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ESAB B Series Installation, Operation And Maintenance Manual

Precision plasmarc system
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F15-800
November, 2003
Installation, Operation and Maintenance for the
PT-24 Precision Plasmarc System
Series "B"
411 South Ebenezer Road
Florence, SC 29501-0545

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  • Page 1 F15-800 November, 2003 Installation, Operation and Maintenance for the PT-24 Precision Plasmarc System Series “B” 411 South Ebenezer Road Florence, SC 29501-0545...
  • Page 2 This manual is ESAB Part Number F15800 This manual is for the convenience and use of the cutting machine purchaser. It is not a contract or other obligation on the part of ESAB Cutting Systems. © ESAB Cutting Systems, 2003...

  • Page 3: Table Of Contents

    Table of Contents SECTION TITLE PAGE PARAGRAPH SECTION 1 Safety ........................... 4 UNPACKING/HOISTING...................... 18 Inspection ..........................18 Hoisting..........................18 SECTION 2 DESCRIPTION........................19 General..........................19 Scope ........................... 19 Package Options Available ....................19 SECTION 3 INSTALLATION........................23 General..........................23 Equipment Required......................23 Location ..........................
  • Page 4 Table of Contents This page intentionally left blank.
  • Page 5 1.1 Introduction The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness.
  • Page 6 SECTION 1 SAFETY 1.2 Safety Notations And Symbols 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 DANGER which, if not avoided, will result in serious...
  • Page 7 SECTION 1 SAFETY 1.3 General Safety Information Machinery often starts automatically. WARNING This equipment moves in various directions and speeds. Moving machinery can crush. • Only qualified personnel should operate or • service this power source. Keep all personnel, materials, and •...

  • Page 8: Safety

    1.4 Installation Precautions Improperly Installed Equipment Can WARNING Cause Injury Or Death. Follow these guidelines while installing machine: • Contact your ESAB representative before installation. He can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure maximum security. •...
  • Page 9 SECTION 1 SAFETY 1.5 Electrical Grounding Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions. Electric shock hazard. WARNING Improper grounding can cause severe injury or death. Machine must be properly grounded before put into service.
  • Page 10 SECTION 1 SAFETY Hazardous voltages. Electric shock WARNING can kill. Do NOT touch plasma torch, cutting table or • cable connections during plasma cutting process. Always turn power off to plasma power • supplies before touching or servicing plasma torch. Always turn power off to plasma power •...
  • Page 11 SECTION 1 SAFETY Radiation hazard. WARNING Arc rays can injure eyes and burn skin. Wear correct eye and body protection. • Wear dark safety glasses or goggles with • side shields. Refer to following chart for recommended lens shades for plasma cutting: Arc Current Lens Shade Up to 100 Amps...
  • Page 12 SECTION 1 SAFETY Burn Hazard. WARNING Heat, spatter, and sparks cause fire and burns. Do not cut near combustible material. • Do not have on your person any • combustibles (e.g. butane lighter). Pilot arc can cause burns. Keep torch •...
  • Page 13 SECTION 1 SAFETY 1.7 Service Precautions Hazardous voltages. Electric shock WARNING can kill. Do NOT touch plasma torch, cutting table or • cable connections during plasma cutting process. Always turn power off to plasma power • supplies before touching or servicing plasma torch.
  • Page 14 SECTION 1 SAFETY Danger of Electric Shock. DANGER Torch may be electrically active. Turn off Plasma Power Console before servicing. Establish and adhere to preventive CAUTION maintenance. A composite program can be established from recommended schedules. Avoid leaving test equipment or hand tools on machine.
  • Page 15 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.
  • Page 16 SECTION 1 SAFETY 1.8.2 International Accident Prevention VBG- Unfallverhütungsvorshriften General Provisions VBG 1 Allgemeine Unfallverhütungsvorshriften Electrical Equipment and operating Equipment VBG 4 Elektrische Anlagen Welding, Cutting and related working methods VBG 15 Schweißen un Schneiden un verwandte Verfahren Shot Blasting Works VBG 48 Strahlarbeiten Gases...
  • Page 17 SECTION 1 SAFETY VDE Regulations VDE - Vorschriften Erection of power installations with normal voltages up to 1000 volts VDE 0100 Bestimmungen für das Errichten von Stakstromanlagen mit Nennspannungen bis 1000 Volt Electrical equipment of industrial machines VDE0113 Elektrishe Ausrüstung von Industriemaschinen Radiation safety of laser products;...
  • Page 18 SECTION 1 SAFETY TRG Technical Rules for Pressure gases TRG – Technische Regein für Druckgase General regulations for pressure gases TRG 100 Allgemeine Bestimmungen für Druckgase Pressure gases TRG 101 Druckgase Technical gas mixtures TRG 102 Technishe Gasgemische Pressure gases; alterative use of compressed gas tanks TRG 104 Druckgase, wahlweise Verwendung von Druckgasbehältem...
  • Page 19 SECTION 1 SAFETY TRGS – Technische Richtlinien für Gefahrstoffe TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe Ermittlung u. Beurteilung der Konzentration gefährlicher TRGS-402 Stoffe in der Luft im Arbeitsbereich TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte) TA-Luft un TA-Lärm (BLm SchV) DIN Standards DIN-Normen DIN 2310...
  • Page 20 SECTION 1 SAFETY DIN EN ISO Harmonized Standards DIN EN ISO-Harmonisierte Normen Safety of machinery DIN EN 292/1 and 2 Sicherheit von Maschinen, Geräten und Anlagen Hoses for welding, cutting and allied processes DIN EN 559 Schläuche für Schweißen, Schneiden und verwandte Verfahren Hose connections and hose couplings for equipment for welding, cutting and allied processes...
  • Page 21 SECTION 1 SAFETY Acceptance testing for oxygen cutting machines DIN EN 28206 Abnahmeprüfung für Brennschneidmaschinen Laser Equipment DIN EN 31252 Lasergeräte Laser and laser related equipment DIN EN 31553 Laser und Laseranlagen Electrical equipment of machines DIN EN 60204-1 Elekrische Ausrüstung von Maschinen Radiation safety of laser products DIN EN 60825...

  • Page 22: Unpacking/Hoisting

    SECTION 1B UNPACKING/HOISTING 1.1 INSPECTION B. Check each container for any loose parts prior to disposing of shipping materials. A. The Precision Plasmarc System will be shipped in C. Check air louvers on the power source and junction four separate containers. The power source, the box and any other opening to ensure that any obstruc- junction box, the flow control box and the PT-24 torch tions are removed.

  • Page 23: Description

    PT-24 torch. 2.3 PACKAGE OPTIONS AVAILABLE Table 2-1 lists Precision Plasmarc package options avail- able through your ESAB dealer. Table 2-1. Available Package Options . t f . t f .
  • Page 24 SECTION 2 DESCRIPTION Table 2-2. Technical Specifications (Precision Plasma System) Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz Input Current 70/60/50/40/30/25 amps per phase Power Factor 0.95 Output Current Range 15-100 amps dc Output Load Voltage 215 V dc Duty Cycle 100% Open Circuit Voltage 315 V dc...
  • Page 25 SECTION 2 DESCRIPTION Table 2-3. Technical Specifications (Plasma Gas) Type , Air Pressure 125 psig (8.6 bar) Flow 100 cfh (47 I/min) max (varies with application) Purity Required -99.8%,N -99.995%, Air-clean, dry, oil-free Recommend Liquid Cylinder Oxygen: R-76-150-540LC (P/N 19777) Service Regulators Inert Gas: R-76-150-580LC (P/N 19977) Recommended Cylinder 2-Stage...
  • Page 26 SECTION 2 DESCRIPTION...

  • Page 27: Installation

    SECTION 3 INSTALLATION 3.1 GENERAL CAUTION Proper installation can contribute materially to the satis- factory and trouble-free operation of the Precision Plasmarc Be sure that the power source is properly configured System. It is suggested that each step in this section be for your input power supply.

  • Page 28: Interconnecting Lines

    SECTION 3 INSTALLATION D. Pull input power cable through the strain relief to allow H. Connect jumper wire to the proper input voltage cable wires sufficient length to connect to the main connector located on the 7-position terminal block. contactor. Tighten strain relief to ensure input power (See Figure 3-1.) cable is secured.
  • Page 29 Note: All service lines have identification numbers stamped on connections CONTROL LEAD (Flow Control to FLOW CONTROL BOX P/N-37416 Junction Box) Power Bundle #6. Coolant to Torch #7. Coolant Return from Torch Torch Power Cable Pilot Arc Lead BACK 14 pin VIEW Gas Bundle #1.
  • Page 30 SECTION 3 INSTALLATION BUNDLE P/N SHEATH 10 FT. (3m) 21902 21884 21875 21878 21887 21881 995832 20 FT. (6m) 21903 21885 21876 21879 21888 21882 995832 30 FT. (9m) 21904 21886 21877 21880 21889 21883 995826 60 FT. (18m) 22334 22337 22343 22345...
  • Page 31 SECTION 3 INSTALLATION No. 6 and No. 7 No. 6 and No. 7 5/8-18 L.H. 5/8-18 L.H. (B-A/W) (B-A/W) PILOT ARC #16 AWG(YELLOW) POWER CABLE#3 AWG POWER BUNDLE SHEATH 21911 21914 995832 (1) 25 FT. (7.6m) P/N-21905 60 FT. (18m) P/N-21906 21912 21915 995832 (2)
  • Page 32 SECTION 3 INSTALLATION E. Connect control lead (Figure 3-9) between the power source and the flow control and from the flow control to the junction box. See Figure 3-2 or Figure 3-3 for the installation location. CONTROL LEADS P/N'S 10 FT. (3m) P/N-21917 60 FT.
  • Page 33 SECTION 3 INSTALLATION G. Remove coolant fill cap at front of console and fill Flow Control Box coolant tank with 4 gallons (15 l) of plasma coolant. See Figure 3-11. Reinstall cap. NOTE Alt. Due to the high electrical conductivity, use of tap water or commercial antifreeze must NOT be used for torch cool- ing.
  • Page 34 SECTION 3 INSTALLATION (a) Place the "plasma gas" select switch, SW-2, (h) Open valves NV-1 (oxygen plasma gas valve) in O position. and NV-5 (cut shield gas valve) approxi- mately two full turns. (b) Place the "shield gas" select switch, SW-3, in O position.
  • Page 35 SECTION 3 INSTALLATION Flow Control Box Alt. NOTE: The numbers in circles correspond with the steps needed to check gas and coolant leaks. Figure 3-14. Gas Coolant Leak Check...
  • Page 36 SECTION 3 INSTALLATION...

  • Page 37: Operation

    SECTION 4 OPERATION 4.1 POWER SOURCE CONTROLS/ INDICATORS Figure 4-1. Front Panel Controls A. Main Power Switch - controls the input power to the F. Pilot Arc High/Low Switch is used to select pilot arc fan, water cooler, and the interface PCB. The amber current.

  • Page 38: Operation

    SECTION 4 OPERATION 4.2 OPERATION 3. If current is to be set from the cutting machine CNC, place the remote panel switch in REMOTE A. Check consumables in torch for damage and be sure position. Consult the CNC instructions for setting they are correct for the material to be cut and gas to currents.

  • Page 39: Sample Procedure For Setting O 2 Gas Flow Rates On Flow Control Box

    SECTION 4 OPERATION With the completion of the above settings the system is 4.4 SAMPLE PROCEDURE FOR now ready for operation. SETTING N GAS FLOW RATES ON FLOW CONTROL BOX (Figure 4-4) 4.3 SAMPLE PROCEDURE FOR SETTING O GAS FLOW RATES ON NOTE FLOW CONTROL BOX (Figure 4-4) This is a sample procedure only and the operator must...
  • Page 40 SECTION 4 OPERATION FM-2 FM-1 FM-3 FM-4 SW-2 SW-3 PLASMA GAS NV-3 NV-6 SHIELD GAS +ALT SW-1 NV-5 NV-1 NV-4 NV-2 Front View Left Side View Figure 4-4. Flow Control Box...

  • Page 41: Process Data Sheets

    ALUMINUM PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE 3 HOLE SHIELD CUP NOZZLE "B" (SEE NOTES) INSULATOR P/N 21536 PT-24 TORCH P/N 22010 P/N 21541 ð...
  • Page 42 ALUMINUM PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE SHIELD CUP NOZZLE "C" 4 HOLE INSULATOR (SEE NOTES) PT-24 TORCH P/N 22010 P/N 21542 P/N 21692 ð...
  • Page 43 ALUMINUM PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE NOZZLE "D" SHIELD CUP 4 HOLE INSULATOR (SEE NOTES) P/N 21543 P/N 22010 P/N 21692 PT-24 TORCH ð...
  • Page 44 ALUMINUM PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE 4 HOLE NOZZLE "E" SHIELD CUP (SEE NOTES) INSULATOR P/N 21692 PT-24 TORCH P/N 21923 P/N 22010 ð...
  • Page 45 CARBON STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR ALT. GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE SHIELD CUP NOZZLE "A" 2 HOLE INSULATOR (SEE NOTES) PT-24 TORCH P/N 22010 P/N 21540 P/N 21852 ð...
  • Page 46 CARBON STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE NOZZLE "B" 3 HOLE SHIELD CUP (SEE NOTES) INSULATOR PT-24 TORCH P/N 21541 P/N 21536 P/N 22010 ð...
  • Page 47 CARBON STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: OXYGEN PRESSURE:125PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125PSI/8.6 BAR SHIELD MIX GAS: OXYGEN PRESSURE:125PSI/8.6 BAR SWIRL BAFFLE NOZZLE "C" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21542 P/N 21692 P/N 22010 PT-24 TORCH ð...
  • Page 48 CARBON STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE NOZZLE "D" SHIELD CUP 4 HOLE INSULATOR (SEE NOTES) P/N 21543 P/N 22010 P/N 21692 PT-24 TORCH ð...
  • Page 49 CARBON STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE 4 HOLE NOZZLE "E" SHIELD CUP (SEE NOTES) INSULATOR P/N 21692 P/N 21923 P/N 22010 PT-24 TORCH ð...
  • Page 50 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE NOZZLE "B" 3 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21541 P/N 21536 PT-24 TORCH P/N 22010 ð...
  • Page 51 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE NOZZLE "C" SHIELD CUP 3 HOLE INSULATOR (SEE NOTES) P/N 21542 P/N 22010 P/N 21536 PT-24 TORCH ð...
  • Page 52 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE 4 HOLE NOZZLE "D" SHIELD CUP (SEE NOTES) INSULATOR P/N 21692 P/N 21543 P/N 22010 PT-24 TORCH ð...
  • Page 53 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: PRESSURE:125 PSI/8.6 BAR SWIRL BAFFLE 4 HOLE NOZZLE "E" SHIELD CUP (SEE NOTES) INSULATOR P/N 21923 P/N 21692 P/N 22010 PT-24 TORCH ð...
  • Page 54 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE NOZZLE "C" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21692 PT-24 TORCH P/N 21542 P/N 22010 ð...
  • Page 55 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE NOZZLE "D" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21543 P/N 21692 PT-24 TORCH P/N 22010 ð...
  • Page 56 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: PRESSURE:125 PSI/8.6 BAR SHIELD GAS: PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE NOZZLE "E" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21923 P/N 21692 PT-24 TORCH P/N 22010 ð...
  • Page 57 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125PSI/8.6 BAR SHIELD MIX GAS: SWIRL BAFFLE NOZZLE "C" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21542 P/N 21692 PT-24 TORCH P/N 22010 ð ð ð...
  • Page 58 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: SWIRL BAFFLE NOZZLE "D" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21543 P/N 21692 PT-24 TORCH P/N 22010 ð...
  • Page 59 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: SWIRL BAFFLE NOZZLE "E" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21923 P/N 21692 PT-24 TORCH P/N 22010 ð...
  • Page 60 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE NOZZLE "D" 4 HOLE SHIELD CUP (SEE NOTES) INSULATOR P/N 21543 P/N 21692 PT-24 TORCH P/N 22010 ð...
  • Page 61 STAINLESS STEEL PROCESS DATA 11/30/99 AMPERAGE: PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR SWIRL BAFFLE SHIELD CUP NOZZLE "E" 4 HOLE INSULATOR (SEE NOTES) PT-24 TORCH P/N 22010 P/N 21923 P/N 21692 ð...

  • Page 62: Kerf

    SECTION 4 OPERATION Aluminum Kerf Values N Aluminum N 30 Amperes Material Thickness (mm) 1.575 1.905 2.286 3.175 4.750 6.350 0.140 3.556 0.120 3.048 0.100 2.540 2.210 0.080 2.032 0.087 1.651 1.524 0.060 1.524 0.065 1.270 1.270 1.270 0.060 0.050 0.050 0.050 0.040...
  • Page 63 SECTION 4 OPERATION Aluminum N 70 Amperes Material Thickness (mm) 4.750 6.350 9.525 12.700 0.190 4.826 0.170 4.318 0.150 3.810 0.130 3.302 3.048 2.845 0.120 0.110 2.794 2.540 2.540 0.112 0.100 0.100 0.090 2.286 0.070 1.778 0.050 1.270 0.187 0.250 0.375 0.500 Material Thickness (inches)
  • Page 64 SECTION 4 OPERATION Carbon Steel Kerf Values O Carbon Steel O 16 Amperes Material Thickness (mm) 1.219 3.404 0.140 3.556 0.120 3.048 0.100 2.540 0.080 2.032 1.473 0.060 1.524 1.118 0.058 0.040 1.016 0.044 0.020 0.508 0.000 0.000 0.048 0.134 Material Thickness (inches) Carbon Steel O 35 Amperes...
  • Page 65 SECTION 4 OPERATION Carbon Steel O 45 Amperes Material Thickness (mm) 3.175 6.350 9.525 0.140 3.556 0.120 3.048 2.413 0.100 2.540 0.095 1.930 0.080 2.032 1.626 0.076 0.060 1.524 0.064 0.040 1.016 0.020 0.508 0.000 0.000 0.125 0.250 0.375 Material Thickness (inches) Carbon Steel O 70 Amperes Material Thickness (mm)
  • Page 66 SECTION 4 OPERATION Carbon Steel O 100 Amperes Material Thickness (mm) 9.525 12.700 19.050 0.140 3.556 3.048 0.120 3.048 0.120 2.540 0.100 2.337 2.540 0.100 0.092 0.080 2.032 0.060 1.524 0.040 1.016 0.020 0.508 0.000 0.000 0.375 0.500 0.750 Material Thickness (inches)
  • Page 67 SECTION 4 OPERATION Stainless Steel Kerf Values O Stainless Steel O 30 Amperes Material Thickness (mm) 0.457 0.584 0.726 1.207 1.588 0.140 3.556 0.120 3.048 0.100 2.540 0.080 2.032 0.060 1.524 1.143 0.889 0.889 0.889 0.889 0.040 1.016 0.045 0.035 0.035 0.035 0.035...
  • Page 68 SECTION 4 OPERATION Stainless Steel Kerf Values Air/Air/CH Stainless Steel Air/Air/CH 70 Amperes Material Thickness (mm) 3.175 4.775 6.350 9.525 12.700 0.140 3.556 2.921 0.120 3.048 0.115 2.540 0.100 2.540 2.286 0.100 2.032 0.090 0.080 2.032 1.778 0.080 0.070 0.060 1.524 0.040 1.016...
  • Page 69 SECTION 4 OPERATION Stainless Steel Kerf Values N Stainless Steel N 70 Amperes Material Thickness (mm) 4.750 6.350 9.525 12.700 0.140 3.556 2.921 0.120 3.048 2.667 0.115 2.413 0.100 2.540 0.105 0.095 2.032 0.080 2.032 0.080 0.060 1.524 0.040 1.016 0.020 0.508 0.000...
  • Page 70 SECTION 4 OPERATION Stainless Steel Kerf Values N Stainless Steel N 50 Amperes Material Thickness (mm) 3.175 4.750 6.350 9.525 0.140 3.556 0.120 3.048 0.100 2.540 2.032 0.080 2.032 1.778 1.651 0.080 1.524 0.070 0.060 1.524 0.065 0.060 0.040 1.016 0.020 0.508 0.000...
  • Page 71 SECTION 4 OPERATION Stainless Steel N 100 Amperes Material Thickness (mm) 6.350 9.525 12.700 15.875 0.190 4.826 0.170 4.318 0.150 3.810 3.556 0.140 0.130 3.302 3.048 2.794 0.120 0.110 2.794 2.540 0.110 0.100 0.090 2.286 0.070 1.778 0.050 1.270 0.250 0.375 0.500 0.625...
  • Page 72 SECTION 4 OPERATION Stainless Steel Kerf Values Air/Air Stainless Steel Air/Air 50 Amperes Material Thickness (mm) 3.175 4.750 6.350 9.525 0.140 3.556 0.120 3.048 2.413 0.100 2.540 2.032 0.095 0.080 2.032 0.080 1.651 1.524 0.060 1.524 0.065 0.060 0.040 1.016 0.020 0.508 0.000...
  • Page 73 SECTION 4 OPERATION Stainless Steel Air/Air 100 Amperes Material Thickness (mm) 6.350 9.525 12.700 15.875 0.190 4.826 0.170 4.318 4.064 0.160 0.150 3.810 3.556 3.302 0.140 0.130 3.302 2.921 0.130 0.110 2.794 0.115 0.090 2.286 0.070 1.778 0.050 1.270 0.250 0.375 0.500 0.625...
  • Page 74 SECTION 4 OPERATION Page intentionally left blank.

  • Page 75: Cutting Quality

    SECTION 5 CUTTING QUALITY 5.1 CUT ANGLE The optimum torch height is just before the part begins to develop a negative cut angle. To expand upon the other two variables, if the torch standoff is correct, too fast of a Cut squareness is always a concern when using nitrogen cutting speed will result in a positive cut angle;...

  • Page 76: Voltage And Cut Quality

    SECTION 5 CUTTING QUALITY ARC VOLTAGE/STANDOFF Standoff and arc voltage are proportional. The higher the torch above the plate (standoff), the higher the operating voltage and vice versa. Standoff Arc Voltage LAG LINES These lines appear on the cut surface. They are used to determine if your process parameters are correct.
  • Page 77 SECTION 5 CUTTING QUALITY ARC VOLTAGE CORRECT Correct Cutting Speed Square Top Edge No Top Dross Little or No Bottom Dross Arc Voltage Cut Face Smooth Uniform Lag Lines Optimum End View Cut Angle Cut Face Figure 5-4. Cut Quality (Arc Voltage Correct) ARC VOLTAGE TOO LOW Correct Cutting Speed Under Cut Top Edge...

  • Page 78: Top Dross

    SECTION 5 CUTTING QUALITY ARC VOLTAGE TOO LOW Correct Cutting Speed Arc Voltage Under Cut Top Edge Negative Cut Angle Under Cut Dross Top Edge End View Cut Face Rough -/+ Cut Angle Vertical Serrated Lag Lines Cut Face Figure 5-6. Cut Quality (Arc Voltage Too Low With An Under Cut Top Edge) 5.3 TOP DROSS.

  • Page 79: Summary

    SECTION 5 CUTTING QUALITY TOP DROSS Splatter appears on the top edge of both pieces of the plate. Lower the voltage in increments 5 V dc (maximum ) until top dross disappears. Figure 5-7. Top Dross HIGH SPEED DROSS Fine roll over dross that welds to bot tom of edge.
  • Page 80 SECTION 5 CUTTING QUALITY...

  • Page 81: Maintenance

    The pressure are as follows: adjustment wheels on the pressure switches should not be touched. Consult your ESAB representative if you A. Check work cable to workpiece connection. have determined that the pressure switches are not functioning properly.

  • Page 82: Torch Maintenance

    Also, Do NOT substitute any other spring 6.6 TORCH MAINTENANCE or ball. If they are dropped, lost, or damaged they must be replaced with genuine ESAB replacement parts. Changes, substitutions or damaged parts will affect set pressures and cause poor starting and WARNING piercing.
  • Page 83 SECTION 6 MAINTENANCE passages for blockage. Clear blockages with an 1. Unscrew the shield cup retainer. The cup may air stream, if blockages cannot be cleared, re- come free with the retainer or stay on the torch. If place the baffle. Do NOT insert anything in these on the torch, pluck it free with your thumbnail.
  • Page 84 SECTION 6 MAINTENANCE Figure 6-2. Schematic Gas Flow...

  • Page 85: Troubleshooting

    SECTION 7 TROUBLESHOOTING 7.1 TROUBLESHOOTING The signal exchange between the PLC and external devices are both time and condition dependent. If a required signal is not received in the proper sequence, the PLC will discontinue the process and WARNING generate a fault signal to the CNC. ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has been externally discon- nected.
  • Page 86 SECTION 7 TROUBLESHOOTING omron PA202 IA111 OC201 OC201 SYSMAC ERR/ALM CJ1M PROGRAMMABLE PRPHL CONTROLLER COMM 12 13 POWER CPU12 BKUP OPEN SW SETTING BATTERY MCPWR BUSY AC100 -240V INPUT L2/N PERIPHERAL AC100V 7mA 50Hz AC250V 2A AC250V 2A PORT 8mA 60Hz DC24V 2A DC24V 2A 1.

  • Page 87: Troubleshooting Procedures

    SECTION 7 TROUBLESHOOTING 7.3 TROUBLESHOOTING PROCEDURES WARNING Check the problem against the symptoms in the follow- ing troubleshooting guide. The remedy may be quite simple. If the cause cannot be quickly located, shut off Voltages in plasma cutting equipment are high enough the input power, open up the appropriate component, to cause serious injury or possibly death.
  • Page 88 SECTION 7 TROUBLESHOOTING e f i n i t y l l a t l c i t . e l y l l a t l t l u o i t a i t t l u l a f n i l t l a h t i...
  • Page 89 SECTION 7 TROUBLESHOOTING y t i ) . t n i t i t s l a i n i t o i t . e l o i t h t i l r i o i t . l e f i h n i t e l i...
  • Page 90 SECTION 7 TROUBLESHOOTING s l i n i l y t l n i l c t i c t i n i l c t i c t i t i s t i s t t i y t i f i l c i f n i l...
  • Page 91 SECTION 7 TROUBLESHOOTING Table 7-3. PT-24 Torch Leak Procedure Front end of torch leaking Remove: shield cup insulator shield retainer insulator ring nozzle retaining cup nozzle swirl baffle electrode Visually inspect nozzle sealing o-ring and electrode o-ring Replace Are o-rings o-ring damaged? Visually inspect nozzle and retaining cup metal-to-metal seat...

  • Page 92: Schematics And Wiring

    D-37414 Figure 7-2. Flow Control Schematic...
  • Page 93 D-37399-D Figure 7-3. Junction Box Schematic and Wiring Diagram...
  • Page 94 D-37413 Figure 7-4. Flow Control Wiring Diagram...
  • Page 96 SECTION 7 TROUBLESHOOTING...
  • Page 97 SECTION 7 TROUBLESHOOTING...
  • Page 98 SECTION 7 TROUBLESHOOTING MOD1 SEE CHART PCB2 omr on PA 202 CJ 1M S YS MAC E RR/ALM IA 111 OC201 OC 201 1 2 3 4 5 6 7 8 P ROGRAMMABLE P RP HL P OW E R CPU12 CO NTROLLE R COMM...
  • Page 99 SECTION 7 TROUBLESHOOTING 1 K5-6 (WHT) PLC CB3-2 (BLK) 1 PLC CB1-2 (BLK) K6-6 (WHT) PLC TB7-10 (BLK) TB3-1 (WHT) PLC TB4-2 (WHT) PLC TB7-12 (BLK) PLC IN1-0 (WHT) PLC TB7-2 (WHT) 2 K7-4 (BRN) PLC J2-2 (WHT) TB3-2 (WHT) PLC PS-L2 (WHT) PLC IN1-1 (BRN) K7-6 (WHT)
  • Page 100 SECTION 7 TROUBLESHOOTING 0558003591 TB4-1 PUMP TB4-4 MOTOR PCB1 ISOLATION AMPLIFIER AND P10-5 18VAC FAULT SIGNAL PCB P10-3 18VAC 38103 P10-4 P2-10 18VAC P2-9 18VAC LED1 LED4 LED7 P2-8 575V P2-16 24VAC P2-15 P7-1 460V P2-14 24VAC P7-3 P2-13 LED2 LED5 LED8 415V...

  • Page 101: Repair Parts

    SECTION 7 TROUBLESHOOTING 0558003591 CNC START CNC PREFLOW ARC ON TO CNC O2 PS N2 PS FAULT TRAVEL FC HF START START GAS FLT CUT GAS FLT FAULT TO CNC 220 VAC START GAS ON, NITROGEN CUT GAS ON, OXYGEN OUTPUT FULL SHIELD MODULE...

  • Page 103: General

    8.2 Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your...
  • Page 104 SECTION 8 REPLACEMENT PARTS 8.3 Plasmarc Power Source-Exterior Components OUTPUTS START-STOP TRAVEL PREFLOW HI FREQUENCY ARC-ON PILOT ARC RELAY PRESSURE POWER SOURCE PRESSURE START GAS PRESS SWI FAULT PILOT CUT GAS PRESS SWI FAULT FAULT OUTPUT FAULT START GAS ON N CUT GAS ON O INPUTS FULL SHIELD...
  • Page 105 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35925YL Cover-Top 995227 Label Warning-Exposed High Volt 2091514 Label Warning 34941 Lens Clear 13734588 Logo ESAB Clear 35924YL Panel Right Side 32403Y Panel Left Side 61328087 Screw, HMH ¼-20 X .50 L...
  • Page 106 SECTION 8 REPLACEMENT PARTS "TEE" Detail Page 7-12...
  • Page 107 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 672508 Switch Toggle 2PST 2 Pos 15A 634518 S2,3 Switch Toggle DPDT 2 Pos 15A 951061 AM1,VM1 Meter LED 5VDC 951061 AM1,VM1 Meter LED 5VDC 634518 S2,3 Switch Toggle DPDT 2 Pos 15A 2234589 POT 10K 10 Turn 954751...
  • Page 108 SECTION 8 REPLACEMENT PARTS...
  • Page 109 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35928GY Door Access Rear 952209 Conn Box Recpt 19 FS SH 952210 Conn Box Recpt 14 FS SH 97W6 3 Strain Relief 23610197 Plug Hole .875 Dia. .125 CT Nyl BK 952571 Fuse 7A 600 VAC Fast Acting 32202GY...
  • Page 110 SECTION 8 REPLACEMENT PARTS 8.4 Plasmarc Power Source-Internal Components Reference: PCB1 Isolation Amp Reference: Meter LED AM1,VM1 PA202 omron IA111 OC201 OC201 SYSMAC CJ1M ERR/ALM POWER PROGRAMMABLE CONTROLLER PRPHL 14 15 CPU12 COMM BKUP OPEN SW SETTING AC100 BATT ERY -240V MCPWR BUSY...
  • Page 111 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35920GY Base, Precision Plasma 635686 Term Block 8 pos 838103 PCB1 PCB Isolation AMP 950096 PCB1 P9,7 Housing Contact, Crimp 3 pin 952053 Standoff #6-32 X .88 L 952034 PCB1 P10 Plug 5 Pos 952030...
  • Page 112 SECTION 8 REPLACEMENT PARTS...
  • Page 113 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 952026 Terminal Block 673502 Contactor 3 Pole 75A 672002GY Shroud, Fan 2062334 Motor, Fan 36417GY Shroud, Fan 951215 Motor, Carb 1/3 Hp 951347 Pump, Carb w/Strainer 950179 Tee, Pipe Branch ¼ Brs 10Z30 Adaptor, B/A-W M ¼...
  • Page 114 SECTION 8 REPLACEMENT PARTS “TEE” Detail...
  • Page 115 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 36538 Hose, Assy Pump Outlet- Torch out 950001 Switch, Flow .25 GPM SPSTB 21124 Valve, Check Assy 36539 Hose, Assy Flowswitch To Core 90858009 TBG, Nylobrade 3/8 I.D X .625 O.D. 36418 Hose Assy Tank Bottom- Pump Inlet 58V75...
  • Page 116 SECTION 8 REPLACEMENT PARTS...
  • Page 117 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 13735961 Heat Exchanger 950823 Bushing, Snap 950167 Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W 995103 Terminal Block 24 POS 15A 36919 Board, Terminal Output 96W10 Holder, Fuse 92W57 Grommet, Rub .63 I.D.
  • Page 118 SECTION 8 REPLACEMENT PARTS...
  • Page 119 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 950823 Bushing, Snap 17750020 R11,12 Res 20 ohm 50W 36527GY Cover, Terminal Board 951161 C1,2 Cap, Metpoly 20uf 400VDC 673458 Contactor, Pilot Arc 3P 40A 2234521 P4,MOD1 Plug, 16 Pos P1,PLC1 P2 2234891 MOD1 P3, 4,...
  • Page 120 SECTION 8 REPLACEMENT PARTS 8.5 PLC Precision Plasma CJIM P/N 0558003578 omron PA202 IA111 OC201 OC201 SYSMAC ERR/ALM CJ1M PROGRAMMABLE PRPHL CONTROLLER COMM 12 13 POWER CPU12 BKUP OPEN SW SETTING BATTERY MCPWR BUSY AC100 -240V INPUT L2/N PERIPHERAL AC100V 7mA 50Hz AC250V 2A AC250V 2A...
  • Page 121 SECTION 8 REPLACEMENT PARTS Item Part Number Quantity Description Number 0558003755 OMRON Power supply 0558003756 0558003758 AC Input Module 0558003757 Relay Output Module 0558003633 Flash Memory...
  • Page 122 SECTION 8 REPLACEMENT PARTS 8.6 Power Source Power Module...
  • Page 123 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35914GY Base Power Module 37102 Bracket, PCB KYDEX 35799 Wire Kit, Power Module 951339 PCB1 P1, 5 Plug, Female 12 Position 951340 PCB1 P2, 6 Plug, Female 14 Position 37101GY Deck, Power Module 951981...
  • Page 124 SECTION 8 REPLACEMENT PARTS Section A-A...
  • Page 125 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 2234877 J3,4 Block Terminal 10 Position 951182 Fan, Axial 950487 Terminal Strip 2 Position 950823 Bushing, Snap 35700 Inductor, Power Factor 17280215 Resistor 1.5K OHM 100W 35680 Inductor Assembly Output 35681 Transformer Assembly, Main...
  • Page 126 SECTION 8 REPLACEMENT PARTS...
  • Page 127 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 2234518 Block Terminal, 8 Position 38047 Shunt, Feedback 2234519 Block Terminal, 16 Position 35917GY Baffle Heatsink 951981 Heatsink 2234877 J3, 4 Block Terminal, 10 Position 674156 Adaptor...
  • Page 128 SECTION 8 REPLACEMENT PARTS...
  • Page 129 SECTION 8 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35940 Transformer Control 951978 Bridge Diode 3PH 130A 951192 Pad Thermal Bridge 35794 Busbar Input Bridge 951979 SCR1 SCR 90A 951196 Pad Thermal SCR Module 951980 Q1,2 IGBT 300A 600V 17750020 R4,5 Resistor 20OHM 50W NI...
  • Page 130 SECTION 8 REPLACEMENT PARTS 8, 9 7, 8 Figure 8-1. Flow Control Box, 37416 (Left, Front Right Side V i e w s ) I t e m Q t y . P a r t C i r c u i t N o .
  • Page 131 SECTION 8 REPLACEMENT PARTS DETAIL 'B' DETAIL 'C' (See Fig. 8-3.) (See Fig. 8-3.) 23, 27, 28 SECTION A-A Figure 8-2. Flow Control Box, 37416 (Top Inside Views) I t e m Q t y . P a r t C i r c u i t N o .
  • Page 132 SECTION 8 REPLACEMENT PARTS 35,38 35, 46 36, 35 35, 45 35, 46 35, 45 35, 46 DETAIL 'B' DETAIL 'C' Figure 8-3. Flow Control Box, 37416 (Inlet Outlet Manifold s e m b l i e s ) I t e m Q t y .
  • Page 133 SECTION 8 REPLACEMENT PARTS PLASTIC TUBING, .250 OD x .040 WALL (TYP.) 90858003 (14.5' TOTAL) Figure 8-4. Flow Control Box, Tubing Network TUBING 90858003 FROM LENGTH FM1(OUT) NV1(IN) 10.50 FM4(OUT) NV4(IN) 10.50 FM2(OUT)R NV2(IN) 12.50 FM3(OUT)L NV5(IN) 12.50 FM1(IN) (OUT)BOT 8.00 FM2(IN) (OUT)TOP...
  • Page 134 SECTION 8 REPLACEMENT PARTS WORK Figure 8-5. Junction Box, 37400 (Inlet View) ITEM PART C I R C U I T N O . R E Q . N O . D E S C R I P T I O N SYMBOL 6271128 CONN.
  • Page 135 SECTION 8 REPLACEMENT PARTS Figure 8-6. Junction (Outlet View) ITEM PART C I R C U I T N O . R E Q . N O . D E S C R I P T I O N SYMBOL 952697 VALVE SOLENOID 3-WAY SOL1...
  • Page 136 SECTION 8 REPLACEMENT PARTS START SHIELD 1 SHIELD 2 COM/COM COM/COM SHIELD2 SHIELD1 START SHIELD 1 SHIELD 2 START GAS CUT GAS SOLENOID SOLENOID SHIELD GAS SOLENOIDS Figure 8-9A. SOLENOID ASSEMBLY, PT-24, 22376 C I R C U I T I T E M P A R T D E S C R I P T I O N...
  • Page 137 SECTION 8 REPLACEMENT PARTS Relay 24 VAC Common Shield 2 and Relay NC Solenoid Plasma 1 and 2 Common Shield 1 and 2 Common Relay Shield 1 and 2 Relay 24VAC Wires Relay NC Plasma 2 Plasma 1 Figure 8-9B. SHUT-OFF VALVE, PT-24,...
  • Page 138 NOTE: Torch is supplied with 70 amp consumables assembled in place.
  • Page 139 Table 8-9. Precision Plasma PT-24 Torch Assembly I T E M PART CODE NO. DESCRIPTION 2 1 7 5 8 BODY & TUBE AY PT-24 TORCH 22568 SLEEVE TORCH PT-24 21761 POWER CABLE 4.5FT (1,4m) PT-24 22424 POWER CABLE 12FT (3,7m) PT-24 22398 POWER CABLE 17FT (5,2m) PT-24 21762...
  • Page 140 B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST Performance Features...

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