Installation, Operation and Maintenance Manual for the
PRECISION PLASMARC SYSTEM
with Electronic Flow Control
CUTTING SYSTEMS
411 s. Ebenezer Road
Florence, SC 29501-0545
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold by ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total customer
This manual is ESAB Part Number F15679
ESAB Cutting Systems first priority is total customer
ESAB Cutting Systems first priority is total customer ESAB Cutting Systems first priority is total customer
satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to
improve our products, service and documentation.
improve our products, service and documentation.
improve our products, service and documentation. improve our products, service and documentation.
As a result, we make e
As a result, we make ennnnhancements and/or de
As a result, we make eAs a result, we make e
changes as r
changes as reeeequired. ESAB makes every possible
changes as rchanges as r
effort to ensure our documentation is current. We
effort to ensure our documentation is current. We
effort to ensure our documentation is current. We effort to ensure our documentation is current. We
cannot guarantee that each piece of docume
cannot guarantee that each piece of documennnntation
cannot guarantee that each piece of documecannot guarantee that each piece of docume
received by our customers reflects the latest design
received by our customers reflects the latest design
received by our customers reflects the latest design received by our customers reflects the latest design
enhancements. Therefore, the information
enhancements. Therefore, the information
enhancements. Therefore, the information enhancements. Therefore, the information
contain
contained in this document is subject to change
containcontain
without n
without nooootice.
without nwithout n
This manual is ESAB Part Number F15679
This manual is ESAB Part Number F15679This manual is ESAB Part Number F15679
New Date (April,01) given to reflect added cable
part Nos. section 2.
(June01) reflects document formatting changes
(Dec01) Corrected/clarified p7-35 part nos.
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
ed in this document is subject to change
ed in this document is subject to change ed in this document is subject to change
quired. ESAB makes every possible
quired. ESAB makes every possible quired. ESAB makes every possible
The process of cutting metals with plasma equipment
1.2 Safety Notations And Symbols
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. With any machine
tool, sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or as an
observer, compliance with established precautions
and safe practices must be accomplished. Failure to
observe certain precautions could result in serious
personnel injury or severe equipment damage. The
following precautions are general guidelines applicable
when working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature. For
a wide scope of safety information on the field of
cutting and welding apparatus, obtain and read the
publications listed in the Recommended References.
The following words and symbols are used throughout
this manual. They indicate different levels of required
safety involvement.
ALERT or ATTENTION. Your safety is involved
!
DANGER
!
WARNING
!
CAUTION
!
CAUTION
NOTICE
or potential equipment failure exists. Used in
concurrence with other symbols and information.
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
Used to call attention to potential hazards
that could result in personal injury or loss of
life.
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
Used to call attention to minor hazards to
equipment.
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.
Precision Plasma with Electronic Flow Control – 1-1
SECTION 1 SAFETY
1.3 General Safety Information
WARNING
!
Machine starts automatically.
This equipment moves in various directions and
This equipment moves in various directions and
This equipment moves in various directions and This equipment moves in various directions and
speeds.
speeds.
speeds.speeds.
• Moving machinery can crush.
Moving machinery can crush.
Moving machinery can crush.Moving machinery can crush.
• Only qualified personnel should operate or service
Only qualified personnel should operate or service
Only qualified personnel should operate or service Only qualified personnel should operate or service
equipment.
equipment.
equipment.equipment.
• Keep all personnel, materials, and equipment not
Keep all personnel, materials, and equipment not
Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not
involved in production process
involved in production process clear of entire
involved in production process involved in production process
system area.
system area.
system area.system area.
• Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or Keep gear racks and rails clear of debris or
obstructions, such as tools or clothing.
obstructions, such as tools or clothing.
obstructions, such as tools or clothing.obstructions, such as tools or clothing.
• Fence off entire work cell to prevent personnel
Fence off entire work cell to prevent personnel
Fence off entire work cell to prevent personnel Fence off entire work cell to prevent personnel
from passing through area or standing in the
from passing through area or standing in the
from passing through area or standing in the from passing through area or standing in the
working envelope of the equipment.
working envelope of the equipment.
working envelope of the equipment. working envelope of the equipment.
• Post approp
Post appropriate WARNING signs at every work
Post appropPost approp
cell entrance.
cell entrance.
cell entrance. cell entrance.
riate WARNING signs at every work
riate WARNING signs at every work riate WARNING signs at every work
clear of entire
clear of entire clear of entire
• Follow lockout procedure before servicing.
Follow lockout procedure before servicing.
Follow lockout procedure before servicing.Follow lockout procedure before servicing.
Failure to follow operating instructions
WARNING
!
could result in death or serious injury.
Read and understand this operator’
Read and understand this operator’s manual before
Read and understand this operator’Read and understand this operator’
using machine.
using machine.
using machine.using machine.
• Read entire procedure before operating or
Read entire procedure before operating or
Read entire procedure before operating or Read entire procedure before operating or
performing any system maintenance.
performing any system maintenance.
performing any system maintenance. performing any system maintenance.
• Special attention must be given to all hazard
Special attention must be given to all hazard
Special attention must be given to all hazard Special attention must be given to all hazard
warnings that provide essential information
warnings that provide essential information
warnings that provide essential information warnings that provide essential information
regarding personnel safety and/or possible
regarding personnel safety and/or possible
regarding personnel safety and/or possible regarding personnel safety and/or possible
equipment dama
equipment damage.
equipment damaequipment dama
• All safety precautions relevant to electrical
All safety precautions relevant to electrical
All safety precautions relevant to electrical All safety precautions relevant to electrical
equipment and process operations must be
equipment and process operations must be
equipment and process operations must be equipment and process operations must be
strictly observed by all having system
strictly observed by all having system
strictly observed by all having system strictly observed by all having system
responsibility or access.
responsibility or access.
responsibility or access. responsibility or access.
• Read all safety publications made available by
Read all safety publications made available by
Read all safety publications made available by Read all safety publications made available by
your company.
your company.
your company.your company.
ge.
ge.ge.
s manual before
s manual before s manual before
Precision Plasma with Electronic Flow Control – 1-2
SECTION 1 SAFETY
Failure to follow safety warning label
WARNING
!
1.4 Installation Precautions
instructions could result in death or
serious injury.
Read and understand all safety warning labels on
Read and understand all safety warning labels on
Read and understand all safety warning labels on Read and understand all safety warning labels on
machine.
machine.
machine.machine.
Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety
information.
information.
information.information.
WARNING
!
Improperly installed equipment can cause
injury or death.
Follow these guidelines while installing
Follow these guidelines while installing machine:
Follow these guidelines while installingFollow these guidelines while installing
Do not connect a cylinder directly to machine inlet. An
Do not connect a cylinder directly to machine inlet. An
Do not connect a cylinder directly to machine inlet. An Do not connect a cylinder directly to machine inlet. An
appropriate cylinder regulator must be installed on a
appropriate cylinder regulator must be installed on a
appropriate cylinder regulator must be installed on a appropriate cylinder regulator must be installed on a
fuel gas cylinder to reduce pressure to a reasonable
fuel gas cylinder to reduce pressure to a reasonable
fuel gas cylinder to reduce pressure to a reasonable fuel gas cylinder to reduce pressure to a reasonable
inlet supply pressure. Machine regulator is then used
inlet supply pressure. Machine regulator is then used
inlet supply pressure. Machine regulator is then used inlet supply pressure. Machine regulator is then used
to obtain pressure required
to obtain pressure required by torches.
to obtain pressure requiredto obtain pressure required
Contact your ESAB representative before installation.
Contact your ESAB representative before installation.
Contact your ESAB representative before installation. Contact your ESAB representative before installation.
He can suggest certain precautions regarding piping
He can suggest certain precautions regarding piping
He can suggest certain precautions regarding piping He can suggest certain precautions regarding piping
installation and machine lifting, etc. to ensure
installation and machine lifting, etc. to ensure
installation and machine lifting, etc. to ensure installation and machine lifting, etc. to ensure
maximum security.
maximum security.
maximum security.maximum security.
Never attempt any machine modifications or apparatus
Never attempt any machine modifications or apparatus
Never attempt any machine modifications or apparatus Never attempt any machine modifications or apparatus
additions withou
additions without first consulting a qualified ESAB
additions withouadditions withou
representative.
representative.
representative.representative.
Observe machine clearance requirements for proper
Observe machine clearance requirements for proper
Observe machine clearance requirements for proper Observe machine clearance requirements for proper
operation and personnel safety.
operation and personnel safety.
operation and personnel safety. operation and personnel safety.
t first consulting a qualified ESAB
t first consulting a qualified ESAB t first consulting a qualified ESAB
by torches.
by torches. by torches.
machine:
machine: machine:
Precision Plasma with Electronic Flow Control – 1-3
SECTION 1 SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to this manual’s
Installation section for detailed grounding instructions.
Electric shock hazard.
WARNING
!
Impr
Improper grounding can cause severe injury or death.
oper grounding can cause severe injury or death.
ImprImpr
oper grounding can cause severe injury or death.oper grounding can cause severe injury or death.
WARNING
!
Machine must be properly grounded before put into
Machine must be properly grounded before put into
Machine must be properly grounded before put into Machine must be properly grounded before put into
service.
service.
service.service.
Improper grounding can damage machine
and electrical components.
• Machine must be properly grounded before put
Machine must be properly grounded before put
Machine must be properly grounded before put Machine must be properly grounded before put
into service.
into service.
into service. into service.
• Cutting table must be properly grounded to
Cutting table must be properly grounded to a good
Cutting table must be properly grounded toCutting table must be properly grounded to
Earth ground rod.
Earth ground rod.
Earth ground rod.Earth ground rod.
a good
a good a good
1.6 Operating A Plasma Cutting Machine
WARNING
!
WARNING
!
Flying debris and loud noise hazards.
• Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear
goggles to protect eyes
goggles to protect eyes from burns and flying
goggles to protect eyesgoggles to protect eyes
debris generated during operation.
debris generated during operation.
debris generated during operation.debris generated during operation.
• Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders Chipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.
should also wear goggles and safety glasses.
should also wear goggles and safety glasses.should also wear goggles and safety glasses.
• From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear From plasma arc can damage hearing. Wear
correct ear protection when cutting above water.
correct ear protection when cutting above water.
correct ear protection when cutting above water. correct ear protection when cutting above water.
from burns and flying
from burns and flying from burns and flying
Burn hazard.
Hot metal can burn.
Hot metal can burn.
Hot metal can burn.Hot metal can burn.
• Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after
cutting. Allow metal time
cutting. Allow metal time to cool, or douse with
cutting. Allow metal timecutting. Allow metal time
water.
water.
water.water.
• Do not touch plasma torch immediately after
Do not touch plasma torch immediately after
Do not touch plasma torch immediately after Do not touch plasma torch immediately after
cutting. Allow torch time to cool.
cutting. Allow torch time to cool.
cutting. Allow torch time to cool.cutting. Allow torch time to cool.
to cool, or douse with
to cool, or douse with to cool, or douse with
Precision Plasma with Electronic Flow Control – 1-4
SECTION 1 SAFETY
WARNING
!
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.
connections during plasma cutting process.
connections during plasma cutting process.connections during plasma cutting process.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
before touching or servicing plasma torch.
before touching or servicing plasma torch.
before touching or servicing plasma torch. before touching or servicing plasma torch.
• Always turn po
Always turn power off to plasma power supplies
Always turn poAlways turn po
before opening or servicing plasma plumbing or
before opening or servicing plasma plumbing or
before opening or servicing plasma plumbing or before opening or servicing plasma plumbing or
flow control box.
flow control box.
flow control box.flow control box.
• Do not touch live electrical parts.
Do not touch live electrical parts.
Do not touch live electrical parts.Do not touch live electrical parts.
• Keep all panels and covers in place when machine
Keep all panels and covers in place when machine
Keep all panels and covers in place when machine Keep all panels and covers in place when machine
is connected to power source.
is connected to power source.
is connected to power source.is connected to power source.
• Insulate yourself from workpiece and electr
Insulate yourself from workpiece and electrical
Insulate yourself from workpiece and electrInsulate yourself from workpiece and electr
ground: wear insulating gloves, shoes and
ground: wear insulating gloves, shoes and
ground: wear insulating gloves, shoes and ground: wear insulating gloves, shoes and
clothing.
clothing.
clothing.clothing.
• Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and
equipment dry.
equipment dry.
equipment dry.equipment dry.
WARNING
!
Pinch hazard.
wer off to plasma power supplies
wer off to plasma power supplies wer off to plasma power supplies
ical
ical ical
Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.
Fume hazard.
WARNING
!
Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
process can be hazardous to your health.
process can be hazardous to your health.process can be hazardous to your health.
• Do NOT breathe fumes.
Do NOT breathe fumes.
Do NOT breathe fumes.Do NOT breathe fumes.
• Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal
system operating properly.
system operating properly.
system operating properly. system operating properly.
• Use additional ventilat
Use additional ventilation to remove fumes if
Use additional ventilatUse additional ventilat
necessary.
necessary.
necessary.necessary.
• Use approved respirator if ventilation is not
Use approved respirator if ventilation is not
Use approved respirator if ventilation is not Use approved respirator if ventilation is not
adequate.
adequate.
adequate.adequate.
ion to remove fumes if
ion to remove fumes if ion to remove fumes if
Precision Plasma with Electronic Flow Control – 1-5
SECTION 1 SAFETY
WARNING
Radiation hazard.
!
Arc rays can injure eyes and burn skin.
Arc rays can injure eyes and burn skin.
Arc rays can injure eyes and burn skin.Arc rays can injure eyes and burn skin.
• Wear correct eye and body protection.
Wear correct eye and body protection.
Wear correct eye and body protection.Wear correct eye and body protection.
• Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side
shields. Refer to following chart for recommended
shields. Refer to following chart for recommended
shields. Refer to following chart for recommended shields. Refer to following chart for recommended
lens shades for plasma cutting:
lens shades for plasma cutting:
lens shades for plasma cutting:lens shades for plasma cutting:
Arc Current
Arc Current Lens Shade
Arc CurrentArc Current
Up
Up to 100 Amps
to 100 Amps Shade No. 8
Up Up
to 100 Ampsto 100 Amps
100
100----200 Amps
200 Amps Shade No. 10
100100
200 Amps200 Amps
200
200----400 Amps
400 Amps Shade No. 12
200200
400 Amps400 Amps
Over 400 Amps
Over 400 Amps Shade No. 14
Over 400 AmpsOver 400 Amps
• Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or
broken
broken
brokenbroken
• Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses
Mishandling gas cylinders can rupture and violently
Mishandling gas cylinders can rupture and violently
Mishandling gas cylinders can rupture and violently Mishandling gas cylinders can rupture and violently
release gas.
release gas.
release gas. release gas.
• Avoid rough handling of cylinders.
Avoid rough handling of cylinders.
Avoid rough handling of cylinders.Avoid rough handling of cylinders.
• Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.
• Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.
• Always secure cylinders in an upright position by
Always secure cylinders in an upright position by
Always secure cylinders in an upright position by Always secure cylinders in an upright position by
chain or strap to a suitable stable object not part of
chain or strap to a suitable stable object not part of
chain or strap to a suitable stable object not part of chain or strap to a suitable stable object not part of
an electrical circuit.
an electrical circuit.
an electrical circuit.an electrical circuit.
• Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.
• Refer to CGA Standard P
Refer to CGA Standard P----1, “Precautions for Safe
Refer to CGA Standard PRefer to CGA Standard P
Handling of Compressed Gases in Cylinders
Handling of Compressed Gases in Cylinders”,
Handling of Compressed Gases in CylindersHandling of Compressed Gases in Cylinders
available from Compressed Gas Association.
available from Compressed Gas Association.
available from Compressed Gas Association.available from Compressed Gas Association.
1, “Precautions for Safe
1, “Precautions for Safe 1, “Precautions for Safe
”,
”, ”,
Precision Plasma with Electronic Flow Control – 1-6
SECTION 1 SAFETY
WARNING
!
CAUTION
Spark hazard.
Heat, spatter, and sparks cause fire a
Heat, spatter, and sparks cause fire and burns.
Heat, spatter, and sparks cause fire aHeat, spatter, and sparks cause fire a
• Do not cut near combustible material.
Do not cut near combustible material.
Do not cut near combustible material.Do not cut near combustible material.
• Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.
• Do not have on your person any combustibles (e.g.
Do not have on your person any combustibles (e.g.
Do not have on your person any combustibles (e.g. Do not have on your person any combustibles (e.g.
butane lighter).
butane lighter).
butane lighter).butane lighter).
• Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activati
away from yourself and others when activating
away from yourself and others when activatiaway from yourself and others when activati
plasma process.
plasma process.
plasma process.plasma process.
• Wear correct eye and body protection.
Wear correct eye and body protection.
Wear correct eye and body protection.Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.
• Wear flame
Wear flame----retardant clothing that covers all
Wear flameWear flame
exposed areas.
exposed areas.
exposed areas.exposed areas.
• Wear cuffless trousers to prevent entry of sparks
Wear cuffless trousers to prevent entry of sparks
Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks
and slag.
and slag.
and slag.and slag.
retardant clothing that covers all
retardant clothing that covers all retardant clothing that covers all
nd burns.
nd burns. nd burns.
ng
ng ng
POOR PERFORMANCE WILL RESULT
WHEN CUTTING ABOVE WATER.
The PT-24 is designed to be a dry cutting
process.
Cutting above water may result in:
Cutting above water may result in:
Cutting above water may result in: Cutting above water may result in:
• reduced consumable life
reduced consumable life
reduced consumable lifereduced consumable life
• degradation of cut quality
degradation of cut quality
degradation of cut qualitydegradation of cut quality
Cutting above water may result in poor cutting
Cutting above water may result in poor cutting
Cutting above water may result in poor cutting Cutting above water may result in poor cutting
performance. Water vapor created when hot
performance. Water vapor created when hot material
performance. Water vapor created when hot performance. Water vapor created when hot
or sparks contact liquid may cause arcing inside torch.
or sparks contact liquid may cause arcing inside torch.
or sparks contact liquid may cause arcing inside torch.or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level
When cutting on a water table, reduce the water level
When cutting on a water table, reduce the water level When cutting on a water table, reduce the water level
to provide maximum clearance between water and
to provide maximum clearance between water and
to provide maximum clearance between water and to provide maximum clearance between water and
material.
material.
material. material.
material
material material
Precision Plasma with Electronic Flow Control – 1-7
SECTION 1 SAFETY
WARNING
!
1.7 Service Precautions
CAUTION
Explosion hazard.
Certain molten aluminum
Certain molten aluminum----lithium (Al
Certain molten aluminumCertain molten aluminum
cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water.
Do not plasma cut the following Al
Do not plasma cut the following Al----Li alloys with
Do not plasma cut the following AlDo not plasma cut the following Al
water:
Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage
could occur to equipment or machine.
could occur to equipment or machine.
could occur to equipment or machine.could occur to equipment or machine.
Extreme caution should be used when probing
Extreme caution should be used when probing
Extreme caution should be used when probing Extreme caution should be used when probing
CAUTION
!
circuitry with an oscilloscope or voltmeter. Int
circuitry with an oscilloscope or voltmeter. Integrated
circuitry with an oscilloscope or voltmeter. Intcircuitry with an oscilloscope or voltmeter. Int
circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage. circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
Power off before using test probes to prevent
Power off before using test probes to prevent Power off before using test probes to prevent
accidental shorting of components.
accidental shorting of components.
accidental shorting of components.accidental shorting of components.
All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables All circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all
gua
guards and covers replaced before power is turned
rds and covers replaced before power is turned
guagua
rds and covers replaced before power is turned rds and covers replaced before power is turned
on.
on.
on.on.
Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while Never plug or unplug a printed circuit board while
machine power is on. Instantaneous surges of voltage
machine power is on. Instantaneous surges of voltage
machine power is on. Instantaneous surges of voltage machine power is on. Instantaneous surges of voltage
and current can damage electronic components.
and current can damage electronic components.
and current can damage electronic components.and current can damage electronic components.
egrated
egrated egrated
Precision Plasma with Electronic Flow Control – 1-8
SECTION 1 SAFETY
1.8 Safety References
The following nationally recognized publications on safety in welding
and cutting operations are recommended. These publications have
been prepared to protect persons from injury or illness and to protect
property from damage, which could result from unsafe practices.
Although some of these publications are not related specifically to this
type of industrial cutting apparatus, the principles of safety apply
equally.
• “Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
• “Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
• “Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
• “Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
• “Safe Practices” - AWS SP, American Welding Society.
• “Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
• “Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
• "Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
• “ Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.
Precision Plasma with Electronic Flow Control – 1-9
SECTION 1 SAFETY
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Precision Plasma with Electronic Flow Control – 1-10
SECTION 2 DESCRIPTION
x
2.1 General
2.2 Scope
2.3 Package Options Available
Precision Plasmarc package options available through your ESAB dealer
PT-24 Torch Electronic Flow Series A/M (one required)
Power Bundle (one required)
Gas Line Bundle (one required)
Control Lead – Flow Console to Junction Bo
(one required)
Flex cable (recommended for
200/230/380/415/460/575) 3-phase 50/60 Hz
power track applications)
The Precision Plasmarc System consists of four
separate components. The power source, the
junction box, the flow control box, and the PT-24
torch. The power source provides power and coolant
to the PT-24 torch via the junction box.
The purpose of this manual is to provide the operator
with all the information required to install and operate
the Precision Plasmarc System. Technical reference
material is also provided to assist in troubleshooting
the cutting package.
P/N 37358
4.5 ft. (1.4 m) P/N 0558001463
12 ft. (4.4 m) P/N 0558001877
17 ft. (5.2 m) P/N 0558001464
12 ft. (3.6 m) P/N 22428
25 ft. (7.6 m) P/N 21905
40 ft. (12.2 m) P/N 22504
60 ft. (18 m) P/N 21906
80 ft. (24.4 m) P/N 22505
100 ft. (30 m) P/N 21907
10 ft. (3 m) P/N 37533
20 ft. (6 m) P/N 37534
30 ft. (9 m) P/N 37535
60 ft. (18 m) P/N 37536
100 ft. (30 m) P/N 37537
10 ft. (3 m) P/N 21917
20 ft. (6 m) P/N 21918
Standard Cable
30 ft. (9 m) P/N 21919
60 ft. (18 m) P/N 21920
100 ft. (30 m) P/N 21921
10 ft. (3 m) P/N 56997111
20 ft. (6 m) P/N 56997112
30 ft. (9 m) P/N 56997113
40 ft. (12 m) P/N 0560986745
60 ft. (18 m) P/N 56997114
100 ft. (30 m) P/N 56997115
Precision Plasma with Electronic Flow Control –
2-1
SECTION 2 DESCRIPTION
30 ft. (9.1 m ) P/N 57002248
50 ft. (15.2 m) P/N 57002249
Control Lead – Power Source to Cutting Machine I/O
High Frequency Power Cable – Power Supply to Junction
Box – or- Power Supply to Cutting Machine I/O, depending
on configuration
• Control lead from the power source to customer CNC is supplied based on customer order.
• Gas supply, hoses, work lead and input primary cable are all supplied by the customer.
• See Process Data Sheets for a list of torch consumable parts.
2.4 Precision Plasma Technical Specifications
75 ft. (22.8 m ) P/N 57002250
100 ft. (30.5 m) P/N 57002251
160 ft. (48.8 m) P/N 57002252
3 ft. (.9 m) P/N 57000419
50 ft. (15.2 m) P/N 57000420
75 ft. (22.8 m) P/N 57000421
100 ft. (30.5 m) P/N 57000422
125 ft. (38.1 m) P/N 57000423
150 ft. (45.7 m) P/N 57000424
175 ft. (53.3 m) P/N 57000425
200 ft. (61 m) P/N 57000426
2.4.1 System
Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz
Input Current 65/60/50/40/30/25 amps per phase
Power Factor 0.95
Output Current Range 15-100 amps dc
Output Load Voltage 120 V dc
Duty Cycle 100%
Open Circuit Voltage 315 V dc
2-2
Precision Plasma with Electronic Flow Control –
SECTION 2 DESCRIPTION
A
A
S
S
S
S
Power Supply
CONTROL
CURRENT
RECISION PLASMARC
PILOT
RC
POWER
Junction Box
44"
(1118 mm)
19.75" (502mm)
10.62" (270mm)
42" (1067mm) Weight = 26.5 lbs (12 kg)
22" (559mm)
Weight = 560 lbs. (254 kg)
Electronic Flow Control Box
6.75"
(171mm)
14.5"
(1118mm)
IR
PLASMA GA
NO.1
NITROGEN
AIR
12.25" (311mm)
ARGON
SHIELD GA
NO.2
SHIELD GA
NO.1
PLASMA GA
NITROGEN
NO.2
NITROGEN
OXYGEN
METHANE
OXYGEN
HYDROGEN
AIR
METH
H-35
N2
N2
O2
AIR
O2
N2
12" (305mm)
Weight = 51 lbs. (23 kg)
Precision Plasma with Electronic Flow Control –
2-3
SECTION 2 DESCRIPTION
2.4.2 Plasma Gas Technical Specifications
Type O
Pressure 125 psig (8.6 bars)
Flow 100 cfh (47 l/min) max. (varies with application)
Purity Required*
Recommended Liquid Cylinder Service
Regulators
Recommended Cylinder 2-Stage Regulators
Recommended Heavy – Duty Hi-flow Station or
Pipeline Regulators
Recommended High-capacity Station or
Pipeline Regulators
Gas Filter Required 25 micron w/bowl guard (P/N 56998133)
Flow 60 cfh (28 l/min) max (varies with application)
Minimum Purity Required 99.995%
2.4.5 Pt-24 Torch Technical Specifications
Type Water-Cooled, Dual Gas
Rating 100 amps @ 100 % duty cycle
Dimensions See Package Options (2.3)
2-4
Precision Plasma with Electronic Flow Control –
SECTION 3 INSTALLATION
3.1 General
NOTICE
Proper installation can contribute materially to the
satisfactory and trouble-free operation of the Precision
Plasmarc System. It is suggested that each step in
this section be studied and carefully followed.
3.2 Equipment Required
3.3 Location
CAUTION
!
• Gas Supply and Hoses. Gas supply may be from
a bulk source or from a bank of manifold cylinders
and regulated to supply 125 psig (8.6 bar) to the
Flow Control (gas flowing).
• Work Lead. No. 4 AWG cable is recommended for
connecting workpiece to power source.
• Primary Input Cable.
• 25 micron gas filters (or better) are required on the
supply side for the EFC to function properly.
• Ventilation is necessary to provide proper cooling
of the power supply.
• Minimize dirt, dust and exposure to external heat
sources.
• Allow a minimum of two feet clearance around the
power supply for free air movement.
Do Not Restrict Air Flow
Restricting intake air with any type of filter on or a
Restricting intake air with any type of filter on or around
Restricting intake air with any type of filter on or aRestricting intake air with any type of filter on or a
the power supply may void the warranty.
the power supply may void the warranty.
the power supply may void the warranty.the power supply may void the warranty.
round
round round
Precision Plasma with Electronic Flow Control - 3-1
SECTION 3 INSTALLATION
3.4 Primary Electrical Input Connections
Electric Shock Can Kill!
DANGER
!
Provide maximum protection against electrical
shock.
Before any connections are made inside the
machine, open the line (wall) disconnect switch
and unplug the power cord.
Machine must be properly configured for your
input power.
The machine is shipped from the factory
configured for 575 V, 60 Hz input.
Do NOT connect a power source of any other
voltage unless machine is reconfigured. Damage
to the machine will occur.
Input Power Connection At Wall
A line (wall) disconnect switch with fuses or circuit
breakers should be provided at the main power panel.
Connect the input power cable of the power source
directly to the disconnect switch or a proper plug and
receptacle may be purchased from a local electrical
supplier. (See table on the next page for
recommended input conductors and fuses )
Recommended Size
Recommended Sizes For Input Conductors And Line Fuses
Recommended SizeRecommended Size
Input requirements
Volts Phase Amps
s For Input Conductors And Line Fuses
s For Input Conductors And Line Fusess For Input Conductors And Line Fuses
Input & ground
conductor,
cu/awg/mm
2
Fuse ratings /
phase, amps
Precision Plasma with Electronic Flow Control - 3-2
SECTION 3 INSTALLATION
The following procedure explains the proper installation
steps for connecting primary electrical power to the
power source.
A. Remove right side panel.
TB2
TB1
200
230
380
415
460
575
200
230
380
415
460
575
200
230
380
415
460
575
200
230
380
415
460
575
1
K1
PHASE 1
PHASE 2
PHASE 3
2
3
4
5
Factory Wired
for 575 Volts
B. Ensure input power cable is disconnected from all
electrical sources.
C. Route input power cable through the strain relief
located at the rear panel.
D. Pull input power cable through the strain relief to
allow cable wires sufficient length to connect to the
main contactor. Tighten strain relief to ensure
input power cable is secured.
E. Connect input power cable ground wire to the
ground lug provided on the base of the power
source.
F. Connect three power leads of the input power
cable to the terminals located atop the main
contactor. Secure the leads by tightening each
screw.
G. Connect jumper power cables from the bottom of
the main contactor to the proper input voltage
marked on the auto transformer. The unit is
factory set for 575 V as shown to the left.
CAUTION
!
Input Power
Input Power Jumper Connection
Input PowerInput Power
Jumper Connection
Jumper Connection Jumper Connection
Ensure each input power jumper cable is connected to
Ensure each input power jumper cable is connected to
Ensure each input power jumper cable is connected to Ensure each input power jumper cable is connected to
the correct input voltage on auto transformer.
the correct input voltage on auto transformer.
the correct input voltage on auto transformer.the correct input voltage on auto transformer.
Factory wired for 575 V.
Factory wired for 575 V.
Factory wired for 575 V.Factory wired for 575 V.
H. Connect jumper wire to the proper input voltage
connector located on the 7-position terminal block.
TB2
Precision Plasma with Electronic Flow Control - 3-3
SECTION 3 INSTALLATION
3.5 Interconnecting Lines
1
2
3
4
A. All interconnecting service lines supplied are
numbered or color coded on each end with
corresponding numbers/colors marked on
the cabinets.
5
1 Black hose
2 Red or orange hose
3 Yellow hose
4 Blue hose
5 Mounting plate (Spacer)
Gas Line Bundle
B. Connect all four lines in Gas Line Bundle to
Flow Control Box and Junction Box. Lines
and connections are color coded. In
addition, mounting plate hole spacing is
asymmetrical to prevent improper
connection. Order of colors should be:
blue, yellow, red/orange, black
Precision Plasma with Electronic Flow Control - 3-4
SECTION 3 INSTALLATION
x
x
Power supply and EFC Connections to J
Power supply and EFC Connections to J----Bo
Power supply and EFC Connections to JPower supply and EFC Connections to J
Box
BoxBo
Power Supply Bundle
1
C. Connect power and coolant lines in Power
Supply Bundle from power source to
junction box. Power bundle consists of #6
and # 7 coolant lines (with 5/8-18 L.H.
fittings), power cable (#3 AWG) and yellow
pilot arc cable (#16 AWG). Both coolant
lines are stamped with a 6 or 7 on the fitting
to assist in identification.
2
6
5
3
4
1 Power supply negative connection
2 #7 hose connection (from power source)
3 Gas bundle connections
4 Control lead from EFC
5 #6 hose connection (to power source)
6 Pilot arc connection
Precision Plasma with Electronic Flow Control - 3-5
SECTION 3 INSTALLATION
Junction Box to torch connections
Junction Box to torch connections
Junction Box to torch connectionsJunction Box to torch connections
4
1
Torch Hose/Power Cable Connection
2
Torch Solenoid Electrical Connection
3
Torch Pilot Arc Connection
4
Torch Bundle
1
2
3
D. Connect Torch Bundle Leads/Hoses to
Junction box. (see Interconnecting Block
Diagram)
Precision Plasma with Electronic Flow Control - 3-6
1 25 micron gas filters
2 electronic flow control box (EFC)
3 Control lead EFC to junction box
4 machine computer control (CNC)
5 High frequency 120 volts AC
6 Gas line bundle
7 High frequency 120 volts AC
8 Power bundle
9 Precision Plasmarc junction box
10 PT-24 torch
11 Cutting table
12 Work lead (negative)
13 Primary power cable
14 Ground rod
15 Control lead – power supply to CNC
9
11
N2O
7
6
2
AirCH
4
Ar
8
12
13
15
Precision Plasma with Electronic Flow Control - 3-7
SECTION 3 INSTALLATION
Gas Line Contamination Will Damage
CAUTION
!
Proportional Valves
Purge Gas Lines
Before connecting gas delivery lines to the
Before connecting gas delivery lines to the
Before connecting gas delivery lines to the Before connecting gas delivery lines to the
Electronic Flow Control, purge all lines thoroughly.
Electronic Flow Control, purge all lines thoroughly.
Electronic Flow Control, purge all lines thoroughly. Electronic Flow Control, purge all lines thoroughly.
Residue from the hose manufacturing process may
Residue from the hose manufacturing process may
Residue from the hose manufacturing process may Residue from the hose manufacturing process may
clog/damage the proportional valves in your EFC.
clog/damage the proportional valves in your EFC.
clog/damage the proportional valves in your EFC.clog/damage the proportional valves in your EFC.
1/4 NPT
E. Purge gas lines between supply and the
EFC before connecting. Proportional valves
in the EFC are very sensitive to dust and
other foreign particles.
F. Connect Gas Delivery lines to Electronic
Flow Control. Install 25 micron Gas filters in
all delivery lines between gas source and
EFC.
Gas filter
25 micron filters
N
O
2
2
AirCH
4
Ar
Precision Plasma with Electronic Flow Control - 3-8
SECTION 3 INSTALLATION
Pilot Arc
Work
Torch
Remove access cover
Pilot Arc
G. Remove panel from rear of console and attach
the pilot-arc, torch and work lead.
Work
Torch
1
2
3
4
8
7
5
6
1 Power cable from wall
2 600 amp Bus fuse
3 CNC Control Lead
4 Flow Control Lead
5 Coolant IN from torch (#6 connection)
6 Coolant OUT to torch (#7 connection)
7 Serial Tag
8 Rating Label
Control Lead
H. Connect control lead between the console and
the Electronic Flow Control. Connect coolant
lines of the Power Bundle.
Precision Plasma with Electronic Flow Control - 3-9
SECTION 3 INSTALLATION
3.6 Torch Mounting
1.812" (46mm)
1.812" (46mm)
1.812" (46mm)1.812" (46mm)
diameter collar
diameter collar
diameter collardiameter collar
CAUTION
2.0" (51mm)
2.0" (51mm)
2.0" (51mm)2.0" (51mm)
diameter sleeve
diameter sleeve
diameter sleevediameter sleeve
Vent Hole
Do Not Cover Vent Hole.
When mounting, do not to cover the small vent hole in
When mounting, do not to cover the small vent hole in
When mounting, do not to cover the small vent hole in When mounting, do not to cover the small vent hole in
the side of the sleeve. This hole allows coolant to
the side of the sleeve. This hole allows coolant to
the side of the sleeve. This hole allows coolant to the side of the sleeve. This hole allows coolant to
drain from inside the sleeve should a leak occur in a
drain from inside the sleeve should a leak occur in a
drain from inside the sleeve should a leak occur in a drain from inside the sleeve should a leak occur in a
service line.
service line.
service line.service line.
Torch Mounting Options.
Torch Mounting Options.
Torch Mounting Options.Torch Mounting Options.
• The torch is normally mounted by the 2.0 inch
diameter (51mm) sleeve. Do not cover vent hole.
• For custom alternative mounting, the torch can be
mounted by the 1.812" (46 mm) dia collar shown.
This insulated collar and its shoulder are machined
relative to the nozzle retainer thread on the torch
body.
• Use only specified mounting surfaces
Precision Plasma with Electronic Flow Control - 3-10
SECTION 3 INSTALLATION
3.7 Torch Coolant
T
O
L
I
P
C
R
L
O
R
T
N
O
C
T
N
E
R
R
U
C
RECISION PLASMARC
A
R
E
W
O
P
• Remove coolant fill cap at front of console and fill
coolant tank with 4 gallons (15 liters) of plasma
coolant, P/N 156F05 (one gallon).
• Do not fill above maximum level
• Reinstall Cap.
Coolant Fill cap
Commercial Antifreeze Will Cause Torch To
CAUTION
!
Malfunction
Use Special Torch Coolant! P/N156F05
Due to high electrical conductivity, DO NOT use tap
Due to high electrical conductivity, DO NOT use tap
Due to high electrical conductivity, DO NOT use tap Due to high electrical conductivity, DO NOT use tap
water or commercial
3.8 Inspection of Gas and Coolant Lines
water or commercial antifreeze for torch cooling. A
water or commercialwater or commercial
specially formulated torch coolant is REQUIRED. This
specially formulated torch coolant is REQUIRED. This
specially formulated torch coolant is REQUIRED. This specially formulated torch coolant is REQUIRED. This
coolant also protects for freezing to
coolant also protects for freezing to ––––34° C.
coolant also protects for freezing to coolant also protects for freezing to
Operating the unit without coolant will cause
Operating the unit without coolant will cause
Operating the unit without coolant will cause Operating the unit without coolant will cause
permanent damage to the coolant pump.
permanent damage to the coolant pump.
permanent damage to the coolant pump.permanent damage to the coolant pump.
antifreeze for torch cooling. A
antifreeze for torch cooling. A antifreeze for torch cooling. A
34° C.
34° C.34° C.
To complete installation, it is necessary to inspect
field assembled connections for leaks.
• Gas lines, use a standard soap solution.
Pressurize the system from the control (SDP file)
• Coolant- check connections for signs of
moisture at connections
Precision Plasma with Electronic Flow Control - 3-11
SECTION 3 INSTALLATION
3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic
Controller (PLC)
The Precision Plasmarc System may be shipped
configured for a manual flow control (Series “A”). If
so, the EPROM in the Programmable Logic
Controller must be replaced with an EFC EPROM.
This EFC EPROM is shipped with the power source.
CAUTION
!
CAUTION
!
CAUTION
!
Using the Wrong EPROM Could Result In
Damaged System Components
The Series “ A” and the EFC EPROMs are
programmed with different software. The EFC
EPROM ignores the process gas pressure
switch inputs and does not include the
process gas purge required for the Series “ A” .
Mishandling Can Damage Electronic
Components.
Handle electronic components with care.
• Do not drop
• Do not bend pins
• Do not touch circuit components- handle
along edges when possible
Electronic Components Are Subject To
Electro-Static-Discharge (ESD) Damage
Integrated Circuit parts are sensitive to over
voltages. The damage may not be seen
immediately but show up as a premature
failure.
The EFC EPROM is shipped in an anti-static
bag. Store EPROM in this bag.
Wear a protective ground strap when handling
sensitive electronic components.
WARNING
!
Precision Plasma with Electronic Flow Control - 3-12
Electric shock Can Kill!
Unplug power cable from wall to power source
before any connections or adjustments are
made inside power source.
SECTION 3 INSTALLATION
L
O
R
T
N
C
O
N
T
E
R
R
U
C
S
I
C
E
R
Left Side Panel
T
O
L
I
P
C
R
A
R
E
W
O
P
C
R
A
M
S
A
L
P
N
O
I
1. Ensure the Plasmarc Power Source is
disconnected from electricity source.
2. Expose the PLC by removing the left side panel
of the Plasmarc Power Source.
3. Pop the EPROM cover on the PLC to expose
the EPROM.
PLC
EFC EPROM package location
Precision Plasma with Electronic Flow Control - 3-13
SECTION 3 INSTALLATION
Using An EPROM Puller Tool May Damage
CAUTION
Socket
Forcibly removing a clamped EPROM in the
PLC may cause the socket/EPROM to break.
Special Zero Force EPROM Socket is used to
eliminate the need for special tools.
4. Remove the EPROM from the socket. THIS
DOES NOT REQUIRE A PULLER. Release the
clamp locking the EPROM in place, lift the
Series “A” EPROM from the socket.
5. Remove the EFC EPROM from the packaging.
6. Carefully align the EFC EPROM pins with the
socket holes and insert.
7. Lock the EPROM by moving the lever back
while holding the EPROM in place.
8. Replace the EPROM cover and the Power
Source left side panel.
EPPESA= Series “A” EPROM, manual flow control
EPROM locked in place
P/N 99513607
EPPSEFC= EFC EPROM, electronic flow control
P/N 99513608
EPROM Lock Released
Precision Plasma with Electronic Flow Control - 3-14
SECTION 4 OPERATION
LOW
4.1 Power Supply Controls
4.1.1 Main Power Switch
DO NOT SWITCH
WHILE CUTTING
EMERGENCY
STOP
Main Power Switch
Controls the input power to the fan, water cooler and
the PC Board. Amber indicator light to the left of the
switch.
4.1.2 Pilot Arc Switch
EMERGENCY
STOP
CAUTION
Pilot Arc Switch
Used to select HIGH or LOW Start Pilot Arc depending
on cutting conditions. See Process Data for more
information on which conditions High and Low Start
are used.
POWER
ON
Adjusting Pilot Arc While in Operation Could
Damage Torch.
Do not adjust pilot arc switch while in operation.
Adjust before torch starts.
Precision Plasma with Electronic Flow Control -
4-1
SECTION 4 OPERATION
4.1.3 Fault Indicator Lights
4.1.4 Meters
Fault Indicator Lights
• Coolant flow will show low coolant flow. When
unit is turned on, the light will briefly show a fault
and then go out.
• Plasma Gas Pressure fault indicator -- low
Plasma Gas Pressure. Torch will not fire when
indicated. Not used for the EFC.
• Start Gas Pressure fault indicator -- low start gas
pressure. Torch will not fire when indicated. Not
used for the EFC.
used for the EFC.
used for the EFC.used for the EFC.
• P/S Temp fault indicator -- over temperature in the
inverter power source. Power source will shut
down.
• P/S Fault Indicator – fault in plasma control PCB
in the inverter power source. Power source will
shut down.
• Over-Under Voltage fault Indicator -- indicate
input voltage is above or below the tolerances of
the PCU console. Will latch until power is recycled
by main power switch.
• Emergency Stop fault indicator -- shows CNC
Interlock condition. Power Source will not work.
Not used for the EFC.
Not used for the EFC.Not used for the EFC.
Not
Not Not
• Cutting Current Meter (A) -- Displays actual
cutting current in amperes.
• Cutting Voltage Meter (V) -- Displays actual
cutting voltage.
4-2
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
4.1.5 Current Control Switch
Control Remote/Panel Switch
• Panel Position – Output current is set by the
output current dial
• Output Current Dial – sets the cutting current
when current setting is made from the console
front panel. Dial reads 0 to 99.9 amps. 70.0 amps
shown.
• Remote Position – output current is set by the
CNC (or remote pot) with an analog dc signal
0-10 Vdc = 0-100 Adc
Precision Plasma with Electronic Flow Control -
4-3
SECTION 4 OPERATION
4.2 Cut Quality
4.2.1 Introduction
NOTICE
Causes affecting cut quality are interdependent.
Changing one variable affects all others. Determining a
solution may be difficult. The following guide offers
possible solutions to different undesirable cutting
results. To begin select the most prominent condition:
§ 4.2.2 Cut Angle, negative or positive
§ 4.2.3 Cut not flat, rounded or undercut
§ 4.2.4 Surface roughness
§ 4.2.5 Dross
Usually the recommended cutting parameters will give
optimal cut quality, occasionally conditions may vary
enough that slight adjustments will be required. If so:
• Make small incremental adjustments when
making corrections.
• Adjust Arc Voltage in 5 volt increments, up or
down as required.
• Adjust cutting speed 5% or less as required
until conditions improve.
Before attempting ANY corrections, check cutting
variables with the factory recommended
settings/consumable part numbers listed in
Process Data.
4-4
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
4.2.2 Cut Angle
Negative Cut Angle
Part
Top dimension is greater than the bottom.
• Misaligned torch
• Bent or warped material
• Worn or damaged consumables
• Standoff low (arc voltage)
• Cutting speed slow (machine travel rate)
Drop Part
Part
Drop Part
Positive Cut Angle
Top dimension is less than the bottom dimension.
• Misaligned torch
• Bent or warped material
• Worn or damaged consumables
• High standoff High (arc voltage)
• Cutting speed fast
• Current high or low. (See Process Data for
recommended current level for specific nozzles).
Precision Plasma with Electronic Flow Control -
4-5
SECTION 4 OPERATION
4.2.3 Cut Flatness
Drop
Part
Top And Bottom Rounded
Condition usually occurs when material is .25” thick
(6,4mm) or less.
• High current for given material thickness (See
Process Data for proper settings).
Top Edge Undercut
• Standoff low (Arc Voltage)
Drop
4-6
Part
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
4.2.4 Surface Finish
Process Induced Roughness
Cut face is consistently rough. May or may not be
confined to one axis.
• Incorrect Shield Gas mixture (See Process Data)
Top View
Machine Induced
or
Process Induced
Roughness
Roughness
• Worn or damaged consumables
MMMMachine Induced Roughness
Can be difficult to distinguish from Process Induced
Roughness. Often confined to only one axis.
Roughness is inconsistent.
Dross is a by-product of the cutting process. It is the
undesirable material that remains attached to the part.
In most cases, dross can be reduced or eliminated
with proper torch and cutting parameter setup. Refer
to Process Data.
Cut Face
High Speed Dross
Material weld or rollover on bottom surface along kerf.
Roll over
Difficult to remove. May require grinding or chipping.
“S” shaped lag lines.
• Standoff high (arc voltage)
• Cutting speed fast
Side view
Lag Lines Cut Face
Globules
Side View
Slow Speed Dross
Forms as globules on bottom along kerf. Removes
easily.
• Cutting speed slow
4-8
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
Side View
Splatter
Cut Face
Top Dross
Appears as splatter on top of material. Usually
removes easily.
• Cutting speed fast
• Standoff high (arc voltage).
Intermittent Dross
Appears on top or bottom along kerf.
Non-continuous. Can appear as any kind of dross
• Possible worn consumables
Other Factors Affecting Dross;
• Material temperature
• Heavy mill scale or rust
• High carbon alloys
Precision Plasma with Electronic Flow Control -
4-9
SECTION 4 OPERATION
4.2.6 Dimensional Accuracy
NOTICE
Generally using the slowest possible speed (within
approved levels) will optimize part accuracy. Select
consumables to allow a lower arc voltage and slower
cutting speed.
Recommended cutting speed and arc voltage will
give optimal cutting performance in most cases.
Small incremental adjustments may be needed
due to material quality, material temperature and
specific alloy. The operator should remember
that all cutting variables are interdependent.
Changing one setting affects all others and cut
quality could deteriorate. Always start at the
recommended settings.
NOTICE
Before attempting ANY corrections, check
cutting variables with the factory recommended
settings/consumable part numbers listed in the
Process Data.
4-10
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction
All gases are not suitable for all situations. Certain
gases assist in cutting specific materials and
thickness. The following explains why certain gases
are selected and their influence on the finished part.
Other influences such as arc voltage and gas
flow/pressure are covered in the Process Data.
NOTICE
4.3.2 Aluminum
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
All thickness’ between .062" to .625" (1,6 mm to 15,9 mm)
• Smooth cut face
• Virtually no dross
Shield Gas:
Shield Gas: Nitrogen/Methane
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1
part methane ratio is desired. Incorrect ratio results in heavy dross.
Refer to Cutting Process Data in this section for
recommended flow/pressure settings.
Precision Plasma with Electronic Flow Control -
4-11
SECTION 4 OPERATION
Refer to Cutting Process Data in the PT24
NOTICE
Manual for recommended flow/pressure
settings.
4.3.3 Carbon Steel
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Oxygen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Oxygen/Nitrogen
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm)
• Smooth cut face
• Virtually no dross
Shield gas is normally nitrogen. A small amount of oxygen combined
with nitrogen can effectively improve dross formation on thin material of
26 GA to 10 GA carbon steel. Also, an oxygen only shield may provide
acceptable results on thinner materials.
.125" to .75" (3,2 mm to 19,1 mm)
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Oxygen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
• Smooth cut face
• Virtually no dross
Cutting carbon steel with oxygen results in an exothermic reaction. This
chemical reaction causes the carbon in the material to burn similar to
when oxy-fuel cutting. This plus the electrical energy uses lower
amperage levels without sacrificing cut speed.
4-12
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
Refer to Cutting Process Data in the PT24
NOTICE
4.3.4 Stainless Steel
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen/Methane
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness: 26 GA (.018") to 16 GA (.062") (0,5 mm to 1,6 mm)
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
22 GA (.028") to 16 GA (.062") (0,7 mm to 1,6 mm)
• Positive cut angle
• Excellent dross performance
• Shiny cut surface.
Because of high cut speeds, a positive cut face angle is expected. Use
a 70-amp nozzle at 50 amps to allow more gas to exit the nozzle.
• Dark cut face
• Virtually dross free
• Improved cut squareness
Manual for recommended flow/pressure
settings.
Plasma Gas:
Plasma Gas: Oxygen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Oxygen/Nitrogen
Shield Gas:Shield Gas:
Low amperage cutting/slower speeds produce squarer cuts in thin
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Air
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Air
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
materials. The oxygen allows for a lower arc voltage, improving cut
squareness. The “B” nozzle is used at 30 amps
• Cut edge dark
• good dross performance
• Good cut angle
When they are the same, the shield and plasma gases combine. This
combination has the effect of increasing the cut gas flow/pressure. This
increased flow/pressure directly influences cut squareness.
Precision Plasma with Electronic Flow Control -
4-13
SECTION 4 OPERATION
NOTICE
Stainless Steel
Material Thickness:
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Air
Plasma Gas:Plasma Gas:
Material Thickness:
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
• Matted cut edge appearance
• Light gray color
• Much smoother finish
• Possible slight increase in cut angle
Shield Gas:
Shield Gas: Air/Methane
Shield Gas:Shield Gas:
Too much methane in the shield gas mixture can result in more dross
Discussion:
Discussion:
Discussion:Discussion:
formation. 4:1 ratio air to methane is recommended. Because methane
is a fuel gas, possible slight increase in cut angles could be experienced.
• Dark cut face similar to air
• Excellent dross performance
• Good cut angle
Refer to Cutting Process Data for recommended
flow/pressure settings.
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen
Shield Gas:Shield Gas:
Shield and plasma gases combine, the volume/pressure of shield gas
Discussion:
Discussion:
Discussion:Discussion:
can negatively affect cut squareness. Higher shield volume produces a
negative cut angle. A lower volume, produces a positive angle.
Material Thickness:
Material Thickness: .187" to .625" (4,7 mm to 15,9 mm)
Material Thickness:Material Thickness:
• Shiny cut face
Cut Qual
Cut Qualities:
Cut QualCut Qual
ities:
ities:ities:
• Lip formation at the bottom
• Dross formation can be extensive and difficult to remove
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen/Methane
Shield Gas:Shield Gas:
Because methane is a fuel gas, flow/pressure rates can affect the cut
angle. High flow/pressure results in a negative cut angle, low
Discussion:
Discussion:
Discussion:Discussion:
flow/pressure results in a positive cut angle. Nitrogen to methane ratio is
10 to 14 parts N
/ 1 part CH4. The lip formed on the cut face bottom is
2
severe, making Nitrogen/Methane shield gas combination unsuitable for
some finished part applications.
4-14
Precision Plasma with Electronic Flow Control -
SECTION 4 OPERATION
4.4 Process Data
4.4.1 Introduction
4.4.1 Introduction
4.4.1 Introduction4.4.1 Introduction
The following information is a result of many hours of
testing and is a general guide for setting up and
cutting with a PT-24 Precision Plasmarc System. In
most cases these settings will provide a quality cut.
The data contains values for:
• cutting aluminum, carbon and stainless steel
• arc voltage (standoff)
• cutting speed
• current (amperes)
• gas flow rates for all plasma/shield gas
combinations
This same data is contained in SDP files. (See your
control manual for more information on SDP files.)