ESAB PLASMARC Installation, Operation And Maintenance Manual
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ESAB PLASMARC Installation, Operation And Maintenance Manual

Precision cutting and high speed marking system with integrated flow control
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F-15-650
December, 2010
Installation, Operation and Maintenance Manual for the
Precision PLASMARC
Cutting
and High Speed Marking SYSTEM
with Integrated Flow Control
411 s. Ebenezer Road
Florence, SC 29501-0545

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  • Page 1 F-15-650 December, 2010 Installation, Operation and Maintenance Manual for the Precision PLASMARC Cutting  and High Speed Marking SYSTEM with Integrated Flow Control 411 s. Ebenezer Road Florence, SC 29501-0545...
  • Page 2 ESAB makes every possible quired. ESAB makes every possible changes as r changes as r quired. ESAB makes every possible quired. ESAB makes every possible effort to ensure our documentation is current.

  • Page 3: Table Of Contents

    3.5 Alternate Connection Locations for IFC ..........4 3.6 IFC Basic Component Identification ............4 3.7 Interconnecting Lines ................5-10 3.8 Precision Plasmarc Component Interconnecting Diagram...... 7 3.9 Torch Mounting ..................11 3.10 Torch Coolant ..................12 3.11 Inspection Of Gas And Coolant Lines........... 12...
  • Page 4 Precision Plasma Integrated Flow Control Table of Contents Section 4 Operation 4.1 Power Supply Controls ................. 4.1.1 Main Power Switch ............... 1 4.1.2 Pilot Arc Switch................1 4.1.3 Fault Indicator Lights ..............2 4.1.4 Meters ..................2 4.1.5 Current Control Switch ..............2 4.2 Cut Quality 4.2.1 Introduction ..................
  • Page 5 Precision Plasma Integrated Flow Control Table of Contents Section 5 Maintenance 5.1 General ....................1 5.2 Inspection and Cleaning ............... 1 5.3 PT-24 Torch Description............... 2-4 5.4 IFC 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 6 Section 7 Replacement Parts 7.1 General....................1 7.2 Ordering ....................1 7.3 Plasmarc Power Source – Exterior Components........2-7 7.4 Plasmarc Power Source – Internal Components ........8-17 7.5 Power Source Module................18-25 7.6 IFC ....................... 26-27 7.7 IFC Manifold ..................28-29 7.8 PT-24 Torch Assembly IFC Series with Marking ........

  • Page 7: 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 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

    • Contact your ESAB representative before Contact your ESAB representative before Contact your ESAB representative before Contact your ESAB representative before installation. He can suggest certain precautions installation. He can suggest certain precautions installation.

  • 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 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 connections during plasma cutting process.
  • Page 12 SECTION 1 SAFETY Radiation hazard. WARNING Arc rays can injure eyes and burn Arc rays can injure eyes and burn skin. skin. Arc rays can injure eyes and burn Arc rays can injure eyes and burn skin. skin. • Wear correct eye and body protection. Wear correct eye and body protection.
  • Page 13 SECTION 1 SAFETY Burn 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 SECTION 1 SAFETY Explosion hazard. WARNING • Certain molten aluminum-lithium (Al- Certain molten aluminum-lithium (Al-Li) alloys can Certain molten aluminum-lithium (Al- Certain molten aluminum-lithium (Al- 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: 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 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 connections during plasma cutting process.

  • Page 16: 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 17: Section 2 Description

    Technical reference material is also provided to assist in troubleshooting the cutting package. 2.3 Package Options Available Precision Plasmarc® Integrated Flow Control package options available through your ESAB dealer Precision Plasmarc® Power Source (200/230/380/415/460/575) 3-phase 50/60 Hz P/N 0558002077 (required) CNC Controllable/Without PLC...

  • 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 , 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% Purity Required* , Ar-99.995% Air-clean, dry and oil free Recommended Liquid Cylinder Service Oxygen: R-76-150-540LC (P/N 19777)
  • Page 20 SECTION 2 DESCRIPTION 2.4.5 Pt-24 Torch Technical Specifications Type Water-Cooled, Dual Gas Rating 100 amps @ 100 % duty cycle Dimensions See Package Options (2.3) Precision Plasma with Integrated Flow Control...

  • Page 21: Section 3 Installation

    INSTALLATION 3.1 General Proper installation can contribute materially to the satisfactory and trouble-free operation of the NOTICE 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. Gas supply may be from a bulk source or from a bank of manifold cylinders and regulated to supply 150 psig (10.4 bar) to the...

  • 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: Alternate Connection Locations For

    SECTION 3 INSTALLATION 3.5 Alternate Connection Locations For IFC I/O Strain Relief Alternate There are two locations for the I/O 24v input and for the torch. This provides flexibility while mounting the box to a machine. NOTE: When changing over alternate Torch connection location, be sure to replace hole...

  • Page 25: Interconnecting Lines

    SECTION 3 INSTALLATION 3.7 Interconnecting Lines Torch Bundle 1. All interconnecting service lines supplied are labeled or color coded on each end with Cooling water corresponding labels/colors marked on the return/Pilot cabinets. arc cable Gas lines Cooling Solenoid water to Cable torch 2.
  • Page 26 SECTION 3 INSTALLATION Power supply and IFC connections Power supply and IFC connections Power supply and IFC connections Power supply and IFC connections 3. Connect power and coolant lines in Power Supply Bundle from power source to IFC box. Power Supply Bundle Power bundle consists of #6 and # 7 coolant lines (with 5/8-18 L.H.

  • Page 27: Precision Plasmarc Component Interconnecting Diagram

    SECTION 3 INSTALLATION 3.8 Precision Plasmarc® Component Interconnecting Diagram wall disconnect (cust. sup.) height control ASIOB enclosure primary power cable integrated flow control box precision plasma power source height control ASIOB cable*(see note) power bundle process ASIOB cable power supply I/O cable...
  • Page 28 SECTION 3 INSTALLATION 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 29 SECTION 3 INSTALLATION Gas connections and I/O Strain Relief 1/4 NPT 5. Connect gas delivery lines to integrated flow control. Install 25 micron gas filters in all delivery lines between gas source and IFC. 25 micron Gas Filter 25 micron Gas Filter 25 micron Gas Filter 25 micron Gas Filter 25 µ...
  • Page 30 SECTION 3 INSTALLATION Remove Access Cover Pilot Arc Work Torch 6. Remove panel from rear of console and attach the pilot-arc, torch and work lead. Power Source 7 Amp 500 Flow Control VAC Fuse Lead Rating Label 7. Connect power supply I/O cable between the console and the CNC.

  • Page 31: Torch Mounting

    SECTION 3 INSTALLATION 3.9 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 32: Torch Coolant

    SECTION 3 INSTALLATION 3.10 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 33 SECTION 3 INSTALLATION 3.12 Using a 5 Solenoid Torch Manifold The 5 solenoid torch manifold 5 solenoid torch manifold 5 solenoid torch manifold 5 solenoid torch manifold allows 1 second conversion from cutting to marking and back to cutting compared to 7 to 10 second switching delay.
  • Page 34 SECTION 3 INSTALLATION Procedure to modify IFC manifold for 4 solenoid Procedure to modify IFC manifold for 4 solenoid Procedure to modify IFC manifold for 4 solenoid Procedure to modify IFC manifold for 4 solenoid torch manifold torch manifold torch manifold torch manifold.

  • Page 35: Power Supply Controls

    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.

  • 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 Coolant flow Coolant flow Coolant flow is turned on, the light will briefly show a fault and then go out. •...

  • 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: §...

  • 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 recommended current level for specific nozzles).

  • 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) Top View •...

  • 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). Cut Face Intermittent Dross Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross •...

  • 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 26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm) Thickness: • Smooth cut face Cut Qualities: •...
  • 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 22 GA (.028") to 16 GA (.062") (0,7 mm to 1,6 mm) Thickness: • Positive cut angle • Cut Qualities: Excellent dross performance •...
  • Page 46 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 47 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: •...
  • Page 48 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 Torch Body...

  • Page 49: Aluminum

    SECTION 4 OPERATION Process Data 15 Initial / 30 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 50 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 Torch Body...

  • Page 51: Aluminum

    SECTION 4 OPERATION Process Data 28 Initial / 55 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 52 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 Torch Body...
  • Page 53 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 54 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 Torch Body...
  • Page 55 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Aluminum Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 56 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 Torch Body...
  • Page 57 SECTION 4 OPERATION Process Data 16 Initial / 16 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 58 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 Torch Body...

  • Page 59: Carbon Steel

    SECTION 4 OPERATION Process Data 18 Initial / 35 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 60 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 Torch Body...
  • Page 61 SECTION 4 OPERATION Process Data 23 Initial / 45 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 62 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 Torch Body...
  • Page 63 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 64 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 Torch Body...
  • Page 65 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Carbon Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 66 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 Torch Body...
  • Page 67 SECTION 4 OPERATION Process Data 15 Initial / 30 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 68 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 Torch Body Torch Body...

  • Page 69: Stainless Steel

    SECTION 4 OPERATION Process Data 25 Intial / 50 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 70 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 Torch Body Torch Body...
  • Page 71 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 72 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 Torch Body Torch Body...
  • Page 73 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 74 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 Torch Body...
  • Page 75 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 76 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 Torch Body...
  • Page 77 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 78 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 Torch Body Torch Body...
  • Page 79 SECTION 4 OPERATION Process Data 25 Intial / 50 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 80 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 Torch Body Torch Body...
  • Page 81 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 82 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 Torch Body Torch Body...
  • Page 83 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 84 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 PT-24 Torch with Integrated Flow Control PT-24 Torch with Integrated Flow Control...
  • Page 85 SECTION 4 OPERATION Process Data 25 Initial / 50 Final Amperes* Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 86 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 Torch Body...
  • Page 87 SECTION 4 OPERATION Process Data 35 Initial / 70 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...
  • Page 88 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 Torch Body...
  • Page 89 SECTION 4 OPERATION Process Data 50 Initial / 100 Final Amperes Precision Plasma Integrated Flow Control Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 2 Shield Gas 2 Shield Gas 2 Shield Gas 2...

  • Page 90: Aluminum Kerf Values

    SECTION 4 OPERATION 4.4.3.1 Aluminum Kerf Values N Aluminum N Aluminum N Aluminum N Aluminum N /N /N 30 Amperes 30 Amperes 30 Amperes 30 Amperes 2 2 2 2 2 2 2 2 4 4 4 4 Material Thickness (mm) 1.575 1.905 2.286...
  • Page 91 SECTION 4 OPERATION Aluminum N Aluminum N Aluminum N Aluminum N /N /N 70 Amperes 70 Amperes 70 Amperes 70 Amperes 2 2 2 2 2 2 2 2 4 4 4 4 Material Thickness (mm) 4.750 6.350 9.525 12.700 0.190 4.826 0.170...

  • Page 92: Carbon Steel Kerf Values

    SECTION 4 OPERATION 4.4.3.2 Carbon Steel Kerf Values O Carbon Steel O Carbon Steel O Carbon Steel O Carbon Steel O /N /N 16 Amperes 16 Amperes 16 Amperes 16 Amperes 2 2 2 2 2 2 2 2 2 2 2 2 Material Thickness (mm) 1.219 3.404...
  • Page 93 SECTION 4 OPERATION Carbon Steel O Carbon Steel O Carbon Steel O Carbon Steel O /N /N 45 Amperes 45 Amperes 45 Amperes 45 Amperes 2 2 2 2 2 2 2 2 2 2 2 2 Material Thickness (mm) 3.175 6.350 9.525...
  • Page 94 SECTION 4 OPERATION Carbon Steel O Carbon Steel O Carbon Steel O Carbon Steel O /N /N 100 Amperes 100 Amperes 100 Amperes 100 Amperes 2 2 2 2 2 2 2 2 2 2 2 2 Material Thickness (mm) 9.525 12.700 19.050...

  • Page 95: Stainless Steel Kerf Values O

    SECTION 4 OPERATION 4.4.3.3 Stainless Steel Kerf Values O Stainless Steel O Stainless Steel O Stainless Steel O Stainless Steel O /N /N 30 Amperes 30 Amperes 30 Amperes 30 Amperes 2 2 2 2 2 2 2 2 2 2 2 2 Material Thickness (mm) 0.457 0.584...

  • Page 96: 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 Stainless Steel Air/Air/CH Stainless Steel Air/Air/CH Stainless Steel Air/Air/CH 70 Amperes 70 Amperes 70 Amperes 70 Amperes 4 4 4 4 Material Thickness (mm) 3.175 4.775 6.350 9.525 12.700 0.140 3.556...

  • Page 97: Stainless Steel Kerf Values N

    SECTION 4 OPERATION 4.4.3.5 Stainless Steel Kerf Values N Stainless Steel N Stainless Steel N Stainless Steel N Stainless Steel N /N /N /N /N 70 Amperes 70 Amperes 70 Amperes 70 Amperes 2 2 2 2 2 2 2 2 4 4 4 4 Material Thickness (mm) 4.750...
  • Page 98 SECTION 4 OPERATION 4.4.3.6 Stainless Steel Kerf Values N Stainless Steel N Stainless Steel N Stainless Steel N Stainless Steel N /N /N /N /N 50 Amperes 50 Amperes 50 Amperes 50 Amperes 2 2 2 2 2 2 2 2 Material Thickness (mm) 3.175 4.750...
  • Page 99 SECTION 4 OPERATION Stainless Steel N Stainless Steel N Stainless Steel N Stainless Steel N /N /N /N /N 100 Amperes 100 Amperes 100 Amperes 100 Amperes 2 2 2 2 2 2 2 2 Material Thickness (mm) 6.350 9.525 12.700 15.875 0.190...

  • Page 100: 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 Stainless Steel Air/Air 50 Amperes Stainless Steel Air/Air 50 Amperes 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...
  • Page 101 SECTION 4 OPERATION Stainless Steel Air/Air 100 Amperes Stainless Steel Air/Air 100 Amperes Stainless Steel Air/Air 100 Amperes 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...
  • Page 102 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 10 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...

  • Page 103: Plasma Marking Data

    SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 104 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 15 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...

  • Page 105: Precision Plasma Integrated Flow Control

    SECTION 4 OPERATION Plasma Marking Process Data 15 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 106 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 10 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 107 SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 108 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 15 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 109 SECTION 4 OPERATION Plasma Marking Process Data 15 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 110 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 15 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 111 SECTION 4 OPERATION Plasma Marking Process Data 15 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 112 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 10 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 113 SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 114 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 20 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 115 SECTION 4 OPERATION Plasma Marking Process Data 20 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 116 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 30 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 117 SECTION 4 OPERATION Plasma Marking Process Data 30 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 118 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 10 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 119 SECTION 4 OPERATION Plasma Marking Process Data 10 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 120 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 30 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 121 SECTION 4 OPERATION Plasma Marking Process Data 30 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 122 SECTION 4 OPERATION Plasma Marking With Precision Plasma And Integrated Flow Control Material: Carbon and Stainless Steel Amperes: 30 Plasma Gas: Argon, Ar @ 150 PSI / 10.4 Bar Shield Gas: Air @ 150 PSI / 10.4 Bar PT-24 Torch with Integrated Flow Control Torch Body Torch Body Torch Body...
  • Page 123 SECTION 4 OPERATION Plasma Marking Process Data 30 Amperes Precision Plasma Integrated Flow Control Carbon and Stainless Steel Plasma Gas Plasma Gas Plasma Gas Plasma Gas Shield Gas 1 Shield Gas 1 Shield Gas 1 Shield Gas 1 Material Thickness ALL Thickness Timers Pierce Delay (sec.)
  • Page 124 SECTION 4 OPERATION This page intentionally left blank. This page intentionally left blank. This page intentionally left blank. This page intentionally left blank. 4-90 Precision Plasma with Integrated Flow Control...

  • Page 125: Section 5 Maintenance

    Precision Plasma, open wall disconnect or wall circuit breaker. 5.2 Inspection And Cleaning Frequent inspection and cleaning of the Precision Plasmarc® System is recommended for safety and proper operation. Consider the following during inspection and cleaning: •...

  • Page 126: 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 127: Ifc Fluid Schematic

    SECTION 5 MAINTENANCE Check Valve IFC Fluid Schematic Proportional Valve • Pressure Switch Plasma Cut and Start Gas. Plasma Cut and Start Gas. These gases enter the Plasma Cut and Start Gas. Plasma Cut and Start Gas. torch through connections that house check valves within the torch body.
  • Page 128 SECTION 5 MAINTENANCE • Shield Gas. Shield preflow, cut shield and Shield Gas. 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 the plasma jet.

  • Page 129: 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 •...
  • Page 130 SECTION 5 MAINTENANCE Sleeve Torch Sleeve Torch Sleeve Torch 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 131: 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! WARNING • Turn power switch on the console OFF. •...
  • Page 132 SECTION 5 MAINTENANCE NOTE: NOTE: NOTE: 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 133 SECTION 5 MAINTENANCE Nozzle 5. Use the tool provided to remove the nozzle. Place the slot around the nozzle groove and pull it free. Electrode and Nozzle Tool P/N 21765 6. Remove the swirl baffle from the nozzle. If the baffle remains in the torch, it will come free when removing the electrode.

  • Page 134: Torch Re-Assembly

    SECTION 5 MAINTENANCE .284" for Electrode Nozzle Removal Slot 7. Use the electrode and nozzle tool provided to unscrew the electrode. (P/N 21765). .189" for Cooling Water Tube 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 135 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 136: 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 137: 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 the IFC box. 1. Access the outside bottom of the unit by unbolting the IFC box from the machine. 2.
  • Page 138 SECTION 5 MAINTENANCE This page intentionally left blank. 5-14 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...

  • Page 139: 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 140: Troubleshooting Guide

    SECTION 6 TROUBLESHOOTING 6.2 Troubleshooting Guide 6.2.1 Reduced Consumable Life Cuttin Cutting Up Skeletons g Up Skeletons Cutting skeletons (discarded material left after all Cuttin Cuttin g Up Skeletons g Up Skeletons pieces have been removed from a plate) to facilitate their removal from the table can adversely affect electrode life by: •...

  • Page 141: 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 (shorted) Pilot Arc Cable Bad (shorted) Pilot Arc Cable Bad (shorted) Pilot Arc Cable Bad (shorted) Pilot Arc Cable Replace Cable Contaminated Electrode Clean or replace electrode Contaminated Electrode Contaminated Electrode Contaminated Electrode...

  • Page 142: Nozzle Life Extremely Short

    SECTION 6 TROUBLESHOOTING 6.2.7 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 Nozzle arcing inside bore...

  • Page 143: Ifc Fluid Schematic

    SECTION 6 TROUBLESHOOTING 6.3 IFC 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 SHIELD GAS 2 OUT PLASMA GAS 2 OUT SHIELD GAS 1 OUT PLASMA GAS 1 OUT...

  • Page 144: Ifc Electrical Schematic

    SECTION 6 TROUBLESHOOTING 6.4 IFC Electrical Schematic Part 1 Next Page PLASMA 2 PLASMA 1 ESAB ASIOB SYSTEM SHIELD 1 SHIELD 2 X35-1 WHITE COMMON SION X35-2 SION GREEN GNDE X35-3 GNDE BLACK VCCE X35-4 VCCE SHIELD GROUND X35-5 GROUND...
  • Page 145 SECTION 6 TROUBLESHOOTING Part 2 IFC Electrical Schematic Previous page P4-1 PLASMA GAS 1 PRESSURE P4-2 P4-3 PLASMA GAS 2 PRESSURE P4-4 P4-5 SHIELD GAS 1 PRESSURE P4-6 P4-7 SHIELD GAS 2 Proportional Valves PRESSURE P4-8 LCD Meter PLASMA GAS 1 9-BAR PROPORTIONAL VALVE V1 Output For 1 +24 VDC...

  • Page 146: Precision Plasma Power Source Electrical Schematic

    SECTION 6 TROUBLESHOOTING 6.5 Precision Plasma Power Source Electrical Schematic Part 1 180VAC 120 VAC 120 VAC P2 J2 NEUTRAL NEUTRAL COOLANT PUMP PCB1 P10-5 18VAC ISOLATION AMPLIFIER AND P10-3 18VAC P10-4 FAULT SIGNAL PCB P2-10 38103 18VAC P2-9 18VAC P2-8 LED1 LED4...
  • Page 147 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 148 SECTION 6 TROUBLESHOOTING 6.6 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 149 SECTION 6 TROUBLESHOOTING Power Module Wiring Diagram Part 2 Previous Page PCB2 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 150: Power Module Schematic

    SECTION 6 TROUBLESHOOTING 6.7 Precision Plasma Power Module Schematic 6-12 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...

  • Page 151: Power Module Schematic - Ce Version

    SECTION 6 TROUBLESHOOTING 6.8 Power Module Schematic - CE Version 6-13 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...

  • Page 152: Power Module Wiring Diagram - Ce Version

    SECTION 6 TROUBLESHOOTING 6.9 Power Module Wiring Diagram – CE Version PAGE 1 6-14 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...
  • Page 153 SECTION 6 TROUBLESHOOTING Power Module Wiring – CE Version PAGE 2 6-15 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...

  • Page 154: Precision Plasma Power Source Wiring Diagram (Includes Ce Version)

    SECTION 6 TROUBLESHOOTING 6.10 Precision Plasma Power Source Wiring Diagram Part 1 Part 1 Part 1 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 PCB1 PCB1...
  • Page 155 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source (Includes CE) Part 2 Part 2 Part 2 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 156 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 3 Part 3 Part 3 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. MOD1 MOD1 MOD1...
  • Page 157 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 4 Part 4 Part 4 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. PCB2-PA(YEL) PLC1 MODULE PCB2...
  • Page 158 SECTION 6 TROUBLESHOOTING Wiring Diagram – Precision Plasma Power Source Part 5 Part 5 Part 5 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) PCB1 P1-13 (BLK) TB6-6 (BRN) PCB1 P1-14 (RED))

  • Page 159: Torch Manifold

    SECTION 6 TROUBLESHOOTING 6.11 6.11 6.11 6.11 Torch Manifold Torch Manifold Torch Manifold 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 6-21 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...
  • Page 160 SECTION 6 TROUBLESHOOTING This page intentionally left blank. 6-22 Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control Precision Plasma with Integrated Flow Control...
  • Page 161 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 162 SECTION 7 REPLACEMENT PARTS 7.3 Plasmarc Power Source-Exterior Components Precision Plasma with Integrated Flow Control...
  • Page 163 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 Precision Plasma with Integrated Flow Control...
  • Page 164 SECTION 7 REPLACEMENT PARTS "TEE" Detail Page 7-12 Precision Plasma with Integrated Flow Control...
  • Page 165 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 166 SECTION 7 REPLACEMENT PARTS Precision Plasma with Integrated Flow Control...
  • Page 167 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 168 SECTION 7 REPLACEMENT PARTS 7.4 Plasmarc Power Source-Internal Components Precision Plasma with Integrated Flow Control...
  • Page 169 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35920GY Base, Precision Plasma 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”...
  • Page 170 SECTION 7 REPLACEMENT PARTS 7-10 Precision Plasma with Integrated Flow Control...
  • Page 171 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 172 SECTION 7 REPLACEMENT PARTS 44" Long 16 X5 “TEE” Detail 7-12 Precision Plasma with Integrated Flow Control...
  • Page 173 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 174 SECTION 7 REPLACEMENT PARTS 7-14 Precision Plasma with Integrated Flow Control...
  • Page 175 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”...
  • Page 176 SECTION 7 REPLACEMENT PARTS 7-16 Precision Plasma with Integrated Flow Control...
  • Page 177 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 178 SECTION 7 REPLACEMENT PARTS 7.5 Power Source Power Module 7-18 Precision Plasma with Integrated Flow Control...
  • Page 179 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 180 SECTION 7 REPLACEMENT PARTS 37097-2-3 Section A-A 7-20 Precision Plasma with Integrated Flow Control...
  • Page 181 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 7-21...
  • Page 182 SECTION 7 REPLACEMENT PARTS 7-22 Precision Plasma with Integrated Flow Control...
  • Page 183 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 7-23 Precision Plasma with Integrated Flow Control...
  • Page 184 SECTION 7 REPLACEMENT PARTS 37097-4-5 7-24 Precision Plasma with Integrated Flow Control...
  • Page 185 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 35940 Transformer Control 951978 Bridge Diode 3PH 130A 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 186 SECTION 7 REPLACEMENT PARTS 7.6 Precision Plasma Flow Control Unit Replacement Parts 7-26 Precision Plasma with Integrated Flow Control...
  • Page 187 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) See Detail IFC Manifold Assembly 37401 Electrode, Spark Gap, .188” (4.7 mm) Dia. w/SolderLug 674969 PCB Special Function Filter 56996230 ASIOB Relay Output Card 2237927 ASIOB Analog Output Card 2237924 ASIOB Control System Motherboard 7-27...
  • Page 188 SECTION 7 REPLACEMENT PARTS 7.7 IFC Flow Control Manifold Assembly - Detail Bottom View- Manifold PS2 Red PS1 Red PS3 Black PS1 Black PS4 Black PS2 Black PS3 Red PS4 Red 7-28 Precision Plasma with Integrated Flow Control...
  • Page 189 SECTION 7 REPLACEMENT PARTS Item Part Number Quantity Description 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”...
  • Page 190 SECTION 7 REPLACEMENT PARTS 7.8 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 191 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 192 SECTION 7 REPLACEMENT PARTS 7.9 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 7-32 Precision Plasma with Integrated Flow Control...
  • Page 193 SECTION 7 REPLACEMENT PARTS Item Part Number Symbol Description Number (Elec-Ay) 0558001502 Flange 952921 2 Way Solenoid Valves 593985 O-Ring 7-33 Precision Plasma with Integrated Flow Control...
  • Page 194 SECTION 7 REPLACEMENT PARTS 7.10 PT-24 IFC Interface Cables 7-34 Precision Plasma with Integrated Flow Control...
  • Page 195 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 12 ft.
  • Page 196 SECTION 7 REPLACEMENT PARTS Notes: 7-36 Precision Plasma with Integrated Flow Control...
  • Page 197 revision history 1. Revision 12/2010 - updated BOM to show correct meter conversions.
  • Page 198 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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