INSTRUCTION MANUAL for the
ESAB SmartFlow
PLASMA CUTTING SYSTEM
F14-129
August, 1997
411 South Ebenezer Road
Florence, SC 29501-0545
The equipment described in this manual is
potentially hazardous. Use caution in installing,
operating, and maintaining this equipment.
The purchaser is solely responsible for the
safe operation and use of all products
purchased, including compliance with OSHA
and other government standards. ESAB
Cutting Systems has no liability for personal
injury or other damage arising out of the use
of any product manufactured or sold by ESAB.
See standard ESAB terms and conditions of
sale for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems is not responsible for
any errors that may appear in this document.
The information in this document is subject to
change without notice.
This manual is ESAB Part Number F14129.
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
ESAB Cutting Systems, 1997
Printed In USA
This manual is not a safety guide for the use of the
equipment. The purchaser, through its own
judgment and safety procedures, is solely
responsible for safe operation. However, in
presenting the information in this manual, a system
of advisory notes has been provided to point out
specific information that will be helpful in the safe
and proper operation of the equipment.
The method used to identify these notes and the
purpose for each are as follows:
An operational procedure or background
information that aids the operator in efficient use
of the system and in performing maintenance, or
information that requires additional emphasis.
An operational procedure which, if not
properly followed, may cause damage to the
system.
An operational procedure that, if not
properly followed, may cause injury to the
operator or others in the operating area.
SmartFlow Plasma System
Preface
This manual applies only to the ESAB SmartFlow
Plasma Cutting System using the Vision CNC and
ASIOB I/O Structure. For plasma systems with
alternate hardware, refer to the appropriate
manual.
The ESAB SmartFlow Plasma Cutting System is
an advanced, numerically controlled plasma
cutting package manufactured by ESAB Cutting
Systems of Florence, South Carolina. This
system is designed to be installed on an ESAB
Gantry Shape Cutting Machine. It is designed to
provide years of dependable, accurate, repeatable
part cutting, with a high degr ee of reliability, ease
of service and ease of operation.
There are various optional configurations possible
with the SmartFlow system. For completeness, all
of these options are described in this manual.
However, not all options or capabilit ies described
in this manual are present on all machines. In
addition, more capabilities and features may be
added in the future, which are not covered in this
manual. ESAB Cutting Systems reserves the
right to change or add features and capabilities
without notice.
Before operating the system, one should become
familiar with this manual in its entirety, wit h special
attention to the SAFETY section.
Contents
1 Safety...................................................................................................1
2 Introduction...........................................................................................5
3 Installation ............................................................................................ 9
1.1 Introduction...............................................................................1
1.2 General Safety Information.......................................................2
1.3 Plasma Marking Precautions.....................................................3
1.3.1 Electrical Shock Prevention...........................................3
1.3.2 Eye Safety..................................................................... 3
1.4 Skin Safety................................................................................ 4
1.5 Electrical Grounding.................................................................. 4
2.1 Overview................................................................................... 5
2.2 System Description...................................................................5
2.2.1 Component Description.................................................5
2.2.2 SmartFlow System with PT-15XL Torch........................6
2.2.3 SmartFlow System with PT-19XL Torch........................7
3.1 Requirements............................................................................9
3.1.1 Gas Supply Requirements.............................................9
3.1.2 Water Supply Requirements.......................................... 9
3.1.3 Deionized Water Requirements (PT-15XL).................... 9
3.1.4 Electrical Input Requirements........................................ 9
3.2 Connections............................................................................ 10
3.2.1 Hose and Cable Connections......................................10
3.2.2 Pilot Arc Cable Connections........................................10
3.3 Supply Setup........................................................................... 11
3.3.1 Gas Supply Pressures................................................. 11
3.3.2 Cut Water Supply Pressure.........................................12
3.3.3 Cut Water Pump Setup................................................ 12
4 Setup..................................................................................................13
4.1 Introduction.............................................................................13
4.2 Prerequisites........................................................................... 13
4.3 Gas Regulator Setup .............................................................. 14
4.3.1 Gas Regulator Panel Setup......................................... 14
4.3.2 Shield Air Regulator..................................................... 15
4.4 CNC Setup.............................................................................. 16
SmartFlow Plasma System
5 Process Data ......................................................................................19
6 Maintenance .......................................................................................25
6.1 Routine Maintenance...............................................................25
6.2 Technical Description..............................................................26
6.2.1 Gas Control..................................................................26
6.2.2 Cut Water Control........................................................28
6.2.3 Secondary Shield Gas Control.....................................30
6.2.4 Cooling Water Circuit...................................................32
6.3 Maintenance Procedures.........................................................34
6.3.1 Introduction..................................................................34
6.3.2 Gas Pressure Switch ...................................................34
6.3.3 Water Pressure Switch ................................................36
6.3.4 Gas Regulator..............................................................37
6.3.5 Interlock Switch............................................................38
6.3.6 Cut Water Pressure .....................................................40
6.3.7 Gas Filters ...................................................................41
6.3.8 Gas Proportional Valve................................................41
6.3.9 Water Proportional Valve.............................................42
6.3.10 Cooling Water Flow Switch ........................................42
6.4 Schematics..............................................................................43
6.5 Troubleshooting.......................................................................47
7 Replacement Parts..............................................................................49
7.1 General Information.................................................................49
7.2 Ordering Information ...............................................................50
7.3 SmartFlow Plasma Flow Control..............................................51
7.3.1 Arc Starter Box Assembly............................................57
7.3.2 Flow Tube Box Assembly.............................................59
1 Safety
1.1 Introduction
SmartFlow Plasma System
ESAB plasma cutting products are designed to
provide both safety and efficiency in operation.
However, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of safety.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious injury to
personnel or severe damage to the equipment.
The following precautions are specific guidelines
applicable to the plasma cutting process. More
general precautions are presented in the instruction
literature pertaining to the cutting machine.
Safety Page 1
Section 1
1.2 General Safety Information
All personnel, materials, and equipment not
involved in the production process must be
kept clear of the entire system area. Only
qualified personnel should be allowed to
operate or service the equipment.
Read entirely through a procedure to become
familiar with the task before operating or
performing maintenance on any part of the
system. Special attention must be given to all
WARNINGS, CAUTIONS, and NOTES which
provide essential information regarding
personnel safety and/or possible damage to
equipment.
All safety precautions relevant to electrical
equipment and the process operations must
be strictly observed by all who have
responsibility or access to the system. DO
NOT touch the plasma marking torch during
operation. Do not operate any part of the
system with any of the protective covers
removed or electrical component boxes open.
Refer to all safety publicati ons made available
by your company.
Fence off the entire work cell to prevent
personnel from passing through the area or
standing within the working envelope of the
equipment. Post appropriate CAUTION signs
at every entrance to the work cell area.
Page 2 Safety
1.3 Plasma Cutting Precautions
1.3.1 Electrical Shock Prevention
SmartFlow Plasma System
The plasma arc cutting process employs high
voltages. High voltage can kill. Do NOT touch the
marking torch, cutting table or cable connections
during the plasma cutting process.
Electrical Shock Can Kill You!
• Always turn off power to the plasma power
supplies before touching or servicing a plasma
marking torch.
• Always turn off power to the plasma power
supplies before opening or servicing the plasma
power supply or interface box.
1.3.2 Eye Safety
• Do not touch live electrical parts.
• Keep all panels and covers in place when the
machine is connected to a power source.
• Insulate yourself from the workpiece and
electrical ground: wear insulating gloves, shoes
and clothing.
• Keep gloves, shoes, clothing, work area, and
this equipment dry.
Arc rays can injure eyes and burn skin.
To protect your eyes from burns caused by high
intensity ultraviolet light, sparks and hot metal :
• Do not look at the arc.
• Wear correct eye protection. Wear dark safety
glasses or goggles with side shields.
• Replace glasses/goggles when the lenses
become pitted or broken
• Warn other people in the area not to look
directly at the arc unless they wear appropriate
Safety Page 3
Section 1
1.4 Skin Safety
safety glasses.
• Prepare the cutting area in a manner that
reduces the reflection and transmission of
ultraviolet light:
• Paint walls and other surfaces with dark colors
to reduce reflections.
• Install protective screens or curtains to reduce
ultraviolet transmission.
To protect skin against burns caused by high
intensity ultraviolet light, sparks and hot metal:
• Wear protective clothing:
1.5 Electrical Grounding
• Wear gauntlet gloves.
• Wear flame-retardant clothing which covers all
exposed areas.
• Wear cuffless trousers to prevent entry of
sparks and slag.
• Do not touch the torch when it is about to sta rt
or while marking. After marking, allow time for
the front of the torch to cool.
Electrical grounding is imperative for proper
machine operation as well as for SAFETY.
All ESAB Shape Cutting Machines must have a
good electrical connection to earth ground.
Page 4 Safety
2 Introduction
2.1 Overview
2.2 System Description
SmartFlow Plasma System
The SmartFlow Plasma Cutting System is a
streamlined, high performance plasma cutting
package designed for use exclusively with the
ESAB Vision CNC. ESAB’s exclusive SmartFlow
technology integrates gas and water control into
the cutting machine CNC.
Using a system of proportional valves driven by
CNC outputs, this system dramatically reduces the
amount of plumbing hardware necessary to c ontrol
the plasma torch. Operation is simplified by putting
control of gas and water flow rates on scre en at the
Vision CNC.
2.2.1 Component Description
The SmartFlow system components include a
plumbing box, a flow tube box, and a regulator
panel. The plumbing box contains the p roportional
valves and plumbing necessary to control gas and
water flows. The flow tube box contains three flow
indicator tubes, which provide visual feedback to
the machine operator of the actual gas and water
flow rates. The regulator panel provides pressure
regulation for the incoming gas and water supplies.
When the PT-15XL water injection torch is used,
the complete SmartFlow cutting system also
includes a plasma power supply, a recirculating
water cooler, a cut water pump, an air curtain
control, and the Vision CNC. If the PT-19XL dry
torch is used, then the cut water supply system and
air curtain control are omitted.
The following pages show the complete system
overviews.
Introduction Page 5
Section 2
2.2.2 SmartFlow System with PT-15XL Torch
The illustration below shows the SmartFlow system
when a PT-15XL water injection torch is used.
Page 6 Introduction
2.2.3 SmartFlow System with PT-19XL Torch
SmartFlow Plasma System
The illustration below shows the SmartFlow system
when the PT-19XL dry torch is used. In this system
the cut water supply equipment is omitted, a
secondary shield is used instead of an air curtain,
and shield gas is controlled through the SmartFlow
plumbing Box.
Introduction Page 7
Section 2
Page 8 Introduction
3 Installation
3.1 Requirements
3.1.1 Gas Supply Requirements
SmartFlow Plasma System
Nitrogen 125 PSI (1/2 NPT)
99.999% Pure
Oxygen 125 PSI (1/2 NPT)
99.999% Pure
Compressed Air (PT-19XL
with Secondary Shield only)
3.1.2 Water Supply Requirements
Cooling Water 120 PSI
3.1.3 Deionized Water Requirements (PT-15XL)
Deionized Water 35 PSI (1/2 NPT)
3.1.4 Electrical Input Requirements
Voltage Supply +24 VDC for proportional valves,
100 PSI (1/2 NPT)
Clean, Dry, Filtered to 5 micron.
1.5 GPM
> 200,000 Ω
.5 GPM for up to 600 Amp cutting
1.5 GPM for 1000 Amp cutting
flow and pressure switches.
+15 VDC for pressure switch.
Voltage Signals 120 VAC input to start gas
solenoid valve.
120 VAC input to cut gas solenoid
valve.
120 VAC input to Arc Starter.
0 - 10 Volt DC inputs to
proportional valves.
Installation Page 9
Section 3
3.2 Connections
3.2.1 Hose and Cable Connections
The SmartFlow Plasma Cutting package is
designed to be interfaced with the ESAB Vision
CNC and any ESP Plasma Power Supply.
Connections to the plumbing box are illustrated
here. A color code is used on the hose
connections between the flow tube box and the
plumbing box:
Green = Oxygen
Yellow = Nitrogen
White = Cooling Water
Blue = Cut Water
The Control Cable Entrance plate can be removed,
allowing the control cables to be installed or
removed without any re-wiring at the plug terminals.
3.2.2 Pilot Arc Cable Connections
The Options Cover is replaced by an additional
hose adaptor when the PT-19XL is used with a
Secondary Shield kit, allowing the plumbing box to
control shield gas flow. The Options Cover also
allows space for a third power cable connector for
PT-15XL installations cutting at 1000 Amps.
The Pilot Arc Cables must be connected properly
to the insulated high voltage terminals at the Arc
Starter Box, as shown here.
The Pilot Arc Ground Cable (from the plasma power
supply) is connected to TB1, toward the open side
of the plumbing box.
The Pilot Arc Torch Cable (from the torch leads) is
connected to TB3, toward the back of the
plumbing box.
TB2 is connected to the Busbar, internal to the
plumbing box.
Page 10 Installation
3.3 Supply Setup
3.3.1 Gas Supply Pressures
SmartFlow Plasma System
The Oxygen and Nitrogen gases may be supplied
from bottles or bulk tanks. The supplies to the
cutting machine must be controlled with the proper
type of regulator. Adjust these pressures as
follows:
Oxygen
Set the Oxygen pressure to 140 PSI while the gas
is flowing.
Nitrogen
Set the Nitrogen pressure to 140 PSI while the gas
is flowing.
Installation Page 11
Section 3
3.3.2 Cut Water Supply Pressure
Installations using the PT-15XL water injection torch
require a supply of deionized water. This water
must be regulated to a minimum of 30 PSI to
prevent the cut water pump from cavitating.
The cut water regulator is located on the Plasma
Regulator Panel. Set the Cut Water pressure to 30
PSI while the water is flowing.
3.3.3 Cut Water Pump Setup
Installations using the PT-15XL water injection torch
require a cut water pump. The cut water pump
supplies high pressure water to the plumbing box,
where the flow is regulated. The cut water pump
must be adjusted to 120 PSI. Refer to Section
6.3.6 for the adjustment procedure.
Page 12 Installation
4 Setup
4.1 Introduction
4.2 Prerequisites
SmartFlow Plasma System
The information in this section is intended for use by
the operator during daily setup prior to starting the
cutting process.
The following setup procedures can only be
completed after all of the requirements,
connections, and suppliy setups have been
properly completed, as detailed in Section 3.
Setup Page 13
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