ESAB m3® Plasma Manual de usuario

Marca: ESAB

Modelo: m3® Plasma

Categoría: Sistema de soldadura

Tipo: Manual de usuario

Este manual también es adecuado para

m3® Plasma Manual Gas Control Plasma System

Manual Gas Control Plasma System

Instruction Manual

0558009546 09/2011

This documentation is for ESAB equipment:

PCC-14 Plumbing Box part number 0558005840

Plasma Control Interface part number 0560948696 (serial #’s beginning at AB-K016006)

PCC-14 Plumbing Box

Plasma Control Interface

See manual # 0558006574 for ESP-150 and ESP-200 applications.

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.0 ESAB m3 Manual Gas Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

PCC-14 Plumbing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 PCC-14 Plumbing Box Dimensions/ Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.3 Plumbing Box Spark Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3.1 VDR Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.4 Plumbing Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.5 EPP-201 / EPP-360 Torch Connections to Plumbing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Plasma Control Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.7 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.8 Plasma Control Interface Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.9 Typical / Recommended ESTOP Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.10 Control Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.11 Plasma Control Interface Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.12 Plasma Control Interface STATUS Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

4.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.0 Marking Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.1 Marking Module Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.0 PT-36R Plasma Torch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.1 PT-36R Technical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.2 Gas Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.3 Recommended Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.4 PT-36R Torch Technical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.0 Coolant Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7.1 Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

7.3 Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

8.0 EPP-201 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

8.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

8.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

9.0 EPP-360 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

9.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

10.0 HOSES AND CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.1 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

10.2 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

11.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

11.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety precau-

tions listed below as well as all other manuals, material

safety data sheets, labels, etc. Failure to observe Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operating

or observing operations. Warn bystanders not to

watch the arc and not to expose themselves to the

rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cu ess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

which could cause a later re. Use re watchers when

necessary.

7. For additional information, refer to NFPA Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

SECCION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las

referencias listadas en la sección "Información Adi-

cional Sobre La Seguridad". Antes de hacer cualquier

instalación o procedimiento de operación , asegúrese

de leer y seguir las precauciones de seguridad listadas

a continuación así como también todo manual, hoja

de datos de seguridad del material, calcomanias, etc.

El no observar las Precauciones de Seguridad puede

resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS--

Algunos procesos de soldadura, corte

y ranurado son ruidosos y requiren

protección para los oídos. El arco,

como el sol , emite rayos ultravioleta

(UV) y otras radiaciones que pueden dañar la piel

y los ojos. El metal caliente causa quemaduras. EL

entrenamiento en el uso propio de los equipos y

sus procesos es esencial para prevenir accidentes.

Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando

esté usando careta de soldar, protector para su cara

u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las

chispas y rayos del arco cuando se esté operando y

observando las operaciones. Alerte a todas las per-

sonas cercanas de no mirar el arco y no exponerse

a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso,

zapato alto al tobillo, y careta de soldar con capucha

para el pelo, para proteger el cuerpo de los rayos y

chispas calientes provenientes del metal fundido.

En ocaciones un delantal a prueba de fuego es

necesario para protegerse del calor radiado y las

chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del

pantalón o los bolsillos. Mangas y cuellos deberán

mantenerse abotonados, bolsillos al frente de la

camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable

como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con

velocidad. Personas cercanas deberán usar gafas

de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de

las amas y el arco pueden ocacionar

fuegos. Escoria caliente y las chispas

pueden causar fuegos y explosiones.

Por lo tanto:

1. Remueva todo material combustible lejos del área

de trabajo o cubra los materiales con una cobija a

prueba de fuego. Materiales combustibles incluyen

madera, ropa, líquidos y gases amables, solventes,

pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en

las grietas y agujeros de pisos y paredes causando

fuegos escondidos en otros niveles o espacios.

Asegúrese de que toda grieta y agujero esté cubierto

para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo

relacionado hasta que la pieza de trabajo esté to-

talmente limpia y libre de substancias que puedan

producir gases inamables o vapores tóxicos. No

trabaje dentro o fuera de contenedores o tanques

cerrados. Estos pueden explotar si contienen vapores

inamables.

4. Tenga siempre a la mano equipo extintor de fu-

ego para uso instantáneo, como por ejemplo una

manguera con agua, cubeta con agua, cubeta con

arena, o extintor portátil. Asegúrese que usted esta

entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por

ejemplo, el calor causado por cable sobrecarga en

los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec-

cione el área de trabajo para cerciorarse de que las

chispas o metal caliente ocasionen un fuego más

tarde. Tenga personal asignado para vigilar si es

necesario.

7. Para información adicional , haga referencia a la

publicación NFPA Standard 51B, "Fire Prevention in

Use of Cutting and Welding Processes", disponible

a través de la National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto

con las partes eléctricas energizadas

y tierra puede causar daño severo o

muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas,

de movimiento connado en lugares estrechos o

si hay posibilidad de caer al suelo.

SECCION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder

esté conectado a tierra através del sistema de

electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de

tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.

Cables y conductores expuestos o con malas

conexiones pueden exponer al operador u otras

personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi-

ciones. Reemplaze cables rotos, dañados o con

conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de

trabajo, los cables, antorchas, pinza del electrodo,

y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están

insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien-

tras trabaja en lugares estrechos o áreas húmedas;

trabaje sobre un pedazo de madera seco o una

plataforma insulada y use zapatos con suela de

goma.

8. Use guantes secos y sin agujeros antes de energizar

el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC

Standard Z49.1 (listado en la próxima página) para

recomendaciones especícas de como conectar el

equipo a tierra. No confunda el cable de soldar a

la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI-

COS - Son peligrosos. La corriente

eléctrica uye através de cualquier

conductor causando a nivel local

Campos Eléctricos y Magnéticos

(EMF). Las corrientes en el área de corte y soldadura,

crean EMF alrrededor de los cables de soldar y las

maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de

soldar. El Campo Electromagnético (EMF) puede

interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced-

imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted

quiere soldar. Asegúrelos uno junto al otro con

cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a

un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los

gases, pueden causar malestar o

daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede

causar falta de oxígeno.

Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,

corte, o ranure materiales con hierro galvanizado,

acero inoxidable, cobre, zinc, plomo, berílio, o cad-

mio a menos que provea ventilación mecánica

positiva . No respire los gases producidos por

estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos

del arco pueden reaccionar con los vapores de

hidrocarburo clorinado para formar un fosfógeno,

o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es

indicación de que la ventilación no es apropiada.

Pare de trabajar y tome las medidas necesarias

para mejorar la ventilación en el área de trabajo.

No continúe operando si el malestar físico per-

siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen-

daciones especícas en la ventilación.

SECCION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti-

liza para soldaduras o cortes,

produce humos o gases, los

cuales contienen químicos

conocidos por el Estado de Cali-

fornia de causar defectos en el

nacimiento, o en algunos casos,

Cancer. (California Health &

Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados

correctamente, pueden romp-

erse y liberar violentamente

gases. Rotura repentina del

cilindro, válvula, o válvula de

escape puede causar daño o

muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la

presión del cilindro de gas . No utilice adapta-

dores. Mantenga las mangueras y las conexiones

en buenas condiciones. Observe las instrucciones

de operación del manufacturero para montar el

regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada

para asegurar el cilindro al carro, transportes, tablil-

leros, paredes, postes, o armazón. Nunca asegure

los cilindros a la mesa de trabajo o las piezas que

son parte del circuito de soldadura . Este puede ser

parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de

protección sobre la válvula si el regulador no

está conectado. Asegure y mueva los cilindros

utilizando un carro o transporte adecuado. Evite

el manejo brusco de los

MANTENIMIENTO DEL EQUIPO -- Equipo

defectuoso o mal mantenido puede

causar daño o muerte. Por lo tanto:

1. Siempre tenga personal cualicado para efec-

tuar l a instalación, diagnóstico, y mantenimiento

del equipo. No ejecute ningún trabajo eléctrico a

menos que usted esté cualicado para hacer el

trabajo.

2. Antes de dar mantenimiento en el interior de la

fuente de poder, desconecte la fuente de poder

del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones,

cable primario, y cualquier otra fuente de poder

en buen estado operacional. No opere ningún

equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga

el equipo lejos de cosas que generen calor como

hornos, también lugares húmedos como charcos

de agua , aceite o grasa, atmósferas corrosivas y

las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y

coverturas del equipo en su posición y en buenas

condiciones.

6. Use el equipo sólo para el propósito que fue

diseñado. No modique el equipo en ninguna

manera.

INFORMACION ADICIONAL DE SEGURI-

DAD -- Para más información sobre las

prácticas de seguridad de los equipos de

arco eléctrico para soldar y cortar, pregunte

a su suplidor por una copia de "Precautions

and Safe Practices for Arc Welding, Cutting

and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de

la American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

SECCION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura

de este folleto: Los Símbolos Sig-

nican ¡Atención! ¡Esté Alerta! Se

trata de su seguridad.

Signica riesgo inmediato que,

de no ser evadido, puede resultar

inmediatamente en serio daño

personal o la muerte.

Signica el riesgo de un peligro

potencial que puede resultar en

serio daño personal o la muerte.

Signica el posible riesgo que

puede resultar en menores daños

a la persona.

SECTION 1 SÉCURITÉ

1.3 Safety - French

INCENDIES ET EXPLOSIONS -- La

chaleur provenant des ammes ou de

l'arc peut provoquer un incendie. Le

laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combus-

tibles de l'aire de travail et recouvrez les matériaux

avec un revêtement protecteur ininammable. Les

matériaux combustibles incluent le bois, les vête-

ments, la sciure, le gaz et les liquides combustibles,

les solvants, les peintures et les revêtements, le

papier, etc.

2. Les étincelles et les projections de métal incan-

descent peuvent tomber dans les ssures dans

les planchers ou dans les ouvertures des murs et

déclencher un incendie couvant à l'étage inférieur

Assurez-vous que ces ouvertures sont bien protégées

des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra-

vail à chaud avant d'avoir complètement nettoyé la

surface de la pièce à traiter de façon à ce qu'il n'ait

aucune substance présente qui pourrait produire

des vapeurs inammables ou toxiques. N'exécutez

pas de travail à chaud sur des contenants fermés

car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction

d'incendie est disponible et prêt à servir, tel qu'un

tuyau d'arrosage, un seau d'eau, un seau de sable

ou un extincteur portatif. Assurez-vous d'être bien

instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de

l'équipement. Par exemple, un câble de soudage

surchargé peut surchauer et provoquer un in-

cendie.

6. Une fois les opérations terminées, inspectez l'aire de

travail pour assurer qu'aucune étincelle ou projec-

tion de métal incandescent ne risque de provoquer

un incendie ultérieurement. Employez des guetteurs

d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,

consultez le NFPA Standard 51B, "Fire Prevention in

Use of Cutting and Welding Processes", disponible au

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec

des pièces électriques ou les pièces

de mise à la terre sous tension peut

causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de

soudage c.a. dans un endroit humide, en espace

restreint ou si un danger de chute se pose.

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils

récapitulent les informations de précaution

provenant des références dans la section

des Informations de sécurité supplémentaires. Avant

de procéder à l'installation ou d'utiliser l'unité, assurez-

vous de lire et de suivre les précautions de sécurité ci-

dessous, dans les manuels, les ches d'information sur la

sécurité du matériel et sur les étiquettes, etc. Tout défaut

d'observer ces précautions de sécurité peut entraîner

des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de

soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et

exige l'emploi d'une protection auditive. L'arc, tout

comme le soleil, émet des rayons ultraviolets en plus

d'autre rayons qui peuvent causer des blessures à la

peau et les yeux. Le métal incandescent peut causer

des brûlures. Une formation reliée à l'usage des

processus et de l'équipement est essentielle pour

prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même

si vous devez porter un casque de soudeur, un écran

facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger

vos yeux, votre visage, votre cou et vos oreilles des

étincelles et des rayons de l'arc lors d'une opération

ou lorsque vous observez une opération. Avertissez

les personnes se trouvant à proximité de ne pas re-

garder l'arc et de ne pas s'exposer aux rayons de l'arc

électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord

et des chaussures montantes an de vous protéger des

rayons de l'arc, des étincelles et du métal incandescent,

en plus d'un casque de soudeur ou casquette pour

protéger vos cheveux. Il est également recommandé

de porter un tablier ininammable an de vous proté-

ger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,

les rebords de pantalons ou les poches. Il est recom-

mandé de garder boutonnés le col et les manches et

de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou

d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de

meulage du laitier. Les écailles de laitier incandescent

peuvent être projetées à des distances considérables.

Les personnes se trouvant à proximité doivent égale-

ment porter des lunettes étanches par dessus leur

lunettes de sécurité.

SECTION 1 SÉCURITÉ

3. Les soudeurs doivent suivre les procédures suivantes

pour minimiser l'exposition aux champs électriques

et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive

lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même

côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée

de votre corps.

LES VAPEURS ET LES GAZ -- peuvent

causer un malaise ou des dommages

corporels, plus particulièrement

dans les espaces restreints. Ne re-

spirez pas les vapeurs et les gaz. Le

gaz de protection risque de causer

l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate

dans l'aire de travail en maintenant une ventila-

tion naturelle ou à l'aide de moyens mécanique.

N'effectuez jamais de travaux de soudage, de

coupage ou de gougeage sur des matériaux tels que

l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,

le plomb, le berylliym ou le cadmium en l'absence

de moyens mécaniques de ventilation ecaces. Ne

respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une

opération de dégraissage ou de pulvérisation. Lor-

sque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher

la formation de phosgène ou d'autres gaz irritants,

tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la

gorge au cours d'une opération indique que la ven-

tilation n'est pas adéquate. Cessez votre travail an

de prendre les mesures nécessaires pour améliorer

la ventilation dans l'aire de travail. Ne poursuivez

pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page

suivante) pour des recommandations spéciques

concernant la ventilation.

1. Assurez-vous que le châssis de la source

d'alimentation est branché au système de mise à

la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de

terre électrique.

3. Branchez le câble de masse à la pièce à traiter et

assurez une bonne connexion an d'éviter le risque

de choc électrique mortel.

4. Utilisez toujours un équipement correctement

entretenu. Remplacez les câbles usés ou endom-

magés.

5. Veillez à garder votre environnement sec, incluant

les vêtements, l'aire de travail, les câbles, le porte-

électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé

de la pièce à traiter et des pièces de la mise à la

terre.

7. Si vous devez eectuer votre travail dans un espace

restreint ou humide, ne tenez vous pas directe-

ment sur le métal ou sur la terre; tenez-vous sur

des planches sèches ou une plate-forme isolée et

portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez

vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever

vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à

la page suivante) pour des recommandations

spéciques concernant les procédures de mise à

la terre. Ne pas confondre le câble de masse avec

le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ-

TIQUES — comportent un risque de

danger. Le courant électrique qui

passe dans n'importe quel conduc-

teur produit des champs électriques

et magnétiques localisés. Le soudage et le cou-

rant de coupage créent des champs électriques

et magnétiques autour des câbles de soudage et

l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une

opération de soudage. Les champs électriques et

magnétiques peuvent causer des ennuis pour cer-

tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour

la santé.

SECTION 1 SÉCURITÉ

1. Efforcez-vous de toujours confier les tâches

d'installation, de dépannage et d'entretien à un

personnel qualié. N'eectuez aucune réparation

électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à

l'intérieur de la source d'alimentation, débranchez

l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre,

les branchements, le cordon d'alimentation et la

source d'alimentation en bon état. N'utilisez ja-

mais un équipement s'il présente une défectuosité

quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez

l'équipement à l'écart de toute source de chaleur,

notamment des fours, de l'humidité, des aques

d'eau, de l'huile ou de la graisse, des atmosphères

corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et

tous les panneaux de la console et maintenez-les

en bon état.

6. Utilisez l'équipement conformément à son usage

prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELA-

TIVES À LA SÉCURITÉ -- Pour obtenir de

l'information supplémentaire sur les règles

de sécurité à observer pour l'équipement

de soudage à l'arc électrique et le coupage,

demandez un exemplaire du livret "Precau-

tions and Safe Practices for Arc Welding,

Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman-

dées et mises à votre disposition par l'American Welding

Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé

dans une opération de soudage ou de

coupage, dégage des vapeurs ou des

gaz contenant des chimiques consid-

éres par l'état de la Californie comme

étant une cause des malformations

congénitales et dans certains cas, du

cancer. (California Health & Safety

Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES --

La manipulation d'un cylindre, sans

observer les précautions nécessaires,

peut produire des fissures et un

échappement dangereux des gaz.

Une brisure soudaine du cylindre, de la soupape ou

du dispositif de surpression peut causer des bles-

sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation

sur les cylindres de gaz comprimé. N'utilisez jamais

d'adaptateur. Maintenez en bon état les tuyaux et

les raccords. Observez les instructions d'opération

du fabricant pour assembler le détendeur sur un

cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot

manuel, un châssis de roulement, un banc, un mur,

une colonne ou un support convenable. Ne xez

jamais un cylindre à un poste de travail ou toute autre

dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran-

ché, assurez-vous que le bouchon de protection de

la soupape est bien en place. Fixez et déplacez les

cylindres à l'aide d'un chariot manuel approprié.

Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des

ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling

of Compressed Gases in Cylinders", mis à votre dis-

position par le Compressed Gas Association, 1235

Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-

ment entretenu de façon défectueuse ou

inadéquate peut causer des blessures

graves ou mortelles. Par conséquent :

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES

Ce symbole, utilisé partout dans ce manuel,

signie "Attention" ! Soyez vigilant ! Votre

sécurité est en jeu.

Signie un danger immédiat. La situation peut

entraîner des blessures graves ou mortelles.

Signie un danger potentiel qui peut entraîner des

blessures graves ou mortelles.

Signie un danger qui peut entraîner des blessures

corporelles mineures.

DANGER

AVERTISSEMENT

ATTENTION

SECTION 2 INTERCONNECT DIAGRAM

2.0 ESAB m3 Manual Gas Control System

The Manual Gas Control System consists of several components: Plasma Control Interface (PCI), PCC-14 Plumbing Box, Power Supply (PS), Coolant Circulator (CC), Torch and customer CNC.

Dotted line denotes optional

PCC-TC OUT

PCC-TC IN

PCC-PA

PCC-PWR

PS-PA

PS-IC

CC-IC

PS-PWR

PCC-SHG

PCC-STG

PCC-VDR

PCC-CTL

PCI-CTL

PCI-VDR

PCC-CG

CC-TC IN

CC-TC OUT

PS-ES

PS-CC

PCI-ES

PCI-EP

PCI-CI

PCI-CC

SM-AS

PCI-AS

PT-36R

PCC-AR

REG-AR

REG-CG

REG-STG

REG-SHG

Customer CNC

Ext. 115/230VAC

Control Interface

PS Contol Cable

E-Stop

Cut Gas

Start Gas

Shield Gas

Power Cable

Pilot Arc Cable

Coolant Supply Hose

Coolant Return Hose

Argon Select

Mark / Cut

Switching Module

CC11

(Coolant Circulator)

Plasma Gas

Shield Gas

Power, Pilot Arc, Coolant

Air Curtain

PT36R

Torch

VDR

Air Curtain Control

PCC-14 Control

CC-11 Control Cable

POWER

DATA

LIQUID Optional

GAS

(Power Supply)

PCI

(Plasma Control Interface)

PCC-14

(Plasma Cutting Control)

0558009781-OR

Manual Gas Control System Interconnect Diagram

SECTION 2 INTERCONNECT DIAGRAM

PCC-14 Plumbing Box

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

The PCC-14 Plumbing Box is a Plasmarc Cutting Control used to connect the PT-36R

Plasma Torch to a remotely located EPP-201 or EPP-360 power supply system. The

PCC-14 includes high frequency starting circuits to eliminate starting problems

with long torches and to minimize high frequency interference with other customer

systems.

Weight: 41 lbs. (18.6 kg)

WARNING

THIS EQUIPMENT CAN BE HAZARDOUS IF NOT PROPERLY

OPERATED AND MAINTAINED.

READ AND UNDERSTAND ALL EQUIPMENT LITERATURE AND

WARNING LABELS BEFORE OPERATING THIS EQUIPMENT.

FOLLOW THESE INSTRUCTIONS TO PREVENT INJURY OR

PROPERTY DAMAGE.

YOU MUST COMPLY WITH LOCAL, STATE AND NATIONAL

ELECTRICAL AND SAFETY CODES.

ONLY TRAINED PERSONNEL SHOULD PERFORM MAINTENANCE

OR REPAIRS ON THIS EQUIPMENT.

3.0 General

3.1 Scope

The purpose of this manual is to provide the operator with all the information re-

quired to install and operate the Plumbing Box & Plasma Control Interface. Technical

reference material is also provided to assist in troubleshooting.

Specications: PCC-14 Plumbing Box

Plasma and Start Gases:

The PCC-14 may be used with Air , O2, N2, or H-35 (35% H2/65% Ar) at a maximum input pressure of 110 psig (7.6 bar).

It is recommended, but not required, that N2 be used as the start gas when using H-35. The ow rate of gas will depend on

the pressure set, the torch connected to the plumbing box, and the parts installed in the torch. Without a torch attached,

the maximum ow rate for these gases at 100 psig (6.9 bar) is about 1000 scfh (28.3 cu-m/h). The minimum acceptable

pressure for the start gas is 15 psig (1.0 bar); for the cut gas it is 24 psig (1.7 bar). Below these pressures the pressure switches

may not be satised.

Shield Gases:

The PCC-14 may be used with Air, N2, Ar, or CO2. The maximum pressure is for Air, N2, Ar, or CO2 is 110 psig (7.6 bar). This

will result in a ow of 250 scfh (7.1 cu-m/h) N2. See Graph 3-1. There is no pressure interlock on the shield gas.

Coolant:

The PCC-14 is designed for use with plasma torch coolant (ESAB P/N’s 156F05 or 0558004297). Maximum design pressure

is 200 psig (13.8 bar). Flow rates depend on the torch but typically vary from 0.9 to 2 gpm (4.1 to 9.1 l/m).

Install the PCC-14 Plumbing Box in an appropriate location so as to maintain adequate and unrestricted airow

into and out of the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions

in the base of this unit.

16.625"

(422.28 mm)

12.500"

(317.5 mm)

1.060"

(26.92 mm)

6.875"

(174.63 mm)

4.500"

(114.3 mm)

2.125"

(53.98 mm)

3.2 PCC-14 Plumbing Box Dimensions/ Mounting Hole Locations

13.0"

(330.2 mm)

15.4"

(391.2 mm)

18.8"

(477.5 mm)

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Gas Purging:

When switching between H-35 and an oxidizing gas (air or oxygen) it is recommended that the following procedure be

followed:

1. Turn o the gas.

2. Put the system into plasma gas test until line pressure is exhausted. If the start gas is being switched to or from

H-35, switch to start gas test until that line is exhausted as well.

3. Disconnect the old gas and connect a relatively inert gas such as nitrogen, argon, carbon dioxide, C-25, etc. Set the

pressure to 50 psig (3.5 bar) and purge each aected line for 60 seconds.

4. Then shut o the gas and exhaust each line per Step 2.

5. Connect the gas to be used. Set the pressure to recommended values for the cutting condition to be used, and

purge each aected line for 15 seconds per 25 ft. (7.6 m) of line.

Flashback arrestors are required to prevent re from propagating

back to the gas supply through lines carrying oxygen or fuel gases.

Use AWG 2/0 power cable to carry electrode current from the power

source to the PCC-14. See section 9.0 for additional cables.

Avoid using the same supply lines for both oxygen and air if oil may

be mixed with the air. Oil in the presence of 100% oxygen can be

highly ammable.

Failure to observe above cautions may result in personal injury and /

or damage to the equipment.

CAUTION

Note:

The expected life of the internal exible hoses is 10 years. Replace them earlier if cracking or brittleness is noted.

Note:

When marking, make sure the start gas line is pressurized to avoid pressure switch errors.

Marking option

With the optional Marking Module installed, the PCC-14 will allow you to switch the cut gas to Argon for plate marking. With

the Marking Module installed, Argon gas input to the Marking Module is 125 psig (8.6 Bar).

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

250 (7.1)

240 (6.8)

230 (6.5)

220 (6.2)

210 (5.9)

200 (5.7)

190 (5.4)

180 (5.1)

170 (4.8)

160 (4.5)

150 (4.2)

140 (4.0)

130 (3.7)

120 (3.4)

110 (3.1)

100 (2.8)

90 (2.5)

80 (2.3)

70 (2.0)

60 (1.7)

50 (1.4)

40 (1.1)

30 (0.8)

20 (0.6)

10 (0.3)

0 10 20 30 40 50 60 70 80 90 100 110 120 130

(0.7) (1.4) (2.1) (2.8) (3.5) (4.1) (4.8) (5.5) (6.2) (6.9) (7.6) (8.3) (9.0)

PSIG (BAR) Pressure Setting to 0.052 in. (1.32 mm) Diameter Orice

Shield Gas Flow SCFH (CU-M/H) N

Graph 3-1 - Gas Pressure / Flow

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

3.3 Plumbing Box Spark Gap Adjustment

1. Disconnect input power to power source.

2. Remove access cover from spark gap opening.

3. Check / set to recommended spark gap of 0.040” (1 mm).

4. Replace cover.

Spark Gap

Access Cover

Spark Gap

ELECTRICITY CAN KILL!

HIGH VOLTAGE CAN BE PRESENT BEHIND COVER PLATE. DO NOT OP

ERATE WITHOUT COVER PLATE IN PLACE. BEFORE REMOVING COVER

PLATE OR PERFORMING ANY MAINTENANCE OR ASSEMBLY OF THIS

EQUIPMENT, ENSURE THE POWER SOURCE IS TURNED OFF AND DIS

CONNECTED.

WARNING

Only qualied maintenance personnel should repair and maintain

this equipment.

Unit is NOT designed for use in rain or snow. Damage to equipment

may result.

Unit is to be lifted only by the handle provided . Failure to do so may

result in damage to the equipment.

CAUTION

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX

BEFORE MAKING ANY CONNECTIONS TO THE PCC14.

WARNING

3.3.1 VDR Adjustment

VDR

Cover Plate

The VDR is set from the factory at a ratio of 25:1 for cutting operations and automatically adjusts to 12.5:1 for

marking operations. As shown, access to the VDR can be made by removing the VDR cover plate. If not using an

ESAB CNC, adjustment may be required. Please contact a qualied ESAB service technician for adjustment pro-

cedures. Contact info can be located on the back page of this manual.

VDR adjustment screw

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Connection Locations Inside Plumbing Box

3.4 Plumbing Box Connections

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Plasma Gas Hose From Torch

Shield Gas Hose From Torch

Pilot Arc Cable

From Power Supply

Pilot Arc Cable From Torch

Power / Coolant Supply

Hose From Torch

Power / Coolant Return

Hose From Torch

Coolant Supply Hose

Power Cables

Coolant Return Hose

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX BEFORE

MAKING ANY CONNECTIONS TO THE POWER SUPPLY.

DISCONNECT CURRENT SUPPLY AT WALL DISCONNECT BEFORE SERVICING

PLUMBING BOX.

• DO NOT OPERATE PLUMBING BOX WITH ANY COVERS REMOVED / OPEN.

• DO NOT TOUCH ANY TORCH FRONTEND PARTS WITH POWER ON.

• DO NOT ATTEMPT TO SERVICE UNLESS POWER HAS BEEN DISCONNECTED

AT THE WALL.

WARNING

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

1. Torch connections are rst made in the PCC-14 plumbing box. Remove the cover of the plumbing box to access input

and output connections . For both manual and mechanized torch applications, pass the torch lines through the

openings in the front of plumbing box and make connections as shown.

3.5 EPP-201 / EPP-360 Torch Connections to Plumbing Box

ELECTRIC SHOCK CAN KILL!

TURN OFF PRIMARY INPUT POWER AT THE WALL DISCONNECT BOX

BEFORE MAKING ANY CONNECTIONS TO THE PCC14.

WARNING

Coolant Supply

(Electrode Cable)

Coolant Return

(Electrode Cable)

Plasma Gas

Pilot Arc

Shield Gas

1 Shield Gas Hose

2 Electrode Cable / Coolant Return Hose

3 Plasma Gas Hose

4 Electrode Cable / Coolant Supply Hose

5 Pilot Arc Cable

Lines from torch

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Chassis Ground

Note:

Chassis ground to be connected from PCC-14 Plumbing Box to either the cutting machine or to the chassis

of the power supply using the supplied ground wire.

(Ensure star washer is installed on the ground stud for the PCC-14 connections).

Hose connections should be wrench-tight.

Ensure plug of the switch lead is rmly locked in place. Then close hinged cover.

Interconnection Diagram - EPP-201/360

Electrode (-)

Pilot Arc (+)

Electrode (-)

Pilot Arc (+)

SECTION 3 PCC14 PLUMBING BOX DESCRIPTION / INSTALLATION

Connections to the Power Supply

1. A power output cable attaches to a large bolted connection labeled “Electrode”.

2. The Pilot Arc cable connects to a small threaded stud labeled “Pilot Arc”.

3. The Plasma Control Interface connects to the power supply. The PCC-14 Plumbing Box control cable connects to the

Plasma Control Interface.

4. A work cable connects to the "Work" terminal on the front-lower-left of the console. The other end is attached to the

cutting table or work piece.

Connections to the rear of the Plumbing Box

1. The Start, Cut & Shield gas hoses from the regulator panel attach to the rear of the plumbing box.

2. The Plumbing Box Control cable from the Plasma Control Interface connects to the amphenol receptacle labeled

“CONTROL CABLE FROM POWER SOURCE”.

Both power cables, the pilot arc cable and both coolant hoses enter the plumbing box from the rear and are connected

internally.

Connections to the Coolant Circulator

1. The coolant supply and return lines connect to the supply and return ttings on the coolant circulator.

Plasma Control Interface

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

Weight : 17.0 lbs. (7.7 kg)

This unit is an integral component of the m3 Manual Gas Control Plasma

system used by an external controller (e.g. CNC) to interface with the PCC-

14 Plumbing Box. It controls all the sequencing required for handling the

plasma cutting/marking operation leaving the external controller with a

simple interface to the Plasma Control Interface (PCI).

3.6 General

3.7 Scope

The purpose of this manual is to provide the operator with all the informa-

tion required to install and operate the Plumbing Box & Plasma Control

Interface. Technical reference material is also provided to assist in trouble-

shooting.

Specications: Plasma Control Interface

15.50”

(393.7 mm)

6.59”

(167.4 mm)

13.67”

(347.2 mm)

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

Note:

Chassis must be connected

to the machine ground.

ITEM Description

A ON/OFF SWITCH

B POWER INPUT

C MODE SELECT

D READY/FAULT INDICATOR

E PILOT ARC

F ARGON SELECT OUTPUT

G CAN INPUT

H VDR INPUT

J GROUND STUD

A C D

J H G

3.8 Plasma Control Interface Connections

A. On/O Switch – This switch controls the input power on/o to the PCI.

B. Power Input – Connect the 120/230VAC supply to this connector.

C. Mode Select - The PCI can be operated in four dierent modes which can be set using the “MODE SELECT” switch.

1. Operate – Used for normal cutting/marking operation.

2. Start Gas Test – Used for testing and setting the start gas pressure. The pressure value can be monitored on the

“Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value

can be monitored on the “Shield Gas” gauge display.

3. Cut Gas Test - Used for testing and setting the cutting gas pressure. The pressure value can be monitored on the

“Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value

can be monitored on the “Shield Gas” gauge display.

4. Mark Gas Test (Optional) - Used for testing and setting the argon gas pressure. The pressure value can be moni-

tored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output

and it’s value can be monitored on the “Shield Gas” gauge display.

D. Ready/Fault Indicator – This LED indicates the dierent fault modes encountered by the PCI. Refer to “Plasma Con-

trol Interface STATUS Codes” section for more details.

E. Pilot Arc - The Pilot Arc High/Low switch on the unit is set based on the type of material being cut. Depending on

the material to be cut, the position of this switch is obtained from the PCC-14 Cut Data manual provided with the

plasma system.

F. Argon Select Output – This connector is used to select the argon solenoid for plasma gas when marking.

G. Can Input – Not used

H. VDR Input – Supplies the arc voltage value divided with a ratio of 25:1 for cutting and 12.5:1 for marking to the PCI.

From the PCI this value is supplied to the external controller for torch height control.

J. Ground Stud – Connect the machine chassis to this stud.

FRONT VIEW

ELECTRIC SHOCK CAN KILL!

SHUT OFF POWER AT THE POWER SUPPLY BEFORE ATTEMPTING ANY

MAINTENANCE.

WARNING

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

BA C

H G F

ITEM Description

A PS

B E-STOP

C FUSE 1A

D FUSE 2A

E FUSE 2A

F AIR CURTAIN/BUBBLE MUFFLER

A. PS – Connects directly to the EPP-201/360 power supply. It carries all the control signals for the power supply.

B. E-STOP – Provides interconnection between the E-STOP actuator on the power supply and the customer’s E-STOP

control circuit. See section 3.9 Typical / Recommended ESTOP Connection for typical wiring schematic.

C. Fuse 1A – This fuse is rated at 1 Amp and is for protecting the internal transformer in the PCI.

D. Fuse 2A – This fuse is rated at 2 Amp and is for protecting the internal transformer in the PCI.

E. Fuse 2A – This fuse is rated at 2 Amp and is for protecting the internal transformer in the PCI.

F. Air curtain/Bubble Muer (Optional) – Connects with an ESAB supplied Air Curtain or Bubble Mu er unit.

G. PCC-14 – Connects with the PCC-14 Plumbing Box.

H. CNC – Connects to the external CNC.

REAR VIEW

PIN Function

A Not Used

B Coolant Flow SW

C Mark Mode

D Chassis

E E-Stop to PS– 24vac

F E-Stop to PS– 24vac

G 24 VDC to PS

H Master Select

J Current Ref Common

K Coolant Level SW

L Current Reference

M Plasma Start

N Pilot Ref Common

P Main Arc On

Q Pilot Arc Select Bit 1

R 120 VAC from PS

S Pilot Arc Select Bit 0

T Current Range Select

V Upslope Select

W Power Supply Fault

Y Main Arc Actual Current

Z 120 VAC Common

PIN Function

A E-Stop to CNC

B E-Stop to CNC

PIN Function

A 24 VDC to Pressure SW

B Pressure SW Input

C Not Used

D Not Used

E Start Gas ON

F Solenoid Common

G Cut Gas ON

H Shield Gas ON

J Solenoid 2 Common

M Plasma HF ON

N HF Common

Not Used

PIN Function

A Cycle Start

B Mark Mode

C 24 VDC to CNC

D Fault

E Motion Enable

F CNC Common

G Remote Current Ref

H Remote Current COM

J E-stop to PS

K E-stop to PS

L VDR -

M VDR +

N E-stop to CNC

P E-stop to CNC

R Preow

E-STOPPS

CNC

PCC-14

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

The external controller/CNC connector pin out is described below:

CNC:

A) Cycle Start - Digital input to the PCI which starts the cutting operation when the mode select is in Operate setting.

B) Mark Mode - Digital input to the PCI which enables marking mode on the PCI and the Power Supply.

C) 24VDC to CNC – Supplied to the CNC for Cycle Start and Mark Mode inputs.

D) Fault - Digital output to the CNC reporting a fault with the plasma system.

E) Motion Enable - Digital output to the CNC conrming arc transfer.

F) CNC Common - Voltage supplied from the CNC for fault and motion enable.

G) Remote Current Ref - 0-10 VDC Analog voltage input to PCI which corresponds to 0-360 Amps on the Power Supply.

H) Remote Current Com - DC common for analog voltage.

J) ESTOP to PS - 24 VAC supply to dry contact on emergency stop circuit on CNC. Used to report emergency stop on

external controller or machine to the Power Supply.

K) ESTOP to PS - 24 VAC return on dry contact on emergency stop circuit on CNC. Used to report emergency stop on

external controller to the Power Supply.

L) VDR(-) - Arc voltage feedback to the torch height control circuit on CNC.

M) VDR(+) - Arc voltage common to the torch height control circuit on CNC.

N) ESTOP to CNC - Dry contact from Power Supply. Used to report emergency stop on Power Supply to external con-

troller.

P) ESTOP to CNC - Dry contact from Power Supply. Used to report emergency stop on Power Supply to external con-

troller.

R) Preow - Unit is switched to preow to purge gas lines.

E-STOP

3.9 Typical / Recommended ESTOP Connection

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

3.10 Control Sequence



  



  



      

























      

3.11 Plasma Control Interface Mounting Hole Locations

15.50"

(393.7 mm)

14.50"

(368.3 mm)

7.25"

(184.2 mm)

1.75"

(44.5 mm)

6.50"

(165.1 mm)

3.50"

(88.9 mm)

4 X Ø 0.28” (7.1 mm)

Install the Plasma Control Interface in an appropriate location so as to maintain adequate and unrestricted airow into and

out of the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions in the base of this unit.

SECTION 3 Plasma Control InterfaCe DesCrIPtIon / InstallatIon

STATUS Code Label List:

The STATUS code is determined by counting the number of intermittent “ON” ashes of the Ready/Fault LED on the

Plasma Control Interface.

# of LED

ashes

Fault Description/Solution

1 Power Supply Fault Fault from power supply, check the power supply front panel for details.

2 Pressure Switch Fault Pressure switch inside PCC-14 is not closed, either due to low gas pres-

sure or a bad pressure switch. There are two pressure switches for start

and cut gas which are in series. Both lines must be at the recommended

PS-1 for the switches to stay closed.

3 Coolant Flow Fault No coolant ow. Check CC-11.

4 Coolant Level Fault Need to rell coolant to CC-11.

5 Ignition Fault Arc was not able to transfer.

6 Arc On Lost Fault Arc is lost while cutting.

3.12 Plasma Control Interface STATUS Codes

Ready/Fault LED

WHEN SUPPLYING POWER TO THE PLASMA CONTROL INTERFACE

BOX, FOR SAFE OPERATION, IT IS STRONGLY ADVISED TO TURN OFF

POWER TO THE PLASMA CONTROL INTERFACE BOX WHENEVER AN

EMERGENCY STOP IS ENCOUNTERED ON THE SYSTEM.

WARNING

SECTION 4 MAINTENANCE

4.0 Maintenance

Maintenance work must be performed by an experienced person. Do not permit untrained persons to inspect, clean, or

lubricate this equipment.

On a regular basis, check cylinder valves, regulators, hoses, and gas connections for leaks using a soap solution or a leak

test solution.

Keep the equipment dry, free of oil and grease, and protected at all times from damage by hot metal and sparks.

Periodically, remove the covers from the equipment and, wearing proper eye protection, blow accumulated dust and dirt

from the air passages and the interior components using clean low-pressure air. It is imperative that the air passages to the

interior of the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air.

The length of time between cleaning will depend on the location of the unit and the amount of dust in the atmosphere.

After cleaning with low-pressure air, check for and tighten any loose hardware, including all electrical connections. Check

for frayed and/or cracked insulation on all power cables and replace if necessary.

ELECTRIC SHOCK CAN KILL! ENSURE THE LINE WALL DIS

CONNECT SWITCH OR CIRCUIT BREAKER IS OPEN BEFORE AT

TEMPTING ANY INSPECTION OR WORK ON THE INSIDE OF THE

PLUMBING BOX. ALWAYS WEAR SAFETY GOGGLES WITH SIDE

SHIELDS WHEN BLOWING OUT THE EQUIPMENT WITH LOW

PRESSURE AIR.

ELECTRIC SHOCK CAN KILL! FAILURE TO REPLACE WORN OR

DAMAGED CABLES MAY RESULT IN A BARE CABLE TOUCHING

A GROUNDED SURFACE. THE RESULTING ELECTRICAL ARC MAY

DAMAGE THE UNPROTECTED EYES AND WILL PRESENT A SE

RIOUS FIRE HAZARD. BODILY CONTACT WITH A BARE CABLE,

CONNECTOR, OR CONDUCTOR MAY RESULT IN SEVERE ELEC

TRICAL SHOCK, CAUSING SERIOUS BURNS OR DEATH.

4.1 General

4.2 Cleaning

WARNING

SECTION 4 MAINTENANCE

The Marking Module option is installed external to the PCC-14 Plumbing box and is controlled from the PCI Plasma Control

Interface. This module will route the normal cut gas to the Plumbing Box until the operator selects a Marking operation.

When this happens, the PCI Interface will switch the cut gas sent to the torch to Argon for marking operations. The module

is supplied with 24 VAC from the PCI for operation

Gas connection:

Cut gas and Argon are connected as in the photo below. The gas output is sent to the Plumbing Box.

Electrical connection:

A three pin cable is connected from the Marking Module to the PCI to switch the gas supplied to the torch. By default the

Marking Module will pass the cut gas to the Plumbing Box. This cable is supplied with the module at installation. This cable

routes 24VAC to the Marking Module from the PCI during marking operations.

SECTION 5 MARKING MODULE

5.0 Marking Module

Gas out to PCC-14

Cut Gas

Argon

PCI connection

SECTION 5 MARKING MODULE

5.1 Marking Module Mounting Hole Locations

Install the Marking Module in an appropriate location so as to maintain adequate and unrestricted airow into and out of

the cabinetry. For permanent mounting refer to the gure below for mounting hole dimensions in the base of this unit.

TYP

(4) PLCS

.50

TYP

.25

2.87

1.50

SECTION 6 PT36R PLASMA TORCH

6.0 PT-36R Plasma Torch

Note:

See appropriate PT-36R Plasma Torch equipment literature (0558006829) for operating conditions and

instruction information.

Torch

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

PT-36R m3

Plasma Torch

1.4m (4.5’) 0558006811

1.8m (6’) 0558006812

2.2m (7.2’) 0558006781

3.6m (12’) 0558006813

4.3m (14’)

mini-bevel

0558006814

4.6m (15’) 0558006815

5.2m (17’) 0558006816

6.1m (20’) 0558006782

7.6m (25’) 0558006817

NOTE:

Clamp only on insulated torch sleeve not less than

1.25" (31.7mm) from the torch end of sleeve.

SECTION 6 PT36R PLASMA TORCH

6.1 PT-36R Technical Specications

6.2 Gas Specications

2.00"

(50.8mm)

7.54"

(191.5mm)

6.17"

(156.7mm)

10.50" (266.7mm)

Length of Sleeve

9.13"

(231.9mm)

Typical requirements for ow delivered at 125 psig: Maximum Plasma Gas: 300 scfh Maximum Shield Gas: 350 scfh

Argon 125 PSI (8,6 bar) with 0.25” NPT, 99.995% purity, Filtered to 25 microns

Nitrogen 125 PSI (8,6 bar) with 0.25” NPT, 99.99% purity, Filtered to 25 microns

Oxygen 125 PSI (8,6 bar) with 0.25” NPT, 99.5% purity, Filtered to 25 microns

H-35 (Argon/Hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns

Methane 75 PSI (5,2 bar) with 0.25” NPT, 93% purity, Filtered to 25 microns

Compressed Air

(Clean, dry & oil-free shop

air)

80 PSI @ 1200cfh (5,5 bar @ 35 m

h), Filtered to 25 microns

Note:

These do not represent actual ows used in any condition, but are the design maximums of the system.

SECTION 6 PT36R PLASMA TORCH

6.3 Recommended Regulators

Liquid Cylinder Service:

: R-76-150-540LC ................................................................................................................P/N 19777

: R-76-150-580LC ................................................................................................................P/N 19977

High Pressure Cylinder Service:

: R-77-150-540 .................................................................................................................. P/N 998337

Ar & N

: R-77-150-580 .......................................................................................................... P/N 998344

& CH

: R-77-150-350 ..................................................................................................... P/N 998342

Industrial Air : R-77-150-590 ............................................................................................ P/N 998348

Station/Pipeline Service:

: R-76-150-024 .....................................................................................................................P/N 19151

Ar & N

: R-76-150-034 .............................................................................................................P/N 19155

Air, H

, & CH

: R-6703 .............................................................................................................P/N 22236

6.4 PT-36R Torch Technical Specications

Type: Water cooled, Dual gas, mechanized plasmarc cutting torch

Current Rating: 750 Amps @ 100% duty cycle

Mounting Diameter: 2 inches (50.8 mm)

Length of Torch without leads: 18.5 inches (47 cm)

IEC 60974-7 Voltage Rating: 500 volts peak

Striking Voltage (maximum value of HI-FREQUENCY voltage): 8000 vac

Minimum Coolant Flowrate: 1.0 USGPM (3.8 L/min)

Minimum Operating Coolant Pressure at Inlet: 175 psig (12.1 bars)

Maximum Operating Coolant Pressure at Inlet: 200 psig (13.8 bars)

Minimum Acceptable Rating of Coolant Recirculator:

16,830 BTU/HR (4.9 kW) at High Coolant Temperature - Ambient = 45

F (25

C) and 1.6 USGPM (6 L/min)

Maximum Safe Gas Pressures at Inlets to Torch: 125 psig (8.6 bars)

Recommended Input Pressure: 125 psig (8.6 bars)

Safety Interlocks: This torch is intended for use with ESAB Plasmarc cutting systems and controls employing a water ow

switch on the coolant return line from the torch. Removal of the nozzle retaining cup to service the torch breaks the

coolant return path.

SECTION 6 PT36R PLASMA TORCH

SECTION 7 COOLANT CIRCULATOR

7.0 Coolant Circulator

Note:

See appropriate Coolant Circulator equipment literature (0558007523) for operating conditions and

instruction information.

7.1 Specications

Dimensions: 34.00” high (864 mm) x 21.75” wide (552 mm) x 28.00 deep (711 mm)

Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg)

Pump Type: Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.),

CW rotation as viewed from nameplate.

Radiator Type: Copper tubing, aluminum nned air-to-water type with galvanized steel frame.

AC Input Voltages

50Hz, 1 Phase Input Power 60Hz, 1 Phase Input Power

200 / 230 / 400 / 460 / 575 V., + / - 10%

AC Input Amperage 9 / 8 / 5 / 4 / 3 Amperes

Pump Capacity

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

1.60 gpm at 175 psi

(6.0 l/min at 12 bars)

Cooling Capacity @ 1.60 gpm (6.0 l/min) 16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts)

at 45° F (25° C) temperature dierence between high coolant temperature and ambient air temperature using ESAB cool-

ant P/N 0558004297 (25% propylene glycol / 75% distilled water).

Max. Delivery Pressure 175 psig (12 bars)

Reservoir Capacity 4 gallons (15.2 liters)

SECTION 7 COOLANT CIRCULATOR

7.2 Installation

Install the CC-11 in an appropriate location so as to maintain adequate and unrestricted airow into and out of the cabine-

try. For permanent mounting refer to Figure 6.1 for mounting hole dimensions in the base of this unit.

Figure 6.1 Mounting Dimensions

0.531” (13.5 mm) diameter hole, typical, 8 places

19.50”

(495 mm)

1.69”

(43 mm)

3.42”

(87 mm)

17.78”

(452 mm)

3.42”

(87 mm)

SECTION 7 COOLANT CIRCULATOR

Figure 6.2 Voltage Links

7.3 Input Power Connections

A 3-conductor power cable suitable to meet the required input power must be installed. The cable must have 0.25" (6.4

mm) ring lugs installed on the machine end. Connect the power leads to the L1 and L2 terminals on TB1 Input Power Ter-

minal Board and the ground lead to the ground lug on the back of the fan support panel. A strain relief tting is provided

to feed a power cable through the rear panel of the cabinet. Refer to Figure 6.2 for proper Input Voltage Link placement,

Figure 6.2 shows link in place for 460 volt input. Electrical installation must be in accordance with local electrical codes for

this type of equipment.

SECTION 7 COOLANT CIRCULATOR

NOTE:

Voltage link is shipped in

this location which is for

575 volt operation.

CAUTION

Voltage link MUST be moved if equipment is operated at any volt-

age other than 575V. Failure to move voltage link to location that

matches input voltage can result in damage to equipment.

Figure 6.3 Input Connection Diagram

Typical Installation -

User-supplied single phase fused power disconnect box with

receptacle and plug

Input Power Cable

ELECTRIC SHOCK CAN KILL! BEFORE MAKING ELECTRICAL INPUT

CONNECTIONS TO THE POWER SOURCE, "MACHINERY LOCKOUT

PROCEDURES" SHOULD BE EMPLOYED. IF THE CONNECTIONS ARE

TO BE MADE FROM A LINE DISCONNECT SWITCH, PLACE THE SWITCH

IN THE OFF POSITION AND PADLOCK IT TO PREVENT INADVERTENT

TRIPPING. IF THE CONNECTION IS MADE FROM A FUSE BOX, REMOVE

THE CORRESPONDING FUSES AND PADLOCK THE BOX COVER. IF IT IS

NOT POSSIBLE TO USE PADLOCKS, ATTACH A RED TAG TO THE LINE

DISCONNECT SWITCH OR FUSE BOX WARNING OTHERS THAT THE

CIRCUIT IS BEING WORKED ON.

WARNING

SECTION 7 COOLANT CIRCULATOR

SECTION 8 POWER SUPPLIES

8.0 EPP-201 Power Supply

Note:

See appropriate EPP-201 Power Supply equipment literature (0558007900) for operating conditions and

instruction information.

8.1 Dimensions and Weight

40.75”

(1035 mm)

47.25”

(1200 mm)

23.75”

(603.25 mm)

Weight = 492 kg (1085 lbs.)

SECTION 8 POWER SUPPLIES

8.2 Input Power Connection

ELECTRIC SHOCK CAN KILL!

PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK.

BEFORE ANY CONNECTIONS ARE MADE INSIDE THE MACHINE, OPEN

THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.

WARNING

Primary Power

EPP-201 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit

breakers in accordance to local or state regulations.

Dedicated power line may be necessary.

EPP-201 is equipped with line voltage compensation but to avoid

impaired performance due to an overloaded circuit, a dedicated

power line may be required.

NOTICE

Input current =

(V arc) x (I arc) x 0.73

(V line)

Recommended input conductor and line fuse sizes:

* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than

three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

To estimate the input current for a wide range of output conditions, use the formula below.

Input at Rated Load Input and Ground

conductor* CU/

(AWG)

Time delay

Fuse size

(amperes)

Volts Amperes

380 60 35 (2/0)* 100

400 57 35 (2/0)* 100

460 51 35 (2/0)* 100

575 41 35 (2/0)* 60

Rated load is output of 200A at 160V

SECTION 8 POWER SUPPLIES

SECTION 9 POWER SUPPLIES

9.0 EPP-360 Power Supply

Note:

See appropriate EPP-360 Power Supply equipment literature (0558007676) for operating conditions and

instruction information.

9.1 Dimensions and Weight

40.75”

(1035 mm)

47.25”

(1200 mm)

23.75”

(603.25 mm)

SECTION 9 POWER SUPPLIES

Weight = 492 kg (1085 lbs.)

9.2 Input Power Connection

ELECTRIC SHOCK CAN KILL!

PROVIDE MAXIMUM PROTECTION AGAINST ELECTRICAL SHOCK.

BEFORE ANY CONNECTIONS ARE MADE INSIDE THE MACHINE, OPEN

THE LINE WALL DISCONNECT SWITCH TO TURN POWER OFF.

WARNING

Primary Power

EPP-360 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit

breakers in accordance to local or state regulations.

Dedicated power line may be necessary.

EPP-360 is equipped with line voltage compensation but to avoid

impaired performance due to an overloaded circuit, a dedicated

power line may be required.

NOTICE

Input current =

(V arc) x (I arc) x 0.73

(V line)

***Recommended input conductor and line fuse sizes:***

* Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than

three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above.

To estimate the input current for a wide range of output conditions, use the formula below.

Rated load is output of 360A at 200V

SECTION 9 POWER SUPPLIES

Input at Rated Load Input and Ground

conductor* CU/

(AWG)

Time delay Fuse size

(amperes)

Volts Amperes

380 140 50 (1) 200

400 132 35 (2) 150 slo-blo +10%/-0

460 115 35 (2)* 150

575 92 35 (2)* 125

SECTION 9 POWER SUPPLIES

SECTION 10 HOSES AND CABLES

10.0 HOSES AND CABLES

Hose

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

Air / Shield Gas Hose

1.5m (5’) 0558006200

5m (16’) 0558006201

6m (19’) 0558006202

7m (23’) 0558006203

8m (26’) 0558006204

9m (30’) 0558006205

10m (33’) 0558006206

11m (36’) 0558006207

12m (39’) 0558006208

13m (43’) 0558006209

14m (46’) 0558006210

15m (49’) 0558006211

16m (52’) 0558006212

17m (56’) 0558006213

18m (59’) 0558006214

19m (62’) 0558006215

20m (66’) 0558006216

30m (98') 0558008813

2.3m (7.5’) 0558007315

4m (13’) 0558008359

0.5m (1.7’) 0558008447

1m (3.3’) 0558008448

3m (10’) 0558008449

10.1 Hoses

SECTION 10 HOSES AND CABLES

Hose

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

N2 / PG-1 Hose

1.5m (5’) 0558006089

5m (16’) 0558006090

6m (19’) 0558006091

7m (23’) 0558006092

8m (26’) 0558006093

9m (30’) 0558006094

10m (33’) 0558006095

11m (36’) 0558006096

12m (39’) 0558006097

13m (43’) 0558006098

14m (46’) 0558006099

15m (49’) 0558006100

16m (52’) 0558006101

17m (56’) 0558006102

18m (59’) 0558006103

19m (62’) 0558006104

20m (66’) 0558006105

30m (98') 0558008814

2.3m (7.5’) 0558007313

4m (13’) 0558008357

0.5m (1.7’) 0558008441

1m (3.3’) 0558008442

3m (10’) 0558008443

SECTION 10 HOSES AND CABLES

Hose

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

O2 / PG-2 Hose

1.5m (5’) 0558006106

5m (16’) 0558006107

6m (19’) 0558006108

7m (23’) 0558006109

8m (26’) 0558006110

9m (30’) 0558006111

10m (33’) 0558006112

11m (36’) 0558006113

12m (39’) 0558006114

13m (43’) 0558006115

14m (46’) 0558006116

15m (49’) 0558006117

16m (52’) 0558006118

17m (56’) 0558006119

18m (59’) 0558006120

19m (62’) 0558006121

20m (66’) 0558006122

30m (98') 0558008815

2.3m (7.5’) 0558007314

4m (13’) 0558008358

0.5m (1.7’) 0558008444

1m (3.3’) 0558008445

3m (10’) 0558008446

SECTION 10 HOSES AND CABLES

Hose

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

H35 / CH4 Hose

0.5m (1.7’) 0558008371

1m (3.3’) 0558008372

2.3m (7.5’) 0558008373

3m (10’) 0558008374

4m (13’) 0558008375

5m (16’) 0558008376

6m (19’) 0558008377

7m (23’) 0558008378

8m (26’) 0558008379

9m (30’) 0558008380

10m (33’) 0558008381

11m (36’) 0558008382

12m (39’) 0558008383

13m (43’) 0558008384

14m (46’) 0558008385

15m (49’) 0558008386

16m (52’) 0558008387

17m (56’) 0558008388

Argon Hose

5m (16’) 0558008390

6m (19’) 0558008391

7m (23’) 0558008392

8m (26’) 0558008393

9m (30’) 0558008394

10m (33’) 0558008395

11m (36’) 0558008396

12m (39’) 0558008397

13m (43’) 0558008398

14m (46’) 0558008399

15m (49’) 0558008400

16m (52’) 0558008401

17m (56’) 0558008402

40m (132’) 0558008816

SECTION 10 HOSES AND CABLES

Hose

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

Coolant Hose

10.1m (33’) 0558005563

15.2m (50’) 0558005564

20.1m (66’) 0558005565

35.1m (115’) 0558005566

50.3m (165’) 0558005567

4.9m (16’) 0558005246

29.9m (98’) 0558005247

39.9m (131’) 0558005248

59.7m (196’) 0558005249

Air Curtain Hose

1.4m (4.5’) 0558004841

1.8m (6’) 0558004842

3.6m (12’) 0558004843

4.6m (15’) 0558004844

5.2m (17’) 0558004845

7.6m (25’) 0558004846

6m (20’) 0558006865

7m (23’) 0558008502

8m (26’) 0558008503

9m (30’) 0558008504

10m (33’) 0558008505

11m (36’) 0558008506

12m (40’) 0558008507

SECTION 10 HOSES AND CABLES

Cable

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

E-Stop Cable

( E-Stop )

7.6m (25’) 0558009621

10m (33’) 0558009622

15m (50’) 0558009623

22m (75’) 0558009624

30m (100’) 0558009625

40m (131’) 0558009626

45m (150’) 0558009627

50m (164’) 0558009628

60m (200’) 0558009629

Air Curtain / Bubble Mu er

Control Cable ( optional )

2.1m (6.75’) 0558009771

5m (16.5’) 0558009772

10m (33') 0558009773

VDR Cable ( VDR )

Mark Solenoid Cable ( ARG )

0.5m (1.7’) 0560947067

1.5m (5’) 0560947075

3m (10’) 0560947076

4m (13’) 0560947068

5m (16’) 0560947077

6m (19’) 0560947069

6.1m (20') 0560946782

7m (23’) 0560947070

8m (26’) 0560947071

9m (30’) 0560947072

10m (33’) 0560947078

15m (49’) 0560947073

20m (66’) 0560947074

25m (82') 0560946758

10.2 Cables

SECTION 10 HOSES AND CABLES

Cable

Description

Available

Lengths

m ( ft. )

ESAB

Part Number

PCC-14 Interface Cable

( PCC-14 )

0.9m (3’) 2238279

1.8m (6’) 2237958

3.0m (10’) 0558009510

4.0m (13’) 0558009511

4.9m (16’) 0558009512

6.1m (20’) 0558009513

7.0m (23’) 0558009514

7.9m (26’) 0558009515

9.1m (30’) 0558009516

10.1m (33’) 0558009517

15.2m (50’) 2237959

22.9m (75’) 2237960

30.5m (100’) 2237934

38.1m (125’) 2237935

45.7m (150’) 2237936

53.3m (175’) 2237937

61.0m (200’) 2237938

115 / 230 VAC Input Power Cable

( POWER )

5m (16’) 0558008261

10m (33’) 0558008262

15m (49') 0558008810

20m (66’) 0558008811

25m (82') 0558008812

CNC Cable

( CNC )

4.6m (15’) 0560936665

7.6m (25’) 0560936666

15m (50’) 0560936667

22.8m (75’) 0560936668

25m (82’) 0560948159

EPP Control Cable

( PS-1 )

7.6m (25’) 0558004651

10m (33’) 0558008360

15m (50’) 0558004652

22.8m (75’) 0558004653

30.5m (100’) 0558004654

40m (131’) 0558003978

45.7m (150’) 0558004655

50m (164’) 0558008355

60m (200’) 0558008356

SECTION 10 HOSES AND CABLES

SECTION 11 REPLACEMENT PARTS

11.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on

the unit nameplate.

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 ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone

numbers.

11.2 Ordering

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

Note

11.0 Replacement Parts

Note

Replacement Parts, Schematics and Wiring Diagrams are

printed on 279.4mm x 431.8mm (11” x 17”) paper and are

included inside the back cover of this manual.

NOTES

REVISION HISTORY

1. Preliminary release - 05/2010

2. Ocial release - 08/2010.

3. Revision 05/2011 - minor changes to chart on page 35 and 68.

4. Revision 09/2011 - minor changes to illustrations on pages 26, 27, and 28 per K. Li.

A. CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST

Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:

Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST

Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:

Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST

Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS:

Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST

Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST

Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM EST

visit us on the web at http://www.esabna.com

The ESAB web site oers

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ESAB Welding & Cutting Products, Florence, SC

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Transcripción de documentos

Manual Gas Control Plasma System PCC-14 Plumbing Box Plasma Control Interface Instruction Manual This documentation is for ESAB equipment: PCC-14 Plumbing Box part number 0558005840 Plasma Control Interface part number 0560948696 (serial #’s beginning at AB-K016006) See manual # 0558006574 for ESP-150 and ESP-200 applications. 0558009546 09/2011 Be sure this information reaches the operator. You can get extra copies through your supplier. caution These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 2 table of contents Section / Title 1.0 2.0 Page Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 ESAB m3 Manual Gas Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 PCC-14 Plumbing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 3.0 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 PCC-14 Plumbing Box Dimensions/ Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 Plumbing Box Spark Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 VDR Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Plumbing Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 EPP-201 / EPP-360 Torch Connections to Plumbing Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 21 22 25 25 26 28 Plasma Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 3.6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.7 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 3.8 Plasma Control Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 3.9 Typical / Recommended E-stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 3.10 Control Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3.11 Plasma Control Interface Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 3.12 Plasma Control Interface STATUS Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 4.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.0 Marking Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 5.1 Marking Module Mounting Hole Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 6.0 PT-36R Plasma Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.1 PT-36R Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 6.2 Gas Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 6.3 Recommended Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.4 PT-36R Torch Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.0 Coolant Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 7.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 7.3 Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.0 EPP-201 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 8.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 8.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 9.0 EPP-360 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 9.1 Dimensions and Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 9.2 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 10.0 HOSES AND CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 10.1 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 10.2 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 11.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 11.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 3 table of contents 4 section 1 safety precautions 1.0 Safety Precautions 1.1 Safety - English WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death. FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc. 2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“ 3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode. 4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use. 5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard. 6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary. 7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore: 1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required. 2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal. 3. Wear flameproof gauntlet type gloves, heavy longsleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks. 4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing. 5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains. 6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses. ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. 5 section 1 safety precautions 1. Be sure the power source frame (chassis) is connected to the ground system of the input power. 3. Welders should use the following procedures to minimize exposure to EMF: 2. Connect the workpiece to a good electrical ground. A. Route the electrode and work cables together. Secure them with tape when possible. 3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work cables. Route cables on the same side of your body. 4. Use well-maintained equipment. Replace worn or damaged cables. 5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source. D. Connect the work cable to the workpiece as close as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible. 6. Make sure that all parts of your body are insulated from work and from ground. 7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes. 8. Put on dry, hole-free gloves before turning on the power. Therefore: 9. Turn off the power before removing your gloves. FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation. 1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials. 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable. 2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases. ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists. 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations. 2. Exposure to EMF may have other health effects which are unknown. 6 section 1 safety precautions 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) 1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power. 3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition. CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather. 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder. 5. Keep all safety devices and cabinet covers in position and in good repair. 6. Use equipment only for its intended purpose. Do not modify it in any manner. 2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit. ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. 3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders. 4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder. The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 7 section 1 safety precautions 5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“ 6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“ 7. AWS SP - "Safe Practices" - Reprint, Welding Handbook. 8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances." Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life. Means potential hazards which could result in personal injury or loss of life. Means hazards which could result in minor personal injury. 8 secCION 1 sEGURIDAD 1.2 Safety - Spanish La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. ADVERTENCIA: Estas Precauciones de Seguridad son para su protección. Ellas hacen resumen de información proveniente de las referencias listadas en la sección "Información Adicional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte. FUEGO Y EXPLOSIONES -- El calor de las flamas y el arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto: 1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc. 2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos. 3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables. 4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso. 5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego. 6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario. 7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. El arco, como el sol , emite rayos ultravioleta (UV) y otras radiaciones que pueden dañar la piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. Por lo tanto: 1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección. 2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido. 3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas. 4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados. 5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable como división. 6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo. 9 CHOQUE ELECTRICO -- El contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. NO use soldadura de corriente alterna (AC) en áreas húmedas, de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo. secCion 1 sEGURIDAD 1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de tierra física. 3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal. 4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con conductores expuestos. 5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder. 6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra. 7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma. 8. Use guantes secos y sin agujeros antes de energizar el equipo. 9. Apage el equipo antes de quitarse sus guantes. 10. Use como referencia la publicación ANSI/ASC Standard Z49.1 (listado en la próxima página) para recomendaciones específicas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra. 3. Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF: A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible. B. Nunca envuelva los cables de soldar alrededor de su cuerpo. C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo. D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura. E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo. HUMO Y GASES -- El humo y los gases, pueden causar malestar o daño, particularmente en espacios sin ventilación. No inhale el humo o gases. El gas de protección puede causar falta de oxígeno. Por lo tanto: 1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica positiva . No respire los gases producidos por estos materiales. 2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es. 3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico persiste. 4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación. CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente eléctrica fluye através de cualquier conductor causando a nivel local Campos Eléctricos y Magnéticos (EMF). Las corrientes en el área de corte y soldadura, crean EMF alrrededor de los cables de soldar y las maquinas. Por lo tanto: 1. Soldadores u Operadores que use marca-pasos para el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos. 2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos. 10 secCion 1 sEGURIDAD 5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el Estado de California de causar defectos en el nacimiento, o en algunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) 1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo. 2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria. 3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones. 4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo. 5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones. 6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera. MANEJO DE CILINDROS-- Los cilindros, si no son manejados correctamente, pueden romperse y liberar violentamente gases. Rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. Por lo tanto: 1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido. INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "Precautions and Safe Practices for Arc Welding, Cutting and Gouging-Form 52-529. 2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico. Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted: 3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto: 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 11 secCion 1 sEGURIDAD SIGNIFICADO DE LOS sImbolOs -- Según usted avanza en la lectura de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se trata de su seguridad. Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte. Significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte. Significa el posible riesgo que puede resultar en menores daños a la persona. 12 section 1 sÉCURITÉ 1.3 Safety - French INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l'arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent : AVERTISSEMENT : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, dans les manuels, les fiches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles. 1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc. 2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent. 3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser. 4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement. 5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie. 6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin. 7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l'emploi d'une protection auditive. L'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. Par conséquent: 1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches. 2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent. 3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement. 4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant. 5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininflammable. 6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité. CHOC ÉLECTRIQUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose. 13 section 1 sÉCURITÉ 1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée. 2. Branchez la pièce à traiter à une bonne mise de terre électrique. 3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel. 4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation. 6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre. 7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc. 8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous. 9. Mettez l'équipement hors tension avant d'enlever vos gants. 10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre. 3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques : A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible. B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps. C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps. D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder. E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps. LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l'asphyxie. Par conséquent : CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n'importe quel conducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. Par conséquent : 1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques. 2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé. 14 1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique. N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux. 2. N'effectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques. 3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste. 4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation. section 1 sÉCURITÉ 5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques considéres par l'état de la Californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.) ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent : 1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualifié. N'effectuez aucune réparation électrique à moins d'être qualifié à cet effet. 2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique. 3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité quelconque. 4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des flaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries. 5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état. 6. Utilisez l'équipement conformément à son usage prévu et n'effectuez aucune modification. MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent : 1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé. 2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique. 3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin. 4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer l'arc sur un cylindre. 5. Pour de l'information supplémentaire, consultez CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding, Cutting and Gouging", Form 52-529. Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 : 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 15 section 1 sÉCURITÉ SIGNIFICATION DES SYMBOLES Ce symbole, utilisé partout dans ce manuel, signifie "Attention" ! Soyez vigilant ! Votre sécurité est en jeu. DANGER Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles. AVERTISSEMENT Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles. ATTENTION Signifie un danger qui peut entraîner des blessures corporelles mineures. 16 Manual Gas Control System Interconnect Diagram CC-11 Control Cable 17 LIQUID GAS CC-TC IN CC-TC OUT REG-SHG REG-STG REG-CG REG-AR Optional PCC-CG PCC-AR Coolant Return Hose Coolant Supply Hose Pilot Arc Cable Power Cable Shield Gas Start Gas Cut Gas Ar PS Contol Cable PCI-AS PCC-TC OUT PCC-TC IN PCC-PA PCC-PWR PCC-SHG PCC-STG Mark / Cut Switching Module SM-AS Argon Select PCI-CC PCI-ES PCI-EP PCI-CI PCC-14 (Plasma Cutting Control) PCI (Plasma Control Interface) PCC-VDR PCC-CTL PCI-CTL PCI-VDR PT-36R VDR POWER DATA (Coolant Circulator) CC11 CC-IC PS-PA PS-PWR PS-CC PS-ES E-Stop Ext. 115/230VAC Control Interface Customer CNC PCC-14 Control PS-IC (Power Supply) PS Dotted line denotes optional Power, Pilot Arc, Coolant Shield Gas Plasma Gas Air Curtain Air Curtain Control PT36R Torch The Manual Gas Control System consists of several components: Plasma Control Interface (PCI), PCC-14 Plumbing Box, Power Supply (PS), Coolant Circulator (CC), Torch and customer CNC. 2.0 ESAB m3 Manual Gas Control System R section 2 INTERCONNECT DIAGRAM section 2 INTERCONNECT DIAGRAM 18 PCC-14 Plumbing Box 19 20 section 3 WARNING PCC-14 Plumbing Box DESCRIPTION / INSTALLATION This equipment can be hazardous if not properly operated and maintained. Read and understand all equipment literature and warning labels before operating this equipment. Follow these instructions to prevent injury or property damage. You must comply with local, state and national electrical and safety codes. Only trained personnel should perform maintenance or repairs on this equipment. 3.0 General The PCC-14 Plumbing Box is a Plasmarc Cutting Control used to connect the PT-36R Plasma Torch to a remotely located EPP-201 or EPP-360 power supply system. The PCC-14 includes high frequency starting circuits to eliminate starting problems with long torches and to minimize high frequency interference with other customer systems. 3.1 Scope The purpose of this manual is to provide the operator with all the information required to install and operate the Plumbing Box & Plasma Control Interface. Technical reference material is also provided to assist in troubleshooting. Specifications: PCC-14 Plumbing Box Weight: 41 lbs. (18.6 kg) Plasma and Start Gases: The PCC-14 may be used with Air , O2, N2, or H-35 (35% H2/65% Ar) at a maximum input pressure of 110 psig (7.6 bar). It is recommended, but not required, that N2 be used as the start gas when using H-35. The flow rate of gas will depend on the pressure set, the torch connected to the plumbing box, and the parts installed in the torch. Without a torch attached, the maximum flow rate for these gases at 100 psig (6.9 bar) is about 1000 scfh (28.3 cu-m/h). The minimum acceptable pressure for the start gas is 15 psig (1.0 bar); for the cut gas it is 24 psig (1.7 bar). Below these pressures the pressure switches may not be satisfied. Shield Gases: The PCC-14 may be used with Air, N2, Ar, or CO2. The maximum pressure is for Air, N2, Ar, or CO2 is 110 psig (7.6 bar). This will result in a flow of 250 scfh (7.1 cu-m/h) N2. See Graph 3-1. There is no pressure interlock on the shield gas. Coolant: The PCC-14 is designed for use with plasma torch coolant (ESAB P/N’s 156F05 or 0558004297). Maximum design pressure is 200 psig (13.8 bar). Flow rates depend on the torch but typically vary from 0.9 to 2 gpm (4.1 to 9.1 l/m). 21 section 3 3.2 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION PCC-14 Plumbing Box Dimensions/ Mounting Hole Locations Install the PCC-14 Plumbing Box in an appropriate location so as to maintain adequate and unrestricted airflow into and out of the cabinetry. For permanent mounting refer to the figure below for mounting hole dimensions in the base of this unit. 13.0" (330.2 mm) 15.4" (391.2 mm) 18.8" (477.5 mm) 16.625" (422.28 mm) 2.125" (53.98 mm) 12.500" (317.5 mm) 1.060" (26.92 mm) 4.500" (114.3 mm) 6.875" (174.63 mm) 22 section 3 caution PCC-14 Plumbing Box DESCRIPTION / INSTALLATION Flashback arrestors are required to prevent fire from propagating back to the gas supply through lines carrying oxygen or fuel gases. Use AWG 2/0 power cable to carry electrode current from the power source to the PCC-14. See section 9.0 for additional cables. Avoid using the same supply lines for both oxygen and air if oil may be mixed with the air. Oil in the presence of 100% oxygen can be highly flammable. Failure to observe above cautions may result in personal injury and / or damage to the equipment. Gas Purging: When switching between H-35 and an oxidizing gas (air or oxygen) it is recommended that the following procedure be followed: 1. 2. 3. 4. 5. Turn off the gas. Put the system into plasma gas test until line pressure is exhausted. If the start gas is being switched to or from H-35, switch to start gas test until that line is exhausted as well. Disconnect the old gas and connect a relatively inert gas such as nitrogen, argon, carbon dioxide, C-25, etc. Set the pressure to 50 psig (3.5 bar) and purge each affected line for 60 seconds. Then shut off the gas and exhaust each line per Step 2. Connect the gas to be used. Set the pressure to recommended values for the cutting condition to be used, and purge each affected line for 15 seconds per 25 ft. (7.6 m) of line. Note: The expected life of the internal flexible hoses is 10 years. Replace them earlier if cracking or brittleness is noted. Marking option With the optional Marking Module installed, the PCC-14 will allow you to switch the cut gas to Argon for plate marking. With the Marking Module installed, Argon gas input to the Marking Module is 125 psig (8.6 Bar). Note: When marking, make sure the start gas line is pressurized to avoid pressure switch errors. 23 section 3 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION 250 (7.1) 240 (6.8) 230 (6.5) 220 (6.2) 210 (5.9) 200 (5.7) 190 (5.4) 180 (5.1) Shield Gas Flow SCFH (CU-M/H) N2 Graph 3-1 - Gas Pressure / Flow 170 (4.8) 160 (4.5) 150 (4.2) 140 (4.0) 130 (3.7) 120 (3.4) 110 (3.1) 100 (2.8) 90 (2.5) 80 (2.3) 70 (2.0) 60 (1.7) 50 (1.4) 40 (1.1) 30 (0.8) 20 (0.6) 10 (0.3) 0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 (0.7) (1.4) (2.1) (2.8) (3.5) (4.1) (4.8) (5.5) (6.2) (6.9) (7.6) (8.3) (9.0) PSIG (BAR) Pressure Setting to 0.052 in. (1.32 mm) Diameter Orifice 24 section 3 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION WARNING Electricity Can Kill! HIGH VOLTAGE CAN BE PRESENT BEHIND COVER PLATE. DO NOT OPERATE WITHOUT COVER PLATE IN PLACE. Before REMOVING COVER PLATE OR performing any maintenance or assembly of this equipment, ensure the power source is turned off and disconnected. caution Only qualified maintenance personnel should repair and maintain this equipment. Unit is NOT designed for use in rain or snow. Damage to equipment may result. Unit is to be lifted only by the handle provided . Failure to do so may result in damage to the equipment. WARNING Electric Shock Can Kill! Turn off primary input power at the wall disconnect box before making any connections to the PCC-14. 3.3 Plumbing Box Spark Gap Adjustment Spark Gap Spark Gap Access Cover 1. 2. 3. 4. Disconnect input power to power source. Remove access cover from spark gap opening. Check / set to recommended spark gap of 0.040” (1 mm). Replace cover. 3.3.1 VDR Adjustment VDR Cover Plate VDR adjustment screw The VDR is set from the factory at a ratio of 25:1 for cutting operations and automatically adjusts to 12.5:1 for marking operations. As shown, access to the VDR can be made by removing the VDR cover plate. If not using an ESAB CNC, adjustment may be required. Please contact a qualified ESAB service technician for adjustment procedures. Contact info can be located on the back page of this manual. 25 section 3 3.4 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION Plumbing Box Connections Connection Locations Inside Plumbing Box 26 section 3 WARNING PCC-14 Plumbing Box DESCRIPTION / INSTALLATION Electric Shock Can Kill! Turn off primary input power at the wall disconnect box before making any connections to the power supply. Disconnect current supply at wall disconnect before servicing plumbing box. • Do not operate plumbing box with any covers removed / open. • Do not touch any torch front-end parts with power on. • Do not attempt to service unless power has been disconnected at the wall. Pilot Arc Cable From Power Supply Shield Gas Hose From Torch Plasma Gas Hose From Torch Pilot Arc Cable From Torch Power / Coolant Supply Hose From Torch Coolant Supply Hose Power / Coolant Return Hose From Torch Power Cables Coolant Return Hose 27 section 3 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION Electric Shock Can Kill! Turn off primary input power at the wall disconnect box before making any connections to the PCC-14. WARNING 3.5 EPP-201 / EPP-360 Torch Connections to Plumbing Box 1. Torch connections are first made in the PCC-14 plumbing box. Remove the cover of the plumbing box to access input and output connections . For both manual and mechanized torch applications, pass the torch lines through the openings in the front of plumbing box and make connections as shown. 2 5 4 3 1 Lines from torch 1 Shield Gas Hose 2 Electrode Cable / Coolant Return Hose 3 Plasma Gas Hose 4 Electrode Cable / Coolant Supply Hose 5 Pilot Arc Cable 1 Shield Gas 2 Coolant Return (Electrode Cable) 1 5 3 Plasma Gas 4 Coolant Supply (Electrode Cable) 5 Pilot Arc 3 4 2 28 section 3 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION Pilot Arc (+) Chassis Ground Electrode (-) Pilot Arc (+) Electrode (-) Interconnection Diagram - EPP-201/360 Note: Chassis ground to be connected from PCC-14 Plumbing Box to either the cutting machine or to the chassis of the power supply using the supplied ground wire. (Ensure star washer is installed on the ground stud for the PCC-14 connections). Hose connections should be wrench-tight. Ensure plug of the switch lead is firmly locked in place. Then close hinged cover. 29 section 3 PCC-14 Plumbing Box DESCRIPTION / INSTALLATION Connections to the Power Supply 1. 2. 3. 4. A power output cable attaches to a large bolted connection labeled “Electrode”. The Pilot Arc cable connects to a small threaded stud labeled “Pilot Arc”. The Plasma Control Interface connects to the power supply. The PCC-14 Plumbing Box control cable connects to the Plasma Control Interface. A work cable connects to the "Work" terminal on the front-lower-left of the console. The other end is attached to the cutting table or work piece. Connections to the rear of the Plumbing Box 1. 2. The Start, Cut & Shield gas hoses from the regulator panel attach to the rear of the plumbing box. The Plumbing Box Control cable from the Plasma Control Interface connects to the amphenol receptacle labeled “CONTROL CABLE from Power Source”. Both power cables, the pilot arc cable and both coolant hoses enter the plumbing box from the rear and are connected internally. Connections to the Coolant Circulator 1. The coolant supply and return lines connect to the supply and return fittings on the coolant circulator. 30 Plasma Control Interface 31 32 section 3 Plasma Control Interface DESCRIPTION / INSTALLATION 3.6 General This unit is an integral component of the m3 Manual Gas Control Plasma system used by an external controller (e.g. CNC) to interface with the PCC14 Plumbing Box. It controls all the sequencing required for handling the plasma cutting/marking operation leaving the external controller with a simple interface to the Plasma Control Interface (PCI). 3.7 Scope The purpose of this manual is to provide the operator with all the information required to install and operate the Plumbing Box & Plasma Control Interface. Technical reference material is also provided to assist in troubleshooting. Specifications: Plasma Control Interface Weight : 17.0 lbs. (7.7 kg) 6.59” (167.4 mm) 13.67” (347.2 mm) 15.50” (393.7 mm) 33 section 3 3.8 Plasma Control Interface DESCRIPTION / INSTALLATION Plasma Control Interface Connections Front view A B C D E J Note: Chassis must be connected to the machine ground. WARNING A. B. C. H ITEM Description A ON/OFF SWITCH B POWER INPUT C MODE SELECT D READY/FAULT INDICATOR E PILOT ARC F ARGON SELECT OUTPUT G CAN INPUT H VDR INPUT J GROUND STUD F G Electric Shock Can Kill! Shut off power at the POWER SUPPLY before attempting any maintenance. On/Off Switch – This switch controls the input power on/off to the PCI. Power Input – Connect the 120/230VAC supply to this connector. Mode Select - The PCI can be operated in four different modes which can be set using the “Mode Select” switch. 1. Operate – Used for normal cutting/marking operation. 2. Start Gas Test – Used for testing and setting the start gas pressure. The pressure value can be monitored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value can be monitored on the “Shield Gas” gauge display. 3. Cut Gas Test - Used for testing and setting the cutting gas pressure. The pressure value can be monitored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value can be monitored on the “Shield Gas” gauge display. 4. Mark Gas Test (Optional) - Used for testing and setting the argon gas pressure. The pressure value can be monitored on the “Plasma Gas” gauge display on the PCC-14 Plumbing Box. This also turns on the shield gas output and it’s value can be monitored on the “Shield Gas” gauge display. D. E. F. G. H. J. Ready/Fault Indicator – This LED indicates the different fault modes encountered by the PCI. Refer to “Plasma Control Interface STATUS Codes” section for more details. Pilot Arc - The Pilot Arc High/Low switch on the unit is set based on the type of material being cut. Depending on the material to be cut, the position of this switch is obtained from the PCC-14 Cut Data manual provided with the plasma system. Argon Select Output – This connector is used to select the argon solenoid for plasma gas when marking. Can Input – Not used VDR Input – Supplies the arc voltage value divided with a ratio of 25:1 for cutting and 12.5:1 for marking to the PCI. From the PCI this value is supplied to the external controller for torch height control. Ground Stud – Connect the machine chassis to this stud. 34 section 3 Plasma Control Interface DESCRIPTION / INSTALLATION Rear view A B H E G D C ITEM Description A PS B E-STOP C FUSE 1A D FUSE 2A E FUSE 2A F AIR CURTAIN/BUBBLE MUFFLER F A. PS – Connects directly to the EPP-201/360 power supply. It carries all the control signals for the power supply. B. E-STOP – Provides interconnection between the E-STOP actuator on the power supply and the customer’s E-STOP control circuit. See section 3.9 Typical / Recommended E-stop Connection for typical wiring schematic. C. Fuse 1A – This fuse is rated at 1 Amp and is for protecting the internal transformer in the PCI. D. Fuse 2A – This fuse is rated at 2 Amp and is for protecting the internal transformer in the PCI. E. Fuse 2A – This fuse is rated at 2 Amp and is for protecting the internal transformer in the PCI. F. Air curtain/Bubble Muffler (Optional) – Connects with an ESAB supplied Air Curtain or Bubble Muffler unit. G. PCC-14 – Connects with the PCC-14 Plumbing Box. H. CNC – Connects to the external CNC. 35 section 3 Plasma Control Interface DESCRIPTION / INSTALLATION PS PIN CNC PCC-14 E-STOP Function PIN Function PIN Function PIN Function A Not Used A E-Stop to CNC A 24 VDC to Pressure SW A Cycle Start B Coolant Flow SW B E-Stop to CNC B Pressure SW Input B Mark Mode C Mark Mode C Not Used C 24 VDC to CNC D Chassis D Not Used D Fault E E-Stop to PS– 24vac E Start Gas ON E Motion Enable F E-Stop to PS– 24vac F Solenoid Common F CNC Common G 24 VDC to PS G Cut Gas ON G Remote Current Ref H Master Select H Shield Gas ON H Remote Current COM J Current Ref Common J Solenoid 2 Common J E-stop to PS K Coolant Level SW M Plasma HF ON K E-stop to PS L Current Reference N HF Common L VDR - M Plasma Start Not Used M VDR + N Pilot Ref Common Not Used N E-stop to CNC P Main Arc On Not Used P E-stop to CNC Q Pilot Arc Select Bit 1 Not Used R Preflow R 120 VAC from PS Not Used S Pilot Arc Select Bit 0 Not Used T Current Range Select Not Used V Upslope Select Not Used W Power Supply Fault Y Main Arc Actual Current Z 120 VAC Common 36 section 3 Plasma Control Interface DESCRIPTION / INSTALLATION The external controller/CNC connector pin out is described below: CNC: A) Cycle Start - Digital input to the PCI which starts the cutting operation when the mode select is in Operate setting. B) Mark Mode - Digital input to the PCI which enables marking mode on the PCI and the Power Supply. C) 24VDC to CNC – Supplied to the CNC for Cycle Start and Mark Mode inputs. D) Fault - Digital output to the CNC reporting a fault with the plasma system. E) Motion Enable - Digital output to the CNC confirming arc transfer. F) CNC Common - Voltage supplied from the CNC for fault and motion enable. G) Remote Current Ref - 0-10 VDC Analog voltage input to PCI which corresponds to 0-360 Amps on the Power Supply. H) Remote Current Com - DC common for analog voltage. J) E-stop to PS - 24 vac supply to dry contact on emergency stop circuit on CNC. Used to report emergency stop on external controller or machine to the Power Supply. K) E-stop to PS - 24 vac return on dry contact on emergency stop circuit on CNC. Used to report emergency stop on external controller to the Power Supply. L) VDR(-) - Arc voltage feedback to the torch height control circuit on CNC. M) VDR(+) - Arc voltage common to the torch height control circuit on CNC. N) E-stop to CNC - Dry contact from Power Supply. Used to report emergency stop on Power Supply to external controller. P) E-stop to CNC - Dry contact from Power Supply. Used to report emergency stop on Power Supply to external controller. R) Preflow - Unit is switched to preflow to purge gas lines. 3.9 Typical / Recommended E-stop Connection E-STOP 37 section 3 3.10 Plasma Control Interface DESCRIPTION / INSTALLATION Control Sequence                                    38 section 3 3.11 Plasma Control Interface DESCRIPTION / INSTALLATION Plasma Control Interface Mounting Hole Locations Install the Plasma Control Interface in an appropriate location so as to maintain adequate and unrestricted airflow into and out of the cabinetry. For permanent mounting refer to the figure below for mounting hole dimensions in the base of this unit. 15.50" (393.7 mm) 14.50" (368.3 mm) 7.25" (184.2 mm) 6.50" (165.1 mm) 4 X Ø 0.28” (7.1 mm) 1.75" (44.5 mm) 3.50" (88.9 mm) 39 section 3 Plasma Control Interface DESCRIPTION / INSTALLATION WARNING 3.12 when supplying power to the Plasma Control Interface box, For safe operation, it is strongly advised to turn off power to the Plasma Control Interface box whenever an Emergency Stop is encountered on the system. Plasma Control Interface STATUS Codes Ready/Fault LED STATUS Code Label List: The STATUS code is determined by counting the number of intermittent “ON” flashes of the Ready/Fault LED on the Plasma Control Interface. # of LED flashes Fault Description/Solution 1 Power Supply Fault Fault from power supply, check the power supply front panel for details. 2 Pressure Switch Fault Pressure switch inside PCC-14 is not closed, either due to low gas pressure or a bad pressure switch. There are two pressure switches for start and cut gas which are in series. Both lines must be at the recommended PS-1 for the switches to stay closed. 3 Coolant Flow Fault No coolant flow. Check CC-11. 4 Coolant Level Fault Need to refill coolant to CC-11. 5 Ignition Fault Arc was not able to transfer. 6 Arc On Lost Fault Arc is lost while cutting. 40 section 4 maintenance WARNING 4.0 Electric shock can kill! Ensure the line (wall) disconnect switch or circuit breaker is open before attempting any inspection or work on the inside of the plumbing box. Always wear safety goggles with side shields when blowing out the equipment with low pressure air. Maintenance 4.1 General Maintenance work must be performed by an experienced person. Do not permit untrained persons to inspect, clean, or lubricate this equipment. On a regular basis, check cylinder valves, regulators, hoses, and gas connections for leaks using a soap solution or a leak test solution. Keep the equipment dry, free of oil and grease, and protected at all times from damage by hot metal and sparks. 4.2 Cleaning Periodically, remove the covers from the equipment and, wearing proper eye protection, blow accumulated dust and dirt from the air passages and the interior components using clean low-pressure air. It is imperative that the air passages to the interior of the unit be kept free of dirt accumulation to ensure adequate circulation of cooling air. The length of time between cleaning will depend on the location of the unit and the amount of dust in the atmosphere. After cleaning with low-pressure air, check for and tighten any loose hardware, including all electrical connections. Check for frayed and/or cracked insulation on all power cables and replace if necessary. WARNING Electric shock can kill! Failure to replace worn or damaged cables may result in a bare cable touching a grounded surface. The resulting electrical arc may damage the unprotected eyes and will present a serious fire hazard. Bodily contact with a bare cable, connector, or conductor may result in severe electrical shock, causing serious burns or death. 41 section 4 maintenance 42 section 5 5.0 Marking Module Marking Module The Marking Module option is installed external to the PCC-14 Plumbing box and is controlled from the PCI Plasma Control Interface. This module will route the normal cut gas to the Plumbing Box until the operator selects a Marking operation. When this happens, the PCI Interface will switch the cut gas sent to the torch to Argon for marking operations. The module is supplied with 24 VAC from the PCI for operation Gas connection: Cut gas and Argon are connected as in the photo below. The gas output is sent to the Plumbing Box. Electrical connection: A three pin cable is connected from the Marking Module to the PCI to switch the gas supplied to the torch. By default the Marking Module will pass the cut gas to the Plumbing Box. This cable is supplied with the module at installation. This cable routes 24VAC to the Marking Module from the PCI during marking operations. Cut Gas Gas out to PCC-14 Argon PCI connection 43 section 5 5.1 Marking Module Marking Module Mounting Hole Locations Install the Marking Module in an appropriate location so as to maintain adequate and unrestricted airflow into and out of the cabinetry. For permanent mounting refer to the figure below for mounting hole dimensions in the base of this unit. 2.87 .25 .25 1.50 .25 TYP .50 TYP (4) PLCS 44 section 6 6.0 PT-36R PLASMA TORCH PT-36R Plasma Torch Note: See appropriate PT-36R Plasma Torch equipment literature (0558006829) for operating conditions and instruction information. Torch Description PT-36R m3 Plasma Torch 45 Available Lengths m ( ft. ) ESAB Part Number 1.4m (4.5’) 0558006811 1.8m (6’) 0558006812 2.2m (7.2’) 0558006781 3.6m (12’) 0558006813 4.3m (14’) mini-bevel 0558006814 4.6m (15’) 0558006815 5.2m (17’) 0558006816 6.1m (20’) 0558006782 7.6m (25’) 0558006817 section 6 6.1 PT-36R PLASMA TORCH PT-36R Technical Specifications 7.54" (191.5mm) NOTE: Clamp only on insulated torch sleeve not less than 1.25" (31.7mm) from the torch end of sleeve. 2.00" (50.8mm) 9.13" (231.9mm) 6.17" (156.7mm) 10.50" (266.7mm) Length of Sleeve 6.2 Gas Specifications Argon Nitrogen Oxygen H-35 (Argon/Hydrogen) Methane Compressed Air (Clean, dry & oil-free shop air) 125 PSI (8,6 bar) with 0.25” NPT, 99.995% purity, Filtered to 25 microns 125 PSI (8,6 bar) with 0.25” NPT, 99.99% purity, Filtered to 25 microns 125 PSI (8,6 bar) with 0.25” NPT, 99.5% purity, Filtered to 25 microns 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns 75 PSI (5,2 bar) with 0.25” NPT, 93% purity, Filtered to 25 microns 80 PSI @ 1200cfh (5,5 bar @ 35 m3h), Filtered to 25 microns Typical requirements for flow delivered at 125 psig: Maximum Plasma Gas: 300 scfh Maximum Shield Gas: 350 scfh Note: These do not represent actual flows used in any condition, but are the design maximums of the system. 46 section 6 PT-36R PLASMA TORCH 6.3 Recommended Regulators Liquid Cylinder Service: O2 : R-76-150-540LC .................................................................................................................P/N 19777 N2 : R-76-150-580LC .................................................................................................................P/N 19977 High Pressure Cylinder Service: O2 : R-77-150-540 . ................................................................................................................. P/N 998337 Ar & N2 : R-77-150-580........................................................................................................... P/N 998344 H2 & CH4 : R-77-150-350 . .................................................................................................... P/N 998342 Industrial Air : R-77-150-590 ............................................................................................ P/N 998348 Station/Pipeline Service: O2 : R-76-150-024 . ....................................................................................................................P/N 19151 Ar & N2 : R-76-150-034..............................................................................................................P/N 19155 Air, H2, & CH4 : R-6703 ..............................................................................................................P/N 22236 6.4 PT-36R Torch Technical Specifications Type: Water cooled, Dual gas, mechanized plasmarc cutting torch Current Rating: 750 Amps @ 100% duty cycle Mounting Diameter: 2 inches (50.8 mm) Length of Torch without leads: 18.5 inches (47 cm) IEC 60974-7 Voltage Rating: 500 volts peak Striking Voltage (maximum value of HI-FREQUENCY voltage): 8000 vac Minimum Coolant Flowrate: 1.0 USGPM (3.8 L/min) Minimum Operating Coolant Pressure at Inlet: 175 psig (12.1 bars) Maximum Operating Coolant Pressure at Inlet: 200 psig (13.8 bars) Minimum Acceptable Rating of Coolant Recirculator: 16,830 BTU/HR (4.9 kW) at High Coolant Temperature - Ambient = 45°F (25°C) and 1.6 USGPM (6 L/min) Maximum Safe Gas Pressures at Inlets to Torch: 125 psig (8.6 bars) Recommended Input Pressure: 125 psig (8.6 bars) Safety Interlocks: This torch is intended for use with ESAB Plasmarc cutting systems and controls employing a water flow switch on the coolant return line from the torch. Removal of the nozzle retaining cup to service the torch breaks the coolant return path. 47 section 6 PT-36R PLASMA TORCH 48 section 7 7.0 COOLANT CIRCULATOR Coolant Circulator Note: See appropriate Coolant Circulator equipment literature (0558007523) for operating conditions and instruction information. 49 section 7 COOLANT CIRCULATOR 7.1 Specifications Dimensions: 34.00” high (864 mm) x 21.75” wide (552 mm) x 28.00 deep (711 mm) Weight: 215 lb. dry (97.5 kg) / 249 lb. wet (113 kg) Pump Type: Positive displacement, rotary vane type with adjustable by-pass valve (200 psi / 13.8 bars max.), CW rotation as viewed from nameplate. Radiator Type: Copper tubing, aluminum finned air-to-water type with galvanized steel frame. AC Input Voltages 50Hz, 1 Phase Input Power 200 / 230 / 400 / 460 / 575 V., + / - 10% AC Input Amperage Pump Capacity Cooling Capacity @ 1.60 gpm (6.0 l/min) 60Hz, 1 Phase Input Power 9 / 8 / 5 / 4 / 3 Amperes 1.60 gpm at 175 psi 1.60 gpm at 175 psi (6.0 l/min at 12 bars) (6.0 l/min at 12 bars) 16,830 BTU / hr. (4900 watts) 20,200 BTU / hr. (5900 watts) at 45° F (25° C) temperature difference between high coolant temperature and ambient air temperature using ESAB coolant P/N 0558004297 (25% propylene glycol / 75% distilled water). Max. Delivery Pressure 175 psig (12 bars) Reservoir Capacity 4 gallons (15.2 liters) 50 section 7 7.2 COOLANT CIRCULATOR Installation Install the CC-11 in an appropriate location so as to maintain adequate and unrestricted airflow into and out of the cabinetry. For permanent mounting refer to Figure 6.1 for mounting hole dimensions in the base of this unit. 0.531” (13.5 mm) diameter hole, typical, 8 places 19.50” (495 mm) 1.69” (43 mm) 3.42” (87 mm) 17.78” (452 mm) 3.42” (87 mm) Figure 6.1 Mounting Dimensions 51 section 7 7.3 COOLANT CIRCULATOR Input Power Connections A 3-conductor power cable suitable to meet the required input power must be installed. The cable must have 0.25" (6.4 mm) ring lugs installed on the machine end. Connect the power leads to the L1 and L2 terminals on TB1 Input Power Terminal Board and the ground lead to the ground lug on the back of the fan support panel. A strain relief fitting is provided to feed a power cable through the rear panel of the cabinet. Refer to Figure 6.2 for proper Input Voltage Link placement, Figure 6.2 shows link in place for 460 volt input. Electrical installation must be in accordance with local electrical codes for this type of equipment. CAUTION Voltage link MUST be moved if equipment is operated at any voltage other than 575V. Failure to move voltage link to location that matches input voltage can result in damage to equipment. NOTE: Voltage link is shipped in this location which is for 575 volt operation. Figure 6.2 Voltage Links 52 section 7 WARNING COOLANT CIRCULATOR ELECTRIC SHOCK CAN KILL! Before making electrical input connections to the power source, "Machinery Lockout Procedures" should be employed. If the connections are to be made from a line disconnect switch, place the switch in the off position and padlock it to prevent inadvertent tripping. If the connection is made from a fuse box, remove the corresponding fuses and padlock the box cover. If it is not possible to use padlocks, attach a red tag to the line disconnect switch (or fuse box) warning others that the circuit is being worked on. Typical Installation User-supplied single phase fused power disconnect box with receptacle and plug Input Power Cable Figure 6.3 Input Connection Diagram 53 section 7 COOLANT CIRCULATOR 54 section 8 POWER SUPPLIES 8.0 EPP-201 Power Supply Note: See appropriate EPP-201 Power Supply equipment literature (0558007900) for operating conditions and instruction information. 55 section 8 8.1 POWER SUPPLIES Dimensions and Weight 47.25” (1200 mm) 23.75” (603.25 mm) 40.75” (1035 mm) Weight = 492 kg (1085 lbs.) 56 section 8 8.2 POWER SUPPLIES Input Power Connection WARNING Electric Shock Can Kill! Provide maximum protection against electrical shock. Before any connections are made inside the machine, open the line wall disconnect switch to turn power off. Primary Power EPP-201 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations. Recommended input conductor and line fuse sizes: Input at Rated Load Volts Amperes 380 400 460 575 60 57 51 41 Input and Ground conductor* CU/ mm2 (AWG) 35 (2/0)* 35 (2/0)* 35 (2/0)* 35 (2/0)* Time delay Fuse size (amperes) 100 100 100 60 Rated load is output of 200A at 160V * Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above. To estimate the input current for a wide range of output conditions, use the formula below. Input current = NOTICE (V arc) x (I arc) x 0.73 (V line) Dedicated power line may be necessary. EPP-201 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required. 57 section 8 POWER SUPPLIES 58 section 9 POWER SUPPLIES 9.0 EPP-360 Power Supply Note: See appropriate EPP-360 Power Supply equipment literature (0558007676) for operating conditions and instruction information. 59 section 9 9.1 POWER SUPPLIES Dimensions and Weight 47.25” (1200 mm) 23.75” (603.25 mm) 40.75” (1035 mm) Weight = 492 kg (1085 lbs.) 60 section 9 9.2 POWER SUPPLIES Input Power Connection WARNING Electric Shock Can Kill! Provide maximum protection against electrical shock. Before any connections are made inside the machine, open the line wall disconnect switch to turn power off. Primary Power EPP-360 is a 3-phase unit. Input power must be provided from a line (wall) disconnect switch that contains fuses or circuit breakers in accordance to local or state regulations. * * * Recommended input conductor and line fuse sizes: * * * Input at Rated Load Volts 380 400 460 575 Input and Ground Time delay Fuse size conductor* CU/ (amperes) Amperes mm2 (AWG) 140 50 (1) 200 132 35 (2) 150 slo-blo +10%/-0 115 35 (2)* 150 92 35 (2)* 125 Rated load is output of 360A at 200V * Sizes per National Electrical Code for a 90° C (194˚ F) rated copper conductors @ 40° C (104˚ F) ambient. Not more than three conductors in raceway or cable. Local codes should be followed if they specify sizes other than those listed above. To estimate the input current for a wide range of output conditions, use the formula below. Input current = NOTICE (V arc) x (I arc) x 0.73 (V line) Dedicated power line may be necessary. EPP-360 is equipped with line voltage compensation but to avoid impaired performance due to an overloaded circuit, a dedicated power line may be required. 61 section 9 POWER SUPPLIES 62 section 10 HOSES AND CABLES 10.0 HOSES AND CABLES 10.1 Hoses Hose Description Available Lengths m ( ft. ) ESAB Part Number Air / Shield Gas Hose 1.5m (5’) 5m (16’) 6m (19’) 7m (23’) 8m (26’) 9m (30’) 10m (33’) 11m (36’) 12m (39’) 13m (43’) 14m (46’) 15m (49’) 16m (52’) 17m (56’) 18m (59’) 19m (62’) 20m (66’) 30m (98') 2.3m (7.5’) 4m (13’) 0.5m (1.7’) 1m (3.3’) 3m (10’) 0558006200 0558006201 0558006202 0558006203 0558006204 0558006205 0558006206 0558006207 0558006208 0558006209 0558006210 0558006211 0558006212 0558006213 0558006214 0558006215 0558006216 0558008813 0558007315 0558008359 0558008447 0558008448 0558008449 63 section 10 HOSES AND CABLES Hose Description Available Lengths m ( ft. ) ESAB Part Number N2 / PG-1 Hose 1.5m (5’) 5m (16’) 6m (19’) 7m (23’) 8m (26’) 9m (30’) 10m (33’) 11m (36’) 12m (39’) 13m (43’) 14m (46’) 15m (49’) 16m (52’) 17m (56’) 18m (59’) 19m (62’) 20m (66’) 30m (98') 2.3m (7.5’) 4m (13’) 0.5m (1.7’) 1m (3.3’) 3m (10’) 0558006089 0558006090 0558006091 0558006092 0558006093 0558006094 0558006095 0558006096 0558006097 0558006098 0558006099 0558006100 0558006101 0558006102 0558006103 0558006104 0558006105 0558008814 0558007313 0558008357 0558008441 0558008442 0558008443 64 section 10 HOSES AND CABLES Hose Description Available Lengths m ( ft. ) ESAB Part Number O2 / PG-2 Hose 1.5m (5’) 5m (16’) 6m (19’) 7m (23’) 8m (26’) 9m (30’) 10m (33’) 11m (36’) 12m (39’) 13m (43’) 14m (46’) 15m (49’) 16m (52’) 17m (56’) 18m (59’) 19m (62’) 20m (66’) 30m (98') 2.3m (7.5’) 4m (13’) 0.5m (1.7’) 1m (3.3’) 3m (10’) 0558006106 0558006107 0558006108 0558006109 0558006110 0558006111 0558006112 0558006113 0558006114 0558006115 0558006116 0558006117 0558006118 0558006119 0558006120 0558006121 0558006122 0558008815 0558007314 0558008358 0558008444 0558008445 0558008446 65 section 10 HOSES AND CABLES Hose Description H35 / CH4 Hose Argon Hose 66 Available Lengths m ( ft. ) ESAB Part Number 0.5m (1.7’) 1m (3.3’) 2.3m (7.5’) 3m (10’) 4m (13’) 5m (16’) 6m (19’) 7m (23’) 8m (26’) 9m (30’) 10m (33’) 11m (36’) 12m (39’) 13m (43’) 14m (46’) 15m (49’) 16m (52’) 17m (56’) 5m (16’) 6m (19’) 7m (23’) 8m (26’) 9m (30’) 10m (33’) 11m (36’) 12m (39’) 13m (43’) 14m (46’) 15m (49’) 16m (52’) 17m (56’) 40m (132’) 0558008371 0558008372 0558008373 0558008374 0558008375 0558008376 0558008377 0558008378 0558008379 0558008380 0558008381 0558008382 0558008383 0558008384 0558008385 0558008386 0558008387 0558008388 0558008390 0558008391 0558008392 0558008393 0558008394 0558008395 0558008396 0558008397 0558008398 0558008399 0558008400 0558008401 0558008402 0558008816 section 10 HOSES AND CABLES Available Lengths m ( ft. ) 10.1m (33’) 15.2m (50’) 20.1m (66’) 35.1m (115’) 50.3m (165’) 4.9m (16’) 29.9m (98’) 39.9m (131’) 59.7m (196’) 1.4m (4.5’) 1.8m (6’) 3.6m (12’) 4.6m (15’) 5.2m (17’) 7.6m (25’) 6m (20’) 7m (23’) 8m (26’) 9m (30’) 10m (33’) 11m (36’) 12m (40’) Hose Description Coolant Hose Air Curtain Hose 67 ESAB Part Number 0558005563 0558005564 0558005565 0558005566 0558005567 0558005246 0558005247 0558005248 0558005249 0558004841 0558004842 0558004843 0558004844 0558004845 0558004846 0558006865 0558008502 0558008503 0558008504 0558008505 0558008506 0558008507 section 10 HOSES AND CABLES 10.2 Cables Cable Description E-Stop Cable ( E-Stop ) Air Curtain / Bubble Muffler Control Cable ( optional ) VDR Cable ( VDR ) Mark Solenoid Cable ( ARG ) 68 Available Lengths m ( ft. ) ESAB Part Number 7.6m (25’) 0558009621 10m (33’) 0558009622 15m (50’) 0558009623 22m (75’) 0558009624 30m (100’) 0558009625 40m (131’) 0558009626 45m (150’) 0558009627 50m (164’) 0558009628 60m (200’) 0558009629 2.1m (6.75’) 0558009771 5m (16.5’) 0558009772 10m (33') 0558009773 0.5m (1.7’) 0560947067 1.5m (5’) 0560947075 3m (10’) 0560947076 4m (13’) 0560947068 5m (16’) 0560947077 6m (19’) 0560947069 6.1m (20') 0560946782 7m (23’) 0560947070 8m (26’) 0560947071 9m (30’) 0560947072 10m (33’) 0560947078 15m (49’) 0560947073 20m (66’) 0560947074 25m (82') 0560946758 section 10 HOSES AND CABLES Cable Description PCC-14 Interface Cable ( PCC-14 ) 115 / 230 VAC Input Power Cable ( POWER ) CNC Cable ( CNC ) EPP Control Cable ( PS-1 ) 69 Available Lengths m ( ft. ) ESAB Part Number 0.9m (3’) 2238279 1.8m (6’) 2237958 3.0m (10’) 0558009510 4.0m (13’) 0558009511 4.9m (16’) 0558009512 6.1m (20’) 0558009513 7.0m (23’) 0558009514 7.9m (26’) 0558009515 9.1m (30’) 0558009516 10.1m (33’) 0558009517 15.2m (50’) 2237959 22.9m (75’) 2237960 30.5m (100’) 2237934 38.1m (125’) 2237935 45.7m (150’) 2237936 53.3m (175’) 2237937 61.0m (200’) 2237938 5m (16’) 0558008261 10m (33’) 0558008262 15m (49') 0558008810 20m (66’) 0558008811 25m (82') 0558008812 4.6m (15’) 0560936665 7.6m (25’) 0560936666 15m (50’) 0560936667 22.8m (75’) 0560936668 25m (82’) 0560948159 7.6m (25’) 0558004651 10m (33’) 0558008360 15m (50’) 0558004652 22.8m (75’) 0558004653 30.5m (100’) 0558004654 40m (131’) 0558003978 45.7m (150’) 0558004655 50m (164’) 0558008355 60m (200’) 0558008356 section 10 HOSES AND CABLES 70 section 11 replacement parts 11.0 Replacement Parts 11.1 General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 11.2 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 ESAB Distributor. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers. Note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. Note Replacement Parts, Schematics and Wiring Diagrams are printed on 279.4mm x 431.8mm (11” x 17”) paper and are included inside the back cover of this manual. 71 NOTES 72 revision history 1. 2. 3. 4. Preliminary release - 05/2010 Official release - 08/2010. Revision 05/2011 - minor changes to chart on page 35 and 68. Revision 09/2011 - minor changes to illustrations on pages 26, 27, and 28 per K. Li. 73 ESAB Welding & Cutting Products, Florence, SC COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Part Numbers Technical Applications Specifications Hours: 8:00 AM to 5:00 PM EST Equipment Recommendations D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123 Fax: (843) 664-4462 Hours: 7:30 AM to 5:00 PM EST or visit us on the web at http://www.esabna.com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback & Support