Page 1 F-15-804 December, 2010 Installation, Operation and Maintenance Manual for the IEFC-S PT-24 Precision Plasmarc System With Integrated Flow Control (Separable) Gas Bundle Flow Console Ignition Console Power Console Cutting Systems 411 South Ebenezer Road Torch Florence, South Carolina, U.S.A...
Page 2 This manual is ESAB Part Number F15804 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
Precision Plasma IEFC-S Table of Contents Section 1 Safety Page 1--(_) 1.1 Introduction..................1.2 Safety Notations And Symbols ............. 1.3 General Safety Information ..............1.4 Installation Precautions ................ 1.5 Electrical Grounding ................1.6 Operating A Plasma Cutting Machine ........... 7-11 1.7 Service Precautions ................
Page 4 Precision Plasma IEFC-S Table of Contents Section 3 Installation Page 3--(_) 3.1 General....................1 3.2 Equipment Required ................1 3.3 Location ....................1 3.4 Primary Electrical Input Connections ............. 2-3 3.5 Alternate Connection Locations for IFC ..........4 3.6 IFC Basic Component Identification ............4 3.7 Ignition Console Basic Components and Connection Points ....
Page 5 Precision Plasma IEFC-S Table of Contents Section 4 Operation Page 4--(_) 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..................
Page 6 Precision Plasma IEFC-S Table of Contents Section 5 Maintenance Page 5--(_) 5.1 General....................1 5.2 Inspection and Cleaning................ 1 5.3 PT-24 Torch Description............... 2-4 5.4 IEFC-S Fluid Schematic ................ 3 5.4 Torch Maintenance ................5-6 5.5 PT-24 Consumable Disassembly and Inspection........7-10 5.6 PT-24 Torch Re-Assembly..............
Page 7 Precision Plasma IEFC-S Table of Contents Section 7 Replacement Parts Page 7--(_) 7.1 General ....................7.2 Ordering....................7.3 Plasmarc Power Source – Exterior Components ........7.4 Plasmarc Power Source – Internal Components........8-17 7.5 Power Source Module................18-25 7.6 IEFC-S Gas Console ................26-27 7.7 IEFC-S Gas Manifold................
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Page 9: Section 1 Safety
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 10: Safety Notations And Symbols
SECTION 1 SAFETY The following words and symbols are used throughout 1.2 Safety Notations And Symbols 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.
Page 11: General Safety Information
SECTION 1 SAFETY 1.3 General Safety Information Some subjects listed are not related specifically to NOTICE the type of equipment covered in this manual. However, the safety principles still apply. They are offered as a reminder that this equipment or related apparatus should be operated with alertness and understanding.
Page 12 SECTION 1 SAFETY Failure to follow operating instructions WARNING could result in death or serious injury. Read and understand this operator’s manual before using machine. • Read entire procedure before operating or performing any system maintenance. • Special attention must be given to all hazard warnings that provide essential information regarding personnel safety and/or possible equipment damage.
Page 13: Installation Precautions
Machine regulator is then used to obtain pressure required by torches. • Contact your ESAB representative before installation. He can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure maximum security.
Page 14: 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. Machine must be properly grounded before put into service.
Page 15: Operating A Plasma Cutting Machine
SECTION 1 SAFETY 1.6 Operating A Plasma Cutting Machine Flying debris and loud noise hazards. • Hot spatter can burn and injure eyes. Wear WARNING goggles to protect eyes from burns and flying debris generated during operation. • Chipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses.
Page 16 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. •...
Page 17 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 18 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 nozzle away from yourself and others when activating plasma process.
Page 19 SECTION 1 SAFETY Explosion hazard. WARNING • Certain molten aluminum-lithium (Al-Li) alloys can cause explosions when plasma cut OVER water. These alloys should only be dry cut on a dry table. DO NOT dry cut over water. Contact your aluminum supplier for additional safety information regarding hazards associated with these alloys •...
Page 20: Service Precautions
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 21: 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 22 SECTION 1 SAFETY 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 23 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 24 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 25 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 26 SECTION 1 SAFETY 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 Strahlensicherheit von Laseranlagen Arrangement of protection devices DIN EN 999 Anordnung von Schutzeinrichtungen VDI Guidelines...
Page 27: Section 2 Description
2.1 General The PT-24 Precision Plasmarc IEFC-S System provides programmable gas switching and pressure control. The IEFC-S is the third generation electronic flow control for the ESAB 100A precision plasma system. Advantages over the original electronic flow control are: •...
Page 28: Package Options Available
SECTION 2 DESCRIPTION 2.3 Package Options Available Precision Plasmarc® IEFCS package options available through your ESAB dealer Precision Plasmarc® Power Console (200/230/380/415/460/575) 3-phase 50/60 Hz P/N 0558003587 (required) CNC Controllable/Without PLC Split IEFC Control System (reference) P/N 0558003639 Consists of: Gas console, Ignition console & Interconnection bundle...
Page 29: 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 215 Vdc Duty Cycle 100% Open Circuit Voltage 315 V dc...
Page 30: Plasma Gas
SECTION 2 DESCRIPTION 2.4.2 Plasma Gas Technical Specifications Type , Ar, Air Pressure 150 psig (10.4 bars) O , Air: 85 psig (5.9 bars) Ar Flow 100 cfh (47 l/min) max. (varies with application) -99.8 to 99.995% N , Ar-99.995% Purity Required* Air-clean, dry and oil free Recommended Liquid Cylinder Service...
Page 31: Section 3 Installation
SECTION 3 INSTALLATION 3.1 General Proper installation can contribute materially to NOTICE the satisfactory and trouble-free operation of the Precision Plasmarc® System. It is suggested that each step in this section be studied and carefully followed. 3.2 Equipment Required • Gas Supply and Hoses.
Page 32: 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 CAUTION Machine must be properly configured for your input power.
Page 33 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 34 SECTION 3 INSTALLATION 3.5 Alternate Connection Locations For IEFC-S Gas Console There are two locations for the torch strain relief in the ignition console. This provides flexibility while mounting the box to a machine. NOTE: When changing over to an alternate connection location, plug unused I/O strain relief holes to seal box.
Page 35: Ignition Console Basic Components And Connection Points
SECTION 3 INSTALLATION 3.7 Ignition Console Basic Components and Connections Points Pilot Arc Strain Relief Alternate Torch Torch Bundle Strain Bundle Strain Relief Relief Location Cooling Water to Torch/Arc Current Chassis Ground Cooling water from Torch/Pilot Arc H.F. 120V Input Spark Gap Adjustment Torch Power Strain Relief...
Page 36: Interconnecting Lines
SECTION 3 INSTALLATION 3.8 Interconnecting Lines Torch Bundle All interconnecting service lines supplied are labeled or color coded on each end with corresponding labels/colors marked on the cabinets. COOLING WATER TO TORCH/ARC CURRENT CABLE COOLING WATER FREOM TORCH/ PILOT ARC CABLE TORCH BUNDLE GAS LINES P-2 SOLENOID CONTROL CABLE 1.
Page 37: Joining Ignition And Gas Consoles
SECTION 3 INSTALLATION 3.9 Joining Ignition and Gas Consoles to Form One Unit Remove black button head filler screws from mating faces of the consoles. Some of these screws are captured with hex nuts from the inside of the gas console. Remove top covers.
Page 38: Connection Separated Gas And Ignition Consoles
SECTION 3 INSTALLATION 3.10 Connecting Separated Gas and Ignition Consoles An interconnect bundle is required to connect separated consoles Gas console connections. Hoses/cables and fixed fittings are labeled. Fasten faceplate to the ignition console using 4 screws provided. Ignition Console Interface Bundle Faceplate View inside Ignition console with face plate...
Page 39: Power Console Connections
SECTION 3 INSTALLATION 3.11 Power Console Connections 2. Connect power and coolant lines in Power Supply Bundle from power console to ignition Power Supply Bundle console. Power bundle consists of #6 and # 7 coolant lines (with 5/8-18 L.H. fittings), power cable (#3 AWG) and yellow pilot arc cable (#16 AWG).
Page 40 SECTION 3 INSTALLATION 3.13 Precision Plasmarc® Separated Gas and Ignition Console Component Interconnecting Diagram PT-24 Precision Plasma with IEFC-S Consoles 3-10...
Page 41 SECTION 3 INSTALLATION wall disconnect (cust. sup.) primary power cable precision plasma power console power bundle power supply I/O cable earth ground work cable (+) torch and height control height control I/O cable 10 torch bundle height control ASIOB enclosure ignition console height control ASIOB cable*(see note) process ASIOB cable...
Page 42 SECTION 3 INSTALLATION 3.14 Precision Plasmarc® Combined Gas and Ignition Console Component Interconnecting Diagram PT-24 Precision Plasma with IEFC-S Consoles 3-12...
Page 43 SECTION 3 INSTALLATION wall disconnect (cust. sup.) primary power cable precision plasma power console power bundle power supply I/O cable earth ground work cable (+) torch and height control height control I/O cable 10 torch bundle height control ASIOB enclosure ignition console height control ASIOB cable*(see note) process ASIOB cable...
Page 44: Input To Gas Console
SECTION 3 INSTALLATION 3.15 Input To Gas Console Gas Line Contamination Will CAUTION Damage Proportional Valves And Check Valves Purge Gas Lines Before connecting gas delivery lines to the Integrated Flow Control, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your flow control.
Page 45 SECTION 3 INSTALLATION Gas Console Input 1/4 NPT 2. Connect gas delivery lines to integrated flow control. Install 25 micron gas filters in all delivery lines between gas source and gas console. 25 micron gas filter 25 micron filters H-35 PT-24 Precision Plasma with IEFC-S Consoles 3-15...
Page 46: Input To Power Console
SECTION 3 INSTALLATION 3.16 Input to Power Console Proportional And Check Valves Are CAUTION Sensitive To Dirt And Debris. Thoroughly purge the gas delivery system with before connecting to the gas console. Hose manufacturing often leaves a fine dust inside. This dust may cause proportional valves to prematurely fail.
Page 47: Torch Mounting
SECTION 3 INSTALLATION 3.17 Torch Mounting CAUTION Do Not Cover Vent Hole. When mounting, do not to cover the small vent hole in the side of the sleeve. This hole allows coolant to drain from inside the sleeve should a leak occur in a service line.
Page 48: Torch Coolant
SECTION 3 INSTALLATION 3.18 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 49: Using The 5 Solenoid Torch Manifold
SECTION 3 INSTALLATION 3.20 Using a 5 Solenoid Torch Manifold The 5 solenoid torch manifold allows 1 second conversion from cutting to marking and back to cutting compared to 7 to 10 second switching delay. The IEFC-S is shipped configured to use the 5 solenoid torch manifold.
Page 50 SECTION 3 INSTALLATION Procedure to modify IEFC manifold for 4 solenoid torch manifold. View A-A A. Locate and remove access plug (1/8 NPT) next to the argon flow control solenoid as shown. To plasma From gas outlet plasma gas B. Remove port plug (1/16 NPT) from bottom of inlet access hole.
Page 51: Section 4 Operation
SECTION 4 OPERATION 4.1 Power Supply Controls 4.1.1 Main Power Switch 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. EMERGENCY STOP 4.1.2 Pilot Arc Switch Pilot Arc Switch Previously a manual setting, This switch has been eliminated from the CNC controllable power console.
Page 52: 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. • P/S Fault Indicator – fault in plasma control PCB in the inverter power source.
Page 53: 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 4.2.3 Cut not flat, rounded or undercut 4.2.4 Surface roughness...
Page 54: 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 recommended current level for specific nozzles).
Page 55: 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) Top View •...
Page 56: 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 57: Dross
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). Cut Face Intermittent Dross Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross •...
Page 58: 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.
Page 59: 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 60: Carbon Steel
SECTION 4 OPERATION Refer to Cutting Process Data in the PT24 Manual for recommended flow/pressure NOTICE settings. 4.3.3 Carbon Steel Material 26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm) Thickness: • Smooth cut face Cut Qualities: •...
Page 61: Stainless Steel
SECTION 4 OPERATION Refer to Cutting Process Data in the PT24 NOTICE Manual for recommended flow/pressure settings. 4.3.4 Stainless Steel Material 22 GA (.028") to 16 GA (0.062") (0,7 mm to 1,6 mm) Thickness: • Positive cut angle • Cut Qualities: Excellent dross performance •...
Page 62 SECTION 4 OPERATION Refer to Cutting Process Data for NOTICE recommended flow/pressure settings. Stainless Steel Material .125" to .625" (3,2 mm to 15,9 mm) Thickness: • Matted cut edge appearance • Light gray color Cut Qualities: • Much smoother finish •...
Page 63: Introduction
SECTION 4 OPERATION 4.4 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.
Page 64 SECTION 4 OPERATION 4.4.2 IFC PT-24 Process Data Material: Aluminum Initial Amperes: 15 Final Amperes: 30 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 65: Aluminum
SECTION 4 OPERATION Process Data 15 Initial / 30 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,062 0,075 0,09 0,125 0,187 0,250 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 93,1 93,1...
Page 66 SECTION 4 OPERATION Material: Aluminum Initial Amperes: 28 Final Amperes: 55 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 67 SECTION 4 OPERATION Process Data 28 Initial – 55 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,062 0,125 0,125 0,250 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar...
Page 68 SECTION 4 OPERATION Material: Aluminum Initial Amperes: 35 Final Amperes: 70 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 69 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,187 0,250 0,375 0,500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 76,6 76,6...
Page 70 SECTION 4 OPERATION Material: Aluminum Initial Amperes: 50 Final Amperes: 100 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 71 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,250 0,375 0,500 0,625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 76,4 76,4...
Page 72 SECTION 4 OPERATION Material: Carbon Steel Initial Amperes: 16 Final Amperes: 16 Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 73: Carbon Steel
SECTION 4 OPERATION Process Data 16 Initial / 16 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 20Ga 18Ga 16Ga 14Ga 12Ga 10Ga Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 71,3 71,3...
Page 74 SECTION 4 OPERATION Material: Carbon Steel Initial Amperes: 18 Final Amperes: 35 Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 75 SECTION 4 OPERATION Process Data 18 Initial / 35 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 14Ga 0,125 0,135 0,187 0,250 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 86,9 86,9...
Page 76 SECTION 4 OPERATION Material: Carbon Steel Initial Amperes: 23 Final Amperes: 45 Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 77 SECTION 4 OPERATION Process Data 23 Initial / 45 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,125 0,135 0,187 0,250 0,375 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 73,8 73,8...
Page 78 SECTION 4 OPERATION Material: Carbon Steel Initial Amperes: 35 Final Amperes: 70 Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 79 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,187 0,250 0,312 0,375 0,500 0,625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 66,7...
Page 80 SECTION 4 OPERATION Material: Carbon Steel Initial Amperes: 50 Final Amperes: 100 Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 81 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,312 0,375 0,500 0,625 0,750 12,9 15,9 19,1 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 77,5...
Page 82 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 15 Final Amperes: 30 Plasma Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Oxygen, O2 @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 83: Stainless Steel
SECTION 4 OPERATION Process Data 15 Initial / 30 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 26Ga 24Ga 22Ga 18Ga 16Ga Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 99,8 99,8...
Page 84 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 25 Final Amperes: 50 Plasma Gas: Air @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body P/N 21758 Water Baffle...
Page 85 SECTION 4 OPERATION Process Data 25 Intial / 50 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,125 0,187 0,250 0,375 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1- psi/bar...
Page 86 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 35 Final Amperes: 70 Plasma Gas: Air @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body P/N 21758 Water Baffle...
Page 87 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,187 0,250 0,375 0,500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 79,1 79,1...
Page 88 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 50 Final Amperes: 100 Plasma Gas: Air @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body P/N 21758 Water Baffle...
Page 89 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,250 0,375 0,500 0,625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 79,1 79,1...
Page 90 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 35 Final Amperes: 70 Plasma Gas: Air @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 91 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,125 0,187 0,250 0,375 0,500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 80,5 80,5...
Page 92 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 50 Final Amperes: 100 Plasma Gas: Air @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 93 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,250 0,375 0,500 0,625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 78,6 78,6...
Page 94 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 25 Final Amperes: 50 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body P/N 21758 Water Baffle...
Page 95 SECTION 4 OPERATION Process Data 25 Intial / 50 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,125 0,187 0,250 0,375 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 78,5 78,5...
Page 96 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 35 Final Amperes: 70 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body P/N 21758 Water Baffle...
Page 97 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,187 0,250 0,375 0,500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 81,1 81,1...
Page 98 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 50 Final Amperes: 100 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control Torch Body P/N 21758 Water Baffle...
Page 99 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,250 0,375 0,500 0,625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 79,1 79,1...
Page 100 SECTION 4 OPERATION Material: Thin Stainless Steel Initial Amperes: 30A With special nozzle P/N 21923SS Final Amperes: 60A Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control With Special Nozzle for Stainless Torch Body...
Page 101 SECTION 4 OPERATION Process Data 30 Amperes Initial 60 Amperes Final Precision Plasma Integrated Flow Control Stainless Steel Using Special Nozzle P/N 21923SS Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,030 0,039 0,059 0,75 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1-...
Page 102 SECTION 4 OPERATION Material: Thin Stainless Steel Initial Amperes: 40A With special nozzle P/N 21923SS Final Amperes: 80A Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: PT-24 Torch with Integrated Flow Control With Special Nozzle for Stainless Torch Body...
Page 103 SECTION 4 OPERATION Process Data 40 Amperes Initial 80 Amperes Final Precision Plasma Integrated Flow Control Stainless Steel Using Special Nozzle P/N 21923SS Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness 0,118 In. 0,078 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters Plasma Start Gas 1-...
Page 104 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 25 Final Amperes: 50 -- using 70A nozzle Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 105 SECTION 4 OPERATION Process Data 25 Initial / 50 Final Amperes* Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 22Ga 20Ga 18Ga 16Ga Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 78,5 78,5...
Page 106 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 35 Final Amperes: 70 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 107 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,187 0,250 0,375 0,500 12,7 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 79,6 79,6...
Page 108 SECTION 4 OPERATION Material: Stainless Steel Initial Amperes: 50 Final Amperes: 100 Plasma Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar Shield Gas: Nitrogen, N2 @ 150 PSI /10.4 Bar ® Shield Mix Gas: Methane, CH4 @ 100 PSI / 6,9 Bar PT-24 Torch with Integrated Flow Control Torch Body P/N 21758...
Page 109 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Shield Gas 1 Shield Gas 2 Material Thickness In. 0,250 0,312 0,375 0,500 0,625 12,7 15,9 Timers Pierce Delay (sec.) Initial to Final Current (sec.) Setup Parameters 79,6...
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) 4-64 PT-24 Precision Plasma System IEFC-S...
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
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 0.095 2.032 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 0.080 1.651 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 Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 10 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 123: Plasma Marking Data
SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 124 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 15 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 125 SECTION 4 OPERATION Plasma Marking Process Data 15 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 126 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 10 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 127 SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 128 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 15 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 129 SECTION 4 OPERATION Plasma Marking Process Data 15 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 130 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 15 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 131 SECTION 4 OPERATION Plasma Marking Process Data 15 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 132 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 10 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 133 SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 134 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 20 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 135 SECTION 4 OPERATION Plasma Marking Process Data 20 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 136 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 30 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 137 SECTION 4 OPERATION Plasma Marking Process Data 30 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 138 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 10 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 139 SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 140 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 30 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 141 SECTION 4 OPERATION Plasma Marking Process Data 30 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 142 SECTION 4 OPERATION Plasma Marking With Precision Plasma And IEFC-S Material: Carbon and Stainless Steel RECISION Amperes: 30 Plasma Gas : Argon, Ar @ 83.2 PSI / 5,6 Bar LASMARC (4 Solenoid) Plasma Gas : Argon, Ar @ 85 PSI / 5,9 Bar (5 Solenoid) Shield Gas: Air @ 150 PSI / 10.4 Bar Torch Body...
Page 143 SECTION 4 OPERATION Plasma Marking Process Data 30 Amperes Precision Plasma IEFC-S Carbon and Stainless Steel Plasma Gas Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.) 4 Solenoid 5 Solenoid Setup Parameters Assembly Assembly Plasma Start Gas 1- psi 83.2/5.6 bar 85/5,87 bar Plasma Cut Gas 1- psi...
Page 144 SECTION 4 OPERATION This page intentionally left blank. 4-94 Precision Plasma with IEFC-S...
Page 145: 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. Electric Shock Can Kill! WARNING Before attempting any inspection or repair inside...
Page 146: 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 eye and face protection, blow out the inside of the power source, flow control, and junction box using low-pressure, clean/dry compressed air.
Page 147 SECTION 5 Maintenance Check Valve IEFC-S Gas Console Fluid Schematic Proportional Valve • Pressure Switch Plasma Cut and Start Gas. These gases enter the torch through connections that house check valves within the torch body. The valves acting in 2 Way Solenoid Valve conjunction with solenoid valves control the back and forth switching of start and cut gases.
Page 148 SECTION 5 Maintenance • Shield Gas. Shield preflow, cut shield and 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 the plasma jet. •...
Page 149: Torch Maintenance
SECTION 5 Maintenance 5.4 Torch Maintenance Electric Shock Can Kill DANGER Before performing torch maintenance: • Turn power switch on the console to the OFF position. • Disconnect primary input power. Torch Body O-Rings • Each day before starting operation, check O-rings on the torch body.
Page 150 SECTION 5 Maintenance Sleeve Torch Sleeve P/N 22568 • The torch sleeve P/N 22568 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 151: Consumable Disassembly And Inspection
SECTION 5 Maintenance 5.5 PT-24 Consumable Disassembly And Inspection Hot Torch Will Burn! WARNING • Allow torch to cool before servicing. • Torch is water cooled, but may be hot immediately after use. Electric Shock Can Kill! DANGER • Turn power switch on the console OFF. •...
Page 152 SECTION 5 Maintenance NOTE: If the console is on, the pump will be running and coolant pressure behind the retainer will prevent it from turning freely. Check the console before attempting to remove the nut. Notice that a small amount of coolant is lost each time consumables are removed.
Page 153 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 Nozzle nozzle create a metal to metal seal for the coolant. Any damage to this sealing surface will cause a leak resulting in poor cutting.
Page 154 SECTION 5 Maintenance 6. Remove the swirl baffle from the nozzle. If the baffle remains in the torch, it will come free when removing the electrode. Check the small gas passages of the swirl baffle for blockage and clear blockages with an air stream. If blockages cannot be cleared, replace baffle.
Page 155 SECTION 5 Maintenance 5.6 PT-24 Torch Tip Re-assembly 1. Electrode Apply a thin film of silicone grease to the O-ring, just enough to produce a shiny surface. Thread electrode in place and tighten snugly with tool provided. DO NOT OVER TIGHTEN. Nozzle Retainer 2.
Page 156 SECTION 5 Maintenance 4. Shield Cup Insulator Push the shield cup insulator on the nozzle retainer. This component is a press fit and may remain assembled when the assembly was taken apart. Shield Cup Insulator Nozzle Retainer 5. Insulator Shield Retainer Apply a thin coat of silicone grease to the O-ring and thread insulator shield retainer on to Shield Cup.
Page 157: Flow Control
SECTION 5 Maintenance 5.7 Flow Control Nitrogen Is Vented Inside Integrated NOTICE Flow Control Box. A small amount of nitrogen gas is vented internally to provide cooling, safety, and a slight positive pressure. Chamber Vent To prevent continuous building of pressure, the flow control chamber is externally vented.
Page 158: Proportional Valve Removal
SECTION 5 Maintenance 5.8 Proportional Valve Removal Proportional Valves can be removed if replacement is required, without disassembling the manifold from gas console. 1. Access the outside bottom of the unit by unbolting the IEFC-S gas console from the machine. 2.
Page 159: 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 Console. High Voltages Can Be Stored In WARNING Capacitors.
Page 160: Troubleshooting Guide
SECTION 6 TROUBLESHOOTING 6.2 Troubleshooting Guide 6.2.1 Reduced Consumable Life Cutting Up Skeletons Cutting skeletons (discarded material left after all pieces have been removed from a plate) to facilitate their removal from the table can adversely affect electrode life by: •...
Page 161: Poor Cut Quality
SECTION 6 TROUBLESHOOTING See Cut Quality In Section 4 6.2.2 Poor Cut Quality 6.2.3 No Pilot Arc Bad (open) Pilot Arc Cable Replace Cable Contaminated Electrode Clean or replace electrode Insufficient spark gap setting Set spark gap to 0.040” in plumbing box. Torch negative lead open No open circuit voltage Pilot Arc Contactor (PAC) Replace contactor...
Page 162: Nozzle Life Extremely Short
SECTION 6 TROUBLESHOOTING 6.2.7 Nozzle Life Extremely Short Pilot Arc H/L switch Refer to Process Data in wrong position Nozzle arcing inside bore Gas quality below purity specification Start gas flow too low Check Process Data cutting parameters 6.2.8 Short Electrode Life Insufficient cooling Check cooling pump for 115 psi output pressure Start gas quality Gas quality below purity specification Cut gas quality Gas quality below purity specification...
Page 163 SECTION 6 TROUBLESHOOTING 6.3 Gas Console Fluid Schematic and Manifold Valve Identification Schematic Legend ARGON Check Valve AIR 2 AIR 1 Proportional Valve O2-2 O2-1 N2-3 N2-1 N2-2 Pressure Switch 50 psi rising H-35 Solenoid Valve H-35 METHANE PT-24 Precision Plasma System IEFC-S...
Page 164 SECTION 6 TROUBLESHOOTING 6.4 IEFC Gas Console Schematic Part 1 PT-24 Precision Plasma System IEFC-S...
Page 165 SECTION 6 TROUBLESHOOTING 6.4 Part 2 IEFC Gas Console Schematic PT-24 Precision Plasma System IEFC-S...
Page 166: Ignition Console Electrical Schematic
SECTION 6 TROUBLESHOOTING 6.5 Ignition Console Electrical Schematic STEP UP TRANSFORMER ESAB P/N 8951179 SPARK GAP 0.040 AC LINE P1-B FILTER 120 VAC INPUT CORCOM C1, C2 2500 pF 2VB3 P1-A TORCH (-) ESAB P/N REACTOR 8674969 REACTORS ARE TORCH POWER...
Page 167: Troubleshooting
SECTION 6 TROUBLESHOOTING This page intentionally left blank. PT-24 Precision Plasma System IEFC-S...
Page 168 SECTION 6 TROUBLESHOOTING Part 1 6.7 Precision Plasma Power Console Electrical Schematic 180VAC 120 VAC 120 VAC NEUTRAL NEUTRAL COOLANT TB4-1 PUMP PCB1 P10-5 18VAC ISOLATION AMPLIFIER AND P10-3 18VAC P10-4 FAULT SIGNAL PCB P2-10 18VAC 38103 P2-9 18VAC P2-8 LED1 LED4 LED7...
Page 169 SECTION 6 TROUBLESHOOTING Part 2 Component Legend zone item description zone item description Transformer control, plasma interface Terminal brd Terminal strip MOV1,2,3 Mov 610V Terminal strip Auto transformer Recepacle 10 pos Receptacle 19 pos Plug 10 pos Potentiometer 10K Receptacle 16 pos Zener diode 180v Plug 16 pos K2,3...
Page 170 SECTION 6 TROUBLESHOOTING 6.8 Precision Plasma Power Console Wiring Diagram Part 1 Note: PLC1 (connection) refers to an area located on an enclosure that housed the former Programmable Logic Controller. This plasma power supply is CNC (cutting machine) controlled and does not use a PLC. PCB1 P4-10(VIO) P4-11(GRY)
Page 171 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Console Part 2 Note: PLC1 (connection) refers to an area located on an enclosure that housed the former Programmable Logic Controller. This plasma power supply is CNC (cutting machine) controlled and does not use a PLC. LINE LOAD BR1-A T2-AH2...
Page 172 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Console Part 3 Note: PLC1 (connection) refers to an area located on an enclosure that housed the former Programmable Logic Controller. This plasma power supply is CNC (cutting machine) controlled and does not use a PLC. PCB2-PA(YEL) PLC1 MODULE PCB2...
Page 173 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Console Part 4 Note: PLC1 (connection) refers to an area located on an enclosure that housed the former Programmable Logic Controller. This plasma power supply is CNC (cutting machine) controlled and does not use a PLC. MOD1 CB1-2(GRY) M1-1(BLK)
Page 174 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Console Part 5 MOD1 PCB1 P4-3(RED) PCB1 P4-3 (RED) R10-1 (GRY) PCB1 P4-4(YEL) PCB1 P4-4 (YEL) TB5-WORK(BLK) PCB1 P4-15(BLU) PCB1 P4-15 (BLU) PCB1 P4-16(ORN) PCB1 P4-16 (ORN) Note: PLC1 (connection) or PLC MOD refers to a PCB1 P1-13 (BLK) TB6-6 (BRN) location that housed the former Programmable...
Page 175 SECTION 6 TROUBLESHOOTING Page Intentionally left blank. PT-24 Precision Plasma System IEFC-S 6-17...
Page 176 SECTION 6 TROUBLESHOOTING 6.9 Power Module Schematic Part 1 6-18 PT-24 Precision Plasma System IEFC-S...
Page 177 SECTION 6 TROUBLESHOOTING Power Module Schematic Page 2 PT-24 Precision Plasma System IEFC-S 6-19...
Page 178 SECTION 6 TROUBLESHOOTING 6.10 Power Module Wiring Diagram PAGE 1 6-20 PT-24 Precision Plasma System IEFC-S...
Page 179 SECTION 6 TROUBLESHOOTING Power Module Wiring PAGE 2 PT-24 Precision Plasma System IEFC-S 6-21...
Page 180: Torch Manifold
SECTION 6 TROUBLESHOOTING 6.11 Torch Manifold Plasma 2 Plasma 1 Shield 2 Shield 1 Wire Shield 1 & Shield 2 Common Numbers Plasma 1 & Plasma 2 Common Argon Common Argon 6-22 PT-24 Precision Plasma System IEFC-S...
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 PT-24 Precision Plasma System IEFC-S...
Page 183 SECTION 7 REPLACEMENT PARTS Item Part Number Elec. Symbol Description Number 35925YL Cover-Top 995227 Label Warning-Exposed High Volt 2091514 Label Warning 35924YL Panel, Side 61328087 Screw, HMH ¼-20 X .50 L 13734588 Logo ESAB Clear PT-24 Precision Plasma System IEFC-S...
Page 184 SECTION 7 REPLACEMENT PARTS "TEE" Detail Page 7-12 PT-24 Precision Plasma System IEFC-S...
Page 185 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 672508 Switch Toggle 2PST 2 Pos 15A 951061 AM1,VM1 Meter LED 5VDC 954928 Overlay, Control Panel CNC 951061 AM1,VM1 Meter LED 5VDC 634518 S2,3 Switch Toggle DPDT 2 Pos 15A 2062018 Pot LIN 10.0K 2.00W 0.63L 1 turn 32286GY...
Page 186 SECTION 7 REPLACEMENT PARTS PT-24 Precision Plasma System IEFC-S...
Page 187 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35928GY Door Access Rear 952209 Conn Box Recpt 19 FS SH 97W63 3 Strain Relief 23610197 Plug Hole .875 Dia. .125 CT Nyl BK 950874 Circuit Breaker 7 AMP 952137 Fuse 7A 500 VAC Fast Acting 32202GY...
Page 188: Plasmarc Power Source-Internal Components
SECTION 7 REPLACEMENT PARTS 7.4 Plasmarc Power Source-Internal Components PT-24 Precision Plasma System IEFC-S...
Page 189 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) Base, Precision Plasma 35920GY 950487 Term Block 2 pos 9639533 Bushing, Snap .88 I.D. X 1.09 MH X .45 L 38103 PCB1 PCB Isolation AMP 950096 PCB1 P9,7 Housing Contact, Crimp 3 pin 952053 Standoff #6-32 X .88 L 952034...
Page 190 SECTION 7 REPLACEMENT PARTS 7-10 PT-24 Precision Plasma System IEFC-S...
Page 191 SECTION 7 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 13735308 Relay Enclose DPDT 120VAC 20A 0558002158 Kit, Wire Primary 33550...
Page 192 SECTION 7 REPLACEMENT PARTS 44" Long 16 X5 “TEE” Detail 7-12 PT-24 Precision Plasma System IEFC-S...
Page 193 SECTION 7 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 36423...
Page 194 SECTION 7 REPLACEMENT PARTS 7-14 PT-24 Precision Plasma System IEFC-S...
Page 195 SECTION 7 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 35919 Board, Terminal Output 2017483 Holder, Fuse 92W57 Grommet, Rub .63 I.D.
Page 196 SECTION 7 REPLACEMENT PARTS 7-16 PT-24 Precision Plasma System IEFC-S...
Page 197 SECTION 7 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 K2,3 Contactor, Pilot Arc 3P 40A 2234521 P4,MOD1 Plug, 16 Pos P1,PLC1 P2 2234877 PLC1 J1...
Page 198 SECTION 7 REPLACEMENT PARTS 7.5 Power Source Power Module 7-18 PT-24 Precision Plasma System IEFC-S...
Page 199 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35914GY Base Power Module 37102 Bracket, PCB KYDEX 35918 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 200 SECTION 7 REPLACEMENT PARTS CE only CE only Section A-A 7-20 PT-24 Precision Plasma System IEFC-S...
Page 201 SECTION 7 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 952160...
Page 202 SECTION 7 REPLACEMENT PARTS 7-22 PT-24 Precision Plasma System IEFC-S...
Page 203 SECTION 7 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 PT-24 Precision Plasma System IEFC-S 7-23...
Page 204 SECTION 7 REPLACEMENT PARTS CE units only 7-24 PT-24 Precision Plasma System IEFC-S...
Page 205 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35940 Transformer Control Bridge Diode 3PH 130A 951978 952611 Bridge Diode 3 PH 951192 Pad Thermal Bridge 951833 Pad Termal IGBT 1200V 35794 Busbar Input Bridge 951979 SCR1 SCR 90A 951196 Pad Thermal SCR Module 951980...
Page 206: Iefc-S Gas Console
SECTION 7 REPLACEMENT PARTS 7.6 IEFC-S Gas Console Replacement Parts VALVE 1 PLASMA 1 AIR 1 AIR2 VALVE 2 ARGON PLASMA 2 O2-2 O2-1 VALVE 3 SHIELD 1 N2-3 N2-1 N2-2 VALVE 4 SHIELD 2 H-35 METHANE P4-B P4-A 7-26 PT-24 Precision Plasma System IEFC-S...
Page 207 SECTION 7 REPLACEMENT PARTS IEFC-S Gas Console P/N 0558003641 Item Part Number Symbol Description Number (Elec-Ay) 0558002074 IIEFC-S Manifold Assembly without Proportional Valves 2237924 ASIOB Control System Motherboard 0002256475 ASIOB Relay Output Card 2237927 ASIOB Analog Output Card “C” 2237927* ASIOB Analog Output Card “D”...
Page 208 SECTION 7 REPLACEMENT PARTS 7.7 IEFC-S Gas Console Manifold Assembly w/o prop. valves - P/N 0558002074 AIR 2 AIR 1 ARGON O2-1 O2-2 N2-3 N2-2 N2-1 H-35 METHANE Bottom View PT-24 Precision Plasma System IEFC-S 7-28...
Page 209 SECTION 7 REPLACEMENT PARTS Item Number 0558002074 Manifold Assembly without Proportional Valves 952921 Valve, Solenoid 2-way, Man Mt. O2. S2 24/60 1/8 Or. 10Z30 Pipe Ftg Brass, Adptr ¼ MNPT X Male 5/8 –11 Hose 74S76 Pipe Ftg Brass, Adptr ¼ FNPT X Female 5/8 –11 Hose 3389 Pipe Ftg Brass, Adptr ¼...
Page 210: Iefc-S Ignition Console
SECTION 7 REPLACEMENT PARTS 7.8 IEFC-S Ignition Console Replacement Parts PILOT TORCH PLASMA 1 SHIELD 1 ARGON PLASMA 2 SHIELD 2 SECTION A-A 7-30 PT-24 Precision Plasma System IEFC-S...
Page 211 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 674969 PCB Special Function Filter 37401 Electrode, Spark Gap w/Solder Lug PT-24 Precision Plasma System IEFC-S 7-31...
Page 212: Torch Assembly
SECTION 7 REPLACEMENT PARTS 7.9 PT-24 Torch Assembly IFC Series P/N 0558002396 Shield 1 IN Orange Shield 1 OUT Orange Shield 2 IN Black Plasma 2 IN Yellow Plasma 2 OUT Yellow Argon IN Red Plasma 1 OUT Blue Plasma 1 IN Blue .284"...
Page 213 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 21758 Body & Tube Assembly PT-24 Torch 22568 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 214 SECTION 7 REPLACEMENT PARTS 7.10 Torch Ar Gas Manifold PT24 IFC Plasma 2 Plasma 1 Shield 2 Shield 1 Shield 1 & Shield 2 Common Plasma 1 & Plasma 2 Common Argon Common Argon 7-34 PT-24 Precision Plasma System IEFC-S...
Page 215 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 0558001502 Flange 952921 2 Way Solenoid Valves 593985 O-Ring PT-24 Precision Plasma System IEFC-S 7-35...
Page 216 SECTION 7 REPLACEMENT PARTS 7.11 PT-24 IFC Interface Cables 7-36 PT-24 Precision Plasma System IEFC-S...
Page 217 SECTION 7 REPLACEMENT PARTS Item Part Number Description Number Reference Gas Supply Lines Reference Main Power Cable Reference 120 VAC/24 VDC Cable Reference Process ASIOB Cable Reference Height Control ASIOB Cable (comes from a junction with process ASIOB cable inside the flow control 22428 3,7m (12 ft.) Power Bundle 21905...
Page 218 SECTION 7 REPLACEMENT PARTS Notes: 7-38 PT-24 Precision Plasma System IEFC-S...
Page 219: Revision History
revision history 1. Revision of 02/2005 - updated process data page for 16 amps , carbon steel. New data for shield gas, arc voltage, travel speed. 2. Revision of 10/2005 -Section 2 - Added Split IEFC Control System p/n 0558003639 package reference. Section 6 - Updated IEFC Gas console schematics at section 6.4. Section 7 - Changed IEFC-S Gas Console P/N 0558003641, item 3 p/n from: 56996230 to: 0002256475. 3. Revision 12/2010 - updated BOM to show correct meter conversions.
Page 220 Customer // Technical Support (843) 664-4405 (800) ESAB-123 (372-2123) ESAB Welding and Cutting Products PO BOX 100545 Ebenezer Road Florence, SC 29501-0545 http://www.esab.com ESAB Cutting Systems – Canada 6010 Tomken Road Mississauga, Ontario Canada L5T 1X9 Phone: (905) 670-0220 Fax: (905) 670-4879...

ESAB Precision Plasmarc IEFC-S PT-24 Installation, Operation And Maintenance Manual

Section 1 Safety

Section 2 Description

Section 3 Installation

Section 4 Operation

Section 5 Maintenance

Section 6 Troubleshooting

Section 7 Replacement Parts

Quick Links

Troubleshooting

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Summary of Contents for ESAB Precision Plasmarc IEFC-S PT-24

Table of Contents