April 2007
Installation, Operation, and Maintenance for the
SmartFlow 2.5
Plasma System Plumbing Box
F-15-732
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 be 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 satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15732
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.
© ESAB Cutting Systems, 2003 ,2004
All rights reserved
Printed in U.S.A.
Table Of Contents
Safety (Section 1)
1.1 Introduction.........................................................................................................1-1
1.2 Safety Notations And Symbols...........................................................................1-2
1.3 General Safety Information.................................................................................1-3
1.4 Installation Precautions ......................................................................................1-4
1.5 Electrical Grounding...........................................................................................1-5
1.6 Operating A Plasma Cutting Machine ................................................................1-6
1.8 Safety References............................................................................................1-13
1.8.1 USA Domestic............................................................................................1-14
1.8.2 International ...............................................................................................1-15
Description (Section 2)
2.1 Introduction.........................................................................................................2-1
2.2 SmartFlow II
2.3 SmartFlow II
2.4 SmartFlow II
2.5 Gas Requirements..............................................................................................2-2
2.6 Water Supply Requirements...............................................................................2-3
2.7 Electrical Input Requirements.............................................................................2-3
2.8 Dimensions.........................................................................................................2-4
V
and PT-15XL................................................................................2-1
V
and PT-19XLS/PT-600.................................................................2-2
V
Options ........................................................................................2-2
Installation (Section 3)
3.1 Introduction.........................................................................................................3-1
3.2 Box Mounting (Bottom View)..............................................................................3-1
3.3 Hose and Cable Connections.............................................................................3-2
3.3.1 Starter Box Connections..............................................................................3-4
3.3.2 PC Board Connections.................................................................................3-5
3.3.3 Torch Cooling Water Connections...............................................................3-6
3.3.4 Power Source To SMF II
3.4 Nomex Insulation................................................................................................3-8
3.5 Gas Connections................................................................................................3-8
3.5.1 Gas Lines From Supply................................................................................3-8
3.5.2 Gas Pressure Setup...................................................................................3-10
3.6 Cut Water Setup (PT-15XL) .............................................................................3-10
3.7 Secondary Shield Gas Setup (PT-19XLS/PT-600)...........................................3-11
3.8 A Component Relationship Block Diagram ......................................................3-12
3.9 Fluid Schematic – SmartFlow II
V
Buss Connection................................................3-7
V
Standard and H-35 Versions........................3-14
SmartFlow 2.5
Table Of Contents
Operation (Section 4)
4.1 Operation Introduction........................................................................................4-1
Maintenance (Section 5)
5.1 SmartFlow II
5.2 Pressure Switches...............................................................................................5-2
5.3 Spark Gap Of the Arc Starter..............................................................................5-3
5.4 Spark Adjustment Procedure ..............................................................................5-4
5.5 Gas Proportional Valves......................................................................................5-5
5.6 Cutwater/Secondary Shield Proportional Valve ..................................................5-5
5.7 Cooling Water Flow Switch .................................................................................5-6
5.8 Gas Filters...........................................................................................................5-7
Troubleshooting (Section 6)
6.1 Troubleshooting Introduction...............................................................................6-1
6.2 Cooling Water Circuit .........................................................................................6-2
6.3 Cut Water and Auxiliary Cut Water ....................................................................6-3
6.4 Plasma Gas........................................................................................................6-4
6.5 Secondary Shield...............................................................................................6-5
6.6 Arc Start .............................................................................................................6-6
6.6.1 Setting the Spark Gap..................................................................................6-6
6.6.2 Spark Gap Size Attributes............................................................................6-7
6.6.3 Spark Viewing..............................................................................................6-8
6.7 Fluid Schematic..................................................................................................6-9
6.8 SmartFlow II
6.9 SmartFlow II Secondary Shield Gas Proportional Valve Calibration................6-13
Replacement Parts (Section 7)
7.1 General...............................................................................................................7-1
7.2 Ordering .............................................................................................................7-1
7.3 Inside Right View – SF 2.5 (without H-35 capability) DISCONTINUED.............7-2
7.4 Inside Right View – SF 2.5 (with H-35 capability) ..............................................7-4
7.5 Outside Front View.............................................................................................7-6
7.6 Inside Left View..................................................................................................7-8
7.7 Outside Back View...........................................................................................7-10
V
Maintenance Introduction.............................................................5-1
V
Interface PCB Schematic (3 pages) ..........................................6-10
SmartFlow 2.5
SECTION 1 SAFETY
1.1 Introduction
ESAB cutting machines are designed to provide
both operational safety and efficiency. However,
as with any machine tool, sensible attention to
operating procedures, precautions, and safe
practices is necessary. Whether an individual is
involved with operation, servicing, or as an
observer, compliance with established
precautions and safe practices must be carried
out. Failure to observe warnings/ precautions
could result in death/serious personal injury or
severe equipment damage. The following are
general guidelines applicable when working with
cutting machines. Additional precautions
pertaining to this equipment are found throughout
this literature. For a wide scope of safety
information on the field of cutting and welding,
obtain and read the publications listed in the
Recommended References at the end of this
section.
SmartFlow 2.5
1-1
SECTION 1 SAFETY
1.2 Safety Notations and Symbols
DANGER
WARNING
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 or
potential equipment failure exists. Used 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.
CAUTION
CAUTION
NOTICE
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.
1-2
SmartFlow 2.5
SECTION 1 SAFETY
1.3 General Safety Information
Failure to follow operating instructions
WARNING
could result in death or serious injury.
Read and understand this operator’s manual
before using machine.
• Read entire procedure before operating or
performing any system maintenance.
• Special attention must be given to all
hazard warnings that provide essential
information regarding personnel safety
and/or possible equipment damage.
• All safety precautions relevant to electrical
equipment and process operations must
be strictly observed by all having system
responsibility or access.
• Read all safety publications made
available by your company.
Failure to follow safety warning label
WARNING
instructions could result in death or
serious injury.
Read and understand all safety warning labels
on machine.
Refer to operator’s manual for additional
safety information.
SmartFlow 2.5
1-3
SECTION 1 SAFETY
1.4 Installation Precautions
Improperly Installed Equipment Can
WARNING
Cause Injury Or Death.
Follow these guidelines while installing
machine:
• Do not connect a cylinder directly to
machine inlet. An appropriate cylinder
regulator must be installed on a fuel gas
cylinder to reduce pressure to a
reasonable inlet supply pressure.
Machine regulator is then used to obtain
pressure required by torches.
• Contact your ESAB representative before
installation. He can suggest certain
precautions regarding piping installation
and machine lifting, etc. to ensure
maximum security.
• Never attempt any machine modifications
or apparatus additions without first
consulting a qualified ESAB
representative.
• Observe machine clearance requirements
for proper operation and personnel safety.
• Always have qualified personnel perform
installation, troubleshooting and
maintenance of this equipment.
• Provide a wall mounted disconnect switch
with proper fuse sizes close to the power
supply.
1-4
SmartFlow 2.5
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
Improper grounding can cause severe injury
or death.
Machine must be properly grounded before
put into service.
Improper Grounding Can Damage
WARNING
Machine And Electrical
Components.
• Machine must be properly grounded
before put into service.
• Cutting table must be properly grounded
to
a good Earth ground rod.
SmartFlow 2.5
1-5
SECTION 1 SAFETY
1.6 Operating a Plasma Cutting Machine
WARNING
hazards.
• Hot spatter can burn and injure eyes.
Wear goggles to protect eyes from burns
and flying debris generated during
operation.
• Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.
• Noise from plasma arc can damage
hearing. Wear correct ear protection when
cutting above water.
Burn hazard.
WARNING
Hot metal can burn.
• Do not touch metal plate or parts
immediately after cutting. Allow metal time
to cool, or douse with water.
Flying debris and loud noise
• Do not touch plasma torch immediately
after cutting. Allow torch time to cool.
1-6
SmartFlow 2.5
SECTION 1 SAFETY
WARNING
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table
or cable connections during plasma
cutting process.
• Always turn power off to plasma power
supplies before touching or servicing
plasma torch.
• Always turn power off to plasma power
supplies before servicing any system
component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Wear insulating gloves, shoes, and
clothing to insulate yourself from the
workpiece and electrical ground.
• Keep gloves, shoes, clothing, work area,
and equipment dry.
• Replace worn or damaged cables.
SmartFlow 2.5
1-7
SECTION 1 SAFETY
Fume hazard.
WARNING
Fumes and gases generated by the plasma
cutting process can be hazardous to your
health.
• Do NOT breathe fumes.
• Do not operate plasma torch without fume
removal system operating properly.
• Use additional ventilation to remove
fumes if necessary.
• Use approved respirator if ventilation is
not adequate.
• Provide positive mechanical ventilation
when cutting galvanized steel, stainless
steel, copper, zinc, beryllium, or cadmium.
Do not breathe these fumes.
• Do not operate near degreasing and
spraying operations. Heat or arc rays can
react with chlorinated hydrocarbon vapors
to form phosgene, a highly toxic gas and
other irritant gases.
1-8
SmartFlow 2.5
SECTION 1 SAFETY
Radiation hazard.
WARNING
Arc rays can injure eyes and burn skin.
• Wear correct eye and body protection.
• Wear dark safety glasses or goggles with
side shields. Refer to following chart for
recommended lens shades for plasma
cutting:
Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 Amps Shade No. 10
200-400 Amps Shade No. 12
Over 400 Amps Shade No. 14
• Replace glasses/goggles when lenses are
pitted or broken
• Warn others in area not to look directly at
the arc unless wearing appropriate safety
glasses.
• Prepare cutting area to reduce reflection
and transmission of ultraviolet light.
Paint walls and other surfaces with
dark colors to reduce reflections.
Install protective screens or curtains
to reduce ultraviolet transmission.
SmartFlow 2.5
1-9
SECTION 1 SAFETY
Ruptured Gas Cylinders Can Kill
WARNING
Mishandling gas cylinders can rupture and
violently release gas.
• Avoid rough handling of cylinders.
• Keep cylinder valves closed when not in
use.
• Maintain hoses and fittings in good
condition.
• Always secure cylinders in an upright
position by chain or strap to a suitable
stable object not part of an electrical
circuit.
• Locate cylinders away from heat, sparks
and flames. Never strike an arc on a
cylinder.
• Use approved pressure reducing regulator
for the specific gas.
• Refer to CGA Standard P-1, “Precautions
for Safe Handling of Compressed Gases in
Cylinders”, available from Compressed
Gas Association.
Explosion hazard.
WARNING
• Certain molten aluminum-lithium (Al-Li)
alloys can cause explosions when plasma
cut OVER water.
These alloys should only be dry cut
on a dry table.
DO NOT dry cut over water.
Contact your aluminum supplier for
additional safety information
regarding hazards associated with
these alloys
• Do not cut in atmospheres containing
explosive dust or vapors.
• Do not carry any combustibles on your
person (e.g. butane lighter)
.
1-10
• Do not cut containers that have held
combustibles.
SmartFlow 2.5
SECTION 1 SAFETY
WARNING
Burn Hazard.
Heat, spatter, and sparks cause fire and
burns.
• Do not cut near combustible material.
• Do not have on your person any
combustibles (e.g. butane lighter).
• Pilot arc can cause burns. Keep torch
nozzle away from yourself and others
when activating plasma process.
• Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and
hat.
• Wear flame-retardant clothing covering all
exposed areas.
• Wear cuff-less trousers to prevent entry of
sparks and slag.
• Have fire extinguishing equipment
available for use.
SmartFlow 2.5
1-11
SECTION 1 SAFETY
1.7 Service Precautions
WARNING
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table
or cable connections during plasma
cutting process.
• Always turn power off to plasma power
supplies before touching or servicing
plasma torch.
• Always turn power off to plasma power
supplies before removing covers or
panels to service any system component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Keep gloves, shoes, clothing, work area,
and equipment dry.
• Inspect power and ground leads cables for
wear or cracking. Replace worn or
damaged cables. Do not use if damaged.
• Never bypass safety interlocks.
• Follow lock-out procedures.
Establish and adhere to preventive
CAUTION
maintenance. A composite program can be
established from recommended schedules.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical
damage could occur to equipment or
machine.
1-12
SmartFlow 2.5
SECTION 1 SAFETY
Extreme caution should be used when
CAUTION
probing circuitry with an oscilloscope or
voltmeter. Integrated circuits are susceptible
to over voltage damage. Power off before
using test probes to prevent accidental
shorting of components.
All circuit boards securely seated in sockets,
all cables properly connected, all cabinets
closed and locked, all guards and covers
replaced before power is turned on.
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.
SmartFlow 2.5
1-13
SECTION 1 SAFETY
1.8.1 USA Domestic
• “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 Society, 2501 NW 7th Street,
Miami, Florida, 33125.
• “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.
1-14
SmartFlow 2.5
SECTION 1 SAFETY
1.8.2 International
Accident Prevention
VBG 1 General Provisions
VDE Regulations
TRAC Technical Rules for Acetylene and Carbide Stores
VBG 4 Electrical Equipment and operating
Equipment
VBG 15 Welding, Cutting and related working
methods
VBG 48 Shot Blasting Works
VBG 61 Gases
VBG 62 Oxygen
VBG 87 Operating liquid jet cutting machines
VBG 93 Laser beams, accident prevention and
Electro-technology
VBG 121 Noise
VDE 0100 Erection of power installations with normal
voltages up to 1000 volts
VDE0113 Electrical equipment of industrial machines
VDE 0837 Radiation safety of laser products; users
guide (DIN EN 60825)
VDE 0837-
50
TRAC-204 Acetylene lines
Specification for laser guards
TRAC-206 Acetylene cylinder battery systems
TRAC-207 Safety devices
TRG Technical Rules for Pressure gases
TRG 100 General regulations for pressure gases
TRG 101 Pressure gases
TRG 102 Technical gas mixtures
TRG 104 Pressure gases; alterative use of
compressed gas tanks
SmartFlow 2.5
1-15
SECTION 1 SAFETY
DIN Standards
DIN EN ISO Harmonized Standards
DIN 2310
Part 1
DIN 2310
Part 2
DIN 2310
Part 4
DIN 2310
Part 5
DIN 4844
Part 1
DIN EN
292/1 and 2
DIN EN 559 Hoses for welding, cutting and allied
DIN EN 560 Hose connections and hose couplings for
DIN EN 561 Gas welding equipment hose couplings
Thermal cutting; terminology and
nomenclature
Thermal cutting; determination of quality of cut
faces
Thermal cutting; arc plasma cutting; process
principles, quality, dimensional tolerances
Thermal cutting; laser beam cutting of metallic
materials; process principles
Safety markings (DIN EN 7287)
Safety of machinery
processes
equipment for welding, cutting and allied
processes
DIN EN
626-1
DIN EN
848-1
DIN EN
1829
DIN EN
9013
DIN EN
12584
DIN EN
12626
DIN EN
28206
DIN EN
31252
DIN EN
31553
DIN EN
60204-1
DIN EN
60825
DIN EN 999 Arrangement of protection devices
Safety of machines, reduction of risks to
health
Single spindle vertical milling machines
High pressure water jet machines
Thermal cutting, oxygen cutting, process
principles, dimensional tolerances
Imperfections in oxy/fuel flame cuts, laser
beam cuts and plasma
Laser processing machines
Acceptance testing for oxygen cutting
machines
Laser Equipment
Laser and laser related equipment
Electrical equipment of machines
Radiation safety of laser products
VDI Guidelines
1-16
VDI 2906 Quality of cut faces on metallic workpieces;
VDI 2084 Room air; Technical systems for welding
SmartFlow 2.5
abrasive water jet cutting and arc plasma
cutting
workshops
SECTION 2 DESCRIPTION
2.1 Introduction
The SmartFlow 2.5 Cutting System is a
streamlined, high performance-cutting package
designed for use exclusively with the ESAB Vision
CNC. This advanced technology integrates gas
and water control into the machine CNC.
Using a system of proportional valves driven by
CNC outputs, this system:
• dramatically reduces the amount of plumbing
hardware necessary to control the plasma
torch
• reduced purge time/increased part throughput
• simplified operation with gas and water flow
rates manually controlled at the Vision CNC
process parameter screen
• allows for programmed/automated control of
gas and water flow rates using SDP Files
(SchneidDatenPaket = Cutting Data Package,
see Vision control and programming manuals
for details on SDP Files. Data used to
generate SDP files can be found in your model
specific torch manual.)
• can be used with either a PT-15XL water
injection torch or a PT-600/PT-19XLS dry
cutting torch with secondary shield gas. (The
PT-600 and the PT-19XLS are both dry cutting
torches of similar design.)
2.2 SmartFlow 2.5 and PT-15XL
When the PT-15XL water injection torch is used,
the complete cutting system also requires the
following components:
• PT-15XL plasma torch
• a plasma power supply
• a recirculating water cooler
• coolant pump
• cut water pump
• air curtain regulator
• Vision CNC.
SmartFlow 2.5
2-1
SECTION 2 DESCRIPTION
2.3 SmartFlow
2.5
and PT-19XLS/PT-600
When a dry torch (no water injection) is used, the
SmartFlow 2.5 water injection components are
used to control the secondary shield pressure.
The components of The SmartFlow II Cutting
System with dry torch requires the following
components:
• Vision CNC,
• PT-19XLS or PT-600 plasma torch,
• power supply,
• a recirculating water cooler,
• and coolant pump.
2.4 SmartFlow
2.5
Options
SmartFlow 2.5 with H-35 capability
(H-35 is industry accepted nomenclature
for a gas mixture of 65% argon and 35%
2.5 Gas Requirements
Nitrogen
Oxygen
Compressed Air
SmartFlow 2.5 without H-35 capability
(DISCONTINUED)
hydrogen)
P/N 0560935258 P/N 0560935257
• 125 PSI (8,63 bar) with 0.5”
NPT
• 99.999% purity
• Filtered to 25 microns
• 125 PSI (8,63 bar) with 0.5”
NPT
• 99.999% purity
• Filtered to 25 microns
• 100 PSI (6,9 bar) with 0.5” NPT
• Clean, dry and filtered to 25
microns
2-2
• 150 PSI (10,4 bar)
H-35 (argon/hydrogen)
• Filtered to 25 microns
SmartFlow 2.5
SECTION 2 DESCRIPTION
2.6 Water Supply Requirements
Cooling Water
Deionized Water
(PT-15XL only)
2.7 Electrical Input Requirements
Voltage Supply
Voltage Signals
• 120 PSI (8,28 bar)
• 1.5 gallons per minute (5.68 liters/minute)
• 35 PSI (2,42 bar)
• >200,000 ohms (resistance)
• .5 gallons/minute (1,89 liters/minute) for up to
600A cutting
• 1.5 gallons/minute (5,68 liters/minute) for
600A to 1000A cutting
• +24 VDC for proportional valves, flow and
pressure switches
• +15 VDC for pressure switch
• 120 VAC input to start gas solenoid valve
• 120 VAC input to cut gas solenoid valve
• 120 VAC input to arc starter
• 0-10 VDC input to proportional valves
SmartFlow 2.5
2-3
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