

Requirements

Start signal (Close contacts to start arc)

Arc ON signal to CNC

Current control signal (Variable DC Voltage)

Vmax = 3.5 V Vmin = 0.3 V

ESP Interface

Plug (J2)

J2-N

J2-M

J2-I

J2-G

J2-L

J2-J

Precision Etch-Arc Power Supply

Start signal to power supply

Contact closes when arc starts

3.5 V = 35 A

0.3 V = 3.0 A

Voltage divider signal to voltage height control

ESP Interface

J2-C

J2-H

Work

20:1 Electrode

SECTION 3 INSTALLATION

3.2 Requirements

Electrical Input Requirements:

Rated primary input @ 35A / 120V output: 208/230VAC, 1 Phase 64/58A, 50/60 Hz. 208/230/400/575 VAC, 3 Phase 28/25/16/11A, 50/60 Hz.

A fused breaker (either on the cutting machine gantry or wall mounted) is required to disconnect power to the Precision Etch-Arc power supply. A machine mounted disconnect should be used when the power supply is mounted on the cutting machine.

Recommended sizes for input conductors and line fuses:

Rated Input Input & Gnd Fuse Size Conductor Volts Amps Phase CU/AWG Amps 208 64 1 No. 4 90 230 58 1 No. 4 90 208 28 3 No. 10 50 230 25 3 No. 10 40 400 16 3 No. 10 25 575 11 3 No. 10 20

Gas Supply Requirements:

Argon - 100 psi (1/4" NPT) 99.999% Pure

Service Air - 100 psi (1/4" NPT) Clean, dry, oil-free

SECTION 3 INSTALLATION

3.3 Connections to the Precision Etch-Arc

3.3.1 Rear Panel

Solenoid

Regulator/Filter

Shield Gas (Air)

Plasma Gas (Argon)

Primary Power

Tee

There are 3 input lines to connect to the power supply. These are made to the back of the unit.

Shield Gas • Plasma Gas • Primary power•

Shield Gas - Preltered (clean and dry) Air, customer supplied, 90 to 150 PSI max. 1/4" NPT

Plasma Gas - 99.999% purity, 100 PSI, 1/4" NPT

Primary Power - 208/230 VAC unit is supplied with a 3prong plug on a 10 ft. power cable when used as a single phase Precision Etch-Arc power supply. If used as a 3-phase unit, disassemble plug and discard. Un-tape red lead and connect. The Precision Etch-Arc 460 and 575 VAC power supplies are 3-phase and must be hard wired into the wall disconnect box.

3-prong plug used on the single phase 208/230 VAC Precision Etch-Arc

Red lead terminated and not used on the 1-phase Precision Etch-Arc

Inside the 3 prong plug

SECTION 3 INSTALLATION

3.3.2 Converting a 230 VAC power supply to 208 VAC

The Precision Etch-Arc is factory wired for 1-phase 230 volts AC. If using 208 VAC, the Precision Etch-Arc must be reconnected as follows before connecting to your input primary power.

D2 D1

TB3

Remove cover from the Precision Etch-Arc Power 1. Supply. Locate output bridge (D2) and TB3 on left side to-2. wards the front panel. Disconnect X2 and X3 leads from these two locations 3. and interchange wire connections. Move X2 from D2-3 to TB3.4. Move X3 lead that was on TB3 to D2-3.5.

Locate the input bridge (IBR) and TB5 terminal block 6. on the left side towards the rear panel. Disconnect gray lead from TB5-2 and reconnect to 7. TB5 -1.

TB5-1

TB5-2

Gray Lead

TB5-2 to TB5-1

SECTION 3 INSTALLATION

3.3.3 Torch Lead Connections, Front Panel

Torch Lead Bundle

Torch Lead Connections

The torch lead bundle consists of;

one hose for the plasma gas, one cable for the pilot arc current, and one combination gas hose and cable for the shield gas/plasma current. (The current conductor is inside the air conduit gas hose). The torch lead to torch connections are covered in section 3.4.

Pilot Arc Cable

Argon Hose (Cut Gas)

Coolant in (Air)

Shield Gas

Front End Connections

Remove the torch lead connection access 1. panel to connect coolant and pilot arc cable.

Torch Lead Connection Access Panel

SECTION 3 INSTALLATION

Pilot Arc Connection

Connect pilot arc cable and shield gas hose. (The 2. plasma arc connection is made when the coolant hose is threaded into the bulkhead tting.)

Coolant Gas

Connect plasma gas hose to the bulkhead. Re-3. place access panel.

Plasma Gas Connection (Argon)

Connect shield gas to the solenoid.4.

Shield Gas

SECTION 3 INSTALLATION

3.4 PT-24 Installation

Pilot Arc lead, connect to Shield Gas hookup.

Coolant Out

Shield Gas In (Air)

Cut Gas In (Argon Line)

Start Gas (not used)

Shield Gas

Coolant In

Coolant Crossover Tube

Start Gas

Cut Gas

Coolant Out

Note:

All itings have dierent threads to ensure correct connection on the torch end of the lead

SECTION 3 INSTALLATION

SECTION 4 OPERATION

EtchArc-1125

GAS

CURRENT CONTROL

35 MAX

ARGON

CNC

AIR

PRESSURE

(70 psig)

FAULT

POWER

TEST

OPERATE

WORK

TORCH

4.1 Precision Etch-Arc Setup

The Precision Etch-Arc control panel should be set properly before the marking operation. Check the following items:

FAULT - The Fault lamp should be o.

POWER - The Power On lamp should be on.

GAS TEST - Place this switch in the OPERATE position for normal operation. TEST position energizes the gas solenoids to allow presetting of the argon and air gases.

CURRENT CONTROL - The Current Control knob can be left in any position. This potentiometer is normally disconnected for remote current control. (Plasma Marking current is controlled by the cutting machine CNC.) If the control does not support remote current, the current control potentiometer can be reconnected. (see back of manual for wiring diagrams)

SECTION 4 OPERATION

4.2 Gas Setup

Test/Operate Switch

The plasma marking system uses two compressed gases for operation. Compressed air is used for elec-

trode cooling and shield gas, argon is used as plasAir Pressure Gauge

Air Pressure Regulator

ma gas. The plasma gas constricts the arc as it exits

through the nozzle orice. The shield gas creates a

secondary shield around the arc and improves torch

cooling. Before operating the system, check gas pres-

sure settings for both compressed gases.

Set the Test/Operate switch to the TEST po-1. sition to energize the solenoid valves for both compressed air and argon. Adjust the air pressure regulator on the rear 2. of the unit while observing the pressure gauge on the front of the unit. Set pressure to 90 PSI while the air is owing. The argon pressure is adjusted at the sepa-3. rate regulator panel mounted to the cutting machine. While the argon is owing, set the pressure to 75 psi. When nished adjusting gas pressures, set 4. the TEST/OPERATE switch back to the OPERATE position.

Argon Pressure Gauge

PLASMA MARKER GAUGE

Argon Pressure Regulator

SECTION 4 OPERATION

4.3 CNC Setup

The Precision Etch-Arc plasma marker may be interfaced to any cutting machine CNC. The following parameters may or may not be supported by your interface. Before plasma marking, check these parameters, or their equivalents, at the machine control:

Stando - On the Vision CNC, this parameter adjusts the actual cutting height (or arc voltage) the torch will maintain after the arc has started.

Initial Height - Sets the distance the torch will be raised after sensing the plate. When VHC is turned on, the torch will lower to the plate, then retract this distance before starting the arc.

Plasma Travel Delay - Sets the length of time the machine will remain motionless after the arc strikes. Set to zero for the plasma marking process.

Marker Remote Current - This parameter sets the marking current in amperes.

These parameters are preset when using SDP* marker les.*The Vision family of CNCs allows the user to store multiple process parameter les. The les, called SDP les (ScheidDatenPaket = Cutting data package), contain all the same information that can be manually adjusted on the process parameter screen. (See your programming manuals for more information)

4.4 Process Data

The Precision Etch-Arc can produce marked lines in a wide range of widths and depths. It can also operate over a wide range of speeds. The operator must balance these two factors based on the requirements for a specic job. The following pages provide process data for dierent amperage settings. Each page shows the setup parameters for that amperage and a chart with marking speed range. From the charts, the operator should select the speed setting based on the quality of mark that can be accepted.

SECTION 4 OPERATION

7 Amp Marking

CURRENT ...........................................................................................7 Amps

NOZZLE "A" .030" .............................................................. P/N 56996876

MATERIAL ......................................CARBON STEEL (unprimed plate)

PLASMA GAS .....................................................ARGON @ 90 PSI (6 bar)

SHIELD GAS ...............................................................AIR @ 90 PSI (6 bar)

COOLANT GAS .......................................................................60 psi (4 bar)

PIERCE HEIGHT ................................................................... .125" (3 mm)

ARC VOLTAGE ............................................................................................. 66

Electrode 2237857

Nozzle "A" 56996876

Shield Cup 0558005309

Travel

Speed

inch/min mm/min Width Depth

300 7620 .030" .0015" EXCELLENT

Notes

Corner current set for 5 Amps in machine MIP.1. Slow travel speeds usually have top spatter on mark edges.2. Width and depth of mark will vary slightly depending on measuring methods. 3. This information is for estimated results.4.

Plasma

Mark

Quality

SECTION 4 OPERATION

10 Amp Marking

CURRENT .........................................................................................10 Amps

NOZZLE "A" .030" .............................................................. P/N 56996876

MATERIAL ..............................CARBON STEEL (thinly primed plate)

PLASMA GAS .....................................................ARGON @ 90 PSI (6 bar)

SHIELD GAS ...............................................................AIR @ 90 PSI (6 bar)

COOLANT GAS .......................................................................60 psi (4 bar)

PIERCE HEIGHT ................................................................... .125" (3 mm)

ARC VOLTAGE ............................................................................................. 66

Electrode 2237857

Nozzle "A" 56996876

Shield Cup 0558005309

Travel

Speed

inch/min mm/min Width Depth

100 2540 .030" .010" EXCELLENT

Notes

Plasma

Mark

Quality

SECTION 4 OPERATION

15 Amp Marking

CURRENT .........................................................................................15 Amps

NOZZLE "A" .030" .............................................................. P/N 56996876

MATERIAL ..............................CARBON STEEL (heavy primed plate)

PLASMA GAS .....................................................ARGON @ 90 PSI (6 bar)

SHIELD GAS ...............................................................AIR @ 90 PSI (6 bar)

COOLANT GAS .......................................................................60 psi (4 bar)

PIERCE HEIGHT ................................................................... .125" (3 mm)

ARC VOLTAGE ............................................................................................. 66

Electrode 2237857

Nozzle "A" 56996876

Shield Cup 0558005309

Travel

Speed

inch/min mm/min Width Depth

100 2540 .030" .015" EXCELLENT

Notes

Plasma

Mark

Quality

SECTION 5 MAINTENANCE

5.1 Routine Maintenance

The Plasma Marking System consists of an Precision Etch-Arc plasma power supply, the marking torch and argon supply. The following routine maintenance should be performed on the plasma marker system.

ELECTRIC SHOCK CAN KILL OR INJURE!

WARNING

CAUTION

ENSURE THE WALL DISCONNECT SWITCH OR CIRCUIT BREAKER IS OPEN BEFORE REMOVING COVER OR DOING MAINTENANCE.

ELECTRIC SHOCK CAN KILL! ENSURE POWER SUPPLY POWER SWITCH IS OFF BEFORE SERVICING THE PM60 PRECISION ETCHARC TORCH.

COMPRESSED AIR MAY DISPLACE DEBRIS CAUSING EYE INJURIES. ALWAYS WEAR APPROVED SAFETY EYE AND FACE PROTECTION WHENEVER USING COMPRESSED AIR TO CLEAN EQUIPMENT. DUST AND DEBRIS CAN BE DEFLECTED BACK TOWARDS THE FACE, POSSIBLY RESULTING IN A SERIOUS EYE INJURY. ENSURE OTHERS NEARBY ARE PROTECTED ALSO.

CAUTION

WATER AND OIL CONTAMINANTS IN COMPRESSED AIR MAY DAMAGE POWER SUPPLY COMPONENTS. SHOP AIR OCCASIONALLY CONTAINS ACCUMULATED OIL OR WATER. BEFORE USING COMPRESSED SHOP AIR TO CLEAN THE INTERIOR OF THE POWER SUPPLY, REDIRECT THE FIRST AIR BLAST AWAY FROM POWER SUPPLY.

Inspect the supply hoses, torch leads, ground cable • and interface cables for damage or wear weekly. Inspect and clean the Precision Etch-Arc monthly. • The unit can be blown out using a clean, dry gas source, such as compressed air or nitrogen. Occasionally drain all water from beneath the air • lter-regulator.

SECTION 5 MAINTENANCE

5.2 Flow Switch

The Flow Switch (P/N 951202) may need to be cleaned

if excessive contamination is found in the air supply.

Note:

The ow switch can be disassembled and cleaned without extraction from the

power supply.

Turn O power supply.1. Remove piston plug.2. Remove the spring. Use care when handling 3. spring to prevent distortion. Remove the piston.4.

Flow Switch Location

Piston Plug

Clean all parts with warm water and a mild 5. detergent. Allow parts to dry thoroughly before reassembly. Reassemble switch in reverse order.6.

Spring

Piston

Flow Switch Body

SECTION 6 TROUBLESHOOTING

6.1 Troubleshooting Guide

ELECTRIC SHOCK CAN KILL! ENSURE THAT ALL PRIMARY POWER TO THE MACHINE HAS BEEN EX

WARNING

TERNALLY DISCONNECTED. OPEN THE LINE WALL DISCONNECT SWITCH OR CIRCUIT BREAKER BEFORE ATTEMPTING INSPECTION OR WORK INSIDE THE POWER SUPPLY.

HIGH VOLTAGES CAN CAUSE SERIOUS INJURY OR DEATH. VOLTAGE IN PLASMA EQUIPMENT IS HIGH ENOUGH TO CAUSE SERI OUS INJURY OR DEATH. BE PARTICULARLY CAUTIOUS WHEN AROUND EQUIPMENT WHEN COVERS ARE REMOVED.

Location of fuse (F1).

Power Light Does Not Come on.

A) Visually inspect the machine for damage.

B) Check if the cooling fan is running. If not, then check the following:

B1) Check if the machine power cord is plugged into the input power receptacle.

B2) Measure the input power at the receptacle. If not present, check the wall disconnect switch and related fuses.

B3) Check fuse (F1). If fuse is ok, check the input circuit breaker (CB1) for proper operation. Replace if defective.

C) If above items check OK, the problem is internal. Send unit to an Authorized Repair Station.

C1) If cooling fan is running, measure voltage between pins P2-11 and P2-14 of the control board. Voltage should be 115 VAC. If there is no voltage, then replace transformer T2.

C2) If voltage is present, the pilot light may be burned out.

SECTION 6 TROUBLESHOOTING

No air ow.

Check air inlet supply. Unit requires 320 • CFH at 65 psig. Check air hose connections.• Does air ow when “air test” switch is in • test position? If not, check torch consumables, replace if • necessary. If above items check OK, the problem is • internal. Take unit to an Authorized Repair Station.

Over Temperature.

The fault light will be illuminated for 1/10th of a second every second. This generally indicates that the • air ow has been blocked. Clear blockage and allow the power supply to cool before operating. Thermal switch may be open. It will open if the heat sink temperature reaches 80 degrees C. With the • machine power o, check the continuity between P1-1 and P1-2 of the control board. If the switch is OK, then the ohmmeter should read a direct short. If not, then it should read open. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing switch.•

Over current.

The fault light will be continuously illuminated. This indicates the input current to the main transformer • has exceeded preset limits. To check if the output is shorted, measure resistance by putting ohmmeter leads (ensure HI Freq leads • are disconnected) “+” of the meter to torch, “+” output terminal and work, “-“ lead of the meter to the “-“ output terminal. Reading should be about 2K OHMS. Reverse the voltmeter leads, the resistance reading should be less than 1.5 OHMS. Resistance reading is dierent than above, check torch, the output bridge and lter board (PCB5).•

Arc does not transfer to plate.

Make sure work clamp has a good connection to material to be marked. • Check consumables. Replace if necessary.•

SECTION 6 TROUBLESHOOTING

Poor marking performance

Check gas regulators. Should be set to 65 to 70 psig.• The air supply should be free of oil/water.• Check condition of consumables.• Check open circuit voltage.• With high frequency leads disconnected, measure open circuit voltage. • It should be 275 VDC between “Work” and “Torch” terminals.

If not then check one of the following:

Check operation of the Thermal Switch. (See Over Temperature)• Check Air Flow Switch for internal short. Should have Fault Light. Light blinking o for 1/10th second • every second indicates low air ow. Put the Gas Test Switch to TEST. Air should ow through torch. If not, then the ow switch may be stuck in the open position. To check if ow switch is open, put voltmeter leads between P1-12 and P1-1. It should read about 12 VDC. When ow switch closes, voltage drops to zero volts. Clean or replace ow switch. (see instructions in Section 5)

Gas does not shut o.

Check gas solenoids for operation.• Does gas ow when CNC cable is unplugged. If yes, repair torch. If no, send unit to an authorized repair • station for repair. Check voltage to solenoid coils. If present when start contact is disconnected, replace PCB1 (marker • board). If voltage is “0”, replace solenoid valve.

SECTION 6 TROUBLESHOOTING

Fault light activates when start contacts are closed.

The fault light is used to monitor conditions necessary for the safe operation of the Precision Etch-Arc. The fault light will glow amber under the following conditions and the unit will stop working:

High/Low Voltage. The fault light will rapidly blink on and o (5 times per • second). This indicates that the input voltage is outside the “+” or “-“ 15% safe operating range. Flow Fault. The fault light will be mostly on but will blink o for 1/10th of • a second every second. This indicates the gas ow is low.

Check gas pressure at the machine regulator. It should be adjusted to 65 psig. If no gas pressure, check 1. the gas at the supply point. Also check for obstructions in the gas hose. Gas ow may be blocked at the torch tip. Check torch consumables. Also check for any obstructions in 2. the torch leads. Note. If above items check OK, the problem is internal will have to be sent to an authorized

repair station.

Put the Gas Check switch to the on position. Gas should ow through the torch. If not, then the ow 3. switch may be stuck due to oil or dirt in the gas. Clean ow switch per instructions in the maintenance section or replace switch. To check if the ow switch is open, put a voltmeter leads between P1-12 and P1-1. It should read 12 VDC. When the switch closes, voltage will drop to “0”. Gas Test Switch may be malfunctioning.4.

Cut Gas Circuit Failure

The plasma gas circuit consists of a pressure switch and a solenoid. The pressure switch is a normally opened, non-adjustable switch. The switch closes when sucient pressure is applied. It comes preset to 15 psi.

SECTION 6 TROUBLESHOOTING

Gas is on but nothing happens when start contacts are closed.

Check the pilot arc fuse located on the rear panel. If open, re-1. place. Check to ensure high frequency is present at the torch. If not, 2. then listen for high frequency at the high frequency generator. It is located on the bottom/right side of the unit. The high frequency gap is set at 0.030 inches. Disconnect HI Frequency leads. Check for 115 supply voltage between P2-12 and P2-13 of the control board. With high frequency leads disconnected, measure open circuit 3. voltage. It should be 275 VDC between “work” and Torch terminals. If not present, then any one of the following may not be working properly: Check for operation of the thermal switch. (see Over Tempera-• ture) Check Gas Check switch operation. It might be stuck in the ON • position. Pilot arc will not initiate if the switch is in the ON position.

Check Gas ow Switch. There may be an internal short. Measure voltage across C1 and C2 capacitors. It •

should be as follows:

approximately 294 VDC with a 208v unit.• approximately 325 VDC with a 230v unit.• approximately 325 VDC with a 460v unit.• approximately 400 VDC with a 575v unit.•

If readings are not correct then one of the following could be malfunctioning.

Check capacitors C1 and C2 for damage.• Check input bridge/SCR Module (IBR). Replace if malfunctioning.• Check Inrush Current Resistor, R10 and SCR1. Both are located on the input bridge heat sink. Replace if • necessary. Check current output. Use a calibrated current probe capable of measuring 100 amps in the presence • of high frequency.

Main arc is dicult to start

Worn or missing consumables. Check and replace if necessary.• Input gas (argon or air) must be clean and dry.• Input air pressure is between 65 and 75 psig.• Torch connections must be tight.• Work cable or clamp must make a good electrical connection to the material to be marked.• Initial height is too far from plate. (see process data for recommended distances)• Pilot arc is missing or weak.• Check spark gap.• Check pilot arc fuse.•

NOTE:

SECTION 6 TROUBLESHOOTING

Auxiliary Solenoid/Shield Gas Failure

For solenoid/shield gas connections and troubleshooting refer to the wiring diagram below.

NOTE:

Schematics and Wiring Diagrams on 11” x 17”

paper are included

inside the back cover of this manual.

SECTION 7 REPLACEMENT PARTS

7.1 General

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

7.2 Ordering

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

Replacement parts may be ordered from your ESAB Distributor.

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

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

Note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

SECTION 7 REPLACEMENT PARTS

7.3 Precision Etch-Arc -- Front and Rear View all models

Item No Qty Part Number Description Circuit Symbol

1 1 23602576 Strain Relief 2 Reference Bulkhead Connector (See Argon Circuit) 3 1 6271128 Conn Box Recpt 14 MP Shell 20 CNC Plug 5 1 21711 Gauge -- 1.50" dia – 160 PSI -- white 6 1 13730611 Knob 1 0558001176 POT. 10K 2W R1 (Nomex insulation—676876) 7 1 951474 Switch Seal 1 634518 Switch Toggle DPDT 2 Pos 15A 125V S2 8 1 993426 Rubber Grommet 1.50" x 1.76" O.D. 9 2 951575 Handle 10 1 21710 Filter Regulator 1 10Z30 Adapter, B/A—WM x ¼" NPTM 11 1 952559 Fuse, 3A Fast Acting F1 12 1 36107 Switch, Power 600 V 63A

SECTION 7 REPLACEMENT PARTS

7.4 Precision Etch-Arc Inside Right View –208/230v P/N 0588000967

Item No Qty Part Number Description Circuit Symbol

1 1 31488 Shunt Board Assembly PCB4 1 951515 Capacitor, 0.047uf, 660 VAC C23 2 1 37603 Main Transformer Assembly T1 3 2 17300012 Resistor, 300W 12 ohm R11, R12 4 1 952232 Inductor, PFC L2 5 1 35940 XFMR Assembly Control T2 6 1 950487 Term. Block, 2 pos, 20A TB1 7 1 0558001245 Wire Kit T3 8 1 0558001180 Spark Gap Assembly SG 9 1 37699 Reactor Assembly, HI Freq 10 4 182W12 Rubber Foot

SECTION 7 REPLACEMENT PARTS

7.5 Precision Etch-Arc Inside Left View –208/230v- P/N 0588000967

SECTION 7 REPLACEMENT PARTS

Item No Qty Part Number Description Circuit Symbol

1 1 36822 Hose Assembly, B/A x ¼" NPT Rub 2 2 951940 Capacitor, 1uf, 630W VDC C15, C16 3 2 0558001177 PCB Assembly, 1GBT Driver Board PCB2, PCB3 4 2 952237 Capacitor, 1800uf, 450 VDC C1, C2 5 .75 ft. 90858003 Plastic Tubing, 0.250" o.d. x 0.04" w Blk (9”) 6 1 952002 Core, Saturable L3 7 2 951185 Bridge, 100ADC, 100NS, 600v D1, D2 (includes Pad – 951516) 8 4 17721020 Resistor, WWFAHT, 25W, 1%, 20 ohms NI R2,3,4,5 4 951313 Capacitor, Pulse, 0.01uf, 1KV C5,6,7,8 9 1 952255 Capacitor, 40uf, 400 VDC C4 10 1 950711 Thermal Switch, 195 degrees F TS1 11 1 17750010 Resistor, WW, 50W, 3%, 10 ohm R7 12 1 17250010 Resistor, WW, 50W, Fixed, 10 ohm R10 13 2 952873 Module, Dual IGBT, 200A, 600V Q1, Q2 14 1 952871 Module, Input Bridge/SCR 100A, 1600V IBR

SECTION 7 REPLACEMENT PARTS

7.6 Precision Etch-Arc Inside Top View (cover removed) –208/230v -- P/N 0588000967

Item No Qty Part Number Description Circuit Symbol

1 1 38214 Marker Control Board PCB1 2 2 0588000980 PC Board, Start Up PCB5 3 1 Reference Pressure Gauge

SECTION 7 REPLACEMENT PARTS

7.7 Precision Etch-Arc Inside Top View Cross Section 1 –208/230v -- P/N 0588000967

Item No Qty Part Number Description Circuit Symbol

1 1 951182 Fan, AC Axial, M1 2 2 17240310 Resistor, 10K, 25W R2, R15 3 1 952233 Inductor, Output L1

SECTION 7 REPLACEMENT PARTS

7.8 Precision Etch-Arc Inside Top View Cross Section 2–208/230v -- P/N 0588000967

Item No Qty Part Number Description Circuit Symbol

4 1 673458 Contactor, 3 Pole, 110VAC, 40A K1 5 1 0558001180 Spark Gap Assembly SG 6 1 951202 Switch, Flow, .25 GPN SPST FS 7 1 950249 Valve, Solenoid, ¼" NPT. 165 PS1, 24VAC SOL1 8 1 952026 Terminal Block, 7 pos, 25A, 12-18 ga, TB4

SECTION 7 REPLACEMENT PARTS

7.9 Precision Etch-Arc Inside Right View – 460v P/N 0588000949 & 575v P/N 0588000966

Item No Qty Part Number Description Circuit Symbol

1 1 31488 Shunt Board Assembly PCB4 1 951515 Capacitor, 0.047uf, 660 VAC C23 2 1 37603 Main Transformer Assembly T1 3 2 17300012 Resistor, 300W 12 ohm R11, R12 4 1 673458 Contactor, 3 pole, 110VAC, 40A K1 5 1 35940 XFMR Assembly Control T2

6 1 950487 Term. Block, 2 pos, 20A TB1 7 1 0558001245 Wire Kit T3 8 1 0558001180 Spark Gap Assembly SG 9 1 37699 Reactor Assembly, HI Freq 10 4 182W12 Rubber Foot

SECTION 7 REPLACEMENT PARTS

7.10 Precision Etch-Arc Inside Left View –460v P/N 0588000949 & 575v P/N 0588000966

SECTION 7 REPLACEMENT PARTS

Item No Qty Part Number Description Circuit Symbol

1 1 36822 Hose Assembly, B/A x ¼" NPT Rub 2 2 951940 Capacitor, 1uf, 630W VDC C15,C16 3 2 0558001197 PCB Assembly, 1GBT Driver Board PCB2 4(460V) 2 952237 Capacitor, 1800uf, 450 VDC C1, C2 (460v unit only) 4(575V) 2 952562 Capacitor, 1800uf, 500 VDC C1, C2 (575v unit only) 5 .75 ft. 90858003 Plastic Tubing,

0.250" o.d. x 0.04" w Blk (9”) 6(460v) 1 952872 Module, Dual IGBT, 200A, 1200v Q1 (460v unit) 6(575v) 1 951831 Module, Dual IGBT, 200A, 1400v Q1 (575v unit) 7 1 952002 Core, Saturable L3 8 2 51185 Bridge, 100ADC, 100NS, 600v D1, D2 (includes Pad – 951516) 9 4 17721020 Resistor, WWFAHT, 25W, 1%, 20 ohms NI R2,3,4,5 4 951313 Capacitor, Pulse, 0.01uf, 1KV C5,6,7,8 10(460v) 1 952255 Capacitor, 40uf, 400 VDC (460v unit only) C4 10(575v) 1 952585 Capacitor, 20uf, 600 VDC (575v unit only) C4 11 1 32958 XFMR Assembly, Current T4 12 1 17750010 Resistor, WW, 50W, 3%, 10 ohm R7 13 1 17250010 Resistor, WW, 50W, Fixed, 10 ohm R10 14 1 952235 Module, Input Bridge/SCR 75A, 1600V IBR 15 1 950711 Thermal Switch, 195 degrees F TS1

SECTION 7 REPLACEMENT PARTS

7.11 Precision Etch-Arc Inside Top View – 460v P/N 0588000949 & 575v P/N 0588000966

Item No Qty Part Number Description Circuit Symbol

1 1 38214 Marker Control Board PCB1 2 2 0588000980 PC Board, Start Up PCB5 3 1 Reference Pressure Gauge

SECTION 7 REPLACEMENT PARTS

7.12 Precision Etch-Arc Inside Top View Cross 1 – 460v P/N 0588000949 & 575v P/N 0588000966

Item No Qty Part Number Description Circuit Symbol

1 1 951182 Fan, AC Axial, M1 2 2 17240310 Resistor, 10K, 25W R2, R15 3 1 952233 Inductor, Output L1

SECTION 7 REPLACEMENT PARTS

7.13 Precision Etch-Arc Inside Top View Cross 2 – 460v P/N 0588000949 & 575v P/N 0588000966

Item No Qty Part Number Description Circuit Symbol

4 1 37565 Wire Kit, Primary (460v unit only) 1 37566 Wire Kit, Primary (575v unit only) 5 1 0558001245 Wire Kit, Primary 6 1 0558001180 Spark Gap Assembly SG 7 1 951202 Switch, Flow, .25 GPN SPST FS 8 1 950249 Valve, Solenoid, ¼" NPT. 165 PS1, 24VAC SOL1 9 1 952026 Terminal Block, 7 pos, 25A, 12-18 ga, TB4

SECTION 7 REPLACEMENT PARTS

7.14 Argon Gas Circuit (cut gas)

Item No Qty Part Number Description Circuit Symbol

1 1 952920 Pressure Switch, 50 psi, non-adjustable PS

1 67101075 Reducer (1/4" to 1/8")

2 1 68161103 T-Connector, 1/4" NPT

3 1 10" Male to Male Hose Assembly

4 2 58V75 Bulkhead Connector, B,F,LH to 1/4" NPTM

5 Reference Bulkhead

6 1 950249 Valve, Solenoid, 2 way, NC, 24V SOL2

7 1 15" Male to Female Hose Assembly

8 1 951213 NPL, Hex, 1/4" NPTF

SECTION 7 REPLACEMENT PARTS

7.15 Auxiliary Solenoid Parts

8 7

Item No Qty Part Number Description Circuit Symbol

1 1 21711 Gauge 1.5" 160 PSI max 2 1 950249 Solenoid Valve 2-way 24 VAC 3 1 21710 Regulator Filter Air 4 1 2135688 Nipple 1/4 NPTM - 1/4 NPTM 5 1 182W82 Elbow Street 90 1/4 NPT 6 1 0560938441 Plate Mounting AUX Solenoid 7 2 2064005 Nipple 5/16 Hose B 8 2 36Z40 Nut B Air/Water 9 5" 9085806 Hose 5/16 ID Clear 10 1 461107 Tee Street 1/4 NPT 11 1 810Z30 Adapt B/A-W X M 1/4 NPTM old 12 2 Crimp 5/16 ID Hose

SECTION 7 REPLACEMENT PARTS

7.16 PT-24 Marking Torch

3 4

SECTION 7 REPLACEMENT PARTS

Item

Number

1 2

3 4 5 6 7 8 9 10 11 12 13 15 17 19 20

21 22 23 24

Part Number Description

21758 22568 0558004612 22381 22380 22382 See Process Data See Process Data 22007 22010 21712 21539 22531 0558002340 21765 77500101 (NOT SHOWN) 996565 0558002510 0558002511 0558002512 21739 21740 21741 73585064 (NOT SHOWN) 73585065 (NOT SHOWN) 05609943843

Body & Tube Assembly PT-24 Torch Sleeve, Torch PT-24 Sleeve, Torch PT-24 EXT Gas Line Start Blue Gas Line Cut Yellow Gas Line Shield Orange/Red Swirl Bae (See Process Data) Nozzle (see Process Data) Retainer/Diuser Insulator Shield Cup Insulator Shield Retainer Electrode 250 AMP Cup Shield w/Retainer Torch Ar Gas Manifold PT24 IFC Tool Electrode & Nozzle LUB Grease DOW DC-111 Clamp, Hose PT-24 Cable Bundle Assembly 4.5 Ft. PT-24 Cable Bundle Assembly 12 Ft. PT-24 Cable Bundle Assembly 17 Ft. Check Valve Body Ball Spring Dupont Krytox 2 oz tube Dupont Krytox 8 oz tube PT-24 Plasma Marker Start-Up / Repair Kit

SECTION 7 REPLACEMENT PARTS

7.17 Torch Bundles and Other System Parts

131214

SECTION 7 REPLACEMENT PARTS

Item No Qty Part Number Description

1 Ref. Reference CNC or Relay Box 2 Ref. 57002248 Control Cable Assembly, 30 ft. (9.1m) Ref. 57002219 Control Cable Assembly, 50 ft. (15.2m) Ref. 57002250 Control Cable Assembly, 75 ft. (22.9m) Ref. 57002251 Control Cable Assembly, 90 ft. (27.4m) Ref. 57002252 Control Cable Assembly, 160 ft. (48.8m) 3 Reference Argon Hose to Torch (component of No. 5) 4 93020601 Ground Wire, 6 AWG, Black 5 0560938411 19 ft. (5.8 m), PT-24 Torch Lead Assembly 0560938412 25 ft. (7.6 m), PT-24 Torch Lead Assembly 0560938413 32 ft. (9.8m), PT-24 Torch Lead Assembly 0560938414 40 ft. (12.2 m), PT-24 Torch Lead Assembly 0560938415 50 ft. (15.2 m), PT-24 Torch Lead Assembly

7 Reference Work Piece and Cutting Table 8 Reference Earth Ground 9 21710 Air Filter/Regulator, 5 micron, 7 to 120 psig, with bowl guard 10 2238370 Air Hose Assembly, B-A/W, 40 ft. (12.2m) 2238371 Air Hose Assembly, B-A/W, 50 ft. (15.2m) 2238372 Air Hose Assembly, B-A/W, 60 ft. (18.3m) 2238348 Air Hose Assembly, B-A/W, 70 ft. (21.3m) 2238349 Air Hose Assembly, B-A/W, 80 ft. (24.4m) 2238373 Air Hose Assembly, B-A/W, 90 ft. (27.4m) 11 33132 Argon Hose Assembly, B-A/W x B-A/W, 25 ft. (7.6m) 33133 Argon Hose Assembly, B-A/W x B-A/W, 50 ft. (15.2m) 12 Reference Primary Power Cable 13 999134 Argon Supply Regulator 14 Reference Air supply 15 Reference Fused Disconnect, used only when Precision Etch-Arc is mounted on machine 16 Reference Wall Disconnect, Customer Supplied.

NOTES

REVISION HISTORY

1. Original release of this manual: 12/2004.

2. Revision 01/2007 - added ® to front cover title.

3. Revision 03/2007 - Changed p/n frm: 38214 to: 38214 throughout manual.

4. 02/2009 - Updated contents of start-up kit and several illustrations of torch and shield cup per Drew Park inputs.

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM EST

visit us on the web at http://www.esabna.com

The ESAB web site oers

Comprehensive Product Information

Material Safety Data Sheets

Warranty Registration

Instruction Literature Download Library

Distributor Locator

Global Company Information

Press Releases

Customer Feedback & Support

0558004910 02 / 2009

ESAB Precision Etch-Arc Plasma Marking System Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual