ESAB SmartFlow II Plasma System Plumbing Box Instruction manual

Installation, Operation, and Maintenance for the

SmartFlow II

Plasma System Plumbing Box

F-15-487

July, 2001

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 to

ESAB Cutting Systems first priority is total customer

ESAB Cutting Systems first priority is toESAB Cutting Systems first priority is to 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 design

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 contained in this document is subject to change

contained in this document is subject to change

contained in this document is subject to change contained in this document is subject to change without n

without nooootice.

without nwithout n

This manual is ESAB Part Number F15487

This manual is ESAB Part Number F15487This manual is ESAB Part Number F15487 Date reflects rewritten and updated.

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.

quired. ESAB makes every possible

quired. ESAB makes every possible quired. ESAB makes every possible

tice.

tice.tice.

hancements and/or design

hancements and/or design hancements and/or design

tal customer

tal customer tal customer

tation

tation tation

Printed in U.S.A.

©©©© ESAB Cutting Systems, 2001

Table of Contents

Page Section 1 Safety

1.1 Introduction......................................................................................... 1

1.2 Safety Notations And Symbols............................................................. 1

1.3 General Safety Information................................................................... 2

1.4 Installation Precautions........................................................................ 3

1.5 Electrical Grounding ............................................................................ 4

1.6 Service Precautions............................................................................. 8

1.7 Safety References ............................................................................... 10

Section 2 Description

2.1 Introduction......................................................................................... 1

2.2 SmartFlow II and PT-15XL Plasma Torch ............................................. 1

2.3 SmartFlow II and PT-19XLS/PT-600 Plasma Torch .............................. 2

2.4 SmartFlow II Options ........................................................................... 2

2.5 Gas Requirements................................................................................ 2

2.6 Water Supply Requirements ................................................................ 3

2.7 Electrical Input Requirements............................................................... 3

2.8 Physical Dimensions............................................................................ 4

Section 3 Installation

3.1 Introduction......................................................................................... 1

3.2 Mounting............................................................................................. 1

3.3 Hose and Cable Connections .............................................................. 2

3.3.1 Starter Box Connections.............................................................. 3

3.3.2 PC Board Connections................................................................ 3

3.3.3 Torch Cooling Water Connections................................................ 4

3.3.4 Power Source (ESP) to SmartFlow II Buss Connections................ 4

3.4 Nomex Insulation................................................................................. 5

3.5 Gas Connections................................................................................. 5

3.5.1 Gas Lines From Supply................................................................ 5

3.5.2 Gas Pressure Setup..................................................................... 7

3.6 Cutwater Setup (PT-15XL only)............................................................ 7

3.7 Secondary Shield Gas Setup (PT-19XLS and PT-600)......................... 7

3.8 System Component Block Diagram ..................................................... 8

3.9 Fluid Schematic – SF II ........................................................................ 9

i

Table of Contents

Page Section 4 Operation

4.1 Introduction ........................................................................................ 1

4.2 Pressure Gages.................................................................................. 1

4.3 Pressure Switches .............................................................................. 1

Section 5 Maintenance

5.1 Introduction ........................................................................................ 1

5.2 Pressure Switches .............................................................................. 2

5.3 Arc Starter Spark Gap......................................................................... 3

5.4 Spark Gap Adjustment Procedure....................................................... 4

5.5 Gas Proportional Valves ...................................................................... 5

5.6 Cutwater/ Secondary Shield Proportional Valve ................................... 5

5.7 Cooling Water Flow Switch.................................................................. 6

5.8 Gas Filters .......................................................................................... 7

Section 6 Troubleshooting

6.1 Introduction ........................................................................................ 1

6.2 Cooling Water Circuit .......................................................................... 2

6.3 Cutwater and Auxiliary Cutwater.......................................................... 3

6.4 Plasma Gas Circuit ............................................................................. 4

6.5 Secondary Shield................................................................................ 5

6.6 Arc Start

6.6.1 Setting the Spark Gap................................................................. 6

6.6.2 Spark Gap Size Attributes ........................................................... 7

6.6.3 Spark Viewing............................................................................. 8

6.7 Fluid Schematic .................................................................................. 9

6.8 SM II Interface PCB Schematic............................................................ 10

6.9 Technical Guide to SmartFlow II Process Diagnostics

6.9.1 Plasma Process Timer Values for Vision Cutting Record File

PARAM.CUT and Interpretation Data File DEF.TEC................................

6.9.2 Vision Keyboard Functions for Plasma System Test .....................

6.9.3 Proportional Valve Analog Flow Values for Vision Cutting Record

File PARAM.CUT and Interpretation File DEF.TEC.................................. 13

6.9.4 Gas Selection Requirements .......................................................

6.9.5 Plasma Process Gas Flowchart ...................................................

6.9.6 Solenoid and Proportional Valve Requirements – Station ON

Flush Cycle...........................................................................................

11 12

13 14

15

ii

Table of Contents

6.9.7 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas N

Error Monitoring Requirements SFII— N2— N2..................................... 16

6.9.8 Solenoid and Proportional Valve Requirements –

PT-19XLS/PT-600 Start Gas H-35, Cut Gas H-35 ................................. 18

Error Monitoring Requirements SFII— H-35— H-35............................ 18

6.9.9 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas N

Error Monitoring Requirements SFII— N2— H-35 ................................ 20

6.9.10 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas N

Error Monitoring Requirements SFII— N2— O2.................................... 22

6.9.11 Solenoid and Proportional Valve Requirements – PT-15XL Start Gas N

, Cut Gas N2....................................................... 24

2

Error Monitoring Requirements SFII— N2— N2..................................... 24

6.9.12 Solenoid and Proportional Valve Requirements –

PT-15XL Start Gas N

, Cut Gas O2...................................................... 26

2

Error Monitoring Requirements SFII— N2— O2.................................... 26

6.9.13 Solenoid and Proportional Valve Requirements –

PT-15XL Start Gas H-35, Cut Gas H-35.............................................. 28

Error Monitoring Requirements SFII— H-35— H-35............................ 28

6.9.14 Solenoid and Proportional Valve Requirements – PT-15XL Start Gas N

, Cut Gas H-35 .................................................. 30

2

Error Monitoring Requirements SFII— N2— H-35 ................................ 30

, Cut Gas N2..........................................

2

, Cut Gas H-35...................................... 20

2

, Cut Gas O2.......................................... 22

2

16

6.9.15 SmartFlow II Test Files............................................................... 32

6.10 Secondary Shield Proportional Valve Calibration Procedure................ 38

Section 7 Replacement Parts

7.1 General............................................................................................... 1

7.2 Ordering ............................................................................................. 1

7.3 Right Inside without H-35 Option......................................................... 2

7.4 Right Inside with H-35 Option.............................................................. 4

7.5 Front Outside...................................................................................... 6

7.6 Left Inside........................................................................................... 8

7.7 Back Outside...................................................................................... 10

Customer/Technical Information Back Manual Cover

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iv

SECTION 1 SAFETY

1.1 Introduction

ESAB cutting machines are designed to provide both

1.2 Safety Notations And Symbols

!

DANGER

!

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.

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.

WARNING

!

CAUTION

!

CAUTION

NOTICE

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.

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SECTION 1 SAFETY

1.3 General Safety Information

WARNING

!

Failure to follow operating instructions could result in death or serious injury.

Read and understand this operator’s manual before

Read and understand this operator’s manual before Read and understand this operator’s manual before using machine.

using machine.

using machine.using machine.

• Read entire p

Read entire procedure before operating or

Read entire pRead entire p 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 damage.

equipment damage.

equipment damage.equipment damage.

• All safety precautions relevant to elect

All safety precautions relevant to electrical

All safety precautions relevant to electAll safety precautions relevant to elect 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.

rocedure before operating or

rocedure before operating or rocedure before operating or

rical

rical rical

• 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.

Failure to follow safety warning label

WARNING

!

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 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 information.

information.

information.information.

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SECTION 1 SAFETY

1.4 Installation Precautions

WARNING

!

Improperly Installed Equipment Can Cause Injury Or Death.

Follow these guidelines while installing machine:

Follow these guidelines while installing machine:Follow these guidelines while installing machine:

• Do not connect a cylinder directl

Do not connect a cylinder directly to machine inlet.

Do not connect a cylinder directlDo not connect a cylinder directl An appropriate cylinder regulator must be installed

An appropriate cylinder regulator must be installed

An appropriate cylinder regulator must be installed An appropriate cylinder regulator must be installed on a fuel gas cylinder to reduce pressure to a

on a fuel gas cylinder to reduce pressure to a

on a fuel gas cylinder to reduce pressure to a on a fuel gas cylinder to reduce pressure to a reasonable inlet supply pressure. Machine

reasonable inlet supply pressure. Machine

reasonable inlet supply pressure. Machine reasonable inlet supply pressure. Machine regulator is then used to obtain pressure required

regulator is then used to obtain pressure required

regulator is then used to obtain pressure required regulator is then used to obtain pressure required by torches.

by torches.

by torches.by torches.

• Contact your ESAB representati

Contact your ESAB representative before

Contact your ESAB representatiContact your ESAB representati installation. He can suggest certain precautions

installation. He can suggest certain precautions

installation. He can suggest certain precautions installation. He can suggest certain precautions regarding piping installation and machine lifting,

regarding piping installation and machine lifting,

regarding piping installation and machine lifting, regarding piping installation and machine lifting, etc. to ensure maximum security.

etc. to ensure maximum security.

etc. to ensure maximum security.etc. to ensure maximum security.

• Never attempt any machine modifications or

Never attempt any machine modifications or

Never attempt any machine modifications or Never attempt any machine modifications or apparatus additions without first consulting a

apparatus additions without first consulting a

apparatus additions without first consulting a apparatus additions without first consulting a qualified ESAB represe

qualified ESAB representative.

qualified ESAB represequalified ESAB represe

• Observe machine clearance requirements for

Observe machine clearance requirements for

Observe machine clearance requirements for Observe machine clearance requirements for proper operation and personnel safety.

proper operation and personnel safety.

proper operation and personnel safety. proper operation and personnel safety.

ntative.

ntative.ntative.

y to machine inlet.

y to machine inlet. y to machine inlet.

ve before

ve before ve before

• Always have qualified personnel perform

Always have qualified personnel perform

Always have qualified personnel perform Always have qualified personnel perform installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of

installation, troubleshooting and maintenance of installation, troubleshooting and maintenance of this equipment.

this equipment.

this equipment.this equipment.

• Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with

Provide a wall mounted disconnect switch with Provide a wall mounted disconnect switch with proper fuse s

proper fuse sizes close to the power supply.

proper fuse sproper fuse s

izes close to the power supply.

izes close to the power supply.izes close to the power supply.

Smart Flow II Plasma Cutting System

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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.

Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into

Machine must be properly grounded before put into Machine must be properly grounded before put into

ice.

ice.ice.

serv

service.

servserv

Improper Grounding Can Damage

WARNING

!

Machine And Electrical Components.

• Machine must be properly gr

Machine must be properly grounded before put

Machine must be properly grMachine must be properly gr

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.

ounded before put

ounded before put ounded before put

a good

a good a good

1.6 Operating A Plasma Cutting Machine

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 from burns and flying

goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying

debris generated during operation.

debris generated during operation.debris generated during operation.

• Chipped slag may be hot and fly far. Bystand

Chipped slag may be hot and fly far. Bystanders

Chipped slag may be hot and fly far. BystandChipped slag may be hot and fly far. Bystand

should also wear goggles and safety glasses.

should also wear goggles and safety glasses.should also wear goggles and safety glasses.

• Noise from plasma arc can damage hearing. Wear

Noise from plasma arc can damage hearing. Wear

Noise from plasma arc can damage hearing. Wear Noise 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.

ers

ers ers

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SECTION 1 SAFETY

WARNING

!

WARNING

!

Burn hazard.

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 to cool, or douse with

cutting. Allow metal time to cool, or douse with

cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with 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 ti

cutting. Allow torch time to cool.

cutting. Allow torch ticutting. Allow torch ti

me to cool.

me to cool.me to cool.

Hazardous voltages. Electric shock can kill.

• Do NOT touch plasma torch, cutting table o

Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table oDo NOT touch plasma torch, cutting table o 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 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 servicing any system component.

before servicing any system component.

before servicing any system component.before servicing any system component.

• Do not touch live electrica

Do not touch live electrical parts.

Do not touch live electricaDo not touch live electrica

l parts.

l parts.l parts.

r cable

r cable r cable

• 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.

• Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to

Wear insulating gloves, shoes and clothing to Wear insulating gloves, shoes and clothing to insulate yourself from workpiece and electrical

insulate yourself from workpiece and electrical

insulate yourself from workpiece and electrical insulate yourself from workpiece and electrical ground.

ground.

ground.ground.

• 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.

• Replac

Replace worn or damaged cables.

ReplacReplac

e worn or damaged cables.

e worn or damaged cables.e worn or damaged cables.

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SECTION 1 SAFETY

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 process ca

process can be hazardous to your health.

process caprocess ca

• 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.

• Use additional ventilation to remove fumes if

Use additional ventilation to remove fumes if

Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if

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.

• Provide posit

Provide positive mechanical ventilation when

Provide positProvide posit

cutting galvanized steel, stainless steel, copper,

cutting galvanized steel, stainless steel, copper, cutting galvanized steel, stainless steel, copper,

zinc, beryllium, or cadmium. Do not breathe these

zinc, beryllium, or cadmium. Do not breathe these zinc, beryllium, or cadmium. Do not breathe these

fumes.

fumes.fumes.

• Do not operate near degreasing and spraying

Do not operate near degreasing and spraying

Do not operate near degreasing and spraying Do not operate near degreasing and spraying

operations. Heat or arc rays can react with

operations. Heat or arc rays can react with operations. Heat or arc rays can react with

chlorinated hydrocarbon v

chlorinated hydrocarbon vapors to form phosgene,

chlorinated hydrocarbon vchlorinated hydrocarbon v

a highly toxic gas and other irritant gases.

a highly toxic gas and other irritant gases. a highly toxic gas and other irritant gases.

n be hazardous to your health.

n be hazardous to your health.n be hazardous to your health.

ive mechanical ventilation when

ive mechanical ventilation when ive mechanical ventilation when

apors to form phosgene,

apors to form phosgene, apors to form phosgene,

Smart Flow II Plasma Cutting System

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SECTION 1 SAFETY

WARNING

!

Radiation hazard.

Arc rays

Arc rays can injure eyes and burn skin.

Arc rays Arc rays

• Wear correct eye and body protection.

• Wear dark safety glasses or goggles with side

• Replace glasses/goggles when lenses are pitted or

• Warn others in area not to look directly at the arc

• Prepare cutting a

can injure eyes and burn skin.

can injure eyes and burn skin.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 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 to 100 Amps

Up to 100 Amps Shade N

Up to 100 AmpsUp to 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 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 unless wearing appropriate safety glasses.

unless wearing appropriate safety glasses.

unless wearing appropriate safety glasses.unless wearing appropriate safety glasses. Prepare cutting area to reduce reflection and

Prepare cutting aPrepare cutting a transmission of ultraviolet light.

transmission of ultraviolet light.

transmission of ultraviolet light.transmission of ultraviolet light.

§ Paint walls and other surfaces with dark

Paint walls and other surfaces with dark

Paint walls and other surfaces with dark Paint walls and other surfaces with dark

colors to reduce reflections.

colors to reduce reflections.colors to reduce reflections.

Lens Shade

Lens Shade Lens Shade

Shade No. 8

Shade NShade N

Shade No. 10

Shade No. 10Shade No. 10 Shade No. 12

Shade No. 12Shade No. 12

Shade No. 14

Shade No. 14Shade No. 14

rea to reduce reflection and

rea to reduce reflection and rea to reduce reflection and

o. 8

o. 8o. 8

§ Install protective screens or curtains to

Install protective screens or curtains to

Install protective screens or curtains to Install protective screens or curtains to

reduce ultraviolet transmission.

reduce ultraviolet transmission.reduce ultraviolet transmission.

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SECTION 1 SAFETY

WARNING

!

Ruptured Gas Cylinders Can Kill

Mishandl

Mishandling gas cylinders can rupture and violently

MishandlMishandl release gas.

release gas.

release gas. 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

• Locate cylinders away from heat, sparks and

• Use approved pressure reducing regulator for the

• Refer to CGA Standard P

ing gas cylinders can rupture and violently

ing gas cylinders can rupture and violently ing gas cylinders can rupture and violently

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. 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

chain or strap to a

chain or strap to a suitable stable object not part of

chain or strap to a chain or strap to a

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

flames. Never strike an arc on a cylinder.

flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder. Use approved pressure reducing regulator for the

Use approved pressure reducing regulator for the Use approved pressure reducing regulator for the

specific gas.

specific gas.specific gas. Refer to CGA Standard P----1, “Precautions for Saf

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 Cylinders”,

available from Compressed Gas Association.

available from Compressed Gas Association.available from Compressed Gas Association.

suitable stable object not part of

suitable stable object not part of suitable stable object not part of

1, “Precautions for Safe

1, “Precautions for Saf1, “Precautions for Saf

e

e e

WARNING

!

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.

§ These alloys should only be dry cut on a dry

These alloys should only be dry cut on a dry

These alloys should only be dry cut on a dry These alloys should only be dry cut on a dry table.

table.

table.table.

§ DO NOT dry cut over water.

DO NOT dry cut over water.

DO NOT dry cut over water.DO NOT dry cut over water.

§ Contact your aluminum supplier for

Contact your aluminum supplier for

Contact your aluminum supplier for Contact your aluminum supplier for additional safety information rega

additional safety information regarding

additional safety information regaadditional safety information rega hazards associated with these alloys

hazards associated with these alloys

hazards associated with these alloyshazards associated with these alloys

• Do not cut in atmospheres containing explosive

Do not cut in atmospheres containing explosive

Do not cut in atmospheres containing explosive Do not cut in atmospheres containing explosive

dust or vapors.

dust or vapors.dust or vapors.

• Do not carry any combustibles on your person

Do not carry any combustibles on your person

Do not carry any combustibles on your person Do not carry any combustibles on your person

(e.g. butane lighter)

(e.g. butane lighter)(e.g. butane lighter)

• 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.

lithium (Al----Li) alloys can

lithium (Allithium (Al

Li) alloys can

Li) alloys can Li) alloys can

rding

rding rding

.

Smart Flow II Plasma Cutting System

Smart Flow II Plasma Cutting System 1-8

Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System

SECTION 1 SAFETY

WARNING

!

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns.

• 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 have on your person a

Do not have on your person any combustibles (e.g.

Do not have on your person aDo not have on your person a 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 activating

away from yourself and others when activating

away from yourself and others when activating away from yourself and others when activating 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 clothi

Wear flameWear flame areas.

areas.

areas.areas.

• Wear cuff

Wear cuff----less trousers to prevent entry of sparks

Wear cuffWear cuff and slag.

and slag.

and slag.and slag.

• Have fire extinguishing equipment available for use.

Have fire extinguishing equipment available for use.

Have fire extinguishing equipment available for use.Have fire extinguishing equipment available for use.

retardant clothing covering all exposed

retardant clothiretardant clothi

less trousers to prevent entry of sparks

less trousers to prevent entry of sparks less trousers to prevent entry of sparks

ny combustibles (e.g.

ny combustibles (e.g. ny combustibles (e.g.

ng covering all exposed

ng covering all exposed ng covering all exposed

Smart Flow II Plasma Cutting System

Smart Flow II Plasma Cutting System 1-9

Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System

SECTION 1 SAFETY

1.6 Service Precautions

WARNING

!

Hazardous voltages. Electric shock can kill.

• Do NOT touch plasma torch, cutti

Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cuttiDo NOT touch plasma torch, cutti

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.

• 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 removing covers or panels to service any

before removing covers or panels to service any before removing covers or panels to service any

system c

system component.

system csystem c

• 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.

• 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.

• Inspect power and ground leads cables for wear or

Inspect power and ground leads cables for wear or

Inspect power and ground leads cables for wear or Inspect power and ground leads cables for wear or

cracking. Replace wor

cracking. Replace worn or damaged cables. Do

cracking. Replace worcracking. Replace wor

not use if damaged.

not use if damaged.not use if damaged.

• Never bypass safety interlocks.

Never bypass safety interlocks.

Never bypass safety interlocks.Never bypass safety interlocks.

omponent.

omponent.omponent.

n or damaged cables. Do

n or damaged cables. Do n or damaged cables. Do

ng table or cable

ng table or cable ng table or cable

• Follow lock

Follow lock----out procedures.

Follow lockFollow lock

Establish and adhere to preventive maintenance. A

CAUTION

Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A composite program can be established from

composite program can be established from

composite program can be established from composite program can be established from recommended schedules.

recommended schedules.

recommended schedules.recommended schedules.

Avoid leaving test equipment

Avoid leaving test equipment or hand tools on

Avoid leaving test equipment Avoid leaving test equipment 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.

out procedures.

out procedures.out procedures.

or hand tools on

or hand tools on or hand tools on

Smart Flow II Plasma Cutting System

Smart Flow II Plasma Cutting System 1-10

Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System

SECTION 1 SAFETY

Extreme caution should be used when probing

CAUTION

!

Extreme caution should be used when probing Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damag

circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damagcircuits are susceptible to over voltage damag 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 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 guards and covers replaced before power is turned

guards and covers replaced before power is turned

guards and covers replaced before power is turned guards and covers replaced before power is turned on.

on.

on.on.

e.

e. e.

1.9 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 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.

Continued next page

Smart Flow II Plasma Cutting System

Smart Flow II Plasma Cutting System 1-11

Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System

SECTION 1 SAFETY

• “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.

Smart Flow II Plasma Cutting System

Smart Flow II Plasma Cutting System 1-12

Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System

SECTION 2 DESCRIPTION

2.1 Introduction

The SmartFlow II 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 (SSSSchneidDDDDatenPPPPaket = 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 II 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 II Plasma Cutting System

SmartFlow II Plasma Cutting System 2-1

SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System

SECTION 2 DESCRIPTION

2.3 SmartFlow II and PT-19XLS/PT-600

2.4 SmartFlow II Options

When a dry torch (no water injection) is used, the SmartFlow II 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.

SmartFlow II with H-35 capability

(H-35 is industry accepted nomenclature for a gas

mixture of 65% argon and 35% hydrogen)

P/N 37538

P/N 37538 P/N 37540

P/N 37538P/N 37538

2.5 Gas Requirements

SmartFlow II without H-35 capability

P/N 37540

P/N 37540P/N 37540

• 125 PSI (8,63 bar) with 0.5” NPT

Nitrogen

• 99.999% purity

• Filtered to 25 microns

• 125 PSI (8,63 bar) with 0.5” NPT

Oxygen

• 99.999% purity

• Filtered to 25 microns

• 100 PSI (6,9 bar) with 0.5” NPT

Compressed Air

• Clean, dry and filtered to 25

microns

• 150 PSI (10,4 bar)

H-35 (argon/hydrogen)

• Filtered to 25 microns

SmartFlow II Plasma Cutting System

SmartFlow II Plasma Cutting System 2-2

SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System

SECTION 2 DESCRIPTION

2.6 Water Supply Requirements

Cooling Water

• 1.5 gallons per minute (5.68 liters/minute)

• 35 PSI (2,42 bar)

• >200,000 ohms (resistance)

• 120 PSI (8,28 bar)

Deionized Water (PT-15XL only)

• .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

2.7 Electrical Input Requirements

• +24 VDC for proportional valves, flow and

Voltage Supply

pressure switches

• +15 VDC for pressure switch

• 120 VAC input to start gas solenoid valve

• 120 VAC input to cut gas solenoid valve

Voltage Signals

• 120 VAC input to arc starter

• 0-10 VDC input to proportional valves

SmartFlow II Plasma Cutting System

SmartFlow II Plasma Cutting System 2-3

SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System

SECTION 2 DESCRIPTION

2.8 Dimensions

12.12" (308mm)

15.62" (396.8mm)

7.5 " (190,5mm)

SmartFlow II Plasma Cutting System

SmartFlow II Plasma Cutting System 2-4

SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System

SECTION 3 INSTALLATION

Electricity Can Kill!

WARNING

!

3.1 Introduction

The SmartFlow II is a plumbing box that interfaces

3.2 Box Mounting

7.25"

184.2 mm

6.515"

165.5 mm

rear

2.015"

51.2 mm

Cable

Clamp

2.125" 54 mm

Before performing any maintenance or assembly of this equipment, ensure the power source (ESP) is turned off and disconnected.

with the ESAB Vision machine controls and the ESP product line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control proportional and solenoid valves. The result is CNC management of gas and cutwater or shield gas delivery to the plasma torch. Analog signal feedback is sent back to the CNC, creating a control loop.

The SmartFlow II can be used with the PT-15 water injection plasma torch or both the dry cutting PT19XLS and PT-600 plasma torches with secondary shield gas.

If mounting the box is required:

The box has four 6 mm threaded mounting holes in a pattern offset from longitudinal center. Note relationship of hole pattern to gauges and cable

Gauges

front

Bottom View

13.125"

333.4 mm

15.125"

384.2 mm

clamp.

SmartFlow II

SmartFlow II 3-1

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.3 Hose and Cable Connections

Control Cable Clamp/Strain Relief

Left side panel removed

1. Remove left side panel of the SmartFlow II box. Rotate ¼ turn fasteners counterclockwise.

2. Disassemble the strain relief/clamp block. (When apart, this strain relief will allow placement of cables and hoses without removing plugs and fittings.)

A. Remove six screws holding block to back of the

SM box.

Control Cables

Power Source Leads (4/0 cable)

B. Remove four side clamping screws.

3. Place cables in block.

4. Replace four side clamp screws. Do not tighten.

5. Reattach block using three mount screws along a vertical line.

6. Adjust cable length and tighten the four side clamp screws.

7. Finish attaching the block to the box with the other three mount screws.

8. Tighten all screws.

Pilot Arc Cable

SmartFlow II

SmartFlow II 3-2

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.3.1 Starter Box Connections

TB4/Buss connection point

TB1

TB1 – Pilot arc ground cable from the plasma

TB1TB1 power source (ESP).

TB4

TB4 – Connected to buss bar (brass block just

TB4TB4 below starter box) inside the SmartFlow box.

TB2

TB2 – Pilot Arc Torch cable from the torch leads.

TB2TB2

3.3.2 PC Board Connections

P1

P1 – 12 pin connector, CNC control lead (valves)

P1 P1 P2

P2 – 8 pin connector, CNC control lead (cutwater/

P2P2 secondary shield)

P3

P3 – 10 pin connector, CNC control lead (cut gas)

P3P3

P1

P3

P6

P6 – Cooling water flow switch

P6P6 P8

P8 – High frequency arc start AC power

P8P8 P9

P9 – Voltage divider

P9P9

P9

P2

P8

P6

Reverse side (not shown) P4

P4 – 10 pin connector, valve control lead (valves)

P4P4 P5

P5 – 8 pin connector, manifold control lead

P5P5 (cutwater/ secondary shield)

P7

P7 – 12 pin connector, manifold control lead (cut

P7P7

To arc start buss

gas)

Note:

Note:Note: For more detailed information, refer to PC board

For more detailed information, refer to PC board

For more detailed information, refer to PC board For more detailed information, refer to PC board schematic in Section 6.

schematic in Section 6.

schematic in Section 6.schematic in Section 6.

SmartFlow II

SmartFlow II 3-3

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.3.3 Torch Cooling Water Connections

AIR

CUT WATER

SERIAL

NUMBER

COOLING WATER

OUT

IN

Coolant Connections To and From Power Source

Coolant Connections To and From Power SourceCoolant Connections To and From Power Source

When packaged with a torch and power supply at the factory, connections are labeled. Additional labels are available if re-labeling becomes necessary. Tracing Smart Flow II interior lines can identify the proper connections. Flow switch is located on the “IN” line.

Coolant

OUT

(from

torch)

Coolant Connections To And From Torch

Coolant Connections To And From TorchCoolant Connections To And From Torch

Note arrows on fittings indicating coolant flow

OUT

IN

Left Side Panel Removed

Coolant

IN (to

torch)

direction. Coolant Out

Coolant Out has right-hand threads.

Coolant OutCoolant Out Coolant In

Coolant In has left-hand threads

Coolant InCoolant In

3.3.4 Power Source To SMF II Buss Connection

4/0 power

source cable

Buss

1. Strip 4/0 insulation, approximately 1½” (38 mm).

2. Insert 4/0 cable in buss hole until copper extends to the edge of the buss block.

3. Tighten locking screw(s) on cable.

Note: The buss will accommodate three cables.

(1) 4/0 – 400 amps (2) 4/0 – 750 amps (3) 4/0 – 1000 amps

Careful attention while stripping insulation

NOTICE

will make installation of the 4/0 cable in the buss easier. Do not spread or flare the copper conductors.

SmartFlow II

SmartFlow II 3-4

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.4 Nomex Insulation

Arc Start Box

Nomex Insulation

Buss

High Frequency Cable from ESP Power Source

Position Nomex insulation to prevent any possible arcing between the buss and arc start box terminals.

Replace side panels of SmartFlow II enclosure.

3.5 Gas Connections

3.5.1 Gas Lines From Supply.

Gas Connections are made on the exterior of the SM box. Gas lines are connected to the back from supply sources and the front for the torch.

Unfiltered Gas Will Clog Proportional

CAUTION

Valves

Dirt particles will clog small orifices in proportional valves.

All gas supplies must have a 25 micron filter installed between supply and gas regulator panel. EASB Filter P/N 56998133 (replacement filter element P/N 0560988406)

When using the PT-19XLS or PT-600 torch with a secondary shield, air supply must be filtered and dry using a minimum 25 micron filter.

Proportional valves contain no serviceable parts. Replace valve assembly with factory parts.

SmartFlow II

SmartFlow II 3-5

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

Gas Line Contamination Will Damage

CAUTION

1

2

NITROGEN

Proportional Valves

Purge Gas Lines

Before connecting gas delivery lines to the SmartFlow II, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your SmartFlow II.

1. Purge gas and air lines completely before connecting to 25 micron gas filters.

3

OXYGEN

4

5

H-3 5

AIR

CUT WATER

SERIAL

NUMBER

COOLING WATER

OUT

IN

Back of SM II Plumbing Box

1 Nitrogen (N2) 2 Oxygen (O2) 3 H-35 (65%Argon, 35% Hydrogen) Optional 4 Torch Air 5 Secondary Shield or Cutwater (depends on torch

2. Connect oxygen, H-35, nitrogen and airlines to gas filters.

3. Purge gas/air lines between regulator panel and SmartFlow II plumbing box.

4. Connect gas/air lines to back of plumbing box.

SmartFlow II

SmartFlow II 3-6

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.5.2 Gas Pressure Setup

Adjust pressure at the regulator panel while gas is flowing.

3.6 Cut Water Setup (PT-15XL)

Gas Type Pressure

Oxygen 125 PSI (8,63 Bar)

Nitrogen 125 PSI (8,63 Bar)

H-35 150 PSI (10,4 Bar)

A supply of deionized water is required for the installation of cutwater when using the PT-15XL. A minimum regulated pressure of 30 psi (2,07 bar)

See system requirements for description of cutwater.

supply is required to prevent cavitation in the cutwater pump.

Pressure from the cutwater pump to the SmartFlow should be adjusted to 120 psi (8,28 bar). Refer to the cutwater pump manual for this procedure.

3.7 Secondary Shield Gas Setup (PT-19XLS/PT-600)

Secondary shield gas (air or N2) must be dry and filtered to a minimum of 25 microns and regulated to 60 PSI (4,14 bar). Excess moisture in shield gas may cause arcing inside the torch and/or poor consumable life. This gas supply (pre-filtered) uses the same fitting as the cutwater hose in back of the plumbing box.

Secondary shield gas regulator

Air regulator

SmartFlow II

SmartFlow II 3-7

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.8 A Component Relationship Block Diagram

3 phase

w/ground

Remote to

CNC I/O to

Smart Flow II

CNC

25 micron

filters

E

S

n

P

t

v

i

e

w

F

ro

B

P

S

E

c

a

w

e

i

v

k

N2

(for PT-15)

O2

Regulator

Panel

Cut Water

Pump

Air

H-35

Torch (-)

Pilot Arc

Smart

Flow

II

Cooling Water

To Torch

Cooling Water

From Torch

On/Off

Control

Work (+)

WC-7

Water

Cooler

Voltage

Height

Control

Plasma Torch

Bundle and

Torch

Earth Ground

SmartFlow II

SmartFlow II 3-8

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

3.9 Fluid Schematic – SmartFlow II

Aux. Cut Water

Secondary Shield/ Cutwater IN

Gauge

Proportional Valve

Flow Switch

2 Way Solenoid Valve

PS2

PS

Valve 3

PS3

PS

Valve 2

0-100 PSI (6,9 Bar)

Check Valve

PS

Pressure Switch

Flow Restriction Orifice

Cutwater/ Secondary Shield

H-35 IN

Oxygen IN

Nitrogen IN

Air IN

Cooling Water IN

Cooling Water OUT

N2 Purge Orifice

IN

PS1

PS

OUT

Vent

0-100 PSI (6,9 Bar)

Plasma Gas

Valve 1

0-50 PSI (3,45 Bar)

Air Curtain

To Torch

SmartFlow II

SmartFlow II 3-9

SmartFlow IISmartFlow II

SECTION 3 INSTALLATION

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SmartFlow II

SmartFlow II 3-10

SmartFlow IISmartFlow II

SECTION 4 OPERATION

4.1 Operation Introduction

A major advantage of the SmartFlow II is that

Note:

NOTICE

4.2 Pressure Gauges

operating parameters are managed by the machine CNC. There are no operating procedures necessary with the SmartFlow II. Management is accomplished either with manual inputs on the Vision cutting parameter screen or using the ESAB system of Process Parameter Files.

Process Parameter Files (know by the acronym … SDP

SDP for SSSSchneidDDDDatkenPPPPaket) are files stored in the

SDPSDP Vision Control memory containing all necessary information for cutting a thickness and a material type. It is specific to material, thickness, torch model, gas and material type. The information used to create SDP files can be found in your torch manual under Cutting Data, Operation, Section 4. Refer to Vision CNC Part Programming manual for more detail on the creation and use of SDP files.

See your specific torch manual for cutting parameter settings for using the SmartFlow II Plumbing Box. These settings can be found in the form of cutting data charts located in the operation section of the torch manual.

Pressure gauges display actual pressure to the

torch. They provide visual feedback to the operator, and can be helpful in spotting torch problems.

4.3 Pressure Switches.

Pressure switches monitor line pressure and

Sm

Smart Flow II

SmSm

provide inputs to the CNC. If the pressure drops below a preset level, the CNC can shut the process down. Switches are in-line between the solenoid and the proportional valve for cut water (or secondary shield), H-35, and oxygen/nitrogen lines.

art Flow II 4-1

art Flow IIart Flow II

SECTION 4 OPERATION

This page intentionally left blank.

Sm

Smart Flow II

art Flow II 4-2

SmSm

art Flow IIart Flow II

SECTION 5 Maintenance

5.1 SmartFlow II Maintenance Introduction

This section provides adjustment or replacement

procedures for those serviceable parts inside the SmartFlow II plumbing box. Only trained personnel should perform maintenance on this equipment.

Electric Shock Can Kill!

WARNING

!

CAUTION

!

Always disconnect power from the ESP power source and the cutting machine before opening or servicing the SmartFlow II plumbing box.

Only Qualified Maintenance Personnel Should Repair And Maintain This Equipment.

Smart Flow II

Smart Flow II 5-1

Smart Flow IISmart Flow II

SECTION 5 Maintenance

5.2 Pressure Switches

P5

1

2

P7

Gas Pressure Switch

Gas Pressure Switch monitors the pressure of

Gas Pressure SwitchGas Pressure Switch plasma gas supply to the plumbing box. One switch monitors both O

and N2 gases. An

2

additional switch is used for monitoring the H-35 option.

Note:

Note:Note: H-35 is an industry name for a mixture of 65 % argon and 35% hydrogen.

Cut Water/Secondary Shield Switch

Cut Water/Secondary Shield Switch monitors the

Cut Water/Secondary Shield SwitchCut Water/Secondary Shield Switch pressure of either cutwater or secondary shield gas, depending on the torch application.

3

4

5

6

1 H-35 (Argon/Hydrogen) Pressure Switch 2 Plasma Gas Pressure Gauge Tap 3 O2/N2 Plasma Gas Pressure Switch 4 Air Curtain Pressure Gauge Tap 5 Cut Water/Secondary Shield Pressure Switch 6 Cut Water Pressure Gauge Tap

These switches are wired as an input to the CNC. Logic codes in the control look for a change of state (low/high) of the input signals, therefore these switches cannot be jumpered out of the circuit.

Both pressure switches are factory set and nonadjustable to close at 50 PSI (3.45 Bar). They contain no serviceable parts. Replacement P/N

952920.

Smart Flow II

Smart Flow II 5-2

Smart Flow IISmart Flow II

SECTION 5 Maintenance

g

5.3 Spark Gap Of the Arc Starter

The SmartFlow II uses a high frequency arc starter to initiate the plasma arc within the cutting torch. The arc starter box is mounted in the upper right corner of the plumbing box. The arc starter box contains an adjustable spark gap.

The recommended spark gap setting is

0.040" (1,0 mm).

0.040" (1,0 mm).0.040" (1,0 mm).

HIGH

Decreased Spark Gap from 0.040” (1 mm):

Decreased Spark Gap from 0.040” (1 mm):Decreased Spark Gap from 0.040” (1 mm):

e

Starting Reliability

• Negative Effect- starting reliability is decreased

• Positive Effect – smaller risk of high frequency

interference

h Frequency

Increased Spark Gap from 0.040” (1 mm):

Increased Spark Gap from 0.040” (1 mm):Increased Spark Gap from 0.040” (1 mm):

• Negative Effect – increased damage risk from

Risk of High Frequency

Risk of Hi

Risk of High Frequency

Risk of Hi

Interference Dama

Interference Damage

Interference Dama

high frequency interference

• Positive Effect - starting reliability increased (to a

LOW

0

.040"

(1 mm)

Spark Gap

Spark GapSpark Gap

point where it doesn’t work at all).

High Frequency Interference Can Damage

CAUTION

Machine Electronic Components

Potentially damaging high frequency interference may result from increasing the spark gap beyond recommendation. This electrical interference may find its’ way to pc boards in the electronics cabinet or Vision control. The result will be failure of some portion of machine function.

Do not set spark gap beyond

recommended distance of 0.040”””” (1,0 mm)

Smart Flow II

Smart Flow II 5-3

Smart Flow IISmart Flow II

SECTION 5 Maintenance

Electric Shock Can Kill!

WARNING

!

5.4 Spark Adjustment Procedure

Always turn power off before opening and servicing the SmartFlow II plumbing box.

1. Disconnect input power to plasma power source (ESP) and cutting machine.

2. Remove left and right side covers from the SmartFlow II. Mounting screws for the arc starter box are accessed from the manifold side (right side) of the SM II.

1111

Spark Gap Access

2222

Fiber Optic Cable

3333

Spark Gap of 0.040” (1 mm)

3. Disconnect fiber optic cable from arc starter box.

4. Remove arc starter box. Mounting screws are accessed from the opposite side of the SM II. Removal of gauge(s) may be necessary to see some screws.

1

2

3

ARC Starter Box

5. Remove access cover from the arc starter.

6. Use a 0.040” (1 mm) feeler gauge or shim to measure the spark gap setting.

7. Adjust as required. When correctly adjusted, there should be slight pressure felt when a back and forth motion is applied to the shim.

8. Replace access cover and remount arc starter box.

9. Replace side panels.

Smart Flow II

Smart Flow II 5-4

Smart Flow IISmart Flow II

SECTION 5 Maintenance

5.5 Gas Proportional Valves

P/N 0558001068

Proportional Valve

N

2/O2

Gas proportional valves contain no user serviceable parts. In case of failure, the valve must be replaced.

P/N 0558001065 H-35 Proportional Valve Easily distinguishable with nickel-plated valve body. Gas proportional valves contain no user serviceable parts. In case of failure, the valve must be replaced.

5.6 Cutwater/Secondary Shield Proportional Valve

P/N 56997044 This proportional valve contains no user serviceable parts. The valve must be replaced in case of failure. This is the only valve that can be calibrated if necessary. See troubleshooting section for calibration procedure.

Smart Flow II

Smart Flow II 5-5

Smart Flow IISmart Flow II

SECTION 5 Maintenance

5.7 Cooling Water Flow Switch

P/N 636383

2

1

2

3

4

The cooling water circuit uses a 1.0 gallon (3.8 liters) flow switch to monitor cooling water flow. It measures actual flow through the torch in the cooling water return line.

The switch is wired as an input to the CNC. The control looks for a change of state of the input signal when the plasma station is turned on. This switch cannot be jumpered out of the circuit.

Type of cooling water problems:

• Insufficient flow due to a restriction in the

cooling water circuit.

The switch may be disassembled and cleaned if found to have a restriction.

• Sufficient flow but no flow closure.

If measurement of the actual cooling water flow rate indicates more than 1.0 gallon (3.8 liters) per minute, but the switch does not close, the switch may be damaged or clogged. Clean or replace as necessary.

1

1 Retainer Ring 2 Flow Switch 3 Spring 4 Piston

Smart Flow II

Smart Flow II 5-6

Smart Flow IISmart Flow II

SECTION 5 Maintenance

5.8 Gas Filters

Nitrogen, oxygen, and secondary shield gases must

be filtered before entering the SmartFlow II. Check these filters regularly (dependent on usage and cleanliness of supply). Replace filter as required.

Unfiltered Gas Will Clog Proportional

CAUTION

Valves

Gas filters must be installed in the gas supply lines in front of the gas regulator panel. A 25 micron filter is required. P/N 56998133. Replacement filter element P/N 0560988406

Smart Flow II

Smart Flow II 5-7

Smart Flow IISmart Flow II

SECTION 5 Maintenance

This page intentionally left blank.

Smart Flow II

Smart Flow II 5-8

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

Electric Shock Can Kill!

WARNING

!

6.1 Troubleshooting Introduction

The SmartFlow II has proven to be a very reliable

Disconnect power before removing side panels.

product. Regular maintenance is important for many years of trouble free use. This section contains a brief description of the most common problems, schematics, and technical diagnostic tools.

• Cooling Water Circuit

• Cut Water

• Plasma Gas

• Secondary Shield

• Spark

• Process Diagnostics

The SmartFlow II is designed to support the PT15XL, PT-19XLS and PT-600 plasma torches.

• The PT-15XL torch uses cutwater.

• PT-19XLS and PT-600 torches introduce a

secondary gas shield. Secondary shield utilizes the same solenoid and proportional valve used for the cutwater on the PT-15XL.

All gases supplied to the SmartFlow II

CAUTION

must be filtered to 25 microns. Small

orifices in proportional valves will become clogged if filters are neglected or bypassed. Do Not Attempt to Clean. Replacement of manifold assembly may be necessary. Replacement of proportional valves only is possible. Thoroughly flush manifold and gas lines with N2 before reassembly. Because proportional valves contain the smallest gas passages, replacement or cleaning of check valves is not recommended.

Avoid any potential problems by appropriately filtering plasma and shield gases.

Smart Flow II

Smart Flow II 6-1

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.2 Cooling Water Circuit

The cooling water circuit consists of two reverse

5

1 Torch 2 To torch check valve 3 Flow Switch 4 Return coolant check valve 5 Water cooler

4

2

3

1

flow check valves and a flow switch. It is a closed loop re-circulating system which cools the electrode

and torch body of the PT-15XL torch. The PT19XLS and PT-600 torches have electrode, nozzle, nozzle retaining cup, and torch body cooled by this system.

The primary concern of the cooling water system is the flow rate. Insufficient cooling flow can result in severe damage to the consumables and torch body.

The cooling water flow switch is calibrated to close at or above a flow rate of 1 gallon (3.8 liters) per minute. If the flow rate drops below this rate, a signal is sent to the CNC and the plasma system is shut down.

5

3

2

6

4

1 Buss Block 2 Coolant line – to torch (from cooler) 3 Coolant line – from torch (to cooler) 4 Flow switch 5 Check Valve – from torch 6 Check Valve – to torch

1

Smart Flow II

Smart Flow II 6-2

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.3 Cut Water and Auxiliary Cut Water

SmartFlow II Manifold

SmartFlow II ManifoldSmartFlow II Manifold

9

8

6

7

5

3

4

2

1

• Cutwater is used with the PT-15 XL torch.

• Deionized water is supplied

➀➀➀➀ to the

plumbing box cutwater solenoid valve

• Check valves built into the manifold are

positioned to prevent back flow to the solenoids. See Schematic below.

• A port inside the manifold re-routes

additional cutwater to the auxiliary cutwater solenoid

➂➂➂➂. This option is used when

cutting with Ar/H2 (H-35) to provide additional cutwater flow. Maximum water flow, with auxiliary water solenoid open and the cutwater proportional valve set to maximum, is 1.5 gpm.

➁➁➁➁.

1 De-ionized cutwater supply connection 2 Cutwater solenoid 3 Aux. Cutwater solenoid 4 Cutwater pressure tap 5 Cutwater Pressure switch 6 Aux cutwater supply hose 7 Cutwater hose manifold to proportional valve 8 Cutwater proportional valve

9 Cutwater torch connection 10 Check valve 11 Cutwater Gage

12 Aux. Cutwater Restriction Orifice

11

4

12

• Back pressure thru the auxiliary cutwater

hose

➅➅➅➅ provides pressure to the cutwater

pressure tap

➃➃➃➃ and line to the cutwater

gauge.

UUUU

• Cutwater pressure switch

is preset and nonadjustable to 50 psi. If pressure drops below 50 psi, a signal is sent to the machine control and process is shut down.

• Cutwater proportional valve

➇➇➇➇ provides a

means of controlling flow at the CNC. This value is automatically set if using SDP files to control cutting parameters. (SDP SSSSchneidDDDDatenPPPPaket = cutting data package contain all the same information that can be individually adjusted on the Vision control process parameter screen. See Vision Programming Manual.)

3

9

8

Cutwater Flow Schematic

PS

5

10

2

1

Smart Flow II

Smart Flow II 6-3

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.4 Plasma Gas

Plasma gases are controlled with proportional

valves mounted on the manifold.

15

14

13

9101112

PS

1

PS

2

3

4

8

567

1 H-35 connection (used only on P/N 37538) 2 Oxygen supply connection 3 Nitrogen supply connection 4 Air curtain supply connection 5 Solenoids 6 Check valves 7 Nitrogen purge orifice 8 Air gage 0-50 psi 9 Nitrogen/oxygen pressure switch 10 H-35 pressure switch (used only on P/N 37538) 11 H-35 proportional valve (used only on P/N 37538) 12 Nitrogen/oxygen proportional valve 13 Plasma gas gage 0-100 psi 14 Plasma gas 15 Air curtain

Note:

Note:Note: Part number 37538, SmartFlow II with H-35,

includes all of the components listed at left. Part number 37540, SmartFlow II without H-35

capabilities, does not include items 1, 10, and

11. The auxiliary water is not removed because of improved piercing of thicker materials when using PT-19 and PT-600. Squarer cuts in thicker materials are also possible using the auxiliary cutwater path for additional shield gas flow.

Smart Flow II

Smart Flow II 6-4

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.5 Secondary Shield

SmartFlow II Manifold

SmartFlow II ManifoldSmartFlow II Manifold

9

1 Shield Gas Supply Connection 2 Secondary Shield Gas Solenoid 3 Auxiliary Shield Gas Solenoid 4 Secondary Shield Pressure Tap 5 Secondary Shield Pressure Switch 6 Secondary Shield Supply Hose 7 Shield Gas Hose To Proportional Valve 8 Secondary Shield Gas Proportional Valve

9 Shield Gas Torch Connection 10 Check Valve 11 Shield Gas Gage

8

6

7

5

3

4

1

2

• Secondary shield gas is used with the PT-

19XLS and PT-600 torches (dry torches)

• Shield gas (nitrogen or air) is supplied

the shield gas solenoid valve

➁➁➁➁.

• Check valves built into the manifold are

positioned to prevent back flow to the solenoids. See Schematic below.

• A port inside the manifold re-routes

additional shield gas to the secondary shield gas solenoid

➂➂➂➂. This option is used when

piercing may require an addition “blast”.

• Back flow thru the secondary shield gas

➅➅➅➅ provides pressure to the shield gas

hose pressure tap

➃➃➃➃.

• Secondary Shield pressure switch

preset and nonadjustable to 50 psi. If pressure drops below 50 psi, a signal is sent to the machine control and process is shut down.

• Shield gas proportional valve

➇➇➇➇ provides a

means of controlling flow at the CNC. This value will be automatically set if using SDP files to control cutting parameters. (SDP SSSSchneidDDDDatenPPPPaket = cutting data package contain all the same information that can be individually adjusted on the Vision control process parameter screen. See Vision Programming Manual.

UUUU

➀➀➀➀ to

is

9

8

Shield Gas Fluid Schematic

11

12

4

PS

5

10

3

1

2

Smart Flow II

Smart Flow II 6-5

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.6 Arc Start

WARNING

!

6.6.1 Setting the Spark Gap

The Arc Spark Gap inside the spark box should be

Electric Shock Can Kill

Disconnect Power before attempting any repairs,

Disconnect Power before attempting any repairs, Disconnect Power before attempting any repairs, disassembly or adjustments.

disassembly or adjustments.

disassembly or adjustments.disassembly or adjustments.

set to 0.040".

Note: Evidence of a spark can be confirmed at the

Note: Evidence of a spark can be confirmed at the Note: Evidence of a spark can be confirmed at the front of the plumbing box during normal operations.

front of the plumbing box during normal operations.

front of the plumbing box during normal operations. front of the plumbing box during normal operations. See 6.6.3.

See 6.6.3.

See 6.6.3.See 6.6.3.

Procedure

ProcedureProcedure

1

2

3

1 Spark Gap Access 2 Fiber Optic Cable 3 Spark Gap of 0.040"""" (1 mm)

1. Disconnect electricity to plasma power source (ESP) and cutting machine.

2. Remove left and right side covers from the SmartFlow II. Mounting screws for the arc starter box are accessed from the manifold side (right side) of the SM II.

3. Remove arc starter box, being careful not to damage the fiber optic cable.

4. Remove access cover from the arc starter.

5. Use a 0.040" (1 mm) feeler gauge or shim to measure the spark gap setting.

6. Adjust as required. When correctly adjusted, there should be slight pressure felt when a back and forth motion is applied to the shim.

7. Replace access cover and remount arc starter box.

8. Replace side panels.

ARC Starter Box

Smart Flow II

Smart Flow II 6-6

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.6.2 Spark Gap Size Attributes

HIGH

Decreased Spark Gap of 0.040" (1 mm):

Decreased Spark Gap of 0.040" (1 mm):Decreased Spark Gap of 0.040" (1 mm):

Starting Reliability

• Negative Effect- starting reliability is decreased

• Positive Effect – smaller risk of high frequency

interference

Increased Spark Gap of 0.040" (1 mm):

Increased Spark Gap of 0.040" (1 mm):Increased Spark Gap of 0.040" (1 mm):

• Negative Effect – increased risk of damage from

Risk of High Frequency

Interference Damage

Risk of High Frequency

Interference Damage

high frequency interference

• Positive Effect - starting reliability increased (to a

LOW

0

.040"

(1 mm)

Spark Gap

Spark GapSpark Gap

point where it doesn’t work at all).

High Frequency Interference Can Damage

CAUTION

Machine Electronic Components

Potentially damaging high frequency interference may result from increasing the spark gap beyond recommendation. This electrical interference may find its way to pc boards in the electronics cabinet or Vision control. The result can be failure of some portion of machine function.

Do not set spark gap beyond

recommended distance of 0.040"""" (1,0 mm)

Smart Flow II

Smart Flow II 6-7

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.6.3 Spark Viewing

The spark can be seen from the front of the plumbing box without removing any covers. An optical cable is connected from the arc start box to a view port on the bottom left front corner of the plumbing box

AIR CURTAIN

60

CUT GAS

100

To Pilot Arc

Start Box

CUT WATER

100

AIR CURTAIN

CUT GAS

CUT WATER

SparkView Port

Smart Flow II

Smart Flow II 6-8

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.7 Fluid Schematic

Aux. Cut Water

Cutwater/ Secondary Shield Gas IN

Gauge

Proportional Valve

Flow Switch

2 Way Solenoid Valve

PS2

PS

Valve 3

PS3

PS

Valve 2

0-100 PSI (6,9 Bar)

Check Valve

PS

Pressure Switch

Flow Restriction Orifice

Cutwater/ Secondary Shield Gas

H-35 IN

Oxygen IN

Nitrogen IN

Air IN

Cooling Water IN

Cooling Water OUT

N2 Purge Orifice

IN

PS1

PS

OUT

Vent

0-100 PSI (6,9 Bar)

Plasma Gas

Valve 1

0-50 PSI (3,45 Bar)

Air Curtain

To Torch

Smart Flow II

Smart Flow II 6-9

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.8 SmartFlow II Interface PCB Schematic

V2PWR

V1PWR

P4

C1

0.1MFD

P1

1

V

A

L

V

E

3

+

2

C

4

V

D

2

V

E

A

V

L

3

VALVE 2 +24 VDC

4

VALVE 2 P-SENSOR

PROVISIONAL

5

V

A

E

V

L

6

E

V

A

L

7

L

V

A

E

PROVISIONAL

8

VALVE 1 SET PT. 24 VDC GROUND

9

10

24 VDC GROUND

11

CHASSIS GROUND

12

.

T

P

E

T

S

3

2

S

T

E

.

T

P

V

4

D

C

2

+

1

P

-

S

E

N

O

P2

1

CUT WATER P-SENSOR +

2

CUT WATER P-SENSOR -

3

PRES. SW. 15 V. SOURCE (SR1)

4

PRES. SW. 24 V. SOURCE (SR2)

PS1 (N2 /O2)

5

6

PS2 (CUT H2O)

7

PS3 (H-35)

FS1 (COOLING H2O)

8

9

V-DIVIDE WORK

Old wiring

configuration

V-DIVIDE ARC VOLTS

10

P3

1

SELECTOR VALVE COMMON

2

AIR

3

N2

4

ALL SELECTOR VALVES

O2

120 VAC 50/60 HZ. 7 WATTS

5

CUT H2O

6

CUT H2O AUX

7

H-35

8

ARC START AC PWR

9

ARC START AC PWR

CUT H2O

H-35

R

O2 / N2 GAS

PROVISIONAL

2

New wiring

P9

configuration

01/28/01

1

N

E

R

A

H

S

3

V

E

A

L

V

N

R

A

H

S

E

A

V

2

V

E

L

HARNESS

E

V

L

A

V

1

PROVISIONAL

1

A

V

3

V

E

L

(RED)

3

(WHITE)

1

(RED)

6

(WHITE)

3

(GREEN)

1

(RED)

6

(WHITE)

3

(GREEN)

2

(BLACK)

V

A

V

L

VALVE 2 +24 VOLTS

V

L

A

V

2

E

V

L

A

V

E

1

A

L

V

VALVE 1 P-SENSOR

A

L

V

VALVE GNDS

VALVE SHIELDS

CUT WATER P-SENSOR +

CUT WATER P-SENSOR -

(O2 / N2)

(CUT H2O)

(H-35)

(COOLING H2O)

CUT H2O AUX

ARC START AC PWR

2

+

E

3

-

P

E

2

+

2

4

E

1

4

S

CUT H2O

O

V

S

T

L

S

E

T

P

.

T

N

S

E

O

R

T

E

S

P

.

T

S

L

O

V

T

P

E

S

T

.

PS1

PS2

PS3

FS2

BUSS BAR

AIR

N2

N2 O2

O2

H-35

10

9

8

7

6

5

3

2

1

10 11

12

4

P5

1

2 3

4 5

6 7

8 9

P8

P6

1

2

3

4

5

6

7

8

1

2

P7

1

2

JP1

JP2

JP3

Jumpers JP1 -- JP4

select either 24 vdc or

JP4

requirements

R1

R2

15K 8W

RC1

RC2

RC3

RC4

RC5

RC6

RC7

15 vdc input

1K 0.5W

CW

N.C.

source file:

135c001c.dxf

Smart Flow II

Smart Flow II 6-10

Smart Flow IISmart Flow II

N.C.

10

SECTION 6 TROUBLESHOOTING

6.9 Technical Guide To SmartFlow II Process Diagnostics

6.9.1 Plasma Process Timer Values For Vision Cutting Record File PARAM.CUT Vision Interpretation Data File DEF.TEC

Please refer to the description of the cutting

package in the Vision manual for a detailed explanation of the PARAM.CUT and DEF.TEC

PARAM.CUT

Timers

TimersTimers

Plasma Preflow/purge/firing/vent time

Plasma Preflow/purge/firing/vent timePlasma Preflow/purge/firing/vent time

High voltage

High voltageHigh voltage

Plasma Pre

Plasma Pre----Switch time

Plasma PrePlasma Pre

Plasma Rise on Pierce Time

Plasma Rise on Pierce TimePlasma Rise on Pierce Time

Plasma Pierce Time

Plasma Pierce TimePlasma Pierce Time

Plasma Travel Delay

Plasma Travel DelayPlasma Travel Delay

Plasma

Plasma AHC Delay

PlasmaPlasma

Switch time

Switch timeSwitch time

AHC Delay

AHC Delay AHC Delay

Master Up

Master UpMaster Up

Plasma Postflow

Plasma PostflowPlasma Postflow

PARAM.CUT DEF.TEC

PARAM.CUTPARAM.CUT

Wx

WxWx

Preset

Preset Preset

value

valuevalue

2.0

2.0 2.0

2.02.0

0.5

0.5 0.5

0.50.5 .01

.01 0.0

.01.01

0.0

0.0 0.0

0.00.0

0.0

0.0 0.0

0.00.0

0.0

0.0 0.0

0.00.0

0.0

0.0 0.0

0.00.0

2.0

2.0 0.0

2.02.0

5.0

5.0 5.0

5.05.0

Ux

UxUx

Lower

Lower Lower

editing limit

editing limitediting limit

V=

V= Hidden Flag Enabled

Hidden Flag Enabled

V= V=

Hidden Flag EnabledHidden Flag Enabled

2.0 2.0

2.02.0

0.5 0.5

0.50.5

0.0 0.3

0.00.0

0.0 50.0

0.00.0

0.0 50.0

0.00.0

0.0 50.0

0.00.0

0.0 50.0

0.00.0

0.0 50.0

0.00.0

5.0 50.0

5.05.0

Qx

QxQx

Upper

Upper Upper

editing limit

editing limitediting limit

2.0 V

2.02.0

0.5 V

0.50.5

0.3

0.30.3

50.0

50.050.0

50.0

50.050.0

50.0

50.050.0

50.0

50.050.0

50.0

50.050.0

50.0 V

50.050.0

DEF.TEC

DEF.TECDEF.TEC

Hidden

Hidden Hidden

VVVV

flag

flagflag

VVV VVV

VVV

Smart Flow II

Smart Flow II 6-11

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

(

)

6.9.2 Vision Keyboard Functions for Plasma System Test

Key Function Description

Plasma AHC Allow Icon

(F2 Push

(F2 Push----Button)

(F2 Push(F2 Push

Button)

Button)Button)

• Icon permits the machine operator to allow or

disallow plasma AHC.

• Icon does not turn plasma AHC on.

Icon does not turn plasma AHC on.

Icon does not turn plasma AHC on.Icon does not turn plasma AHC on.

• Plasma AHC is allowed if the icon is highlighted

(darkened).

• Plasma AHC is not allowed if the icon is not

highlighted.

Plasma AHC Icon

(F3 Push

(F3 Push----Button)

(F3 Push(F3 Push

Button)

Button)Button)

• Icon permits machine operator to manually turn

plasma AHC on or off.

• Icon also permits the operator to perform a

plasma IHS cycle if the plasma process is not active.

• The plasma AHC allow icon must be highlighted

plasma AHC allow icon must be highlighted.

plasma AHC allow icon must be highlightedplasma AHC allow icon must be highlighted

Plasma Start Parameter Test Icon

(F4 Push

(F4 Push----Button)

(F4 Push(F4 Push

Button)

Button)Button)

• Icon permits the machine operator to manually

test/adjust the plasma process start parameters with the exception of the plasma gas 2 start flow.

Plasma Gas 2 Test Icon

F5 Push

F5 Push----Button

F5 Push

Button)

Button

• Icon permits the machine operator to manually

test/adjust the plasma gas 2 start flow.

• The plasma start parameter test icon must be

plasma start parameter test icon must be

plasma start parameter test icon must be plasma start parameter test icon must be

highlighted

highlighted.

highlightedhighlighted

Plasma Cut Parameter Test Icon

(F6 Push

(F6 Push----Button)

(F6 Push(F6 Push

Button)

Button)Button)

• Icon permits the machine operator to manually

test/adjust the plasma process cut parameters.

• The plasma start parameter test icon must be

plasma start parameter test icon must be

plasma start parameter test icon must be plasma start parameter test icon must be

highlighted

highlighted.

highlightedhighlighted

Plasma Start Icon

(F6 Push

(F6 Push----Button)

(F6 Push(F6 Push

Button)

Button)Button)

Smart Flow II

Smart Flow II 6-12

Smart Flow IISmart Flow II

• Icon permits the machine operator to manually

start or stop the plasma process.

• The plasma start parameter test icon must not be

highlighted

highlighted.

highlightedhighlighted

must not be

must not be must not be

SECTION 6 TROUBLESHOOTING

6.9.3 Plasma Process Proportional valve Analog Flow Values For Vision Cutting Record File PARAM.CUT and Vision Interpretation File DEF.TEC

Please refer to the ATAS description of the cutting package for a detailed explanation of PARAM.CUT and DEF.TEC

PARAM.CUT DEF.TEC

Ux

Lower

editing

limit

Analog Output Values

Analog Output ValuesAnalog Output Values

Plasma Gas Start… N

Plasma Gas Start… NPlasma Gas Start… N Plasma Gas Cut… N

Plasma Gas Cut… N

Plasma Gas Cut… NPlasma Gas Cut… N Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas StartPlasma Cut Water/Shield Gas Start Plasma Cut Water/

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Plasma Cut Water/ Plasma Gas Start… H

Plasma Gas Start… H----35

Plasma Gas Start… HPlasma Gas Start… H Plasma Gas Cut… N

Plasma Gas Cut… N

Plasma Gas Cut… NPlasma Gas Cut… N

/O

/O/O

2222

/O

/O/O

2222

Shield Gas Cut

Shield Gas CutShield Gas Cut

35

3535

/O

/O/O

2222

Wx

Preset

Value

25.0 0.0 100.0 0.0 100.0 0.0 255.0

Plasma Gas Purge

Plasma Gas PurgePlasma Gas Purge Plasma Cut Water/Sh

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/ShPlasma Cut Water/Sh

ield Gas Purge

ield Gas Purgeield Gas Purge

100.0 100.0 100.0 V 0.0 100.0 0.0 255.0

6.9.4 Plasma Process Gas Selection Requirements

Qx

Upper

editing

limit

V

Hidden

flag

V = Hidden Flag Enabled

V = Hidden Flag EnabledV = Hidden Flag Enabled

Xx

Lower

parameter

limit

Yy

Upper

parameter

limit

Ix

Lower

channel

limit

Jx

Upper

Channel

limit

Plasma process gas selection is accomplished with

activation of the appropriate SDP file.

The correct Cutting Record Flag must be in each

SDP file. Plasma process gas selection is keyed to the value in the Cutting Record Flag.

Please refer to the ATAS description of the cutting

package for a detailed explanation of the cutting record flag.

Plasma Start Gas Plasma Cut Gas Abbreviation Cutting Record Flag

N

2

N

2

H-35 H-35 SF-H35-H35 M0010000000000000

N

2

O

2

N

2

SF-N2-O2 M1000000000000000 SF-N2-N2 M0100000000000000

H-35 SF-N2-H35 M0001000000000000

Smart Flow II

Smart Flow II 6-13

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.5 Plasma Process Gas Flowchart

No

Yes

Process

pre-switch

Plasma stop?

Error condition?

Station on?

Pre-switch

No

complete?

Process high

frequency

Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

No

Yes

No

Yes

No

Yes

No

Vision

shift/start

Yes

No

Yes

No

Yes

Process

Postflow

Line purge

required?

No

Station on?

Yes

Plasma start?

No

Postflow

complete?

Yes

Flow control

vent

Station on?

Yes

Plasma start?

No

Vent complete?

No

Vent time

complete?

Yes

Station on?

Yes

Error condition?

No

Station off

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Error condition?

No

Yes

Error condition?

No

Station on?

Yes

Station on

flush cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

Station on?

Yes

Flush cycle

required?

No

Line purge

required?

No

Plasma test?

No

Plasma start?

Yes

Process start

Plasma stop?

No

Station on?

Yes

Preflow

complete?

Yes

Process high

volt delay

Plasma stop?

No

Station on?

Yes

High volt delay

complete?

Yes

No

Yes

No

Line purge

Station on?

Flush cycle

Yes

Line purge

No

Plasma test?

Plasma Test

Station on?

Flush cycle

Yes

Line purge

Yes

Plasma test (cut)?

Yes

Plasma test?

Plasma test

Station on?

Flush cycle

Yes

Line purge

Yes

Plasma test?

Plasma test (cut)?

Yes

required?

No

complete?

Yes

No

(start)

Yes

required?

No

required?

No

(cut)

Yes

required?

No

required?

No

Yes

No

Yes

No

Yes

No

Smart Flow II

Smart Flow II 6-14

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.6 Plasma Process Solenoid and Proportional valve Requirements Station On Flush Cycle

This cycle will be initiated each time a

SmartFlow II station is manually

selected

Solenoid Valves

Plasma Gas N Plasma Gas O Plasma Gas H-35 Cutwater/Shield Gas Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water Pump X X X X X X X

2

Analog Output Values

Plasma Gas Start (N2/O2) Plasma Gas Cut (N2/O2) Cutwater/Shield Gas Start Cutwater/Shield Gas Cut Plasma Gas Start (H-35) Plasma Gas Cut (H-35)

Plasma Gas Purge (N2/O2) X X X X X Cutwater/Shield Gas Purge

Note: 0.016 seconds is the minimum timing interval allowed by the system software.

Start

0.096

seconds

3.0 seconds 1.0 seconds 2.0 seconds 1.0 seconds 1.0 seconds

X= open/enabled, Blank = Closed/Disabled, Analog value = 0 - 10 VDC

X X X

Finish 0.016

seconds

Smart Flow II

Smart Flow II 6-15

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.7 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-N2, N2 Plasma Start Gas N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water pump

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield G

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield G Plasma Cut Water/Shield G Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

2222

35

3535

N

N N

N

N N

2222

H----35

H H

H----35

35

H H

3535

N

N N

Note 1: LINE PURGE

Note 2: Plasma Preflow

LINE PURGE will be initiated after the first Station On Flush Cycle

LINE PURGELINE PURGE

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Plasma Postflow

Plasma Postflow was active for a minimum period of 3 seconds.

Plasma Postflow Plasma Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 2, and 4 to 0), once for 0.112 seconds if MKON 4 intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKON

Note 6: Machine motion will be allowed and MIP OVERRIDE

0). Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OV

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKON 8 Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

, Plasma Cut Gas N

2

Station

Off

Ready

2

Line

Plasma

Purge

Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Bla

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, BlaX = open/Enabled, Bla

Process

Plasma

nk = Closed/Disabled, Analog Value = 0----10 VDC

nk = Closed/Disabled, Analog Value = 0nk = Closed/Disabled, Analog Value = 0

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

Process

Note 5

X X X X X X X X X X

X X X X X X X X

Note 8 Note 8 Note 9

X X X X X X X X X X X

/O

/O/O

2222

/O

/O/O

2222

as Start

as Startas Start

X X X X X X X X X X X X X X X X X X

35

3535

X

/O

/O/O

2222

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 2 (MIP constant 58 is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off

MKON 4MKON 4

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

MKONMKON

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

OVERRIDEOVERRIDE

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3

ERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVMIP OV

ERRIDE 3ERRIDE 3

MKON 8 (MIP constant 64) is set to 1 and pre-switching is active.

MKON 8MKON 8 MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

FLOW CONTROL VENTFLOW CONTROL VENT

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 1 (MIP constant 57 is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

MKON 1MKON 1

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 3 (MIP constant 59 is set to 1. (set MKON 1,

MKON 3MKON 3

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to

MKON 5MKON 5

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

High

Freq.

Line Purge is initiated.

Line PurgeLine Purge

2/O2

Pierce

Note 6

Process

10 VDC

10 VDC10 VDC

Cut

Note 9

Process

Post Flow

Flow

Control

Vent

Note 7

Process Postflow and

Process PostflowProcess Postflow

Plasma Process Error Monitoring Requirements, SF--N2--N2 Plasma Start Gas – N2 Plasma Cut Gas – N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Plasma

Line

Purge

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of preX = monitored for pressure present, 0 = monitored for absence of pre

Test

Test (Cut)

(Start)

X = monitored for pressure present, 0 = monitored for absence of pre

CSF = monitored for status of change of state flag (see notes 11, 12, 14)

CSF = monitored for status of change of state flag (see notes 11, 12, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 14)

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Pla

Plasma Torch Cooling Water

sma Torch Cooling Water

PlaPla

sma Torch Cooling Watersma Torch Cooling Water

/O

/O/O

2222

35

3535

Station

Off

Ready

0 0 0 0 0

Note 11

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

start of the Station

Station On Flush Cycle

Station Station

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start monitoring.

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

On Flush Cycle. Switch status is flagged to provide Change of State

On Flush CycleOn Flush Cycle

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process

Plasma

Note 12

Note 14

Change of State error monitoring.

Change of StateChange of State

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process

Start

Preflow

High Volt

Delay

Process

Pre-

Switch

Process

High

Freq.

Process

Pierce

Process

Cut

ssure

ssuressure

X,CSF X,CSF X,CSF X,CSF X,CSF 0

X,CSF X,CSF X,CSF X,CSF X,CSF

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Change of State error

Change of StateChange of State

Process

Post Flow

Flow

Control

Vent

2

Smart Flow II

Smart Flow II 6-16

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge complete?

Plasma test?

D

Plasma Test

(start)

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

No

Yes

No

Yes

vent

H

pre-switch

Plasma stop?

Error condition?

Station on?

Pre-switch

No

complete?

J

Process high

frequency

Process

No

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

Process cut

No

Station on?

No

Yes

No

Yes

No

F

Yes

No

G

Yes

No

Station on?

Yes

Flush cycle

required?

No

Line purge

required?

No

Plasma test?

No

Plasma start?

Yes

Process start

Plasma stop?

No

Error condition?

No

Station on?

Yes

Preflow

complete?

Yes

Process high

volt delay

Plasma stop?

No

Error condition?

No

Station on?

Yes

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

No

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Yes

Plasma test?

Plasma test (cut)?

Station on?

Flush cycle

required?

Line purge

required?

Plasma test

(cut)

Station on?

Flush cycle

required?

Line purge

required?

Smart Flow II

Smart Flow II 6-17

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.8 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-H-35, H-35 Plasma Start Gas H-35, Plasma Cut Gas H-35

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water pump

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

2222

35

3535

N

/O

N N

/O/O

2222

N

/O

N N

/O/O

2222

H----35

35

H H

3535

H----35

35

H H

3535

N

/O

N N

/O/O

2222

Note 1: LINE PUR

Note 2: Plasma Preflow

LINE PURGE

GE will be initiated after the first Station On Flush Cycle

LINE PURLINE PUR

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Plasma Postflow

Plasma Postflow was active for a minimum period of 3 seconds.

Plasma Postflow Plasma Postflow

GEGE

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 2, and 4 to 0), once for 0.112 seconds if MKON 4 intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKON

MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

Note 6: Machine motion will be allowed and MIP OVERRIDE

Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKO Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

Station

Off

Ready

X

X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X

X X X X X X X X X X X X X X X X X X X

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off

MKON 4MKON 4

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

MKONMKON

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

OVERRIDEOVERRIDE

MKON 8

MKOMKO MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

Line

Plasma

Purge

Note 1

N 8 (MIP constant 64) is set to 1 and pre-switching is active.

N 8N 8

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disable

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/DisableX = open/Enabled, Blank = Closed/Disable

MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0),once for 0.080

MKON 1MKON 1

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

FLOW CONTROL VENTFLOW CONTROL VENT

Process

Plasma

Start

Preflow

Note 2

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

High Volt

Process

Delay

Note 3, 4

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0).

MKON 5MKON 5

Process

Pre-

High Freq.

Switch

Note 8 Note 8 Note 9

Note 5

d, Analog Value = 0----10 VDC

d, Analog Value = 0d, Analog Value = 0

Line Purge is initiated.

Line PurgeLine Purge

MKON 3 (MIP constant 59) is set to 1. (set MKON 1,

MKON 3MKON 3

2/O2

Process

Pierce Note 6

Process

Cut

Post Flow

Note 9

10 VDC

10 VDC10 VDC

Process Postflow and

Process PostflowProcess Postflow

Flow

Control

Vent

Note 7

Plasma Process Error Monitoring Requirements

SF-- H-35 -- H-35 Plasma Start Gas – H-35 Plasma Cut Gas – H-35

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Station

Off

Ready

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas

Plasma

Plasma Torch Cooling Water

Torch Cooling Water

Plasma Plasma

Torch Cooling WaterTorch Cooling Water

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

start of the Station On F

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start monitoring.

/O

/O/O

2222

35

3535

Station On Flush Cycle

Station On FStation On F

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

0 0 0 0 0 0

Note 11

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

lush Cycle. Switch status is flagged to provide Change of State

lush Cyclelush Cycle

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Plasma

Line

Purge

Test

Test (Cut)

(Start)

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

CSF = monitored for status of change of state flag (see notes 11, 13, 14)

CSF = monitored for status of change of state flag (see notes 11, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 13, 14)

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Smart Flow II

Smart Flow II 6-18

Smart Flow IISmart Flow II

Process

Plasma

Note 13 Note 14

Change of State error monitoring.

Change of StateChange of State

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Start

Preflow

Process

High Volt

Delay

Process

Pre-

Switch

Process

High

Freq.

Process

Pierce

Process

X,CSF X,CSF X,CSF X,CSF X,CSF 0 X,CSF X,CSF X,CSF X,CSF X,CSF 0

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Change of State error

Change of StateChange of State

Cut

Process

Post Flow

Flow

Control Vent

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge

complete?

Plasma test?

D

Plasma Test

(start)

Yes

No

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

vent

No

Yes

No

Yes

H

Plasma stop?

Error condition?

No

J

Process high

Process

pre-switch

No

Station on?

Yes

Pre-switch complete?

Yes

frequency

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

Station on?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

Station on?

No

Pierce complete?

L

Process cut

Plasma stop?

Error condition?

Yes

Station on?

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Station on?

Flush cycle

Yes

Line purge

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Plasma test

Station on?

Flush cycle

Yes

Line purge

Yes

Plasma test?

Plasma test (cut)?

required?

(cut)

required?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

F

Yes

Error condition?

No

G

Yes

Error condition?

No

Station on?

Flush cycle

required?

Line purge

required?

Plasma test?

Plasma start?

Process start

Plasma stop?

Station on?

Preflow

complete?

Process high

volt delay

Plasma stop?

Station on?

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

Station on?

Yes

Plasma start?

Yes

Vent complete?

No

Vent time

complete?

Station on?

Yes

Error condition?

No

Smart Flow II

Smart Flow II 6-19

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.9 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-N2, H-35 Plasma Start Gas N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

P

Plasma Torch Cooling Water pump

lasma Torch Cooling Water pump

P P

lasma Torch Cooling Water pumplasma Torch Cooling Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma C

Plasma Cut Water/Shield Gas Cut

Plasma C Plasma C Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma high frequency will not be pulsed if MKON

Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

2222

35

3535

N

N N

N

N N

2222

ut Water/Shield Gas Cut

ut Water/Shield Gas Cutut Water/Shield Gas Cut

H----35

H H

H----35

35

H H

3535

N

N N

Note 1: LINE PUR

LINE PURGE

LINE PURLINE PUR

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Note 2: Plasma Preflow

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Plasma Postflow

Plasma Postflow was active for a minimum period of 3 seconds.

Plasma Postflow Plasma Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4 off intervals the first time the plasma is fired after manual station selection.

Note 6: Machine motion will be allowed and MIP OVERRIDE

0).

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKO Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

, Plasma Cut Gas H-35

2

Station

Off

Ready

Line

Plasma

Purge

Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disabled, Analog

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/Disabled, Analog X = open/Enabled, Blank = Closed/Disabled, Analog

Plasma

Process

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

Process

High Freq.

Note 5

X X X X

X X X X X X X X X X X X X X

Note 8 Note 8 Note 9

X X X X X X X X X X X

/O

/O/O

2222

/O

/O/O

2222

X X X

X X X X X X X X

35

3535

Note 10 Note 10

X X X X

/O

/O/O

2222

X X X

GE will be initiated after the first Station On Flush Cycle

GEGE

MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0)., once for 0.096 seconds if MKON 3

MKON 2MKON 2

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second

MKON 4MKON 4

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

MKONMKON

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

OVERRIDEOVERRIDE

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

MKON 8

MKOMKO MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

FLOW CONTROL VENTFLOW CONTROL VENT

N 8 (MIP constant 64) is set to 1 and pre-switching is active.

N 8N 8

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

MKON 1MKON 1

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 3 (MIP constant 59) is set to 1. (set MKON

MKON 3MKON 3

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to

MKON 5MKON 5

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

Value = 0----10 VDC

Value = 0Value = 0

Pierce Note 6

Process

Note 9

10 VDC

10 VDC10 VDC

Line Purge is initiated.

Line PurgeLine Purge

2/O2

Process Postflow and

Process PostflowProcess Postflow

Cut

Process

Post Flow

Flow

Control

Vent

Note 7

Error Monitoring Requirements SF--N2--H -35 Plasma Start Gas – N2 Plasma Cut Gas – H-35

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Station

Off

Ready

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Plasma Torch Cooling Wa

Plasma Torch Cooling Water

Plasma Torch Cooling WaPlasma Torch Cooling Wa

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

the Station On Flush Cycle

Station On Flush Cycle. Switch status is flagged to provide Change of State

Station On Flush CycleStation On Flush Cycle

Note 12: The appropriate Plasma Gas Pressure Switches (N

Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start

/O

/O/O

2222

35

3535

ter

terter

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the start of

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 11

Plasma

Line

Purge

Test

(Start)

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

CSF = monitored for st

CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)

CSF = monitored for stCSF = monitored for st

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

Change of State error monitoring.

Change of StateChange of State

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning of

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning of

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Test (Cut)

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process

Plasma

atus of change of state flag (see notes 11, 12, 13, 14)

atus of change of state flag (see notes 11, 12, 13, 14)atus of change of state flag (see notes 11, 12, 13, 14)

Note 12 Note 13 Note 14

Start

Preflow

Process

High Volt

Delay

Process

Pre-

Switch

Process

High

Freq.

X,CSF X,CSF X,CSF 0

X,CSF X,CSF 0

X,CSF X,CSF X,CSF X,CSF X,CSF 0

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Process

Pierce

Cut

Process

Post Flow

Change of State error monitoring.

Change of StateChange of State

Flow

Control

Vent

Smart Flow II

Smart Flow II 6-20

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge

complete?

Plasma test?

D

Plasma Test

(start)

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

vent

No

Yes

No

Yes

H

Plasma stop?

Error condition?

No

J

Process high

Process

pre-switch

No

Station on?

Yes

Pre-switch complete?

Yes

frequency

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Process cut

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

No

Station on?

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

No

Yes

No

Yes

No

Station on?

Flush cycle

Yes

Line purge

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Plasma test

Station on?

Flush cycle

Yes

Line purge

Yes

Plasma test?

Plasma test (cut)?

required?

(cut)

required?

Station on?

Yes

Flush cycle

required?

No

F

Yes

Error condition?

No

G

Yes

Error condition?

No

Line purge

required?

Plasma test?

No

Plasma start?

Yes

Process start

Plasma stop?

No

Station on?

Yes

Preflow

complete?

Process high

volt delay

Plasma stop?

Station on?

High volt dela y

complete?

No

Smart Flow II

Smart Flow II 6-21

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.10 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-N2, O2 Plasma Start Gas N

Flow

Flow Chart Reference:

Chart Reference: A B C D E F G H J K L M N

FlowFlow

Chart Reference: Chart Reference:

Note: Plasma process gas

selection is accomplished with

activation of the appropriate

SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

Plasma Torch Cooli

Plasma Torch Cooling Water pump

Plasma Torch Cooli Plasma Torch Cooli

2222

35

3535

ng Water pump

ng Water pumpng Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/S

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/S Plasma Cut Water/S Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

Note 1: LINE PURGE

Note 2: Plasma Preflow

N

/O

N N

/O/O

2222

N

/O

N N

/O/O

2222

hield Gas Cut

hield Gas Cuthield Gas Cut

H----35

35

H H

3535

H----35

35

H H

3535

N

N N

LINE PURGE will be initiated after the first Station On Flush Cycle

LINE PURGELINE PURGE

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Postflow

Postflow was active for a minimum period of 3 seconds.

Postflow Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

if MKON 2

MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

0), once for 0.112 seconds if MKON 4 the first time the plasma is fired after manual station selection. Plasma high frequency will not be pulsed if MKON set to 0.

Note 6: Machine motion will be allowed and MIP OVERRIDE

Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKON 8 Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

Plasma Process Error Monitoring Requirements SF--N2--O2 Plasma Start Gas – N2, Plasma Cut Gas – O

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas

Plasma Torch Cooling Water

Plasma Torch Cooling WaterPlasma Torch Cooling Water

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

start of the Station On Flush Cycle

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

of Process Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start monitoring.

Station On Flush Cycle. Switch status is flagged to provide Change of State

Station On Flush CycleStation On Flush Cycle

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

, Plasma Cut Gas O

2

Station Off Ready

2

Line

Plasma

Purge

Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0----10 VDC

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

Plasma

Process

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

Process

High Freq.

Note 5

Process

Pierce Note 6

10 VDC

10 VDC10 VDC

Process

Cut

Note 9

Process

Post Flow

Control

X X X X X X X X X X

X X X X X X X X

Note 8 Note 8 Note 9

X X X X X X X X X X X

Note 7

2222

X X X X X X X X X X X X X X X X X X

X

/O

/O/O

2222

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), pulsed continuously as specified with 0.032 second off intervals

MKON 4MKON 4

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

Station

Off

/O

/O/O

2222

35 0 0 0 0 0 0

3535

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

OVERRIDEOVERRIDE

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

MKON 8 (MIP constant 64) is set to 1 and pre-switching is active.

MKON 8MKON 8 MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

Ready

Note 11

Purge

FLOW CONTROL VENTFLOW CONTROL VENT

Plasma

Line

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

CSF = monitored for status of c

CSF = monitored for status of change of state flag (see notes 11, 12, 14)

CSF = monitored for status of cCSF = monitored for status of c

Test

(Start)

Plasma

Test (Cut)

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080 seconds

MKON 1MKON 1

Process

Start

Preflow

hange of state flag (see notes 11, 12, 14)

hange of state flag (see notes 11, 12, 14)hange of state flag (see notes 11, 12, 14)

Note 12

Note 14

Change of State error monitoring.

Change of StateChange of State

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 3 (MIP constant 59) is set to 1. (set MKON 1, 2, and 4 to

MKON 3MKON 3

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0).

MKON 5MKON 5

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

High Volt

Delay

Process

Pre-

Switch

Line Purge is initiated.

Line PurgeLine Purge

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all

MKONMKON

2/O2

Process

High Freq.

Process

Pierce

Process Postflow and Plasma

Process PostflowProcess Postflow

Process

Cut

Process

Post Flow

Flow

Control

Vent

X,CSF X,CSF X,CSF X,CSF X,CSF 0

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Change of State error

Change of StateChange of State

Plasma

Plasma Plasma

2

Flow

Vent

Smart Flow II

Smart Flow II 6-22

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge complete?

Plasma test?

D

Plasma Test

(start)

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

vent

No

Yes

No

Yes

H

Plasma stop?

Error condition?

No

J

Process high

Process

pre-switch

No

Station on?

Yes

Pre-switch complete?

Yes

frequency

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

Process cut

No

Station on?

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Station on?

Flush cycle

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Plasma test

Station on?

Flush cycle

Yes

Plasma test?

Plasma test (cut)?

required?

Line purge

required?

(cut)

required?

Line purge

required?

Station on?

Flush cycle

required?

No

Line purge

required?

Plasma test?

Plasma start?

No

F

Process start

Yes

Plasma stop?

Yes

Error condition?

No

Station on?

Yes

Preflow

complete?

G

Process high

volt delay

Yes

Plasma stop?

Yes

Error condition?

No

Station on?

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

Smart Flow II

Smart Flow II 6-23

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.11 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-N2, N Plasma Start Gas N2, Plasma Cut Gas N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water pump

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump

2222

35

3535

Station

Off

Ready

X X X X X X X X X X

X X X X X X X X X

X X X X X X X X X X X

2

Line

Plasma

Purge

Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0----10 VDC

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

Plasma

Process

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

Process

High Freq.

Note 5

Process

Pierce

Note 6

Process

Note 9

10 VDC

10 VDC10 VDC

2

Cut

Process

Post Flow

Flow

Control

Vent

Note 7

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plas

Plasma Gas Start

ma Gas Start –––– H

Plas Plas

ma Gas Start ma Gas Start

Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

Note 1: LINE PURGE

Note 2: Plasma Preflow

N

/O

N N

/O/O

2222

N

/O

N N

/O/O

2222

H----35

35

H H

3535

H----35

35

H H

3535

N

/O

N N

/O/O

2222

LINE PURGE will be initiated after the first Station On Flush Cycle

LINE PURGELINE PURGE

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Plasma Postflow

Plasma Postflow was active for a minimum period of 3 seconds.

Plasma Postflow Plasma Postflow

X X X X X X X X X X X X X X X X X X

X

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

Line Purge is initiated.

Line PurgeLine Purge

Process Postflow and

Process PostflowProcess Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 2, and 4 to 0), once for 0.112 seconds if MKON 4 intervals the first time the plasma is fired after manual station selection. Plasma high frequency will not be pulsed if MKON

60) are all set to 0.

Note 6: Machine motion will be allowed and MIP OVERRIDE

0). Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKON 8 Note 9: The auxiliary valve will be opened only if MKON 8

MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off

MKON 4MKON 4

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

OVERRIDEOVERRIDE

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

MKON 8 (MIP constant 64) is set to 1 and pre-switching is active.

MKON 8MKON 8 MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

FLOW CONTROL VENTFLOW CONTROL VENT

Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

Plasma Process Error Monitoring Requirements SF--N2--N2 Plasma Start Gas – N2 Plasma Cut Gas – N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Station

Off

Ready

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Plasma Torch Cooling Water

Plasma Torch Cooling Water

Plasma Torch Cooling WaterPlasma Torch Cooling Water

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

start of the Station On Flush Cycle

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start monitoring.

/O

/O/O

2222

35 0 0 0 0 0

3535

Note 11

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Station On Flush Cycle. Switch status is flagged to provide Change of State

Station On Flush CycleStation On Flush Cycle

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Plasma

Line

Purge

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

CSF = monitored for status of change of state flag (see notes 11, 12, 14)

CSF = monitored for status of change of state flag (see notes 11, 12, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 14)

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

/O

/O/O

2222

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35)

MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

MKON 1MKON 1

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

Plasma

Test

Test (Cut)

(Start)

Note 12

Note 14

Change of State error monitoring.

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

2222

Change of StateChange of State

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process

Start

High Volt

Preflow

Delay

X,CSF X,CSF X,CSF X,CSF X,CSF 0

X,CSF X,CSF X,CSF X,CSF X,CSF

MKON 3 (MIP constant 59) is set to 1. (set MKON 1,

MKON 3MKON 3

MKON 1 thru 4 (MIP constants 57, 58, 59,

MKONMKON

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to

MKON 5MKON 5

2/O2

Process

Pre-

Switch

Process

High Freq.

Process

Pierce

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Process

Cut

Post Flow

Change of State error

Change of StateChange of State

Flow

Control

Vent

2

Smart Flow II

Smart Flow II 6-24

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge complete?

Plasma test?

D

Plasma Test

(start)

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

No

Yes

No

Yes

vent

H

pre-switch

Plasma stop?

Error condition?

Station on?

Pre-switch

No

complete?

J

Process high

frequency

Process

No

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

Process cut

No

Station on?

No

Yes

No

Yes

No

F

Yes

No

G

Yes

No

Station on?

Yes

Flush cycle

required?

No

Line purge

required?

No

Plasma test?

No

Plasma start?

Yes

Process start

Plasma stop?

No

Error condition?

No

Station on?

Yes

Preflow

complete?

Yes

Process high

volt delay

Plasma stop?

No

Error condition?

No

Station on?

Yes

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

No

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Yes

Plasma test?

Plasma test (cut)?

Station on?

Flush cycle

required?

Line purge

required?

Plasma test

(cut)

Station on?

Flush cycle

required?

Line purge

required?

Smart Flow II

Smart Flow II 6-25

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.12 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-N2, O2 Plasma Start Gas N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O P

Plasma Gas H

lasma Gas H----35

P P

lasma Gas Hlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water pump

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

2222

35

3535

N

N N

N

N N

2222

H----35

H H

H----35

35

H H

3535

N

N N

Note 1: LINE PURGE

LINE PURGE will be initiated after the first Station On Flush Cycle

LINE PURGELINE PURGE

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Note 2: Plasma Preflow

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Postflow

Postflow was active for a minimum period of 3 seconds.

Postflow Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 2, and 4 to 0), once for 0.112 seconds if MKON 4 intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKON

Note 6: Machine motion will be allowed and MIP OVERRIDE

Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKON 8 Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

, Plasma Cut Gas O

2

Station

Off

Ready

2

Line

Plasma Purge Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0----10 VDC

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

Plasma

Process

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

High Freq.

X X X X X X X X X X

X X X X X X X X X

X X X X X X X X X X X

/O

/O/O

2222

/O

/O/O

2222

X X X X X X X X X X X X X X X X X X

35

3535

X

/O

/O/O

2222

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0) continuously as specified with 0.032 second off

MKON 4MKON 4

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

MKONMKON

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

OVERRIDEOVERRIDE

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

MKON 8 (MIP constant 64) is set to 1 and pre-switching is active.

MKON 8MKON 8 MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

FLOW CONTROL VENTFLOW CONTROL VENT

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 1 (MIP constant 57 is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

MKON 1MKON 1

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 3 (MIP constant 59 is set to 1. (set MKON 1,

MKON 3MKON 3

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0).

MKON 5MKON 5

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

2/O2

Pierce Note 6

10 VDC

10 VDC10 VDC

Note 5

Line Purge is initiated.

Line PurgeLine Purge

Process

Cut

Note 9

Process

Post Flow

Flow

Control

Vent

Note 7

Process Postflow and Plasma

Process PostflowProcess Postflow

Plasma

Plasma Plasma

Plasma Process Error Monitoring Requirements SF--N2--O2 Plasma Start Gas – N2, Plasma Cut Gas – O

Flow Chart Ref

Flow Chart Reference:

Flow Chart RefFlow Chart Ref

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Plasma Torch Cooling Water

Plasma Torch Cooling Water

Plasma Torch Cooling WaterPlasma Torch Cooling Water

/O

/O/O

2222

35

3535

Note 11: The appropriate Plasma Torch Cooling Water Pressu

start of the Station On Flush Cycle

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start monitoring.

erence: A B C D E F G H J K L M N

erence:erence:

Station

Off

Ready

Plasma

Line

Purge

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

Test

Test (Cut)

(Start)

CSF = monitored for status of change of state flag (see notes 11, 12, 14)

CSF = monitored for status of change of state flag (see notes 11, 12, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 14)

Plasma

Process

Start

Preflow

Note 12

Process

High Volt

Delay

Process

Pre-

Switch

Process

High Freq.

Process

Pierce

Process

Cut

Post Flow

X,CSF X,CSF X,CSF X,CSF X,CSF 0

0 0 0 0 0 0

Note 11

Plasma Torch Cooling Water Pressure Switches

Station On Flush Cycle. Switch status is flagged to provide Change of State

Station On Flush CycleStation On Flush Cycle

Plasma Torch Cooling Water PressuPlasma Torch Cooling Water Pressu

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

re Switches for the selected stations will be checked for absence of pressure (normally open) at the

re Switchesre Switches

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Note 14

Change of State error monitoring.

Change of StateChange of State

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

X,CSF X,CSF X,CSF X,CSF X,CSF 0

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Change of State error

Change of StateChange of State

Process

2

Flow

Control

Vent

Smart Flow II

Smart Flow II 6-26

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge complete?

Plasma test?

D

Plasma Test

(start)

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

vent

No

Yes

No

Yes

H

Plasma stop?

Error condition?

No

J

Process high

Process

pre-switch

No

Station on?

Yes

Pre-switch complete?

Yes

frequency

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

Process cut

No

Station on?

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Station on?

Flush cycle

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Plasma test

Station on?

Flush cycle

Yes

Plasma test?

Plasma test (cut)?

required?

Line purge

required?

(cut)

required?

Line purge

required?

Station on?

Flush cycle

required?

No

Line purge

required?

Plasma test?

Plasma start?

No

F

Process start

Yes

Plasma stop?

Yes

Error condition?

No

Station on?

Yes

Preflow

complete?

G

Process high

volt delay

Yes

Plasma stop?

Yes

Error condition?

No

Station on?

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

Smart Flow II

Smart Flow II 6-27

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.13 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-H-35, H-35 Plasma Start Gas N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Sh

Plasma Cutwater/Shield Gas

Plasma Cutwater/Sh Plasma Cutwater/Sh Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water pump

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma

Plasma Gas Purge

Plasma Plasma Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

2222

35

3535

ield Gas

ield Gas ield Gas

N

N N

N

N N

2222

H----35

H H

H----35

H H

Gas Purge –––– N

Gas Purge Gas Purge

Note 1: LINE PURGE

Note 2: Plasma Preflow

N

N N

LINE PURGE will be initiated after the first Station On Flush Cycle

LINE PURGELINE PURGE

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process P

Plasma PreflowPlasma Preflow

Plasma Postflow

Plasma Postflow was active for a minimum period of 3 seconds.

Plasma Postflow Plasma Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 2, and 4 to 0), once for 0.112 seconds if MKON 4 intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKON

Note 6: Machine motion will be allowed and MIP OVERRIDE

0). Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKON 8 Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

, Plasma Cut Gas N

2

Station

Off

Ready

2

Line

Plasma

Purge

Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0----10 VDC

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

Plasma

Process

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

Process

X

X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X

/O

/O/O

2222

/O

/O/O

2222

X X X X X X X X X

35

3535

/O

/O/O

2222

X X X X X X X X X X

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0) continuously as specified with 0.032 second off

MKON 4MKON 4

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

MKONMKON

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

OVERRIDEOVERRIDE

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

MKON 8 (MIP constant 64) is set to 1 and pre-switching is active.

MKON 8MKON 8 MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

FLOW CONTROL VENTFLOW CONTROL VENT

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 1 (MIP constant 57 is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

MKON 1MKON 1

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 3 (MIP constant 59 is set to 1. (set MKON 1,

MKON 3MKON 3

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to

MKON 5MKON 5

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

High

Pierce

Freq.

Note 5

Note 6

10 VDC

10 VDC10 VDC

Line Purge is initiated.

Line PurgeLine Purge

2/O2

Process

Cut

Post Flow

Note 9

Process Postflow

Process PProcess P

ostflow and

ostflowostflow

Flow

Control

Vent

NOTE 7

Error Monitoring Requirements SF-- H-35 -- H-35 Plasma Start Gas – H-35 Plasma Cut Gas – H-35

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Station

Off

Ready

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas

Plasma Torch Cooling Water

Plasma Torch Cooling WaterPlasma Torch Cooling Water

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

start of the Station On Flush Cycle

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Sw

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start

/O

/O/O

2222

35

3535

0 0 0 0 0 0

Note 11

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Station On Flush Cycle. Switch status is flagged to provide Change of State

Station On Flush CycleStation On Flush Cycle

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H

Plasma Gas Pressure SwPlasma Gas Pressure Sw

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Process Start if the plasma start signal is not originated during Process Post

Process StartProcess Start

itches (H----35)

itches (Hitches (H

Plasma

Line

Purge

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

Test

Test (Cut)

(Start)

CSF = monitored for status of change of state flag (see notes 11, 13, 14)

CSF = monitored for status of change of state flag (see notes 11, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 13, 14)

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

monitoring.

Process

Plasma

Preflow

Note 13 Note 14

Change of State error monitoring.

Change of StateChange of State

Process Postflow

Process PostProcess Post

Process

Start

High Volt

Delay

X,CSF X,CSF X,CSF X,CSF X,CSF 0 X,CSF X,CSF X,CSF X,CSF X,CSF 0

flow. Switch status is flagged to provide Change of State

flowflow

Process

Pre-

Switch

Process

High

Freq.

Process

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Process

Pierce

Change of State error

Change of StateChange of State

Cut

Process

Post Flow

Flow

Control

Vent

Smart Flow II

Smart Flow II 6-28

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge complete?

Plasma test?

D

Plasma Test

(start)

Yes

M

Process Postflow

Line purge

No

Yes

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

vent

No

Yes

No

Yes

H

Plasma stop?

Error condition?

No

J

Process high

Process

pre-switch

No

Station on?

Yes

Pre-switch complete?

Yes

frequency

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

Process cut

No

Station on?

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Station on?

Flush cycle

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Plasma test

Station on?

Flush cycle

Yes

Plasma test?

Plasma test (cut)?

required?

Line purge

required?

(cut)

required?

Line purge

required?

Station on?

Flush cycle

required?

No

Line purge

required?

Plasma test?

Plasma start?

No

F

Process start

Yes

Plasma stop?

Yes

Error condition?

No

Station on?

Yes

Preflow

complete?

G

Process high

volt delay

Yes

Plasma stop?

Yes

Error condition?

No

Station on?

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

Smart Flow II

Smart Flow II 6-29

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.14 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-N2, H-35 Plasma Start Gas N

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Note: Plasma process gas selection is

accomplished with activation of the

appropriate SDP file.

Solenoid Valves

Solenoid ValvesSolenoid Valves

Plasma Gas N

Plasma Gas N Plasma Gas N Plasma Gas O

Plasma Gas O

Plasma Gas O Plasma Gas O Plasma Gas H

Plasma Gas H----35

Plasma Gas H Plasma Gas H Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cut

Plasma Cutwater/Shield Gas Auxiliary

Plasma Cut Plasma Cut

Plasma Torch Cooling Water pump

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump

Analog Values (output)

Analog Values (output)Analog Values (output)

Plasma Gas Start

Plasma Gas Start –––– N

Plasma Gas Start Plasma Gas Start Plasma Gas Cut

Plasma Gas Cut –––– N

Plasma Gas Cut Plasma Gas Cut Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start

Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut

Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Gas Start

Plasma Gas Start –––– H

Plasma Gas Start Plasma Gas Start Plasma Gas cut

Plasma Gas cut –––– H

Plasma Gas cut Plasma Gas cut

Plasma Gas Purge

Plasma Gas Purge –––– N

Plasma Gas Purge Plasma Gas Purge Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge

2222

35

3535

water/Shield Gas Auxiliary

water/Shield Gas Auxiliary water/Shield Gas Auxiliary

N

N N

N

N N

2222

H----35

H H

H----35

35

H H

3535

N

N N

Note 1: LINE PURGE

Note 2: Plasma Preflow

LINE PURGE will be initiated after the first Station On Flush Cycle

LINE PURGELINE PURGE

specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line Purge

Plasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process Postflow

Plasma PreflowPlasma Preflow

Plasma Postflow

Plasma Postflow was active for a minimum period of 3 seconds.

Plasma Postflow Plasma Postflow

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1

seconds if MKON 2 2, and 4 to 0), once for 0.112 seconds if MKON 4 intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKON

Note 6: Machine motion will be allowed and MIP OVERRIDE

0). Machine motion will be allowed and MIP OVERRIDE 2 Machine motion will be allowed and MIP OVERRIDE 3

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENT Note 8: The auxiliary valve will be opened only if MKON 8 Note 9: The auxiliary valve will be opened only if MKON 8 Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N

, Plasma Cut Gas H-35

2

Station

Off

Ready

Line

Plasma

Purge

Note 1

Test

Test (Cut)

(Start)

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0----10 VDC

X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0

Plasma

Process

Start

Preflow

Note 2

Process

High Volt

Delay

Process

Pre-

Switch

Note 3, 4

X X X X X

X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X

/O

/O/O

2222

/O

/O/O

2222

X X X

X X X X X X X X X

35

3535

NOTE 10 NOTE 10

X X X X

/O

/O/O

2222

X X X

Station On Flush Cycle after a Vision Shift/Start

Station On Flush CycleStation On Flush Cycle

MKON 2 (MIP constant 58 is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3

MKON 2MKON 2

MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off

MKON 4MKON 4

MKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

MKONMKON

OVERRIDE 1 (MIP constant 35) will be enabled if MKON 5

OVERRIDEOVERRIDE

MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6

MIP OVERRIDE 2MIP OVERRIDE 2 MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7

MIP OVERRIDE 3MIP OVERRIDE 3

MKON 8 (MIP constant 64) is set to 1 and pre-switching is active.

MKON 8MKON 8 MKON 8 (MIP constant 64) is set to 1.

MKON 8MKON 8

FLOW CONTROL VENT if the SmartFlow II stations were de-selected.

FLOW CONTROL VENTFLOW CONTROL VENT

Vision Shift/Start. Line Purge

Vision Shift/StartVision Shift/Start

MKON 1 (MIP constant 57 is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

MKON 1MKON 1

Line Purge will also be initiated each time SDP file selection

Line PurgeLine Purge

MKON 3 (MIP constant 59 is set to 1. (set MKON 1,

MKON 3MKON 3

MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to

MKON 5MKON 5

MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0).

MKON 6MKON 6 MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

MKON 7MKON 7

Process

High Freq.

Note 5

Process

Pierce

Note 6

10 VDC

10 VDC10 VDC

Line Purge is initiated.

Line PurgeLine Purge

2/O2

Process

Cut

Post Flow

Note 9

Process Postflow and

Process PostflowProcess Postflow

Flow

Control

Vent

NOTE 7

Error Monitoring Requirements SF--N2--H -35 Plasma Start Gas – N2 Plasma Cut Gas – H-35

Flow Chart Reference:

Flow Chart Reference: A B C D E F G H J K L M N

Flow Chart Reference:Flow Chart Reference:

Station

Off

Ready

Process Pressure Switches

Plasma gas N

Plasma gas NPlasma gas N Plasma Gas H

Plasma Gas H----35

Plasma Gas HPlasma Gas H

Plasma Cutwater/Shield Gas

Plasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Plasma Torch Cooling Water

Plasma Torch Cooling Water

Plasma Torch Cooling WaterPlasma Torch Cooling Water

Note 11: The appropriate Plasma Torch Cooling Water Pressure Switches

start of the Station On Flush Cycle

Note 12: The appropriate Plasma Gas Pressure Switches (N

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 13: The appropriate Plasma Gas Pressure Switches (H

of Process Start

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure Switches

beginning of Process Start monitoring.

/O

/O/O

2222

35

3535

Station On Flush Cycle. Switch status is flagged to provide Change of State

Station On Flush CycleStation On Flush Cycle

Process Start if the plasma start signal is not originated during Process Postflow

Process StartProcess Start

Note 11

Plasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches

Plasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N

Plasma Gas Pressure Switches (H----35)

Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H

Plasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches

Plasma

Line

Purge

Test

Test (Cut)

(Start)

X = monitored for pressure pre

X = monitored for pressure present, 0 = monitored for absence of pressure

X = monitored for pressure preX = monitored for pressure pre

CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)

CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)

CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

/O

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

/O/O

2222

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

35)35) Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process

Plasma

Preflow

Note 12 Note 13 Note 14

Change of State error monitoring.

Change of StateChange of State

Process Postflow. Switch status is flagged to provide Change of State

Process PostflowProcess Postflow

Process

Start

High Volt

sent, 0 = monitored for absence of pressure

sent, 0 = monitored for absence of pressuresent, 0 = monitored for absence of pressure

Delay

Process

Pre-

Switch

Process

High

Freq.

Process

Pierce

X,CSF X,CSF X,CSF 0

X,CSF X,CSF 0

X,CSF X,CSF X,CSF X,CSF X,CSF 0

Change of State error monitoring.

Change of StateChange of State

Change of State error monitoring.

Change of StateChange of State

Process

Cut

Post Flow

Change of State error

Change of StateChange of State

Flow Control

Vent

Smart Flow II

Smart Flow II 6-30

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

SmartFlow II Plasma Flow Chart

Note: Circled letters reference columns in process valve and gas error requirement charts

Vision

shift/start

Yes

No

C

Line purge

Station on?

Flush cycle

required?

Line purge complete?

Plasma test?

D

Plasma Test

(start)

Yes

No

Yes

M

Process

Postflow

Line purge

No

Yes

No

Yes

required?

Station on?

Plasma start?

Postflow

complete?

N

Flow control

vent

No

Yes

No

Yes

H

Plasma stop?

Error condition?

Station on?

No

J

Process high

Process

pre-switch

No

Yes

Pre-switch complete?

Yes

frequency

Yes

No

A

No

B

Station off

Station on?

Yes

Station on flush

cycle

Station on?

Yes

Flush cycle

complete?

Yes

Ready

No

Plasma stop?

Error condition?

No

Arc establ ished?

K

Process pierce

Plasma stop?

Error condition?

No

Pierce complete?

L

Plasma stop?

Error condition?

Yes

No

Station on?

Yes

No

Station on?

Yes

Process cut

No

Station on?

No

Yes

No

Yes

No

Yes

No

F

Yes

No

G

Yes

No

Station on?

Yes

Flush cycle

required?

No

Line purge

required?

No

Plasma test?

No

Plasma start?

Yes

Process start

Plasma stop?

No

Error condition?

No

Station on?

Yes

Preflow

complete?

Yes

Process high

volt delay

Plasma stop?

No

Error condition?

No

Station on?

Yes

High volt dela y

complete?

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

No

Yes

Vent complete?

No

Yes

Error condition?

Station on?

Plasma start?

Vent time

complete?

Station on?

No

Station on?

Flush cycle

Yes

Plasma test (cut)?

Yes

Plasma test?

E

Plasma test

Station on?

Flush cycle

Yes

Plasma test?

Plasma test (cut)?

required?

Line purge

required?

(cut)

required?

Line purge

required?

Smart Flow II

Smart Flow II 6-31

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.9.15 SmartFlow II Test Files

3 SP_BEGINN

; SF1.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - O2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 1. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THIS TEST FILE DOES NOT MODIFY ANY OF THE CUTTING PACKAGE PROCESS ; PARAMETERS.

N1 ; Plasma Process

(SF-N2-O2) ; DESIGNATION LINE 1. (NO PARAMETER ALTERATION) ; DESIGNATION LINE 2.

M1000000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

SP_ENDE 4

Smart Flow II

Smart Flow II 6-32

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

3 SP_BEGINN

; SF2.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - N2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 2. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THIS TEST FILE DOES NOT MODIFY ANY OF THE CUTTING PACKAGE PROCESS ; PARAMETERS.

N1 ; Plasma Process

(SF-N2-N2) ; DESIGNATION LINE 1. (NO PARAMETER ALTERATION) ; DESIGNATION LINE 2.

M0100000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

SP_ENDE 4

Smart Flow II

Smart Flow II 6-33

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

3 SP_BEGINN

; SF3.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - H35, PLASMA CUT GAS - H35. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 3. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THIS TEST FILE DOES NOT MODIFY ANY OF THE CUTTING PACKAGE PROCESS ; PARAMETERS.

N1 ; Plasma Process

(SF-H35-H35) ; DESIGNATION LINE 1. (NO PARAMETER ALTERATION) ; DESIGNATION LINE 2.

M0010000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

SP_ENDE 4

Smart Flow II

Smart Flow II 6-34

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

3 SP_BEGINN

; SF1ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - O2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 1. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO.

N1 ; Plasma Process

(SF-N2-O2) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2.

M1000000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

; NA = NOT APPLICABLE TO THIS MATERIAL.

P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS

T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME

SP_ENDE 4

Smart Flow II

Smart Flow II 6-35

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

3 SP_BEGINN

; SF2ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - N2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 2. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO.

N1 ; Plasma Process

(SF-N2-N2) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2.

M0100000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

; NA = NOT APPLICABLE TO THIS MATERIAL.

P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS

T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME

SP_ENDE 4

Smart Flow II

Smart Flow II 6-36

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

3 SP_BEGINN

; SF3ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - H35, PLASMA CUT GAS - H35. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 3. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO.

N1 ; Plasma Process

(SF-H35-H35) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2.

M0010000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

; NA = NOT APPLICABLE TO THIS MATERIAL.

P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS

T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME

SP_ENDE 4

Smart Flow II

Smart Flow II 6-37

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

3 SP_BEGINN

; SF4ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - H35. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 4. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO.

N1 ; Plasma Process

(SF-N2-H35) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2.

M0001000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456

; NA = NOT APPLICABLE TO THIS MATERIAL.

P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS

T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME

SP_ENDE 4

Smart Flow II

Smart Flow II 6-38

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6.10 SmartFlow II Secondary Shield Gas Proportional Valve Calibration Procedure

The Secondary Shield Gas (and Cutwater)

The Secondary Shield Gas (and Cutwater) The Secondary Shield Gas (and Cutwater) Proportional valve is the only proportional valve

NOTICE

P3 P4

Proportional valve is the only proportional valve

Proportional valve is the only proportional valve Proportional valve is the only proportional valve that can be calibrated.

that can be calibrated.

that can be calibrated. that can be calibrated. Plasma Gas proportional valves a

Plasma Gas proportional valves are calibrated

Plasma Gas proportional valves aPlasma Gas proportional valves a by the valve manufacturer to ESAB

by the valve manufacturer to ESAB

by the valve manufacturer to ESAB by the valve manufacturer to ESAB specifications. Do not attempt to calibrate.

specifications. Do not attempt to calibrate.

specifications. Do not attempt to calibrate.specifications. Do not attempt to calibrate.

The following instructions are for calibrating single or multiple station machines to ensure a consistent value for the Cut Water/Shield proportional valve. This calibration procedure will ensure the SDP files developed in the factory conform to the same screen values and output pressures as factory settings.

These instructions are tested for PT19XLS and

These instructions are tested for PT19XLS and These instructions are tested for PT19XLS and PT

PT----600 Secondary Shield only.

600 Secondary Shield only.

PTPT

600 Secondary Shield only.600 Secondary Shield only.

re calibrated

re calibrated re calibrated

P1

S1, S2, S3, S4

Cutwater/Secondary

Shield Proportional

Valve

Pin2

P2

Pin3

Pin1

Pin4

1. Calibrate the frequency of the proportional valve using Pin2 to Pin3 for 300 Hz for gas and water using P4 (potentiometer).

2. Check voltage on Pin2 to Pin3 on Cutwater/Shield proportional valve. At 100 on Vision Parameter Window for "Cut Water or Shield" the voltage should be approximately 10 VDC.

3. Set shield gas regulator to 80 psi on the back of the plumbing box with screen value for "Cutwater/Shield" set to 100.

4. Check shield gas gauge (on front of plumbing box) for max output pressure equal to about 32 psi. Adjust P3 (potentiometer) on proportional valve board to maximum value by turning clockwise until the pressure peaks out. Then turn counterclockwise until the pressure begins to drop. This will insure the valve is at the maximum opening for the voltage.

5. Recheck shield input gas regulator is at 80 psi at 100 on screen. Reset to 80 psi if necessary and recheck for maximum output pressure of 32 psi.

Smart Flow II

Smart Flow II 6-39

Smart Flow IISmart Flow II

SECTION 6 TROUBLESHOOTING

6. Set screen value for "Cut Water or Shield" to

20. Check voltage on Pins 2 to 3 on Cut Water/Shield proportional valve. The voltage should be approximately 2 volts. Check Shield gas gauge for minimum output pressure equal to 4 psi approximately (this is the first tick mark on the gauge above the needle rest). Adjust P1 on proportional valve board to 4 psi. Use a similar procedure to step 4) to reach a consistent value on the gauge. This will result in a minimum opening of the valve at low settings.

P1 (potentiometer)

set at 50 on the screen. This should be approximately 14 psi on the plumbing box gauge (adjust P2 to obtain 14-16 psi ).

8. Lower the inlet gas regulator to 60 psi with the screen value set to 100. This should result in a gauge pressure of approximately 22 psi. This will insure the SDP files generated since January

7. Check the gauge pressure for Secondary Shield

2000 will be consistent in the field.

Smart Flow II

Smart Flow II 6-40

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

7.1 General

7.2 Ordering

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

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

Replacement parts may be ordered from your ESAB Distributor or from:

ESAB Welding and Cutting Products

ATTN: Customer Service Department PO Box 100545 Ebenezer Road Florence, SC USA 29501-0545 Phone (843) 664-4405

(800) ESAB-123 (372-3123)

ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario, Canada L5T 1X9 Phone (905) 670-0220 Fax (905) 670-4879

ESAB Cutting Systems GmbH Robert-Bosch-Strasse 20 Postfach 1128 D-61184 Karben Phone 011-49-6039-400 Fax 011-49-6039-403-02 http://www.esab.de

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

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

Smart Flow II

Smart Flow II 7-1

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

7.3 Right Inside without H-35 Option -- Replacement Parts

10

2

Plasma Gas

Pressure Tap

O2/N

Proportional Valve

Air Curtain

Pressure Tap

Cut Water

Pressure Switch

2

1

Pressure Switch

O2/N

Primary Cut

Water

N

2

O

2

Air Curtain

Aux. Cut

Water

Cut Water

Pressure Tap

4

9

7

8

5

3

6

Smart Flow II

Smart Flow II 7-2

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

Item

Item Item

Number

NumberNumber

1 0558001056 1 Manifold Assembly without H-35 proportional valve 2 0558001068 1 Valve Sentronic 0-6 bar Manifold Mount Oxygen

0558001282 2 O-Ring…Proportional valve 5mm ID X 1mm

0558001283 1 O-Ring…Proportional valve 4mm ID X 1mm 3 0558001066 5 Valve solenoid, 2 way series 2, 120vac 150 mopd 1/8 oriface 4 952920 2 Pressure Switch 50 psi non-adj 5 0558001064 1 Hose ¼ npt M X ¼ npt F X Swivel Ball 13.5" long 6 0558001063 1 Hose ¼ npt M X ¼ npt F X 10.75" long 7 0558001062 1 Hose ¼ npt M X ¼ npt F X 6" long 8 56998261 1 Valve Proportional Water Pulse Width Modulator

56997044 1 Valve Proportional Water 24VDC

Part Number

Part Number Qua

Part NumberPart Number

Quantity

QuaQua

ntity Description

ntityntity

Description

DescriptionDescription

9 0558001067 1 Hose ¼ npt M X ¼ npt F X 13.5" long

10 37540 SmartFlow II Plumbing Box Assembly without H-35

Smart Flow II

Smart Flow II 7-3

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

7.4 Right Inside with H-35 Option – Replacement Parts

10

P4

Plasma Gas

Pressure Tap

Proportional Valve

Pressure Switch

2

P5

O2/N

2

H-35

Air Curtain

Pressure Tap

Cut Water

1

H-35

Pressure Switch

N

Pressure Switch

O

H-35

Primary Cut

Water

P7

2

O2/N

2

Air Curtain

Aux. Cut

Water

Cut Water

Pressure Tap

9

8

7

6

5

11

4

3

Smart Flow II

Smart Flow II 7-4

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

Item

Item Item

Number

NumberNumber

1 0558001061 1 Manifold Assembly H-35 proportional valve 2 0558001068 1 Valve Sentronic 0-6 bar Manifold Mount Oxygen

0558001282 2 O-Ring… Proportional valve 5mm ID X 1mm

0558001283 1 O-Ring… Proportional valve 4mm ID X 1mm 3 0558001066 6 Valve solenoid, 2 way series 2, 120vac 150 mopd 1/8 oriface 4 952920 2 Pressure Switch 50 psi non-adj 5 0558001064 1 Hose ¼ npt M X ¼ npt F X Swivel Ball 13.5" long 6 0558001063 1 Hose ¼ npt M X ¼ npt F X 10.75" long 7 0558001062 1 Hose ¼ npt M X ¼ npt F X 6" long 8 56998261 1 Valve Proportional Water Pulse Width Modulator

56997044 1 Valve Proportional Water 24VDC

Part Number

Part Number Quantity

Part NumberPart Number

Quantity Description

QuantityQuantity

Description

DescriptionDescription

9 0558001067 1 Hose ¼ npt M X ¼ npt F X 13.5" long

10 37538 SmartFlow II Plumbing Box Assembly with H-35 11 0558001065 1 Valve Sentronic 0-6 bar Manifold Mount H-35

0558001282 2 O-Ring… Proportional valve 5mm ID X 1mm

0558001283 1 O-Ring… Proportional valve 4mm ID X 1mm

Smart Flow II

Smart Flow II 7-5

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

7.5 Front Outside Parts – SmartFlow II

1

AIR CURTAIN

60

2

CUT GAS

100

To Pilot Arc

Start Box

6

CUT WATER

5

4

100

AIR CURTAIN

CUT GAS

3

Smart Flow II

Smart Flow II 7-6

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

Item

Item Item

Number

NumberNumber

1 0558001060 1 Pressure Gauge 2½" 60 psi 2 0558001059 2 Pressure Gauge 2½" 100 psi

3 0558001054 1 Label Set 4 33053 1 Strain Relief 2" Torch 5 0558001057 1 Knurled Nut-Fiber Optic Cable Holder 6 0558001058 1 (Internal) Fiber Optic Cable Assembly for spark viewing.

Part Number

Part Number Quantity

Part NumberPart Number

Quantity Description

QuantityQuantity

Description

DescriptionDescription

Smart Flow II

Smart Flow II 7-7

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

7.6 Left Inside Parts

C1

R2

P2

P3

P1

2

1

7

6

5

Smart Flow II

Smart Flow II 7-8

Smart Flow IISmart Flow II

4

3

SECTION 7 REPLACEMENT PARTS

Item

Item Item

Number

NumberNumber

1 0558001055 1 High Freq Arc Starter Box 2 0558001050 1 Printed Circuit Board

3 0558001053 1 Buss Bar Block Assembly 4 0558001051 1 Check Valve ¼ NPT M X ¼ NPT M 5 0558001049 1 Hose ¼ NPT F X ¼ NPT F X 7.5" Long 6 0558001052 1 Hose ¼ NPT M X ¼ NPT M X 11" Long 7 63383 1 Flow Switch 1.0 GPM

0558001051 1 Check Valve ¼ NPT M X ¼ NPT M

Part Number

Part Number Quantity

Part NumberPart Number

Quantity Description

QuantityQuantity

Description

DescriptionDescription

Smart Flow II

Smart Flow II 7-9

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

7.7 Back Outside Parts

1

NITROGEN

OXYGEN

AIR

4

COOLING WATER

OUT IN

CUT WATER

2

Smart Flow II

Smart Flow II 7-10

3

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

Item

Item Item

Number

NumberNumber

1 0558001047 4 Grommet Cable Clamp “Small” 14-15mm

0558001048 3 Grommet Cable Clamp “Large” 27-28mm

2 0558001054 Ref Label Set (Same set as shown on front parts) 3 56997206 3

Part Number

Part Number Quantity

Part NumberPart Number

Quantity Description

QuantityQuantity

Muffler Exhaust Brass

Description

DescriptionDescription

1

/8 NPT Male

4 56998133

Not

shown

0560988406 1 per filter Replacement filter ELEMENT for 56998133

As

required

25 micron gas filter with bowl guard

Smart Flow II

Smart Flow II 7-11

Smart Flow IISmart Flow II

SECTION 7 REPLACEMENT PARTS

This page intentionally left blank.

Smart Flow II

Smart Flow II 7-12

Smart Flow IISmart Flow II

Customer // Technical Support

(843) 664-4405

(800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road

Florence, SC 29501-0545

http://www.esab.com

ESAB Cutting Systems – Canada

6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9

Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB Cutting Systems GMBH

Robert-Bosch-Strasse 20

Postfach 1128

D-61184 Karben 1

Germany Phone 011-49-6039-400 Fax 011-49-6039-403-02

http://www.esab.de

Printed in U.S.A

ESAB SmartFlow II Plasma System Plumbing Box Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.2 Safety Notations And Symbols

1.3 General Safety Information

1.4 Installation Precautions

1.5 Electrical Grounding

1.6 Operating A Plasma Cutting Machine

1.6 Service Precautions

1.9 Safety References

2.5 Gas Requirements

2.6 Water Supply Requirements

2.7 Electrical Input Requirements

2.8 Dimensions

3.2 Box Mounting

3.3 Hose and Cable Connections

3.3.1 Starter Box Connections

3.3.3 Torch Cooling Water Connections

3.4 Nomex Insulation

3.5 Gas Connections

3.5.2 Gas Pressure Setup

3.6 Cut Water Setup (PT-15XL)

4.2 Pressure Gauges

5.2 Pressure Switches

5.3 Spark Gap Of the Arc Starter

5.4 Spark Adjustment Procedure

5.5 Gas Proportional Valves

5.7 Cooling Water Flow Switch

5.8 Gas Filters

6.2 Cooling Water Circuit

6.3 Cut Water and Auxiliary Cut Water

6.6.1 Setting the Spark Gap

6.6.2 Spark Gap Size Attributes

6.6.3 Spark Viewing

6.7 Fluid Schematic

6.9.5 Plasma Process Gas Flowchart

7.1 General

7.2 Ordering

7.7 Back Outside Parts