ESAB Precision Plasmarc Installation, Operation And Maintenance Manual For Residential Installation
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ESAB Precision Plasmarc Installation, Operation And Maintenance Manual For Residential Installation

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F-15-480-D
October, 2000
Installation, Operation and Maintenance Manual for the
PRECISION PLASMARC SYSTEM
with Electronic Flow Control
CUTTING SYSTEMS
411 s. Ebenezer Road
Florence, SC 29501-0545

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Summary of Contents for ESAB Precision Plasmarc

  • Page 1 F-15-480-D October, 2000 Installation, Operation and Maintenance Manual for the PRECISION PLASMARC SYSTEM with Electronic Flow Control CUTTING SYSTEMS 411 s. Ebenezer Road Florence, SC 29501-0545...
  • Page 2 This manual is ESAB Part Number F15480 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, 2000...

  • Page 3: Table Of Contents

    3.2 Equipment Required 3.3 Location 3.4 Primary Electrical Input Connections 3.5 Interconnecting Lines Precision Plasmarc Component Interconnecting Diagram 3.6 Torch Mounting 3.7 Torch Coolant 3.8 Inspection of Gas and Coolant Lines 3.9 Replacement of EPROM in the Plasmarc Power Source...

  • Page 4: Introduction

    Precision Plasma Electronic Flow Control Table of Contents Section 4 Operation 4.1 Power Supply Controls 4.1.1 Main Power Switch 4.1.2 Pilot Arc Switch 4.1.3 Fault Indicator Lights 4.1.4 Meters 4.1.5 Current Control Switch 4.2 Cut Quality 4.2.1 Introduction 4.2.2 Cut Angle 4.2.3 Cut Flatness 4.2.4 Surface Finish 4.2.5 Dross...
  • Page 5 Precision Plasma Electronic Flow Control Table of Contents Section 5 Maintenance 5.1 General 5.2 Inspection and Cleaning 5.3 PT-24 Torch Description 5.4 Torch Maintenance 5.5 PT-24 Consumable Disassembly and Inspection 5.6 PT-24 Torch Re-Assembly Section 6 Troubleshooting 6.1 General Safety 6.2 Programmable Logic Controller (PLC) 6.2.1 PLC LED Introduction 6.2.2 PLC LED Functions...
  • Page 6 Precision Plasma Electronic Flow Control Table of Contents 6.12 Technical Guide to Using/Understanding the Operation of the EFC 6.12.1 Precision Process Timers 6.12.2 Process Timer Values 6.12.3 Process Window Key Functions 6.12.4 Proportional Valve Analog Values for PARAM.CUT PARAM.CUT DEF.TEC DEF.TEC PARAM.CUT PARAM.CUT...

  • Page 7: Safety Notations And Symbols

    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 8: General Safety Information

    SECTION 1 SAFETY 1.3 General Safety Information Machine starts automatically. WARNING This equipment moves in various directions and This equipment moves in various directions and This equipment moves in various directions and This equipment moves in various directions and speeds. speeds.

  • Page 9: Installation Precautions

    Never attempt any machine modifications or apparatus Never attempt any machine modifications or apparatus Never attempt any machine modifications or apparatus additions without first consulting a qualified ESAB additions without first consulting a qualified ESAB additions without first consulting a qualified ESAB additions without first consulting a qualified ESAB representative.

  • Page 10: Electrical Grounding

    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.

  • Page 11: Section 1 Safety

    SECTION 1 SAFETY Hazardous voltages. Electric shock WARNING can kill. Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable •...
  • Page 12 SECTION 1 SAFETY Radiation hazard. WARNING Arc rays can injure eyes and burn Arc rays can injure eyes and burn Arc rays can injure eyes and burn Arc rays can injure eyes and burn skin. skin. skin. skin. Wear correct eye and body protection. Wear correct eye and body protection.
  • Page 13 SECTION 1 SAFETY Spark hazard. WARNING Heat, spatter, and sparks cause fire and burns. 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.

  • Page 14: Service Precautions

    SECTION 1 SAFETY Explosion hazard. WARNING Certain molten aluminum-lithium (Al- Certain molten aluminum-lithium (Al- Certain molten aluminum-lithium (Al- Certain molten aluminum-lithium (Al-Li) alloys can Li) alloys can Li) alloys can Li) alloys can cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water.

  • Page 15: Safety References

    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 This page intentionally left blank. 1-10...

  • Page 17: Section 2 Description

    Precision Plasmarc System. Technical reference material is also provided to assist in troubleshooting the cutting package. 2.3 Package Options Available Precision Plasmarc package options available through your ESAB dealer Precision Plasmarc Power Source ( 200/230/380/415/460/575 3-phase 50/60...

  • Page 18: Technical Specifications

    SECTION 2 DESCRIPTION 2.4 Precision Plasma Technical Specifications 2.4.1 System Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz Input Current 65/60/50/40/30/25 amps per phase Power Factor 0.95 Output Current Range 15-100 amps dc Output Load Voltage 120 V dc Duty Cycle 100% Open Circuit Voltage 315 V dc...

  • Page 19: Plasma Gas

    SECTION 2 DESCRIPTION 2.4.2 Plasma Gas Technical Specifications Type , Air Pressure 125 psig (8.6 bars) 100 cfh (47 l/min) max. (varies with Flow application) -99.995% Purity Required* -99.995% Air-clean, dry and oil free Recommended Liquid Cylinder Service Oxygen: R-76-150-540LC (P/N 19777) Regulators Inert gas: R-76-150-580LC (P/N 19977) Oxygen: R-77-150-540 (P/N 998337...
  • Page 20 SECTION 2 DESCRIPTION Page intentionally left blank.

  • Page 21: Section 3 Installation

    SECTION 3 INSTALLATION 3.1 General Proper installation can contribute materially to the satisfactory and trouble-free operation of the Precision NOTICE Plasmarc System. It is suggested that each step in this section be studied and carefully followed. 3.2 Equipment Required Gas Supply and Hoses. Gas supply may be from •...

  • Page 22: Primary Electrical Input Connections

    SECTION 3 INSTALLATION 3.4 Primary Electrical Input Connections Electric Shock Can Kill! DANGER Provide maximum protection against electrical shock. Before any connections are made inside the machine, open the line (wall) disconnect switch and unplug the power cord. Input Power Configuration WARNING Machine must be properly configured for your input power.
  • Page 23 SECTION 3 INSTALLATION The following procedure explains the proper installation steps for connecting primary electrical power to the power source. 1. Remove right side panel. 2. Ensure input power cable is disconnected from all electrical sources. 3. Route input power cable through the strain relief located at the rear panel.

  • Page 24: Interconnecting Lines

    SECTION 3 INSTALLATION 3.5 Interconnecting Lines Black 1. All interconnecting service lines supplied are Red/Orange numbered or color coded on each end with Yellow Blue corresponding numbers/colors marked on the cabinets. Mounting Plate Gas Line Bundle 2. Connect all four lines in Gas Line Bundle to Flow Gas Bundle Control Box and Junction Box.
  • Page 25 SECTION 3 INSTALLATION Power supply and EFC Connections to J-Box Power supply and EFC Connections to J-Box Power supply and EFC Connections to J-Box Power supply and EFC Connections to J-Box Power Supply Bundle #7 Hose Power Supply Negative Connection 3.
  • Page 26 SECTION 3 INSTALLATION Junction Box to Torch Connections Junction Box to Torch Connections Junction Box to Torch Connections Junction Box to Torch Connections Torch Hose/Power Cable Connection Torch Solenoid 4. Connect Torch Bundle Leads/Hoses to Electrical Junction box. (see Interconnecting Block Connection Diagram) Torch Bundle...

  • Page 27: Precision Plasmarc Component Interconnecting Diagram

    SECTION 3 INSTALLATION Precision Plasmarc Component Interconnecting Diagram 25 micron Filters Control Lead EFC/Junction ASIOB High Frequency High Frequency 120VAC 120VAC Gas Line Bundle Junction Power Bundle Torch Primary Power Cable Work Lead Cutting Table Control Lead Power Supply to CNC...
  • Page 28 SECTION 3 INSTALLATION Gas Line Contamination Will Damage CAUTION Proportional Valves Purge Gas Lines Before connecting gas delivery lines to the Before connecting gas delivery lines to the Before connecting gas delivery lines to the Before connecting gas delivery lines to the Electronic Flow Control, purge all lines thoroughly.
  • Page 29 SECTION 3 INSTALLATION Remove Access Cover Pilot Arc Work Torch 7. Remove panel from rear of console and attach the Pilot Arc pilot-arc, torch and work lead. Work Torch CNC Control Lead Power Source Flow Control 600 amp Lead Bus Fuse Rating Label Serial...

  • Page 30: Torch Mounting

    SECTION 3 INSTALLATION 3.6 Torch Mounting CAUTION Do Not Cover Vent Hole. When mounting, do not to cover the small vent hole in When mounting, do not to cover the small vent hole in When mounting, do not to cover the small vent hole in When mounting, do not to cover the small vent hole in the side of the sleeve.

  • Page 31: Torch Coolant

    SECTION 3 INSTALLATION 3.7 Torch Coolant Remove coolant fill cap at front of console and fill • coolant tank with 4 gallons (15 liters) of plasma coolant, P/N 156F05 (one gallon). Do not fill above maximum level • Coolant Fill Cap Reinstall Cap.

  • Page 32: Replacement Of Eprom In The Plasmarc Power Source Programmable Logic Controller (Plc)

    INSTALLATION 3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic Controller (PLC) The Precision Plasmarc System may be shipped configured for a manual flow control (Series “A”). If so, the EPROM in the Programmable Logic Controller must be replaced with an EFC EPROM.
  • Page 33 SECTION 3 INSTALLATION Left Side Panel 1. Ensure the Plasmarc Power Source is disconnected from electricity source. 2. Expose the PLC by removing the left side panel of the Plasmarc Power Source. 3. Pop the EPROM cover on the PLC to expose the EPROM.
  • Page 34 SECTION 3 INSTALLATION Using An EPROM Puller Tool May Damage CAUTION Socket Forcibly removing a clamped EPROM in the PLC may cause the socket/EPROM to break. Special Zero Force EPROM Socket is used to eliminate the need for special tools. 4.

  • Page 35: Section 4 Operation

    SECTION 4 OPERATION 4.1 Power Supply Controls Main Power Switch 4.1.1 Main Power Switch Controls the input power to the fan, water cooler and the PC Board. Amber indicator light to the left of the switch. DO NOT SWITCH W HILE CUTTING EMERGENCY STOP 4.1.2 Pilot Arc Switch...

  • Page 36: Fault Indicator Lights

    SECTION 4 OPERATION 4.1.3 Fault Indicator Lights Fault Indicator Lights Coolant flow will show low coolant flow. When • unit is turned on, the light will briefly show a fault and then go out. Plasma Gas Pressure fault indicator -- low •...

  • Page 37: Cut Quality

    SECTION 4 OPERATION 4.2 Cut Quality 4.2.1 Introduction Causes affecting cut quality are interdependent. Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to different undesirable cutting results. To begin select the most prominent condition: 4.2.2 Cut Angle, negative or positive §...

  • Page 38: Cut Flatness

    SECTION 4 OPERATION Positive Cut Angle Top dimension is less than the bottom dimension. Part Misaligned torch • Bent or warped material • Worn or damaged consumables • High standoff High (arc voltage) • Cutting speed fast • Current high or low. (See Process Data for •...

  • Page 39: Surface Finish

    SECTION 4 OPERATION Top Edge Undercut Standoff low (Arc Voltage) • Part Drop 4.2.4 Surface Finish Process Induced Roughness Cut face is consistently rough. May or may not be confined to one axis. Incorrect Shield Gas mixture (See Process Data) •...

  • Page 40: Dross

    SECTION 4 OPERATION 4.2.5 Dross Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.
  • Page 41 SECTION 4 OPERATION Side View Splatter Top Dross Appears as splatter on top of material. Usually removes easily. Cutting speed fast • Standoff high (arc voltage). • Face Intermittent Dross Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross Possible worn consumables •...

  • Page 42: Dimensional Accuracy

    SECTION 4 OPERATION 4.2.6 Dimensional Accuracy Generally using the slowest possible speed (within approved levels) will optimize part accuracy. Select consumables to allow a lower arc voltage and slower cutting speed. Recommended cutting speed and arc voltage will NOTICE give optimal cutting performance in most cases. Small incremental adjustments may be needed due to material quality, material temperature and specific alloy.

  • Page 43: Influence Of Gas Options On Cut Quality

    SECTION 4 OPERATION 4.3 Influence of Gas Options on Cut Quality 4.3.1 Introduction All gases are not suitable for all situations. Certain gases assist in cutting specific materials and thickness. The following explains why certain gases are selected and their influence on the finished part. Other influences such as arc voltage and gas flow/pressure are covered in the Process Data.
  • Page 44 SECTION 4 OPERATION Refer to Cutting Process Data in the PT24 NOTICE Manual for recommended flow/pressure settings. 4.3.3 Carbon Steel Material Thickness: Material Thickness: Material Thickness: Material Thickness: 26 GA (.018 " ) to 10 GA (.135 " ) (0,5 mm to 3,4 mm) Smooth cut face •...
  • Page 45 SECTION 4 OPERATION Refer to Cutting Process Data in the PT24 NOTICE Manual for recommended flow/pressure settings. 4.3.4 Stainless Steel Material Thickness: 22 GA (.028 " ) to 16 GA (.062") (0,7 mm to 1,6 mm) Material Thickness: Material Thickness: Material Thickness: Positive cut angle •...
  • Page 46 SECTION 4 OPERATION Refer to Cutting Process Data for recommended NOTICE flow/pressure settings. Stainless Steel Material Thickness: Material Thickness: .125" to .625" (3,2 mm to 15,9 mm) Material Thickness: Material Thickness: Matted cut edge appearance • Light gray color • Cut Qualities: Cut Qualities: Cut Qualities:...

  • Page 47: Process Data 4.4.1 Introduction

    The following information is a result of many hours of testing and is a general guide for setting up and cutting with a PT-24 Precision Plasmarc System. In most cases these settings will provide a quality cut. The data contains values for: cutting aluminum, carbon and stainless steel •...
  • Page 48 SECTION 4 OPERATION 4.4.2 Process Data Aluminum Material: Amperes: Nitrogen @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar Shield Mix Gas: PT-24 Torch Torch Body Torch Body Torch Body Torch Body...

  • Page 49: Aluminum

    SECTION 4 OPERATION Amperes Process Data Aluminum Material Thickness 0.062 0.075 0.090 0.125 0.187 0.250 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 50 SECTION 4 OPERATION Aluminum Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 51 SECTION 4 OPERATION Amperes Process Data Aluminum Material Thickness 0.062 0.125 0.187 0.250 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 4318...
  • Page 52 SECTION 4 OPERATION Aluminum Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 53 SECTION 4 OPERATION Amperes Process Data Aluminum Material Thickness 0.187 0.250 0.375 0.500 12,7 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 2032...
  • Page 54 SECTION 4 OPERATION Aluminum Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 55 SECTION 4 OPERATION Amperes Process Data Aluminum Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 56 SECTION 4 OPERATION Carbon Steel Material: Amperes: Plasma Gas: Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Oxygen @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 57 SECTION 4 OPERATION Amperes Process Data Carbon Steel Material Thickness 20GA 18GA 16GA 14GA 12GA 10GA Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 58 SECTION 4 OPERATION Carbon Steel Material: Amperes: Plasma Gas: Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Oxygen @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...

  • Page 59: Carbon Steel

    SECTION 4 OPERATION Amperes Process Data Carbon Steel Material Thickness 14GA 0.125 0.135 0.187 0.250 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 60 SECTION 4 OPERATION Carbon Steel Material: Amperes: Plasma Gas: Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Oxygen @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 61 SECTION 4 OPERATION Amperes Process Data Carbon Steel Material Thickness 0.125 0.135 0.187 0.250 0.375 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 62 SECTION 4 OPERATION Carbon Steel Material: Amperes: Plasma Gas: Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Oxygen @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 63 SECTION 4 OPERATION Amperes Process Data Carbon Steel Material Thickness 0.187 0.250 0.312 0.375 0.500 0.625 12,7 12,9 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff)
  • Page 64 SECTION 4 OPERATION Carbon Steel Material: Amperes: Plasma Gas: Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Oxygen @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 65 SECTION 4 OPERATION Amperes Process Data Carbon Steel Material Thickness 0.312 0.375 0.500 0.625 0.750 12,9 15,9 19,1 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff)
  • Page 66 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Oxygen @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 67 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 26GA 24GA 22GA 18GA 16GA Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 68 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Air @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...

  • Page 69: Stainless Steel

    SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.125 0.187 0.250 0.375 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 2286...
  • Page 70 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Air @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 71 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.187 0.250 0.375 0.500 12,7 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 72 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Air @ 125 PSI / 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 73 SECTION 4 OPERATION Amperes Process Data Stainless Steel Air Air Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff)
  • Page 74 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 75 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.125 0.187 0.250 0.387 0.500 12,7 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 76 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 77 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 78 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758...
  • Page 79 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.125 0.187 0.250 0.375 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 2286...
  • Page 80 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758...
  • Page 81 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.187 0.250 0.375 0.500 12,7 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 82 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758...
  • Page 83 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.250 0.375 0.500 0.625 12,7 15,9 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 84 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 85 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.187 0.250 0.375 0.500 12,7 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 86 SECTION 4 OPERATION Stainless Steel Material: Amperes: Plasma Gas: Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Shield Gas: Shield Mix Gas: Methane @ 100 PSI / 6.9 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758...
  • Page 87 SECTION 4 OPERATION Amperes Process Data Stainless Steel Material Thickness 0.250 0.375 0.500 0.625 12,7 Pierce Delay (SEC.) Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed...
  • Page 88 SECTION 4 OPERATION Plasma Marking “B” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 89 SECTION 4 OPERATION “B” Nozzle Plasma Marking 10 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 5080 MM/MIN Notes:...
  • Page 90 SECTION 4 OPERATION Plasma Marking “B” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...

  • Page 91: Process Data Settings

    SECTION 4 OPERATION “B” Nozzle Plasma Marking 15 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 7620 MM/MIN Notes:...
  • Page 92 SECTION 4 OPERATION Plasma Marking “C” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 93 SECTION 4 OPERATION “C” Nozzle Plasma Marking 10 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 2540 MM/MIN Notes:...
  • Page 94 SECTION 4 OPERATION Plasma Marking “C” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 95 SECTION 4 OPERATION “C” Nozzle Plasma Marking 15 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 5080 MM/MIN Notes:...
  • Page 96 SECTION 4 OPERATION Plasma Marking “D” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 97 SECTION 4 OPERATION “D” Nozzle Plasma Marking 10 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 2540 MM/MIN Notes:...
  • Page 98 SECTION 4 OPERATION Plasma Marking “D” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 99 SECTION 4 OPERATION “D” Nozzle Plasma Marking 15 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 7620 MM/MIN Notes:...
  • Page 100 SECTION 4 OPERATION Plasma Marking “D” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 101 SECTION 4 OPERATION “D” Nozzle Plasma Marking 20 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 5080 MM/MIN Notes:...
  • Page 102 SECTION 4 OPERATION Plasma Marking “D” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 103 SECTION 4 OPERATION “D” Nozzle Plasma Marking 30 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 12700 MM/MIN Notes:...
  • Page 104 SECTION 4 OPERATION Plasma Marking “E” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 105 SECTION 4 OPERATION “E” Nozzle Plasma Marking 10 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 2540 MM/MIN Notes:...
  • Page 106 SECTION 4 OPERATION Plasma Marking “E” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 107 SECTION 4 OPERATION “E” Nozzle Plasma Marking 20 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 7620 MM/MIN Notes:...
  • Page 108 SECTION 4 OPERATION Plasma Marking “E” Nozzle Amperes: Argon @ 125 PSI / 8.6 Bar Plasma Gas: Shield Gas: Air @ 125 PSI/ 8.6 Bar PT-24 Torch Torch Body Torch Body Torch Body Torch Body P/N 21758 P/N 21758 P/N 21758 P/N 21758 Water Baffle Water Baffle...
  • Page 109 SECTION 4 OPERATION “E” Nozzle Plasma Marking 30 Amperes Process Data Setup Parameters (see notes) Plasma Start Gas 1 Plasma Cut Gas 1 SG1-Start Shield Gas SG1- Cut (Flow Reading) SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed 12700 MM/MIN Notes:...

  • Page 110: Aluminum Kerf Values

    SECTION 4 OPERATION 4.4.3.1 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...
  • Page 111 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 112: Carbon Steel Kerf Values

    SECTION 4 OPERATION 4.4.3.2 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...
  • Page 113 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 114 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) 4-80...

  • Page 115: Stainless Steel Kerf Values O

    SECTION 4 OPERATION 4.4.3.3 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...

  • Page 116: Stainless Steel Kerf Values Air/Air/Ch

    SECTION 4 OPERATION 4.4.3.4 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...

  • Page 117: Stainless Steel Kerf Values N /Ch

    SECTION 4 OPERATION 4.4.3.5 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 2.032 0.095 0.080 2.032 0.080 0.060 1.524 0.040 1.016 0.020 0.508...

  • Page 118: Stainless Steel Kerf Values N

    SECTION 4 OPERATION 4.4.3.6 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...
  • Page 119 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 120: Stainless Steel Kerf Values Air/Air

    SECTION 4 OPERATION 4.4.3.7 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...
  • Page 121 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 122 SECTION 4 OPERATION Page intentionally left blank. 4-88...

  • Page 123: Section 5 Maintenance

    SECTION 5 MAINTENANCE 5.1 General If this equipment does not operate properly, stop work immediately and investigate the cause. Qualified personnel must perform maintenance work. Do NOT permit untrained persons to inspect, clean or repair equipment. Use only recommended replacement parts.

  • Page 124: Pt-24 Torch Description

    SECTION 5 MAINTENANCE Avoid Potential Equipment Damage CAUTION Water and/or oil can accumulate in compressed air lines. Be sure to direct the first air blast away from equipment to avoid damaging the junction box or flow control box. With all input power disconnected and with proper •...
  • Page 125 SECTION 5 MAINTENANCE Gas In from supply Plasma Cut and Start Gas. Plasma Cut and Start Gas. Plasma Cut and Start Gas. Plasma Cut and Start Gas. These gases enter the • torch through connections that house check valves within the torch body. The valves acting in conjunction with solenoid valves control the back and forth switching of start and cut gases.
  • Page 126 SECTION 5 MAINTENANCE Shield Gas. Shield Gas. Shield preflow, cut shield and Shield Gas. Shield Gas. • postflow enter the torch through one connection. These gases pass through: the torch body, § the shield gas diffuser, § out the orifice in the shield cap surrounding §...

  • Page 127: Torch Maintenance

    SECTION 5 MAINTENANCE 5.4 Torch Maintenance Electric Shock Can Kill WARNING Before performing torch maintenance: Turn power switch on the console to the OFF • position. Disconnect primary input power. • Torch Body O-Rings Torch Body O-Rings Torch Body O-Rings Torch Body O-Rings Each day before starting operation, check O-rings •...
  • Page 128 SECTION 5 MAINTENANCE Sleeve Torch Sleeve Torch Sleeve Torch Sleeve Torch Sleeve P/N 822568 The torch sleeve P/N 822568 is threaded onto the • torch body. If the sleeve is too tight for hand removal, use a • large adjustable wrench on the body flats or lightly tighten these flats in a vise.

  • Page 129: Consumable Disassembly And Inspection

    SECTION 5 MAINTENANCE 5.5 PT-24 Consumable Disassembly And Inspection Electric Shock Can Kill! WARNING Turn power switch on the console OFF. Turn power switch on the console OFF. Turn power switch on the console OFF. Turn power switch on the console OFF. •...
  • Page 130 SECTION 5 MAINTENANCE 4. Unscrew the nozzle retainer/diffuser. Inspect for damage, especially where the retainer contacts the nozzle. The surface between the retainer and the Nozzle nozzle creates a metal to metal seal for the coolant. Any damage to this sealing surface will cause a leak resulting in poor cutting.

  • Page 131: Torch Re-Assembly

    SECTION 5 MAINTENANCE 7. Use the electrode and nozzle tool provided to unscrew the electrode. (P/N 21765). 5.6 PT-24 Torch Tip Re-assembly 1. Electrode 1. Electrode 1. Electrode 1. Electrode Apply a thin film of silicone grease to the O-ring, just enough to produce a shiny surface.
  • Page 132 SECTION 5 MAINTENANCE 4. Shield Cup Insulator 4. Shield Cup Insulator 4. Shield Cup Insulator 4. Shield Cup Insulator Push the shield cup insulator on the nozzle retainer. This component is a press fit and may remain Shield Cup Shield Cup Shield Cup Shield Cup assembled when the assembly was taken apart.

  • Page 133: Section 6 Troubleshooting

    SECTION 6 TROUBLESHOOTING 6.1 General Safety Electric Shock Can Kill! WARNING Externally disconnect all primary power to the machine before servicing. Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside the power source. High Voltages Can Be Stored In WARNING Capacitors.

  • Page 134: Plc Led Functions

    SECTION 6 TROUBLESHOOTING 6.2.1 PLC LEDs (Light Emmiting Diode) Highly reliable indicators. It is not likely that one will "burn out". However, if the technician is not OUTPUT 1 CH confident that the LEDs are working, the presence 0 1 2 3 4 5 6 7 of a signal can be confirmed by using a meter and taking a measurement on the appropriate pin.

  • Page 135: Troubleshooting Guide

    SECTION 6 TROUBLESHOOTING 6.3 Troubleshooting Guide 6.3.1 Reduced Consumable Life Cutting Up Skeletons Cutting Up Skeletons Cutting skeletons (discarded material left after all Cutting Up Skeletons Cutting Up Skeletons pieces have been removed from a plate) to facilitate their removal from the table can adversely affect electrode life by: Causing the torch to run off the work.

  • Page 136: Poor Cut Quality

    SECTION 6 TROUBLESHOOTING See Cut Quality In Section 4 6.3.2 Poor Cut Quality 6.3.3 No Pilot Arc Contaminated Electrode Contaminated Electrode Contaminated Electrode Contaminated Electrode Clean or replace electrode Insufficient spark gap setting Insufficient spark gap setting Insufficient spark gap setting Insufficient spark gap setting Set spark gap to 0.040”...

  • Page 137: Nozzle Life Extremely Short

    SECTION 6 TROUBLESHOOTING 6.3.7 Nozzle Life Extremely Short Pilot Arc H/L switch Pilot Arc H/L switch Pilot Arc H/L switch Pilot Arc H/L switch Refer to Process Data in wrong position in wrong position in wrong position in wrong position Nozzle arcing inside bore Nozzle arcing inside bore Nitrogen quality too low.

  • Page 138: Flow Control Schematic

    SECTION 6 TROUBLESHOOTING 6.4 Flow Control Schematic PLASMA GAS 1 PLASMA GAS 1 PLASMA GAS 2 PLASMA GAS 2 SHIELD GAS 1 SHIELD GAS 1 SHIELD GAS 2 SHIELD GAS 2 COMMON COMMON 120 vac (11 ne) A. C. COMMON CHASSIS FUSED 24vac TO CNC 24vac COMMON...

  • Page 139: Gas Flow Schematic

    SECTION 6 TROUBLESHOOTING 6.5 Gas Flow Schematic AIR-1 N2-1 O2-1 AIR-2 N2-2 O2-2 METH N2-3 Solenoid Valve METH Pressure Switch Sentronic Valve Flow Meter Check Valve VALVE 4 VALVE 3 VALVE 2 VALVE 1 Check Valve 6-BAR 6-BAR 9-BAR 9-BAR Interface SENTRONIC SENTRONIC...

  • Page 140: Junction Box Wiring Diagram

    SECTION 6 TROUBLESHOOTING 6.6 Junction Box Wiring Diagram T1-X1 RED PILOT ARC BLU GND1 GRN PCB1 J1-M GRY J1-N BLK H1 H2 SG1-2 BLU SG1-1 RED SG1-1 RED PCB1-1 RED C1-1 BLU PILOT ARC GND1 J1-A GRN PCB1-3 GRN PCB1-2 BLU 1 YEL J1-F A GRN GND1 2 BLU J1-B...

  • Page 141: Junction Box Schematic

    SECTION 6 TROUBLESHOOTING 6.7 Junction Box Schematic PLASMA-1 SOLENOID COMMON GND1 PG-2 PG-1 TO FLOW PLASMA-2 CONTROL SHIELD GAS 1 SHIELD GAS 2 SG-2 SG-1 MANIFOLD EFC A/M .002 uf 2500pf 10KV 15KV X1 X2 PCB1 TORCH CABLE CONNECTIONS CONNECTIONS TO CONSOLE GND1 PILOT...
  • Page 142 SECTION 6 TROUBLESHOOTING 6.8 Power Module Wiring Diagram PCB2 P1 PCB3 P1 PCB1 P3 PCB1 P4 NEXT PAGE PCB1 GND1 PCB1 P1-2(BLK) T1-X7(ORN) J1-3(ORN) PCB1 P1-1(BLK) J1-4(WHT) J1-16(WHT) T1-X9(BRN) T1-X1(YEL) T1-X10(BRN) T1-X8(ORN) T1-X2(YEL) T1-X5(BLU) J1-5(BLK) T1-X6(BLU) SCR1-G (YEL) J1-6(RED) PCB1 P2-14 (VIO) T2-X2(ORN) SCR1(+) (BRN) T2-X1(ORN)
  • Page 143 SECTION 6 TROUBLESHOOTING Power Module Wiring Diagram Part 2 Previous Page J3-1(BLK) J3-1(BLK) J3-2(WHT) J3-3(RED) J3-4(ORN) J3-5(BLU) J3-5(BLU) J3-6(YEL) J3-6(YEL) J3-7(BRN) J3-8(GRY) J3-9(VIO) J3-10(BLK) NOTES: DENOTES SELF LEADS. DENOTES SELF LEADS. DENOTES SPLICE DENOTES SPLICE 3- TP DENOTES TWISTED PAIR 3- TP DENOTES TWISTED PAIR SOLDERING AND CRIMPING WIRES AND TERMINALS ARE VERY IMPORTANT TO THE OPERATION AND RELIABILITY...
  • Page 144 SECTION 6 TROUBLESHOOTING 6.9 Precision Plasma Power Module Schematic 6-12...
  • Page 145 SECTION 6 TROUBLESHOOTING 6.10 Precision Plasma Power Source Wiring Diagram Part 1 Part 1 Part 1 Part 1 PCB1 PCB1 PCB1 PCB1 1 1 1 1 1 1 1 1 P4- 10(VIO) P4- 10(VIO) 1 1 1 1 P4- 11(GRY) P4- 11(GRY) 1 1 1 1 PLC1 P1-1(BRN)
  • Page 146 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 2 Part 2 Part 2 Part 2 F4- 2(BLU) F4- 2(BLU) F4- 2(BLU) F4- 2(BLU) T3-H2(BLK) T3-H2(BLK) T3-H2(BLK) T3-H2(BLK) A A A A T2-AH2 T2-AH2 T2-AH2 T2-AH2 MOD1 MOD1 MOD1 MOD1 T3-H3(GRY)
  • Page 147 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 3 Part 3 Part 3 Part 3 MOD1 MOD1 MOD1 MOD1 CB1-2(GRY) CB1-2(GRY) CB1-2(GRY) CB1-2(GRY) 2 2 2 2 M1-1(BLK) M1-1(BLK) M1-1(BLK) M1-1(BLK) 1 1 1 1 S1-6(RED) S1-6(RED) S1-6(RED) S1-6(RED) M2-1 SPLICE (RED)
  • Page 148 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 4 Part 4 Part 4 Part 4 PLC1 MODULE TB4-1(VIO) PLC-0103(BRN) PLC-L2(BLK) PLC-COMM5(GRY) TB4-1 (VIO) PLC1 J2-1(BLK) TB4-1(VIO) PLC-COMM7(BLU) PLC-COMM1(BLK) 0100 TB3-4 (WHT) PLC-0002(WHT) J1-C(ORN) COMM 2 TB3-3 (ORN) TB3-5 (BLK) TB5-WORK(RED) 0101...
  • Page 149 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 5 Part 5 Part 5 Part 5 MOD1 PCB1 P4-3(RED) PCB1 P1-16(VIO) R10-1 (GRY) PCB1 P4-4(YEL) PCB1 P1-15(BLU) TB5-WORK(BLK) PCB1 P4-15(BLU) PCB1 P3-12(ORN) PCB1 P4-16(ORN) PCB1 P3-13(WHT) TB6-6(BRN) PCB1 P1-13(BLK) TB6-8(GRY) PCB1 P1-14(RED) PCB1 P4-11(RED)

  • Page 150: Power Module Schematic

    SECTION 6 TROUBLESHOOTING 6.11 Schematic- Precision Plasma Power Source Part 1 Part 1 Part 1 Part 1 PUMP 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...
  • Page 151 SECTION 6 TROUBLESHOOTING Schematic- Precision Plasma Power Source Part 2 Part 2 Part 2 Part 2 TB4-1 TB4-2 JUNCTION Ref. 6.4 Ref. 6.7 0 0 0 0 0 0 0 1 HSCOMM 0 0 0 2 0 0 0 3 0 0 0 4 0 1 0 0 0 0 0 6...
  • Page 152 SECTION 6 TROUBLESHOOTING 6.12 Technical Guide To Using And Understanding The Operation Of The Electronic Flow Control Introduction Introduction Introduction Introduction The following information is a guide for troubleshooting The Precision Plasma Electronic Flow Control. Knowledge of machine and control operation is required.

  • Page 153: Precision Process Timers

    SECTION 6 TROUBLESHOOTING 6.12.1 Precision Process Timers Timer Description The minimum interval of time between the receipt of a plasma process start signal and the issuance of the signal Plasma Preflow Time Plasma Preflow Time Plasma Preflow Time Plasma Preflow Time to turn the plasma power supply on.

  • Page 154: Process Timer Values

    SECTION 6 TROUBLESHOOTING 6.12.2 Process Timer Values For Vision Cutting Record File PARAM.CUT Vision Interpretation Data File DEF.TEC PARAM.CUT DEF .TEC V = Hidden Flag Enabled TIMERS Plasma Preflow Time 50.0 50.0 V V V V 50.0 50.0 Line Purge Time 50.0 50.0 50.0...

  • Page 155: Process Window Key Functions

    SECTION 6 TROUBLESHOOTING 6.12.3 Process Window Key Functions Key Function Description Icon permits the machine operator to allow or • Plasma AHC Allow Icon disallow plasma AHC. Icon does not turn plasma AHC on. Icon does not turn plasma AHC on. Icon does not turn plasma AHC on.
  • Page 156 SECTION 6 TROUBLESHOOTING 6.12.4 Proportional Valve Analog Flow Values For Param.Cut And Def.Tec PARAM.CUT PARAM.CUT DEF.TEC DEF.TEC PARAM.CUT PARAM.CUT DEF.TEC DEF.TEC Analog Flow Values Analog Flow Values V = Hidden Flag Enabled V = Hidden Flag Enabled Analog Flow Values Analog Flow Values V = Hidden Flag Enabled V = Hidden Flag Enabled...

  • Page 157: Process Gas Selection Requirements

    SECTION 6 TROUBLESHOOTING 6.12.5 Process Gas Selection Requirements Plasma process gas selection is accomplished • with activation of the appropriate SDP file. The correct CUTTING RECORD FLAG must be in • each SDP file. Selection is keyed to the value in the CUTTING •...

  • Page 158: Efc Process Gas Flow Chart

    SECTION 6 TROUBLESHOOTING 6.12.6 EFC Process Gas Flow Chart Numbers correspond to columns on solenoid/ Vision Shift/Start Line vent proportional valve requirement charts and gas error monitoring charts Flow control vent Idle (Station off) Station Test (start) Section 6.7.7 Process start. for details Station on Flush/ Station on?

  • Page 159: Station On, Flush/Pressurize Cycle Timers

    SECTION 6 TROUBLESHOOTING 6.12.7..Station On, Flush/Pressurize Cycle PG-N ,O2 SG-N X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, SOLENOID VALVES ANALOG VALUE = 0 - 10 VDC...
  • Page 160 SECTION 6 TROUBLESHOOTING 6.12.8 Solenoid And Proportional Valve Requirements Carbon Steel PG-O , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓ X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, SOLENOID VALVES...
  • Page 161 SECTION 6 TROUBLESHOOTING 6.12.9 Gas Error Monitoring Carbon Steel PG-O , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓ X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches...
  • Page 162 SECTION 6 TROUBLESHOOTING 6.12.10 Solenoid And Proportional Valve Requirements Carbon Steel PG-O , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓ X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, SOLENOID VALVES...

  • Page 163: Gas Error Monitoring

    SECTION 6 TROUBLESHOOTING 6.12.11 Gas Error Monitoring Carbon Steel PG-O , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓ X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches...

  • Page 164: Sg-O

    SECTION 6 TROUBLESHOOTING 6.12.12 Solenoid And Proportional Valve Requirements Carbon Steel PG-O , SG-O ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓ X = Open / Enabled, Blank = Closed / Disabled,, SOLENOID VALVES Analog Value = 0 - 10 Vdc Analog Value = 0 - 10 Analog Value = 0 - 10 Analog Value = 0 - 10...

  • Page 165: Sg-O

    SECTION 6 TROUBLESHOOTING 6.12.13 Gas Error Monitoring Carbon Steel PG-O , SG- O ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ ➓ X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches...
  • Page 166 SECTION 6 TROUBLESHOOTING 6.12.14 Solenoid And Proportional Valve Requirements Stainless Steel PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ Solenoid Valves Solenoid Valves X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, Solenoid Valves...

  • Page 167: Stainless Steel Pg-N

    SECTION 6 TROUBLESHOOTING 6.12.15 Gas Error Monitoring Stainless Steel PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches...
  • Page 168 SECTION 6 TROUBLESHOOTING 6.12.16 Solenoid And Proportional Valve Requirements Stainless Steel PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ SOLENOID VALVES SOLENOID VALVES X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, SOLENOID VALVES SOLENOID VALVES X = Open / Enabled, Blank = Closed / Disabled,...

  • Page 169: Stainless Steel Pg-N

    SECTION 6 TROUBLESHOOTING 6.12.17 Gas Error Monitoring Stainless Steel PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches...

  • Page 170: Stainless Steel Pg-Air, Sg-Air

    SECTION 6 TROUBLESHOOTING 6.12.18 Solenoid And Proportional Valve Requirements Stainless Steel PG-Air, SG-Air ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ Solenoid Valves Solenoid Valves Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled,...
  • Page 171 SECTION 6 TROUBLESHOOTING 6.12.19 Gas Error Monitoring Stainless Steel PG-Air, SG-Air ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches...

  • Page 172: Stainless Steel Pg-Air, Sg-Air/Ch

    SECTION 6 TROUBLESHOOTING 6.12.20 Solenoid And Proportional Valve Requirements Stainless Steel PG-Air, SG-Air/CH ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ Solenoid Valves Solenoid Valves Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled,...
  • Page 173 SECTION 6 TROUBLESHOOTING 6.12.21 Gas Error Monitoring Stainless Steel PG-Air, SG-Air/CH ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas 1 1 1 1 Pressure Switch O O O O...

  • Page 174: Aluminum Pg-N , Sg- N

    SECTION 6 TROUBLESHOOTING 6.12.22 Solenoid And Proportional Valve Requirements Aluminum PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ Solenoid Valves Solenoid Valves Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled,...

  • Page 175: Aluminum Pg-N

    SECTION 6 TROUBLESHOOTING 6.12.23 Gas Error Monitoring Aluminum PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas 1 1 1 1 Pressure Switch O O O O...
  • Page 176 SECTION 6 TROUBLESHOOTING 6.12.24 Solenoid And Proportional Valve Requirements Aluminum PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled,...

  • Page 177: Aluminum Pg-N

    SECTION 6 TROUBLESHOOTING 6.12.25 Gas Error Monitoring Aluminum PG-N , SG-N ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas 1 1 1 1 Pressure Switch O O O O...

  • Page 178: Marking Pg-Argon, Sg-Air

    SECTION 6 TROUBLESHOOTING 6.12.26 Solenoid And Proportional Valve Requirements Marking PG-Argon, SG-Air ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled, X = Open / Enabled, Blank = Closed / Disabled, Solenoid Valves Solenoid Valves X = Open / Enabled, Blank = Closed / Disabled,...
  • Page 179 SECTION 6 TROUBLESHOOTING Gas Error Monitoring --Marking PG-Argon, SG-Air ➊ ➋ ➌ ➍ ➎ ➏ ➐ ➑ ➒ X = Monitored For Pressure Present, Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas 1 1 1 1 Pressure Switch O O O O...
  • Page 180 SECTION 6 TROUBLESHOOTING This page intentionally left blank. This page intentionally left blank. This page intentionally left blank. This page intentionally left blank. 6-48...

  • Page 181: Section 7 Replacement Parts

    7.2 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 182: Plasmarc Power Source-Exterior Components

    SECTION 7 REPLACEMENT PARTS 7.3 Plasmarc Power Source-Exterior Components...
  • Page 183 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) D-35925YL Cover-Top A-995227 Label Warning-Exposed High Volt B-2091514 Label Warning A-34941 Lens Clear A-13734588 Logo ESAB Clear C-35924YL Panel Right Side D-35923YL Panel Left Side 61328087 Screw, HMH ¼-20 X .50 L...
  • Page 184 SECTION 7 REPLACEMENT PARTS "TEE" Detail Page 7-12...
  • Page 185 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) A-8672508 Switch Toggle 2PST 2 Pos 15A A-8634518 S2,3 Switch Toggle DPDT 2 Pos 15A A-8951061 AM1,VM1 Meter LED 5VDC A-8951061 AM1,VM1 Meter LED 5VDC A-8634518 S2,3 Switch Toggle DPDT 2 Pos 15A A-2234589 POT 10K 10 Turn B-954751...
  • Page 186 SECTION 7 REPLACEMENT PARTS...
  • Page 187 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) C-35928GY Door Access Rear A952209 Conn Box Recpt 19 FS SH A-952210 Conn Box Recpt 14 FS SH A-897W6 3 Strain Relief A-23610197 Plug Hole .875 Dia. .125 CT Nyl BK A-8952571 Fuse 7A 600 VAC Fast Acting D-32202GY...

  • Page 188: Plasmarc Power Source-Internal Components

    SECTION 7 REPLACEMENT PARTS 7.4 Plasmarc Power Source-Internal Components Reference: PCB1 Isolation Amp Reference: Meter LED AM1,VM1...
  • Page 189 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) D-35920GY Base, Precision Plasma A-950487 Term Block 2 pos D-838103 PCB1 PCB Isolation AMP A-950096 PCB1 P9,7 Housing Contact, Crimp 3 pin A-952053 Standoff #6-32 X .88 L A-952034 PCB1 P10 Plug 5 Pos A952030...
  • Page 190 SECTION 7 REPLACEMENT PARTS 7-10...
  • Page 191 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) A-8952026 Terminal Block A-8673502 Contactor 3 Pole 75A 672002GY Shroud, Fan A82062334 Motor, Fan C-36417GY Shroud, Fan A951215 Motor, Carb 1/3 Hp A8951347 Pump, Carb w/Strainer A8950179 Tee, Pipe Branch ¼ Brs A-810Z30 Adaptor, B/A-W M ¼...
  • Page 192 SECTION 7 REPLACEMENT PARTS “TEE” Detail 7-12...
  • Page 193 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) B-36538 Hose, Assy Pump Outlet- Torch out A-8950001 Switch, Flow .25 GPM SPSTB C-821124 Valve, Check Assy B-36539 Hose, Assy Flowswitch To Core 90858009 TBG, Nylobrade 3/8 I.D X .625 O.D. B-36418 Hose Assy Tank Bottom- Pump Inlet A-858V75...
  • Page 194 SECTION 7 REPLACEMENT PARTS 7-14...
  • Page 195 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) C-13735961 Heat Exchanger A-8950823 Bushing, Snap A-950167 Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W A-995103 Terminal Block 24 POS 15A A-36919 Board, Terminal Output A-896W10 Holder, Fuse A-92W57 Grommet, Rub .63 I.D.
  • Page 196 SECTION 7 REPLACEMENT PARTS 7-16...
  • Page 197 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) A-8950823 Bushing, Snap 17750020 R11,12 Res 20 ohm 50W C-36527GY Cover, Terminal Board A-8951161 C1,2 Cap, Metpoly 20uf 400VDC A-8673458 Contactor, Pilot Arc 3P 40A A-2234521 P4,MOD1 Plug, 16 Pos P1,PLC1 P2 A-2234891 MOD1 P3, 4,...

  • Page 198: Power Source Module

    SECTION 7 REPLACEMENT PARTS 7.5 Power Source Power Module 7-18...
  • Page 199 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35914GY Base Power Module 37102 Bracket, PCB KYDEX 35799 Wire Kit, Power Module 8951339 PCB1 P1, 5 Plug, Female 12 Position 8951340 PCB1 P2, 6 Plug, Female 14 Position 37101GY Deck, Power Module 8951981...
  • Page 200 SECTION 7 REPLACEMENT PARTS Section A-A 7-20...
  • Page 201 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 2234877 J3,4 Block Terminal 10 Position 8951182 Fan, Axial 950487 Terminal Strip 2 Position 8950823 Bushing, Snap 835700 Inductor, Power Factor 17280215 Resistor 1.5K OHM 100W 835680 Inductor Assembly Output 835681 Transformer Assembly, Main 7-21...
  • Page 202 SECTION 7 REPLACEMENT PARTS 7-22...
  • Page 203 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 2234518 Block Terminal, 8 Position 838047 Shunt, Feedback 2234519 Block Terminal, 16 Position 35917GY Baffle Heatsink 8951981 Heatsink 2234877 J3, 4 Block Terminal, 10 Position 8674156 Adaptor 7-23...
  • Page 204 SECTION 7 REPLACEMENT PARTS 7-24...
  • Page 205 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 835940 Transformer Control 8951978 Bridge Diode 3PH 130A 8951192 Pad Thermal Bridge 835794 Busbar Input Bridge 8951979 SCR1 SCR 90A 8951196 Pad Thermal SCR Module 8951980 Q1,2 IGBT 300A 600V 17750020 R4,5 Resistor 20OHM 50W NI...
  • Page 206 SECTION 7 REPLACEMENT PARTS 7.6 Precision Plasma Junction Box Replacement Parts 2 REF Section A-A 7-26...
  • Page 207 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 37515 Wire Kit, Junction Box Precision Plasma 674969 PCB1 PCB Assembly Filter 837250 T2,3 XFMR H.F. Auto 82062119 Conn ( Pos 37391 BKHD A/A-W*F B/A-W*F 37392 BKHD A/A-W*F B/A-W*F 8950256 Cap Mica .002uf 10 KwV 8677905...
  • Page 208 SECTION 7 REPLACEMENT PARTS Section C-C Section B-B 7-28...
  • Page 209 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 6271128 Conn Box Recpt 14 MP Shell 20 37522 Base Kydex J Box 37523 Cover Kydex J Box PCB1 Torch Cable Conn Reference Torch Conn NEG Reference Pilot Arc Torch Reference 7-29...
  • Page 210 SECTION 7 REPLACEMENT PARTS 7-30...
  • Page 211 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 954075 Name Plate 37361 Torch Conn Shield 951188 Locknut, Conduit 2NPT 954509 Label Warning High Volt Symbol 952928 Coupling, Quick Disconn F 14 Hose 950518 Grommet RBR 2.12 I.D. X 2.50 O.D. X .06W 7-31...

  • Page 212: Electronic Flow Control Box

    SECTION 7 REPLACEMENT PARTS 7.7 Electronic Flow Control Box ➀ P/N 952920 ➂ P/N 952921 ➅ P/N 952922 ➁ P/N 952868 Process Argon Air-2 Air-1 Argon Argon Argon Oxygen Oxygen O2-2 O2-1 Nitrogen Nitrogen N2-3 N2-2 N2-1 H-35 Meth H-35 H-35 Methane Methane...
  • Page 213 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 952920 Switch, Pressure 50 PSI Non-Adj 952686 PCB Prec Flow Control Interface Board 952921 Valve Sol 2-Way 0 952913 Manifold Assembly Complete Prec Flow 952915 XMFR Control 115/230V 50/60 HZ 952922 Lamp Pilot 28V Green 952914...
  • Page 214 SECTION 7 REPLACEMENT PARTS Plasma Gas 1 Plasma Gas 2 Shield Gas 1 Shield Gas 2 Vent 1 Vent 2 Vent 3 Vent 4 Valve 1 Valve 2 Valve 3 Valve 4 ➁➂➃➄ P/Ns 952916,952917, 952918, 952919 7-34...
  • Page 215 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) Purchase Locally Fuse, Glass Body, Slow Acting 3AG 4A 952916 Valve, Analog 0-6 Bar 0-10 VDC Valve4 SG2 952917 Valve, Analog 0-6 Bar 0-10 VDC Valve3 SG1 952918 Valve, Analog 0-9 Bar 0-10 VDC Valve2 PG2 952919 Valve, Analog 0-9 Bar 0-10 VDC Valve 1 PG1 639571...

  • Page 216: Torch Assembly Efc Series A/M

    SECTION 7 REPLACEMENT PARTS 7.8 PT-24 Torch Assembly EFC Series A/M P/N 0558001462 Notes: = Plasma 2 in Yellow = Plasma 2 Out Yellow = Plasma 1 in Blue = Plasma 1 Out Blue = Shield 2 In Black = Shield 2 Out Black = Shield 1 In Orange/Red = Shield 1 Out Orange/Red 5/8 - 18...
  • Page 217 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 821758 Body & Tube Assembly PT-24 Torch 822568 Sleeve, Torch PT-24 22381 Gas Line Start Blue 22380 Gas Line Cut Yellow 22382 Gas Line Shield Orange/Red See Process Data Swirl Baffle (See Process Data) See Process Data Nozzle (see Process Data)
  • Page 218 SECTION 7 REPLACEMENT PARTS 7.9 T Gas Shut-off Valve Assembly EFC Series A/M Plasma 1 & 2 Common Shield 1 & 2 Common Shield 1 Shield 2 Plasma 2 Plasma 1 7-38...
  • Page 219 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 0558001502 Flange 8952921 2 Way Solenoid Valves 593985 O-Ring 7-39...
  • Page 220 SECTION 7 REPLACEMENT PARTS 7.10 PT-24 Torch EFC Version 1 Detail Torch Front End Not Shown 7-40...
  • Page 221 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 821758 Body & Tube Assembly PT-24 Torch 822568 Sleeve, Torch PT-24 22381 Gas Line Start Blue 22380 Gas Line Cut Yellow 22382 Gas Line Shield Orange/Red See Process Data Swirl Baffle (See Process Data) See Process Data Nozzle (see Process Data)
  • Page 222 SECTION 7 REPLACEMENT PARTS 7.11 Solenoid Assembly Torch, Electronic Flow Control Version 1 COM/COM COM/COM Shield 2 Shield 1 Plasma 2 Plasma 1 7-42...
  • Page 223 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 22422 Solenoid Assembly Electronic Flow Version 1 596985 O-Ring, 1.42 X .103 NEOP 70A 952931 Plug Block 6 Pos 22421 Bracket, Solenoid EFC 952703 Solenoid, 2 Way 22367 Quick Disconnect Connector, Yellow 952697 Solenoid, 3 Way 22366...
  • Page 224 SECTION 7 REPLACEMENT PARTS Notes: 7-44...
  • Page 226 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...

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