ESAB Precision Plasmarc Installation, Operation And Maintenance Manual For Residential Installation Download Page 150

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SECTION 6

TROUBLESHOOTING

6-18

ØC

ØB

ØA

P3-17(+)

P3-18(-)

120VAC

P3-13

FNT PNL

ON/OFF

ISOLATION AMPLIFIER AND

FAULT SIGNAL PCB

PCB1

CB1

10K

DPDT S3

FRONT PNL

CURRENT

LOCAL/REMOTE

FRONT PNL LOCAL

CURRENT SETTING POT

P3-12

LED6

LED5

LED4

LED3

LED2

LED1

LED9

LED8

LED7

P1-13

P1-14

P1-15

P2-2

P3-1

P3-2

P1-16

P1-2

P1-3

NO FS1

AH2

AH3

AH4

AH5

AH8

AH6

AH1

AH7

P2-4

P2-5

12VAC

P2-6

P2-7

P2-11

P2-12

24VAC

P2-13

P2-14

24VAC

P2-15

P2-16

24VAC

P2-9
P2-8

18VAC

P2-10

18VAC

P10-3
P10-4

P10-5

18VAC
18VAC

TB1

TB2

200V

230V

380V

415V

460V

575V

ZD1,180V

38103

L3 T3

L1 T1

PUMP

MOTOR

-6

-5

AMMETER

AM1

VOLTMETER

POWER MODULE #1

BR1-A
BR1-B
BR1-C

TB2-1

TB2-2

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

9 10

P4-3

P4-4

P4-15

P4-16

P10-2

P10-1

P4-11

P4-12

P4-13

P4-14

SH1-2

SH1-1

TB3-1

575V

460V

415V

380V

230V

200V

BH1

BH2

BH3

BH4

BH5

BH6

BH8

BH7

200V

230V

380V

415V

460V

575V

200V

230V

380V

415V

460V

575V

CH1

CH2

CH3

CH4

CH5

CH6

CH8

CH7

MOV1

610V

MOV2

610V

MOV3

610V

P2-1

SETTING

P9-3
P9-1

P4-1
P4-2
P4-7

P4-8

P4-9

P4-10

P1-9

P1-8

P1-7

P1-10

PLASMA GAS

START GAS

P7-3

P7-1

NOT USED ON

PRECISION PLASMA CONSOLE

MOD1

8
7
6
5
4
3
2
1

5
6

2
3

14
15
16

J4 P4

X13

X12
X11
X16
X15
X14
X6
X5
X8
X7
X4
X3

X10
X9
X2
X1

P1-12

P1-11

P1-17

P1-18

MAX

MIN

-8

-7

-6

4.99K

P5-1

P5-2

120VAC RELAY

C2
20uf

400V

10K

R11

Z D 2
180V AC

PCB TRIM POT

838193

1
2
3

7
9

2
3
4

PLC1

PLC MODULE #1

6.11 Schematic- Precision Plasma Power Source

Part 1

Summary of Contents for Precision Plasmarc

Page 1: ...CUTTING SYSTEMS F 15 480 D October 2000 Installation Operation and Maintenance Manual for the PRECISION PLASMARC SYSTEM with Electronic Flow Control 411 s Ebenezer Road Florence SC 29501 0545 ...

Page 2: ... See standard ESAB terms and conditions of sale for a specific statement of ESAB s responsibilities and limitations on its liability Every effort was made to ensure the accuracy and completeness of this manual Information in this document is subject to change without notice This manual is ESAB Part Number F15480 This manual is ESAB Part Number F15480 This manual is ESAB Part Number F15480 This man...

Page 3: ... Scope 1 2 3 Package Options Available 1 2 4 Technical Specifications 2 4 1 Precision Plasma System 2 2 4 2 Plasma Gas 3 2 4 3 Start Gas 3 2 4 4 Secondary Gas 3 2 4 5 PT 24 Torch 3 Section 3 Installation 3 1 General 1 3 2 Equipment Required 1 3 3 Location 1 3 4 Primary Electrical Input Connections 2 3 5 Interconnecting Lines 4 Precision Plasmarc Component Interconnecting Diagram 8 3 6 Torch Mounti...

Page 4: ...nce of Gas Options on Cut Quality 4 3 1 Introduction 9 4 3 2 Aluminum 9 4 3 3 Carbon Steel 10 4 3 4 Stainless Steel 11 4 4 Process Data 4 4 1 Introduction 13 4 4 2 Process Data Settings 14 Plasma Marking Data 54 4 4 3 Relationship of Kerf Width to Amperes and Material Thickness 76 4 4 3 1 Aluminum Kerf Values 76 4 4 3 2 Carbon Steel Kerf Values 78 4 4 3 3 Stainless Steel Kerf Values O2 N2 O2 81 4 ...

Page 5: ...6 2 2 PLC LED Functions 2 6 3 Troubleshooting Guide 6 3 1 Reduced Consumable Life 3 6 3 2 Poor Cut Quality 4 6 3 3 No Pilot Arc 4 6 3 4 No Arc Transfer 4 6 3 5 No Preflow 4 6 3 6 Torch Fails to Fire 4 6 3 7 Nozzle Life Extremely Short 5 6 3 8 Short Electrode Life 5 6 3 9 Short Electrode AND Nozzle Life 5 6 4 Flow Control Schematic 6 6 5 Gas Flow Schematic 7 6 6 Junction Box Wiring Diagram 8 6 7 Ju...

Page 6: ...arbon Steel PG O2 SG O2 28 Carbon Steel PG O2 SG N2 O2 30 Carbon Steel PG O2 Sg O2 32 Stainless Steel PG N2 SG N2 34 Stainless Steel PG N2 SG N2 CH4 36 Stainless Steel PG Air SG Air 38 Stainless Steel PG Air SG Air CH4 40 Aluminum PG N2 SG N2 42 Aluminum PG N2 SG N2 CH4 44 Marking PG Argon SG Air 46 Section 7 Replacement Parts 7 1 General 1 7 2 Ordering 2 7 3 Plasmarc Power Source Exterior Compone...

Page 7: ...g to the basic machine and accessories are found in the instruction literature For a wide scope of safety information on the field of cutting and welding apparatus obtain and read the publications listed in the Recommended References 1 2 Safety Notations And Symbols The following words and symbols are used throughout this manual They indicate different levels of required safety involvement ALERT o...

Page 8: ...entrance cell entrance cell entrance cell entrance Follow lockout procedure before servicing Follow lockout procedure before servicing Follow lockout procedure before servicing Follow lockout procedure before servicing WARNING Failure to follow operating instructions could result in death or serious injury Read and understand this operator s manual before Read and understand this operator s manual...

Page 9: ...t supply pressure Machine regulator is then used inlet supply pressure Machine regulator is then used inlet supply pressure Machine regulator is then used to obtain pressure required by torches to obtain pressure required by torches to obtain pressure required by torches to obtain pressure required by torches Contact your ESAB representative before installation Contact your ESAB representative bef...

Page 10: ...and flying goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying debris generated during operation debris generated during operation debris generated during operation debris generated during operation Chipped slag may be hot and fly far Bystanders Chipped slag may be hot and fly far Bystanders Chipped slag may be hot and fly far Bystanders Chipped slag may be ...

Page 11: ...ctrical workpiece and electrical ground wear insulating gloves shoes and ground wear insulating gloves shoes and ground wear insulating gloves shoes and ground wear insulating gloves shoes and clothing clothing clothing clothing Keep gloves shoes clothing work area and Keep gloves shoes clothing work area and Keep gloves shoes clothing work area and Keep gloves shoes clothing work area and equipme...

Page 12: ...ther surfaces with dark colors to Paint walls and other surfaces with dark colors to reduce reflections reduce reflections reduce reflections reduce reflections Install protective screens or curtains to reduce Install protective screens or curtains to reduce Install protective screens or curtains to reduce Install protective screens or curtains to reduce ultraviolet transmission ultraviolet transm...

Page 13: ...lame retardant clothing that covers all Wear flame retardant clothing that covers all exposed areas exposed areas exposed areas exposed areas Wear Wear Wear Wear cuffless trousers to prevent entry of sparks cuffless trousers to prevent entry of sparks cuffless trousers to prevent entry of sparks cuffless trousers to prevent entry of sparks and slag and slag and slag and slag POOR PERFORMANCE WILL ...

Page 14: ...ure recommended schedules in the instruction literature Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on machine Severe electrical or mechanical damage machine Severe electrical or mechanical damage machine Severe electrical or mechanical damage machine Severe elec...

Page 15: ...American Welding Society Recommended Practices for Plasma Arc Welding AWS C5 1 American Welding Society Recommended Practices for Arc Cutting AWS C5 2 American Welding Society Safe Practices AWS SP American Welding Society Standard for Fire Protection in Use of Cutting and Welding Procedures NFPA 51B National Fire Protection Association 60 Batterymarch Street Boston Massachusetts 02110 Standard fo...

Page 16: ...SECTION 1 SAFETY 1 10 This page intentionally left blank ...

Page 17: ... N 22406 Junction Box required P N 22407 4 5 ft 1 4 m P N 0558001463 12 ft 4 4 m P N 0558001877 PT 24 Torch Electronic Flow Series A M one required 17 ft 5 2 m P N 0558001464 12 ft 3 6 m P N 22428 25 ft 7 6 m P N 21905 40 ft 12 2 m P N 22504 60 ft 18 m P N 21906 80 ft 24 4 m P N 22505 Power Bundle one required 100 ft 30 m P N 21907 10 ft 3 m P N 37533 20 ft 6 m P N 37534 30 ft 9 m P N 37535 60 ft ...

Page 18: ...GHT 51 lbs 23 kg WEIGHT 51 lbs 23 kg WEIGHT 51 lbs 23 kg WEIGHT 51 lbs 23 kg ELECTRONIC FLOW CONTROL BOX ELECTRONIC FLOW CONTROL BOX ELECTRONIC FLOW CONTROL BOX ELECTRONIC FLOW CONTROL BOX 6 75 171mm 10 62 270mm 19 75 502mm WEIGHT 26 5 lbs 12 kg WEIGHT 26 5 lbs 12 kg WEIGHT 26 5 lbs 12 kg WEIGHT 26 5 lbs 12 kg JUNCTION BOX JUNCTION BOX JUNCTION BOX JUNCTION BOX 2 4 Precision Plasma Technical Speci...

Page 19: ...nded Heavy Duty Hi flow Station or Pipeline Regulators Oxygen R 76 150 024 P N 19151 Recommended High capacity Station or Pipeline Regulators R 6703 P N 22236 Gas Filter Required 25 micron w bowl guard P N 56998133 2 4 3 Start Gas Technical Specifications Type N2 Air Pressure 125 psig 8 6 bar Flow 60 cfh 28 l min max varies with application Minimum Purity Required 99 995 2 4 4 Secondary Gas Techni...

Page 20: ...SECTION 2 DESCRIPTION 2 4 Page intentionally left blank ...

Page 21: ...Cable 25 micron gas filters or better are required on the supply side for the EFC to function properly 3 3 Location Ventilation is necessary to provide proper cooling of the power supply Minimize dirt dust and exposure to external heat sources Allow a minimum of two feet clearance around the power supply for free air movement Do Not Restrict Air Flow Restricting intake air with any type of filter ...

Page 22: ...ll A line wall disconnect switch with fuses or circuit breakers should be provided at the main power panel Connect the input power cable of the power source directly to the disconnect switch or a proper plug and receptacle may be purchased from a local electrical supplier See table on the next page for recommended input conductors and fuses Recommended Sizes For Input Conductors And Line Fuses Rec...

Page 23: ...htening each screw 7 Connect jumper power cables from the bottom of the main contactor to the proper input voltage marked on the auto transformer The unit is factory set for 575 V as shown to the left CAUTION Input Power Jumper Connection Input Power Jumper Connection Input Power Jumper Connection Input Power Jumper Connection Ensure each input power jumper cable is connected to Ensure each input ...

Page 24: ...rs marked on the cabinets 2 Connect all four lines in Gas Line Bundle to Flow Control Box and Junction Box Lines and connections are color coded In addition mounting plate hole spacing is asymmetrical to prevent improper connection Order of colors should be blue yellow red orange black Gas Line Bundle Gas Bundle Installation Black Red Orange Yellow Blue Mounting Plate ...

Page 25: ...oolant lines are stamped with a 6 or 7 on the fitting to assist in identification Power supply and EFC Connections to J Box Power supply and EFC Connections to J Box Power supply and EFC Connections to J Box Power supply and EFC Connections to J Box Power Supply Bundle 7 Hose Connection from power source Gas Bundle Connections Control Lead Connection from EFC 6 Hose Connection to power source Pilo...

Page 26: ...see Interconnecting Block Diagram Junction Box to Torch Connections Junction Box to Torch Connections Junction Box to Torch Connections Junction Box to Torch Connections Torch Bundle Torch Solenoid Electrical Connection Torch Pilot Arc Connection Torch Hose Power Cable Connection ...

Page 27: ... Component Interconnecting Diagram CNC Primary Power Cable Control Lead Power Supply to CNC Torch Junction Box EFC Gas Line Bundle Power Bundle Cutting Table Control Lead EFC Junction Box High Frequency 120VAC High Frequency 120VAC 25 micron Filters Work Lead Ground Rod ...

Page 28: ...ufacturing process may Residue from the hose manufacturing process may Residue from the hose manufacturing process may Residue from the hose manufacturing process may clog damage the proportional valves in your EFC clog damage the proportional valves in your EFC clog damage the proportional valves in your EFC clog damage the proportional valves in your EFC 5 Purge gas lines between supply and the ...

Page 29: ...c torch and work lead 8 Connect control lead between the console and the Electronic Flow Control Connect coolant lines of the Power Bundle CONTROL LEAD Power Source CNC Control Lead Flow Control Lead 600 amp Bus Fuse Rating Label Serial Tag Coolant In from Torch 6 Connection Coolant Out to Torch 7 Connection Remove Access Cover ...

Page 30: ...e should a leak occur in a drain from inside the sleeve should a leak occur in a drain from inside the sleeve should a leak occur in a drain from inside the sleeve should a leak occur in a service line service line service line service line Torch Mounting Options Torch Mounting Options Torch Mounting Options Torch Mounting Options The torch is normally mounted by the 2 0 inch diameter 51mm sleeve ...

Page 31: ...mulated torch coolant is REQUIRED This specially formulated torch coolant is REQUIRED This specially formulated torch coolant is REQUIRED This specially formulated torch coolant is REQUIRED This coolant also protects for freezing to 34 C coolant also protects for freezing to 34 C coolant also protects for freezing to 34 C coolant also protects for freezing to 34 C Operating the unit without coolan...

Page 32: ...uts and does not include the process gas purge required for the Series A CAUTION Mishandling Can Damage Electronic Components Handle electronic components with care Do not drop Do not bend pins Do not touch circuit components handle along edges when possible CAUTION Electronic Components Are Subject To Electro Static Discharge ESD Damage Integrated Circuit parts are sensitive to over voltages The ...

Page 33: ...NTROL CURRENT 1 Ensure the Plasmarc Power Source is disconnected from electricity source 2 Expose the PLC by removing the left side panel of the Plasmarc Power Source 3 Pop the EPROM cover on the PLC to expose the EPROM PLC EFC EPROM Package Location Left Side Panel ...

Page 34: ...RE A PULLER Release the clamp locking the EPROM in place lift the Series A EPROM from the socket 5 Remove the EFC EPROM from the packaging 6 Carefully align the EFC EPROM pins with the socket holes and insert 7 Lock the EPROM by moving the lever back while holding the EPROM in place 8 Replace the EPROM cover and the Power Source left side panel EPPESA Series A EPROM manual flow control P N 9951360...

Page 35: ...Amber indicator light to the left of the switch 4 1 2 Pilot Arc Switch Pilot Arc Switch Used to select HIGH or LOW Start Pilot Arc depending on cutting conditions See Process Data for more information on which conditions High and Low Start are used CAUTION Adjusting Pilot Arc While in Operation Could Damage Torch Do not adjust pilot arc switch while in operation Adjust before torch starts 4 1 1 Ma...

Page 36: ...Indicator fault in plasma control PCB in the inverter power source Power source will shut down Over Under Voltage fault Indicator indicate input voltage is above or below the tolerances of the PCU console Will latch until power is recycled by main power switch Emergency Stop fault indicator shows CNC Interlock condition Power Source will not work 4 1 4 Meters Cutting Current Meter A Displays actua...

Page 37: ...ll give optimal cut quality occasionally conditions may vary enough that slight adjustments will be required If so Make small incremental adjustments when making corrections Adjust Arc Voltage in 5 volt increments up or down as required Adjust cutting speed 5 or less as required until conditions improve NOTICE Before attempting ANY corrections check cutting variables with the factory recommended s...

Page 38: ...mables High standoff High arc voltage Cutting speed fast Current high or low See Process Data for recommended current level for specific nozzles 4 2 3 Cut Flatness Top And Bottom Rounded Condition usually occurs when material is 25 thick 6 4mm or less High current for given material thickness See Process Data for proper settings Part Drop Part Part Drop ...

Page 39: ...ture See Process Data Worn or damaged consumables M M M Machine Induced Roughness Can be difficult to distinguish from Process Induced Roughness Often confined to only one axis Roughness is inconsistent Dirty rails wheels and or drive rack pinion Refer to Maintenance Section in machine owners manual Carriage wheel adjustment or Machine Induced Roughness Part Drop Top View Cut Face Process Induced ...

Page 40: ...orch and cutting parameter setup Refer to Process Data High Speed Dross Material weld or rollover on bottom surface along kerf Difficult to remove May require grinding or chipping S shaped lag lines Standoff high arc voltage Cutting speed fast Slow Speed Dross Forms as globules on bottom along kerf Removes easily Cutting speed slow Cut Face Lag Lines Side View Rollover Lag Lines Cut Face Globules ...

Page 41: ... Cutting speed fast Standoff high arc voltage Intermittent Dross Appears on top or bottom along kerf Non continuous Can appear as any kind of dross Possible worn consumables Other Factors Affecting Dross Material temperature Heavy mill scale or rust High carbon alloys Side View Splatter Cut Face ...

Page 42: ... cutting performance in most cases Small incremental adjustments may be needed due to material quality material temperature and specific alloy The operator should remember that all cutting variables are interdependent Changing one setting affects all others and cut quality could deteriorate Always start at the recommended settings NOTICE Before attempting ANY corrections check cutting variables wi...

Page 43: ...utting Process Data in this section for recommended flow pressure settings 4 3 2 Aluminum Material Thickness Material Thickness Material Thickness Material Thickness All thickness between 062 to 625 1 6 mm to 15 9 mm Cut Qualities Cut Qualities Cut Qualities Cut Qualities Smooth cut face Virtually no dross Plasma Gas Plasma Gas Plasma Gas Plasma Gas Nitrogen Shield Gas Shield Gas Shield Gas Shield...

Page 44: ... nitrogen can effectively improve dross formation on thin material of 26 GA to 10 GA carbon steel Also an oxygen only shield may provide acceptable results on thinner materials Material Thickness Material Thickness Material Thickness Material Thickness 125 to 75 3 2 mm to 19 1 mm Cut Qualities Cut Qualities Cut Qualities Cut Qualities Smooth cut face Virtually no dross Plasma Gas Plasma Gas Plasma...

Page 45: ...ut Qualities Cut Qualities Cut Qualities Cut Qualities Dark cut face Virtually dross free Improved cut squareness Plasma Gas Plasma Gas Plasma Gas Plasma Gas Oxygen Shield Gas Shield Gas Shield Gas Shield Gas Oxygen Nitrogen Discussion Discussion Discussion Discussion Low amperage cutting slower speeds produce squarer cuts in thin materials The oxygen allows for a lower arc voltage improving cut s...

Page 46: ... Good cut angle Plasma Gas Plasma Gas Plasma Gas Plasma Gas Nitrogen Shield Gas Shield Gas Shield Gas Shield Gas Nitrogen Discussion Discussion Discussion Discussion Shield and plasma gases combine the volume pressure of shield gas can negatively affect cut squareness Higher shield volume produces a negative cut angle A lower volume produces a positive angle Material Thickness Material Thickness M...

Page 47: ... 24 Precision Plasmarc System In most cases these settings will provide a quality cut The data contains values for cutting aluminum carbon and stainless steel arc voltage standoff cutting speed current amperes gas flow rates for all plasma shield gas combinations This same data is contained in SDP files See your control manual for more information on SDP files Also included is information on consu...

Page 48: ...l Baffle P N P N P N P N 21536 3 holes 21536 3 holes 21536 3 holes 21536 3 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21541 B 21541 B 21541 B 21541 B Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010...

Page 49: ... 0 Setup Parameters see notes Plasma Start Gas 1 40 40 40 40 40 40 Plasma Cut Gas 1 55 55 55 55 55 55 SG1 Start 45 45 45 45 45 45 SG1 Cut 20 20 20 20 20 20 Shield Gas Flow Reading SG2 Cut Flow 10 10 10 10 10 10 Flow Reading Arc Voltage standoff 150 152 153 158 170 189 Travel Speed IPM 150 135 105 78 30 25 MM MIN 3810 3429 2667 1981 762 635 Notes 1 Pilot Arc LOW 2 Cut and ALT gas mix in Flow Contro...

Page 50: ... N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21542 C 21542 C 21542 C 21542 C Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010...

Page 51: ...elay SEC 0 0 0 0 Setup Parameters see notes Plasma Start Gas 1 45 45 45 45 Plasma Cut Gas 1 75 75 75 85 SG1 Start 55 55 55 55 SG1 Cut 20 20 20 20 Shield Gas Flow Reading SG2 Cut Flow 10 10 10 10 Flow Reading Arc Voltage standoff 136 139 152 168 Travel Speed IPM 170 130 78 46 MM MIN 4318 3302 1981 1168 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 52: ... N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21543 D 21543 D 21543 D 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010...

Page 53: ...lay SEC 0 0 0 1 0 2 Setup Parameters see notes Plasma Start Gas 1 65 65 65 65 Plasma Cut Gas 1 50 50 100 100 SG1 Start 45 45 45 45 SG1 Cut 20 20 20 20 Shield Gas Flow Reading SG2 Cut Flow 10 10 10 10 Flow Reading Arc Voltage standoff 150 157 168 182 Travel Speed IPM 80 65 55 30 MM MIN 2032 1651 1397 762 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 54: ...P N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2201...

Page 55: ...ay SEC 0 0 0 1 0 1 Setup Parameters see notes Plasma Start Gas 1 80 80 80 80 Plasma Cut Gas 1 100 100 100 100 SG1 Start 60 60 60 60 SG1 Cut 31 31 31 31 Shield Gas Flow Reading SG2 Cut Flow 10 10 10 10 Flow Reading Arc Voltage standoff 155 160 166 174 Travel Speed IPM 65 80 65 50 MM MIN 2413 2032 1778 1270 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 56: ...P N P N P N P N 21852 2 holes 21852 2 holes 21852 2 holes 21852 2 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21540 A 21540 A 21540 A 21540 A Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2201...

Page 57: ... 1 0 5 0 1 Setup Parameters see notes Plasma Start Gas 1 20 20 20 20 20 20 Plasma Cut Gas 1 11 11 11 11 11 11 SG1 Start 20 20 20 20 20 20 SG1 Cut 0 0 0 0 0 0 Shield Gas Flow Reading SG2 Cut Flow 6 6 6 6 6 6 Flow Reading Arc Voltage standoff 103 105 115 118 116 117 Travel Speed IPM 100 85 80 60 50 36 MM MIN 2540 2159 2032 1524 1270 914 Notes 1 Pilot Arc LOW 2 Cut and ALT gas mix in Flow Control 3 F...

Page 58: ...P N P N P N P N 21536 3 holes 21536 3 holes 21536 3 holes 21536 3 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21541 B 21541 B 21541 B 21541 B Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2201...

Page 59: ...ay SEC 0 0 0 0 0 Setup Parameters see notes Plasma Start Gas 1 38 38 38 38 38 Plasma Cut Gas 1 15 15 15 15 15 SG1 Start 50 50 50 50 50 SG1 Cut 0 0 0 0 0 Shield Gas Flow Reading SG2 Cut Flow 6 6 6 6 6 Flow Reading Arc Voltage standoff 113 119 120 122 124 Travel Speed IPM 80 55 52 40 30 MM MIN 3032 1397 1320 1016 762 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball...

Page 60: ...P N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21542 C 21542 C 21542 C 21542 C Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2201...

Page 61: ... 0 3 0 3 0 3 0 3 0 4 Setup Parameters see notes Plasma Start Gas 1 50 50 50 50 50 Plasma Cut Gas 1 20 20 20 20 20 SG1 Start 50 50 50 50 50 SG1 Cut 16 16 16 16 10 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 0 Flow Reading Arc Voltage standoff 108 111 114 121 124 Travel Speed IPM 60 50 45 35 20 MM MIN 1524 1270 1143 889 508 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center...

Page 62: ...P N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21543 D 21543 D 21543 D 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2201...

Page 63: ... 0 1 0 2 0 5 Setup Parameters see notes Plasma Start Gas 1 60 60 60 60 60 Plasma Cut Gas 1 25 25 25 25 25 25 SG1 Start 60 60 60 60 60 60 SG1 Cut 33 33 33 33 20 20 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 0 0 Flow Reading Arc Voltage standoff 108 110 114 113 135 140 Travel Speed IPM 110 100 70 60 30 25 MM MIN 2794 2413 1778 1524 762 635 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Contr...

Page 64: ...P N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2201...

Page 65: ... SEC 0 0 0 1 0 1 0 1 Setup Parameters see notes Plasma Start Gas 1 80 80 80 80 80 Plasma Cut Gas 1 30 30 30 30 30 SG1 Start 60 60 60 60 60 SG1 Cut 30 30 30 30 30 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 0 Flow Reading Arc Voltage standoff 115 120 132 137 143 Travel Speed IPM 90 80 50 30 25 MM MIN 2290 2030 1270 760 630 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center...

Page 66: ... P N P N P N P N 21536 3 holes 21536 3 holes 21536 3 holes 21536 3 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21541 B 21541 B 21541 B 21541 B Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 220...

Page 67: ...C 0 0 0 0 0 Setup Parameters see notes Plasma Start Gas 1 45 45 45 45 45 Plasma Cut Gas 1 18 18 18 18 18 SG1 Start 40 40 40 40 40 SG1 Cut 20 20 20 20 20 Shield Gas Flow Reading SG2 Cut Flow 5 5 5 5 5 Flow Reading Arc Voltage standoff 105 105 107 109 111 Travel Speed IPM 250 200 190 140 100 MM MIN 6350 5080 4826 3556 2540 Notes 1 Pilot Arc LOW 2 Cut and ALT gas mix in Flow Control 3 Float Center of...

Page 68: ...P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21542 C 21542 C 21542 C 21542 C Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P ...

Page 69: ...ierce Delay SEC 0 0 01 0 2 Setup Parameters see notes Plasma Start Gas 1 60 60 60 60 Plasma Cut Gas 1 95 95 95 95 SG1 Start 45 45 45 45 SG1 Cut 35 35 35 35 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 Flow Reading Arc Voltage standoff 134 140 145 155 Travel Speed IPM 90 60 40 18 MM MIN 2286 1524 1016 457 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 70: ...P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21543 D 21543 D 21543 D 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P ...

Page 71: ...rce Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 70 70 70 70 Plasma Cut Gas 1 95 95 95 95 SG1 Start 60 60 60 60 SG1 Cut 40 40 40 40 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 Flow Reading Arc Voltage standoff 131 152 158 162 Travel Speed IPM 100 50 28 20 MM MIN 2540 1270 711 609 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 72: ...P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P ...

Page 73: ...erce Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 80 80 80 80 Plasma Cut Gas 1 65 65 65 70 SG1 Start 60 60 60 60 SG1 Cut 35 35 35 40 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 Flow Reading Arc Voltage standoff 129 135 142 150 Travel Speed IPM 80 60 35 25 MM MIN 2030 1520 889 635 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 74: ...N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21543 D 21543 D 21543 D 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 ...

Page 75: ... 2 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 70 70 70 70 70 Plasma Cut Gas 1 100 100 100 100 100 SG1 Start 60 60 60 60 60 SG1 Cut 40 40 40 40 40 Shield Gas Flow Reading SG2 Cut Flow 10 10 10 10 10 Flow Reading Arc Voltage standoff 131 146 154 166 175 Travel Speed IPM 120 80 50 30 24 MM MIN 3048 2032 1270 762 609 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Flo...

Page 76: ...N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 ...

Page 77: ...e Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 80 80 80 80 Plasma Cut Gas 1 100 100 100 100 SG1 Start 60 60 60 60 SG1 Cut 40 40 40 40 Shield Gas Flow Reading SG2 Cut Flow 7 10 10 10 Flow Reading Arc Voltage standoff 140 150 159 170 Travel Speed IPM 80 60 35 25 MM MIN 2030 1524 889 635 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 78: ... N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21542 C 21542 C 21542 C 21542 C Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 220...

Page 79: ...e Delay SEC 0 0 0 1 0 2 Setup Parameters see notes Plasma Start Gas 1 60 60 60 60 Plasma Cut Gas 1 85 85 85 85 SG1 Start 45 45 45 45 SG1 Cut 35 35 35 35 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 Flow Reading Arc Voltage standoff 128 133 144 155 Travel Speed IPM 90 60 40 22 MM MIN 2286 1524 1016 558 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 80: ... N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21543 D 21543 D 21543 D 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 220...

Page 81: ... Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 70 70 70 70 Plasma Cut Gas 1 95 95 95 95 SG1 Start 60 60 60 60 SG1 Cut 40 40 40 40 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 Flow Reading Arc Voltage standoff 132 150 154 159 Travel Speed IPM 75 50 28 24 MM MIN 1905 1270 711 609 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 82: ... N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 220...

Page 83: ...e Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 80 80 80 80 Plasma Cut Gas 1 95 95 95 95 SG1 Start 60 60 60 60 SG1 Cut 50 35 35 35 Shield Gas Flow Reading SG2 Cut Flow 0 0 0 0 Flow Reading Arc Voltage standoff 135 145 153 157 Travel Speed IPM 80 60 35 25 MM MIN 2032 1520 889 635 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 84: ...le P N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21543 D 21543 D 21543 D 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2...

Page 85: ...ce Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 75 75 75 75 Plasma Cut Gas 1 85 85 85 85 SG1 Start 60 60 60 60 SG1 Cut 43 43 43 43 Shield Gas Flow Reading SG2 Cut Flow 5 5 5 5 Flow Reading Arc Voltage standoff 136 150 159 162 Travel Speed IPM 75 50 28 24 MM MIN 1905 1270 711 609 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 86: ...le P N P N P N P N 21692 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 2...

Page 87: ...rce Delay SEC 0 3 0 4 0 5 0 6 Setup Parameters see notes Plasma Start Gas 1 80 80 80 80 Plasma Cut Gas 1 95 95 95 95 SG1 Start 50 70 60 42 SG1 Cut 45 45 45 42 Shield Gas Flow Reading SG2 Cut Flow 5 5 5 7 Flow Reading Arc Voltage standoff 138 150 162 170 Travel Speed IPM 80 60 35 25 MM MIN 2032 1524 889 635 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 88: ... 21536 3 Holes P N 21536 3 Holes P N 21536 3 Holes Nozzle Nozzle Nozzle Nozzle P N 21541 B P N 21541 B P N 21541 B P N 21541 B Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 89: ... Parameters see notes Plasma Start Gas 1 35 Plasma Cut Gas 1 35 SG1 Start 35 SG1 Cut 35 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 200 MM MIN 5080 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 90: ... 21536 3 holes P N 21536 3 holes P N 21536 3 holes Nozzle Nozzle Nozzle Nozzle P N 21541 B P N 21541 B P N 21541 B P N 21541 B Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 91: ... Parameters see notes Plasma Start Gas 1 35 Plasma Cut Gas 1 35 SG1 Start 35 SG1 Cut 35 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 300 MM MIN 7620 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 92: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N 21542 C P N 21542 C P N 21542 C P N 21542 C Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 93: ... Parameters see notes Plasma Start Gas 1 62 Plasma Cut Gas 1 62 SG1 Start 37 SG1 Cut 37 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 100 MM MIN 2540 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 94: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N 21542 C P N 21542 C P N 21542 C P N 21542 C Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 95: ... Parameters see notes Plasma Start Gas 1 62 Plasma Cut Gas 1 62 SG1 Start 35 SG1 Cut 35 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 200 MM MIN 5080 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 96: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N 21543 D P N 21543 D P N 21543 D P N 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 97: ...Parameters see notes Plasma Start Gas 1 77 Plasma Cut Gas 1 77 SG1 Start 100 SG1 Cut 100 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 100 MM MIN 2540 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 98: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 99: ... Parameters see notes Plasma Start Gas 1 62 Plasma Cut Gas 1 62 SG1 Start 37 SG1 Cut 37 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 300 MM MIN 7620 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 100: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N 21543 D P N 21543 D P N 21543 D P N 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 101: ...Parameters see notes Plasma Start Gas 1 77 Plasma Cut Gas 1 77 SG1 Start 100 SG1 Cut 100 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 200 MM MIN 5080 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 102: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N 21543 D P N 21543 D P N 21543 D P N 21543 D Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 103: ...arameters see notes Plasma Start Gas 1 77 Plasma Cut Gas 1 77 SG1 Start 100 SG1 Cut 100 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 500 MM MIN 12700 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 104: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 105: ...Parameters see notes Plasma Start Gas 1 85 Plasma Cut Gas 1 85 SG1 Start 100 SG1 Cut 100 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 100 MM MIN 2540 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 106: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 107: ...Parameters see notes Plasma Start Gas 1 85 Plasma Cut Gas 1 85 SG1 Start 100 SG1 Cut 100 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 300 MM MIN 7620 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 108: ... 4 holes 21692 4 holes 21692 4 holes 21692 4 holes Nozzle Nozzle Nozzle Nozzle P N P N P N P N 21923 E 21923 E 21923 E 21923 E Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser Nozzle Retainer Diffuser P N 22007 P N 22007 P N 22007 P N 22007 Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator Shield Cup Insulator P N 22010 P N 22010 P N 22010 P N 22010 Insulator...

Page 109: ...arameters see notes Plasma Start Gas 1 85 Plasma Cut Gas 1 85 SG1 Start 100 SG1 Cut 100 Shield Gas Flow Reading SG2 Cut Flow 0 Flow Reading Arc Voltage standoff 77 Travel Speed IPM 500 MM MIN 12700 Notes 1 Pilot Arc HIGH 2 Cut and ALT gas mix in Flow Control 3 Float Center of Ball ...

Page 110: ... 775 6 350 0 087 0 065 0 060 0 050 0 050 0 050 2 210 1 651 1 524 1 270 1 270 1 270 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 062 0 075 0 090 0 125 0 187 0 250 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 1 575 1 905 2 286 3 175 4 750 6 350 Aluminum N2 N2 CH4 30 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Ker...

Page 111: ...5 12 700 15 875 0 120 0 100 0 112 0 100 3 048 2 540 2 845 2 540 0 050 0 070 0 090 0 110 0 130 0 150 0 170 0 190 0 187 0 250 0 375 0 500 1 270 1 778 2 286 2 794 3 302 3 810 4 318 4 826 4 750 6 350 9 525 12 700 Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm Kerf inches Aluminum N2 N2 CH4 70 Amperes Aluminum N2 N2 CH4 100 Am...

Page 112: ...524 2 032 2 540 3 048 3 556 1 524 3 175 6 350 0 058 0 044 1 473 1 118 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 048 0 134 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 1 219 3 404 Carbon Steel O2 N2 O2 16 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm Kerf inches Carbon Steel O2 N2 O2 35 Amperes ...

Page 113: ...3 429 6 350 9 525 12 700 0 095 0 076 0 064 2 413 1 930 1 626 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 125 0 250 0 375 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 3 175 6 350 9 525 Carbon Steel O2 N2 O2 45 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm Kerf inches Carbon Steel O2 N2 O2 70 Amperes ...

Page 114: ...8 2 540 2 337 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 375 0 500 0 750 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 9 525 12 700 19 050 Carbon Steel O2 N2 O2 100 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches ...

Page 115: ...35 0 035 1 143 0 889 0 889 0 889 0 889 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 26GA 24GA 22GA 18GA 16GA 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 0 457 0 584 0 726 1 207 1 588 Stainless Steel O2 N2 O2 30 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches ...

Page 116: ... 525 12 700 15 875 0 115 0 100 0 090 0 080 0 070 2 921 2 540 2 286 2 032 1 778 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 125 0 188 0 250 0 375 0 500 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 3 175 4 775 6 350 9 525 12 700 Stainless Steel Air Air CH4 70 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm K...

Page 117: ...4 826 6 350 9 525 12 700 15 875 0 115 0 105 0 095 0 080 2 921 2 667 2 413 2 032 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 187 0 250 0 375 0 500 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 4 750 6 350 9 525 12 700 Stainless Steel N2 N2 CH4 70 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm Kerf inches St...

Page 118: ...48 3 556 4 750 6 350 9 525 12 700 0 080 0 070 0 065 0 060 2 032 1 778 1 651 1 524 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 125 0 187 0 250 0 375 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 3 175 4 750 6 350 9 525 Stainless Steel N2 N2 50 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm Kerf inches Stain...

Page 119: ...8 2 794 2 540 0 050 0 070 0 090 0 110 0 130 0 150 0 170 0 190 0 250 0 375 0 500 0 625 1 270 1 778 2 286 2 794 3 302 3 810 4 318 4 826 6 350 9 525 12 700 15 875 Stainless Steel N2 N2 100 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches ...

Page 120: ...8 3 556 4 750 6 350 9 525 12 700 0 095 0 080 0 065 0 060 2 413 2 032 1 651 1 524 0 000 0 020 0 040 0 060 0 080 0 100 0 120 0 140 0 125 0 187 0 250 0 375 0 000 0 508 1 016 1 524 2 032 2 540 3 048 3 556 3 175 4 750 6 350 9 525 Stainless Steel Air Air 50 Amperes Material Thickness mm Material Thickness inches Kerf mm Kerf inches Material Thickness mm Material Thickness inches Kerf mm Kerf inches Stai...

Page 121: ... 3 556 4 064 0 050 0 070 0 090 0 110 0 130 0 150 0 170 0 190 0 250 0 375 0 500 0 625 1 270 1 778 2 286 2 794 3 302 3 810 4 318 4 826 6 350 9 525 12 700 15 875 Material Thickness mm Material Thickness inches Kerf mm Kerf inches Stainless Steel Air Air 100 Amperes ...

Page 122: ...SECTION 4 OPERATION 4 88 Page intentionally left blank ...

Page 123: ...cleaning of the Precision Plasmarc System is recommended for safety and proper operation Consider the following during inspection and cleaning Check work cable to workpiece connection Check safety earth ground at workpiece and at power source chassis Check heat shield on torch Replace if damaged Check torch electrode and cutting nozzle for wear daily Ensure cable and hoses are not damaged or kinke...

Page 124: ...ch can be mounted by the 2 51 mm dia sleeve or by the 1 812 46 mm dia machined surface shown This insulated surface and its shoulder are machined relative to the nozzle retainer thread on the torch body They are held concentric to the cutting nozzle within a total indicator reading of 0 010 0 25 mm or the nozzle bore is within 0 005 of any point on the 1 812 dia When mounting do not to cover the s...

Page 125: ...r Pressure Switch CH4 100 psi N2 125 psi O2 125 psi Process Air Argon Interface Board H35 100 psi PG1 PG2 SG1 SG2 PT 24 Torch Electronic Manifold Assembly EFC J Box Gas Quick Coupling 2 Way Solenoid Valve Check Valve Check Valve Flow Meter Sentronic Valve Pressure Switch Solenoid Valve PG1 BLU PG2 YEL SG1 ORG SG2 BLK Note Shop air should not be used for process air Gas In from supply METH N2 3 N2 ...

Page 126: ...ant OUT from the torch is through the pilot arc line Water Cooling Water Cooling Water Cooling Water Cooling 1 Coolant enters the torch through the power cable 2 circulates through the torch body and the electrode 3 crosses over to the nozzle section of the torch body through nonconductive crossover tubes 4 travels back through the body and circulates between the nozzle retainer and the nozzle 5 b...

Page 127: ...ozzle is especially critical Damage or wear is not readily apparent because of its location We recommend replacing this O ring on a daily basis Be careful not to scratch or damage the torch surface A wooden toothpick works well for removing O rings The O ring can be replaced without removing the water baffle P N 21725 however if the baffle is removed always use a 3 16 5 mm hex wrench or nut driver...

Page 128: ...actory replacement parts replaced with factory replacement parts replaced with factory replacement parts replaced with factory replacement parts Using non authorized or damaged torch check Using non authorized or damaged torch check Using non authorized or damaged torch check Using non authorized or damaged torch check valve parts will affect set pressures and cause poor valve parts will affect se...

Page 129: ...e running and coolant pressure behind the retainer will prevent it from turning freely Check the console before attempting to remove the nut Notice that a small amount of coolant is lost each time consumables are removed This is normal and the coolant will eventually have to be replaced Check coolant before each operation 1 Unscrew the cup shield retainer Inspect around orifice for damage Replace ...

Page 130: ...Use the tool provided to remove the nozzle Place the slot around the nozzle groove and pull it free 6 Remove the swirl baffle from the nozzle If the baffle remains in the torch it will come free when removing the electrode Check the small gas passages of the swirl baffle for blockage and clear blockages with an air stream If blockages cannot be cleared replace baffle Do NOT Do NOT Do NOT Do NOT in...

Page 131: ...ozzle with the grooved end of the baffle going inside nozzle When properly assembled the small spherical tip of nozzle makes a metal to metal coolant seal with the nozzle retainer Apply a small amount of Krytox anti seizing compound on the small diameter of the nozzle retainer as shown This grease prevents possible galling seizing between the nozzle and retainer It also facilitates a watertight se...

Page 132: ...ainer onto the torch and hand tighten CAUTION O Ring Inspection Lubrication Inspect O rings often for nicks and wear Worn or Inspect O rings often for nicks and wear Worn or Inspect O rings often for nicks and wear Worn or Inspect O rings often for nicks and wear Worn or damaged O rings will affect starting and cut damaged O rings will affect starting and cut damaged O rings will affect starting a...

Page 133: ...rior to performing maintenance 6 2 Programmable Logic Controller PLC Located in the Precision Plasma Power Source Capable of providing predefined outputs depending on state of the inputs The precise conditions are programmed and permanently stored in the PLC Visible through the plexiglas window on the left side panel of the power source Provides predefined outputs in response to input signals from...

Page 134: ...hese indications are useful in isolating a system failure to the most likely device The LEDs are divided into two groups Input 0 15 light when the corresponding signal is detected by the PLC Output 0 11 light when the PLC issues a signal to an external device 6 2 2 PLC LED Functions INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT LED LED LED LED Function Function Function Function LED LED LED ...

Page 135: ...in arc voltage when an automatic height control is in use Usually the voltage change is the result of plate falling away from the arc These problems can effectively be eliminated by disabling the height control and extinguishing the arc earlier when finishing the cut on a falling plate Diving can also be caused by a faulty height control Piercing Standoff Too Low Piercing Standoff Too Low Piercing...

Page 136: ...ve in torch body may be stuck open body may be stuck open body may be stuck open body may be stuck open See maintenance section for check valve repair 6 3 5 No Preflow No start signal No start signal No start signal No start signal Check input 0 LED on PLC Should be lit This verifies a start command has been given Emergency stop signal open Emergency stop signal open Emergency stop signal open Eme...

Page 137: ... Start gas flow too low Start gas flow too low Check Process Data cutting parameters 6 3 8 Short Electrode Life Insufficient cooling Insufficient cooling Insufficient cooling Insufficient cooling Check pump for 115 130 psi output pressure Start gas quality Start gas quality Start gas quality Start gas quality Gas quality needs to be 99 995 purity minimum Cut gas quality Cut gas quality Cut gas qua...

Page 138: ...O2 1 AIR 1 10 9 8 7 6 5 4 3 2 1 8 7 6 10 5 9 4 3 2 1 10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 1 2 3 4 5 9 8 7 6 1 2 4 5 3 10 4 amp COMMON 4 8 7 6 2 3 5 1 VALVE 1 SHIELD SH VALVE 1 GND GN VALVE 1 SET PT SP VALVE 1 24 VALVE PR VALVE 2 SHIELD SH VALVE 2 GND GN VALVE 2 SET PT SP VALVE 2 24V PR VALVE 3 SHIELD SH VALVE 3 GND VALVE 3 SET PT SP VALVE 3 24 V PR VALVE 4 SHIELD SH VALVE 4 GND GN VALVE 4 SET PT SP VAL...

Page 139: ...LVE 4 6 BAR SENTRONIC Ar Air O2 N2 METH PT 24 Torch Gas Quick Coupling 2 Way Solenoid Valve Check Valve Check Valve Flow Meter Sentronic Valve Pressure Switch Solenoid Valve EFC Junction Box Electronic Manifold Assembly Interface Board PG1 BLU PG2 YEL SG1 ORG SG2 BLK CH4 100 psi H35 100 psi N2 125 psi O2 125 psi Process Air 125 psi Argon 125 psi 6 5 Gas Flow Schematic ...

Page 140: ...U T3 X2 BLU T1 X1 RED T3 X1 RED SG1 2 BLU T1 X2 BLU C2 C1 SG1 1 2 1 2 PILOTARC J2 PCB1 2 BLU SPLICE J2 5 WHT J2 6 WHT J2 7 WHT J2 8 WHT J1 C WHT A GRN GND1 B BLU J2 2 C WHT SPLICE D E F YEL J2 1 G H I J BLK J2 3 K L ORN J2 4 M GRY T3 H1 N BLK T3 H2 J1 1 YEL J1 F 2 BLU J1 B 3 BLK J1 J 4 ORN J1 L 5 WHT SPLICE 6 WHT SPLICE 7 WHT SPLICE 8 WHT SPLICE 9 J2 DENOTES IN LINE SPLICE DENOTES SELF LEAD 6 6 Ju...

Page 141: ...V 2500pf 15KV X1 X2 X3 PCB1 GND1 1 3 2 X1 X2 X3 T1 T2 NEG PILOT ARC TORCH CONNECTIONS J1 PLASMA 1 SOLENOID COMMON PLASMA 2 SHIELD GAS 1 SHIELD GAS 2 2 5 6 7 8 1 3 4 9 J2 6 5 3 4 1 2 BLU PG 1 PG 2 ORG SG 1 SG 2 BLK MANIFOLD EFC A M YEL CABLE CONNECTIONS TO CONSOLE NEG PILOT ARC WORK SCHEMATIC DIAGRAM 6 7 Junction Box Schematic ...

Page 142: ...12 12 11 10 9 8 J1 7 6 5 4 3 2 1 16 14 15 13 4 8 10 9 7 6 5 J3 3 2 1 J2 2 6 7 8 3 5 4 1 J1 1 16 J2 1 8 J3 1 10 H1 H2 L1 L2 T3 TB3 SH1 BUSS TO SH1 TS2 2 SPLICE VIO TS1 1 VIO PCB1 P5 1 ORN PCB1 P5 2 WHT PCB1 P5 5 BLK PCB1 P5 6 RED PCB1 P6 12 BLU PCB1 P6 14 BRN PCB1 P2 12 YEL PCB1 P2 12 YEL PCB1 P2 13 GRY PCB1 P2 13 GRY PCB1 P6 10 BLK PCB1 P6 11 RED PCB1 P6 13 ORN PCB1 P6 10 BLK PCB1 P6 11 RED J4 1 B...

Page 143: ... 6 YEL J3 4 ORN J3 3 RED J3 2 WHT J3 1 BLK J3 1 BLK G BLK BLK T1 H1 RED T1 H3 GRY T1 H3 GRY 1 4 SOLDERING AND CRIMPING WIRES AND TERMINALS ARE OF THIS POWER MODULE ADDITIONAL INSPECTION OF THIS POWER MODULE ADDITIONAL INSPECTION VERY IMPORTANT TO THE OPERATION AND RELIABILITY VERY IMPORTANT TO THE OPERATION AND RELIABILITY MUST BE DONE 3 TP DENOTES TWISTED PAIR 3 TP DENOTES TWISTED PAIR Power Modu...

Page 144: ...SECTION 6 TROUBLESHOOTING 6 12 E2 E2 G2 E1 G1 C1 C2E1 C x Q x 4 6 9 Precision Plasma Power Module Schematic DETAIL ...

Page 145: ... GRY TB3 21 GRY TB3 21 GRY TB3 21 GRY TB3 20 BLU TB3 20 BLU TB3 20 BLU TB3 20 BLU PLC 0101 VIO PLC 0101 VIO PLC 0101 VIO PLC 0101 VIO PLC1 J2 9 GRY PLC1 J2 9 GRY PLC1 J2 9 GRY PLC1 J2 9 GRY PLC 0110 WHT PLC 0110 WHT PLC 0110 WHT PLC 0110 WHT K6 A YEL K6 A YEL K6 A YEL K6 A YEL PLC 0111 BRN PLC 0111 BRN PLC 0111 BRN PLC 0111 BRN PLC 0109 GRY PLC 0109 GRY PLC 0109 GRY PLC 0109 GRY K5 A BLK K5 A BLK ...

Page 146: ... T3 H6 ORN T3 H6 ORN T3 H5 BRN T3 H5 BRN T3 H5 BRN T3 H5 BRN T3 H4 YEL T3 H4 YEL T3 H4 YEL T3 H4 YEL T3 H3 GRY T3 H3 GRY T3 H3 GRY T3 H3 GRY T3 H2 BLK T3 H2 BLK T3 H2 BLK T3 H2 BLK F4 2 BLU F4 2 BLU F4 2 BLU F4 2 BLU BLK BLK BLK BLK CB2 1 RED CB2 1 RED CB2 1 RED CB2 1 RED TB2 4 YEL TB2 4 YEL TB2 4 YEL TB2 4 YEL TB2 5 BRN TB2 5 BRN TB2 5 BRN TB2 5 BRN TB2 6 ORN TB2 6 ORN TB2 6 ORN TB2 6 ORN TB2 7 V...

Page 147: ... 10 ORN TB3 9 BLU TB3 9 BLU TB3 9 BLU TB3 9 BLU TB3 12 VIO TB3 12 VIO TB3 12 VIO TB3 12 VIO TB3 11 RED TB3 11 RED TB3 11 RED TB3 11 RED TB3 16 BLK TB3 16 BLK TB3 16 BLK TB3 16 BLK F3 1 RED F3 1 RED F3 1 RED F3 1 RED TB3 19 YEL TB3 19 YEL TB3 19 YEL TB3 19 YEL TB3 18 VIO TB3 18 VIO TB3 18 VIO TB3 18 VIO 6 6 6 6 5 5 5 5 4 4 4 4 3 3 3 3 2 2 2 2 1 1 1 1 13 13 13 13 12 12 12 12 11 11 11 11 10 10 10 10 ...

Page 148: ...6 VIO PLC COMM4 BLU 3 1 6 9 B 4 7 A K8 R8 R7 R1 1 2 1 2 1 2 S2 6 ORN S2 3 BLK R10 1 2 BLU MOD1 SH1 1 GRY R9 1 2 BLU BLU BLU BLU K7 K6 K5 K4 K3 1 3 A B 4 6 7 9 9 6 B 3 1 7 4 A 1 3 9 B 6 A 4 7 6 B 9 3 1 7 4 A 6 B 9 3 1 7 4 A TB4 2 BRN TB4 2 BRN TB4 2 BRN TB4 2 BRN J1 K YEL TB4 1 VIO J1 G BLK PLC 0003 YEL TB4 1 VIO PLC 0105 WHT PLC1 J2 13 GRY PLC 0104 VIO PLC1 J2 12 ORN PLC1 J2 11 WHT PLC 24VDC GRY T...

Page 149: ...3 13 WHT PCB1 P1 13 BLK PCB1 P1 14 RED PCB1 P3 18 BLU PCB TB P1 1 YEL R2 1 ORN NOT USED PCB1 P4 3 RED PCB1 P4 4 YEL PCB1 P4 15 BLU PCB1 P4 16 ORN TB6 6 BRN TB6 8 GRY PCB1 P4 11 RED PCB1 P4 12 BLK PCB1 P4 13 VIO PCB1 P4 14 YEL TB5 WORK BLK R10 1 GRY PCB1 P2 16 YEL PCB1 P2 8 GRY PCB1 P2 9 RED PCB1 P2 10 GRY PCB1 P10 4 WHT PCB1 P10 3 BLK PCB1 P10 5 WHT PLC1 P2 1 VIO PCB1 P9 3 BLK PCB1 P9 1 RED PLC1 P...

Page 150: ... 15 16 9 10 10 9 8 7 6 5 4 3 2 1 J2 P1 P3 P4 P4 3 P4 4 P4 15 P4 16 P10 2 P10 1 P4 11 P4 12 P4 13 P4 14 SH1 2 SH1 1 TB3 1 6 5 4 3 2 1 575V 460V 415V 380V 230V 200V BH1 BH2 BH3 BH4 BH5 BH6 BH8 BH7 7 8 9 10 11 12 200V 230V 380V 415V 460V 575V 200V 230V 380V 415V 460V 575V 13 14 15 16 17 18 CH1 CH2 CH3 CH4 CH5 CH6 CH8 CH7 MOV1 610V MOV2 610V MOV3 610V S1 P2 1 SETTING P9 3 P9 1 P4 1 P4 2 P4 7 P4 8 P4 9...

Page 151: ... 20 18 15 16 14 10 12 13 PLC 24VDC 24VDC 0 0 0 0 0 0 0 1 0 0 0 2 0 0 0 3 0 0 0 4 0 0 0 6 0 0 0 7 COMM7 0 1 1 1 0 1 1 0 0 1 0 9 0 1 0 8 COMM6 0 1 0 7 0 1 0 6 0 1 0 5 0 1 0 4 COMM3 0 1 0 1 COMM2 0 1 0 0 L 2 L 1 COMM5 0 1 0 3 COMM4 0 1 0 2 ZD3 TO JUNCTION BOX J1 TO CUTTING MACHINE CNC 1 2 3 4 7 9 8 10 5 6 14 11 12 13 TB4 1 PA 15 TB4 2 TB6 5 TB6 4 TB6 2 R6 39K 2W 2W 39K R5 R S T U V 2 F3 1 1A HI LO 6 ...

Page 152: ...Understanding The Operation Of The Electronic Flow Control Introduction Introduction Introduction Introduction The following information is a guide for troubleshooting The Precision Plasma Electronic Flow Control Knowledge of machine and control operation is required ...

Page 153: ...ionary AHC disabled machine moving Plasma Arc Delay Plasma Arc Delay Plasma Arc Delay Plasma Arc Delay The interval of time for filtering the arc on signal to allow the signal to assume a stable mode condition Plasma process cut gas flows are in effect during this time Master Up Master Up Master Up Master Up The interval of time allowed to raise the plasma torch after receipt of a plasma process o...

Page 154: ... 0 4 0 4 0 6 0 6 0 6 0 6 0 V V V V Plasma Pierce Time 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 0 50 0 50 0 50 0 Plasma Ahc Delay 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 50 0 50 0 50 0 50 0 Plasma Arc Delay 0 3 0 3 0 3 0 3 0 0 0 0 0 0 0 0 0 5 0 5 0 5 0 5 V V V V Master Up 2 0 2 0 2 0 2 0 0 0 0 0 0 0 0 0 50 0 50 0 50 0 50 0 Analog Channel Disable 600 0 600 0 600 0 600 0 600 0 600 0 600 0 600 0 600 0 600 0 600 0 6...

Page 155: ...s the machine operator to manually test adjust the plasma process start parameters with the exception of the plasma gas 2 start flow Plasma Gas 2 Test Icon F5 F5 F5 F5 Push Button Push Button Push Button Push Button Icon permits the machine operator to manually test adjust the plasma gas 2 start flow The plasma start parameter test icon must be plasma start parameter test icon must be plasma start...

Page 156: ...0 0 100 0 0 0 100 0 0 0 255 0 Plasma Gas 2 Start Flow Analog Out 0 0 0 0 100 0 0 0 100 0 0 0 255 0 Plasma Gas 2 Cut Flow Analog Out 0 0 0 0 100 0 0 0 100 0 0 0 255 0 Shield Gas 1 Start Flow Analog Out 0 0 0 0 100 0 0 0 100 0 0 0 255 0 Shield Gas 1 Cut Flow Analog Out 0 0 0 0 100 0 0 0 100 0 0 0 255 0 Shield Gas 2 Start Flow Analog Out 0 0 0 0 100 0 0 0 100 0 0 0 255 0 Shield Gas 2 Cut Flow Analog ...

Page 157: ...s Shield Gas Shield Gas Abbreviation Abbreviation Abbreviation Abbreviation Cutting Record Flag Cutting Record Flag Cutting Record Flag Cutting Record Flag Carbon steel O2 N2 CS1 O2 N2 M1000000000000000 Carbon steel O2 N2 with O2 mix CS2 O2 N2 O2 M0100000000000000 Carbon steel O2 O2 CS3 O2 O2 M0000000000010000 Stainless steel N2 N2 SS1 N2 N2 M0010000000000000 Stainless steel N2 N2 with CH4 mix SS2...

Page 158: ...P file selected Station on Plasma stop Error condition Station on Process Postflow yes yes yes yes yes yes yes yes yes no no no no no no no no no Test start Station on New SDP files selected Plasma test Plasma test cut Plasma test start O2 Test start O2 Station on New SDP file selected Plasma test Plasma test cut Plasma test start O2 Test cut Station on New SDP file selected Plasma test Plasma tes...

Page 159: ... X X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torch Solenoid Valve X X X X X X X X Shield Gas 1 1 1 1 Torch Solenoid Valv...

Page 160: ... 1 1 1 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2...

Page 161: ...ror monitoring charts 6 12 9 Gas Error Monitoring Carbon Steel PG O2 SG N2 Line Vent Line Vent Line Vent Line Vent Flow Control Vent Flow Control Vent Flow Control Vent Flow Control Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fill Ready Ready Ready Ready Process Start Process Start Process Start Process Start Process Cut Process Cut Process Cut Process Cut P...

Page 162: ... 1 1 X X X X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Tor...

Page 163: ...ring charts 6 12 11 Gas Error Monitoring Carbon Steel PG O2 SG N2 O2 Line Vent Line Vent Line Vent Line Vent Flow Control Vent Flow Control Vent Flow Control Vent Flow Control Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fill Ready Ready Ready Ready Process Start Process Start Process Start Process Start Process Cut Process Cut Process Cut Process Cut Process...

Page 164: ...alve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torch Solenoid Valve X X X X X X X X X X X X X X X X...

Page 165: ...toring charts 6 12 13 Gas Error Monitoring Carbon Steel PG O2 SG O2 Line Vent Line Vent Line Vent Line Vent Flow Control Vent Flow Control Vent Flow Control Vent Flow Control Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fill Ready Ready Ready Ready Process Start Process Start Process Start Process Start Process Cut Process Cut Process Cut Process Cut Process ...

Page 166: ...X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve CH CH CH CH4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torc...

Page 167: ...al valve requirement charts and gas error monitoring charts 6 12 15 Gas Error Monitoring Stainless Steel PG N2 SG N2 Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fill Ready Ready Ready Ready Process Start Process Start Process Start Process Start Process...

Page 168: ... X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve CH CH CH CH4 4 4 4 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torch...

Page 169: ...rement charts and gas error monitoring charts 6 12 17 Gas Error Monitoring Stainless Steel PG N2 SG N2 CH4 Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fill Ready Ready Ready Ready Process Start Process Start Process Start Process Start Process Cut Proce...

Page 170: ...X X X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 To...

Page 171: ...lve requirement charts and gas error monitoring charts 6 12 19 Gas Error Monitoring Stainless Steel PG Air SG Air Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fill Ready Ready Ready Ready Process Start Process Start Process Start Process Start Process Cu...

Page 172: ...lenoid Valve Air 1 Air 1 Air 1 Air 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X...

Page 173: ...9 10 11 Section 6 7 7 for details 12 Numbers correspond to columns on solenoid proportional valve requirement charts and gas error monitoring charts 6 12 21 Gas Error Monitoring Stainless Steel PG Air SG Air CH4 Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Li...

Page 174: ...X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torch Sole...

Page 175: ...3 3 4 5 6 7 8 9 10 11 Section 6 7 7 for details 12 Numbers correspond to columns on solenoid proportional valve requirement charts and gas error monitoring charts 6 12 23 Gas Error Monitoring Aluminum PG N2 SG N2 Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill L...

Page 176: ...Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torch So...

Page 177: ...7 8 9 10 11 Section 6 7 7 for details 12 Numbers correspond to columns on solenoid proportional valve requirement charts and gas error monitoring charts 6 12 25 Gas Error Monitoring Aluminum PG N2 SG N2 CH4 Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Line Fi...

Page 178: ... X Shield Gas 1 1 1 1 Supply Solenoid Valve Air 1 Air 1 Air 1 Air 1 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve N N N N2 2 2 2 3 3 3 3 X X X X Shield Gas 2 2 2 2 Supply Solenoid Valve Ch Ch Ch Ch4 4 4 4 Plasma Gas 1 1 1 1 Torch Solenoid Valve X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Plasma Gas 2 2 2 2 Torch...

Page 179: ...2 13 3 4 5 6 7 8 9 10 11 Section 6 7 7 for details 12 Numbers correspond to columns on solenoid proportional valve requirement charts and gas error monitoring charts Gas Error Monitoring Marking PG Argon SG Air Line Vent Line Vent Line Vent Line Vent Flow Control Flow Control Flow Control Flow Control Vent Vent Vent Vent Line Purge Line Purge Line Purge Line Purge Line Fill Line Fill Line Fill Lin...

Page 180: ...SECTION 6 TROUBLESHOOTING 6 48 This page intentionally left blank This page intentionally left blank This page intentionally left blank This page intentionally left blank ...

Page 181: ... Cutting Products ATTN Customer Service Department PO Box 100545 Ebenezer Road Florence SC USA 29501 0545 Phone 843 664 4405 800 ESAB 123 372 3123 ESAB Cutting Systems Canada 6010 Tomken Road Mississauga Ontario Canada L5T 1X9 Phone 905 670 0220 Fax 905 670 4879 ESAB_HANCOCK GmbH Cutting Technologies P O Box 1128 D 61174 Karbon Robert Bosch Strasse 20 D 61184 Karbon Phone 49 60 39 40 0 Fax 49 60 3...

Page 182: ...SECTION 7 REPLACEMENT PARTS 7 2 1 2 3 4 5 6 7 8 7 3 Plasmarc Power Source Exterior Components ...

Page 183: ... Symbol Elec Ay Description 1 2 3 4 5 6 7 8 D 35925YL A 995227 B 2091514 A 34941 A 13734588 C 35924YL D 35923YL 61328087 Cover Top Label Warning Exposed High Volt Label Warning Lens Clear Logo ESAB Clear Panel Right Side Panel Left Side Screw HMH 20 X 50 L ...

Page 184: ...SECTION 7 REPLACEMENT PARTS 7 4 1 2 3 4 5 6 7 8 9 10 11 See TEE Detail Page 7 12 ...

Page 185: ...A 8951061 A 8634518 A 2234589 B 954751 D 32286GY A 8598481 C 952182 C 36346GY S1 S2 3 AM1 VM1 AM1 VM1 S2 3 R2 Switch Toggle 2PST 2 Pos 15A Switch Toggle DPDT 2 Pos 15A Meter LED 5VDC Meter LED 5VDC Switch Toggle DPDT 2 Pos 15A POT 10K 10 Turn Overlay Precision Plasma Panel Front Gauge 200 PSI Spout Remote Filler w Cap BRKT Remote Filler ...

Page 186: ...SECTION 7 REPLACEMENT PARTS 7 6 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 187: ...571 D 32202GY A 858V75 A 954599 A 8950829 A 950937 A 13730763 A 8950874 J1 J2 F4 CB1 CB2 Door Access Rear Conn Box Recpt 19 FS SH Conn Box Recpt 14 FS SH 3 Strain Relief Plug Hole 875 Dia 125 CT Nyl BK Fuse 7A 600 VAC Fast Acting Panel Rear Adaptor B A W F NPTM BKHD Label Rating Precision Plasma Circuit Breaker 3 AMP Strain Relief Plate Serial Circuit Breaker 7 AMP ...

Page 188: ...SECTION 7 REPLACEMENT PARTS 7 8 1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 17 Reference PCB1 Isolation Amp Reference Meter LED AM1 VM1 3 18 7 4 Plasmarc Power Source Internal Components ...

Page 189: ...952095 71200732 TB4 PCB1 PCB1 P9 7 PCB1 P10 PCB1 P1 3 4 PCB1 P2 PCB1 P5 PLC PCB2 K3 6 8 R1 7 8 9 K7 T2 Base Precision Plasma Term Block 2 pos PCB Isolation AMP Housing Contact Crimp 3 pin Standoff 6 32 X 88 L Plug 5 Pos Plug 18 Pos Plug 16 Pos Receptacle P C 4 Pos Box PLC PLC Controller Board PC Startup Relay Enclosed DPDT 24VAC Resistor 300W 20ohm 10 Relay Enclose DPDT 120VAC 20A Caster Fixed XFM...

Page 190: ...SECTION 7 REPLACEMENT PARTS 7 10 9 10 7 8 1 2 3 4 5 6 7 11 12 13 14 ...

Page 191: ...02GY A82062334 C 36417GY A951215 A8951347 A8950179 A 810Z30 A 182W82 A 37348 B 33551 C 837805 C 32203GY TB2 K1 M1 M2 T3 Terminal Block Contactor 3 Pole 75A Shroud Fan Motor Fan Shroud Fan Motor Carb 1 3 Hp Pump Carb w Strainer Tee Pipe Branch Brs Adaptor B A W M NPTM Elbow 90 DEG NPT Kit Wire Primary BRKT Water Tank Auto XFMR BRKT Auto XFMR ...

Page 192: ...SECTION 7 REPLACEMENT PARTS 7 12 7 9 2 8 7 9 3 13 10 12 11 X5 1 4 5 6 2 3 7 8 9 TEE Detail ...

Page 193: ...A 182W82 A 810Z30 A 8994471 A 8952179 C 952182 A 952181 FS1 Hose Assy Pump Outlet Torch out Switch Flow 25 GPM SPSTB Valve Check Assy Hose Assy Flowswitch To Core TBG Nylobrade 3 8 I D X 625 O D Hose Assy Tank Bottom Pump Inlet Adaptor B A W F NPTM BKHD Elbow 90 Deg NPT Adaptor B A W M NPTM Clamp Hose W D 50 Dia X 1 06 SS Tank Water Spout Remote Filler w Cap Tee Plastic Pipe ...

Page 194: ...SECTION 7 REPLACEMENT PARTS 7 14 1 2 3 4 5 6 7 8 9 7 10 ...

Page 195: ... 8950823 A 950167 A 995103 A 36919 A 896W10 A 92W57 A 639533 D 35930GY A 2234891 TB3 TB5 Heat Exchanger Bushing Snap Grommet Rub 1 12 I D X 1 50 O D X 06 W Terminal Block 24 POS 15A Board Terminal Output Holder Fuse Grommet Rub 63 I D X 88 O D X 06 W Bushing Snap 88 I D X 1 09 MH X 45 L BRKT Heat Exchanger Plug 10 Pos ...

Page 196: ...SECTION 7 REPLACEMENT PARTS 7 16 1 2 3 4 5 6 7 8 9 10 11 12 13 ...

Page 197: ... 2234518 A 2234521 A 2234519 A 635686 A 647065L1 C 838193 R11 12 C1 2 K2 P4 MOD1 P1 PLC1 P2 MOD1 P3 4 PLC1 P1 J3 P1 PLC1 P2 J4 PLC1 J2 TB6 PCB TB Bushing Snap Res 20 ohm 50W Cover Terminal Board Cap Metpoly 20uf 400VDC Contactor Pilot Arc 3P 40A Plug 16 Pos Plug 10 Pos Receptacle 8 Pos Plug 16 Pos Receptacle 16 Pos Terminal Strip 8 Pos Choke Signal Ch12 Printed Circuit Board Trim Pot ...

Page 198: ...SECTION 7 REPLACEMENT PARTS 7 18 1 2 3 4 5 6 7 7 5 Power Source Power Module ...

Page 199: ...c Ay Description 1 2 3 4 5 6 7 35914GY 37102 35799 8951339 8951340 37101GY 8951981 835700 PCB1 P1 5 PCB1 P2 6 L1 Base Power Module Bracket PCB KYDEX Wire Kit Power Module Plug Female 12 Position Plug Female 14 Position Deck Power Module Heat Sink Inductor Power Factor ...

Page 200: ...SECTION 7 REPLACEMENT PARTS 7 20 A A 1 2 3 4 5 6 7 8 Section A A ...

Page 201: ...iption 1 2 3 4 5 6 7 8 2234877 8951182 950487 8950823 835700 17280215 835680 835681 J3 4 M1 TB2 L1 R2 L2 T3 Block Terminal 10 Position Fan Axial Terminal Strip 2 Position Bushing Snap Inductor Power Factor Resistor 1 5K OHM 100W Inductor Assembly Output Transformer Assembly Main ...

Page 202: ...SECTION 7 REPLACEMENT PARTS 7 22 1 2 3 4 5 6 7 ...

Page 203: ... Number Symbol Elec Ay Description 1 2 3 4 5 6 7 2234518 838047 2234519 35917GY 8951981 2234877 8674156 J2 SH1 J1 J3 4 TB3 Block Terminal 8 Position Shunt Feedback Block Terminal 16 Position Baffle Heatsink Heatsink Block Terminal 10 Position Adaptor ...

Page 204: ...SECTION 7 REPLACEMENT PARTS 7 24 1 2 3 4 5 6 7 9 8 10 11 12 13 14 15 16 17 18 19 19 21 22 21 23 24 21 25 26 20 10 27 ...

Page 205: ... Transformer Control Bridge Diode 3PH 130A Pad Thermal Bridge Busbar Input Bridge SCR 90A Pad Thermal SCR Module IGBT 300A 600V Resistor 20OHM 50W NI Pad Thermal Power Resistor 50W Bushing Snap 1 31 I D X 1 5 MH 44 L Resistor 5OHM 50W Capacitor 1uf 600VDC Capacitor 3300 uf Busbar IGBT Capacitor Bushing Snap 687 Busbar IGBT Capacitor Nomex Insulator Pad Thermal IGBT 1200V Wire Kit Module Busbar Shu...

Page 206: ...SECTION 7 REPLACEMENT PARTS 7 26 A A 1 2 3 4 5 Section A A 6 7 8 2 REF 7 6 Precision Plasma Junction Box Replacement Parts ...

Page 207: ... Ay Description 1 2 3 4 5 6 7 8 37515 674969 837250 82062119 37391 37392 8950256 8677905 PCB1 T2 3 J2 C1 SG1 Wire Kit Junction Box Precision Plasma PCB Assembly Filter XFMR H F Auto Conn Pos BKHD A A W F B A W F BKHD A A W F B A W F Cap Mica 002uf 10 KwV Spark Gap Assy ...

Page 208: ...SECTION 7 REPLACEMENT PARTS 7 28 B B Section B B C C Section C C 1 2 3 4 5 6 7 8 ...

Page 209: ...art Number Symbol Elec Ay Description 1 2 3 4 5 6 7 8 6271128 37522 37523 Ref Ref Ref Ref Ref J1 PCB1 J2 Conn Box Recpt 14 MP Shell 20 Base Kydex J Box Cover Kydex J Box Torch Cable Conn Reference Torch Conn NEG Reference Pilot Arc Torch Reference ...

Page 210: ...SECTION 7 REPLACEMENT PARTS 7 30 1 2 3 4 5 ...

Page 211: ...er Part Number Symbol Elec Ay Description 1 2 3 4 5 954075 37361 951188 954509 952928 950518 Name Plate Torch Conn Shield Locknut Conduit 2NPT Label Warning High Volt Symbol Coupling Quick Disconn F 14 Hose Grommet RBR 2 12 I D X 2 50 O D X 06W ...

Page 212: ... SR2 METH H35 N 3 N 2 N 1 O 2 O 1 AIR2 AIR1 AR TB1 ASSY 000 005 0007 JP3 JP2 JP1 JP5 JP4 P4 P3 P2 P1 Air Argon Oxygen Nitrogen H 35 Methane Air N2 Argon O2 Air O2 N2 Meth H 35 N2 Air 1 Air 2 Argon O2 2 O2 1 N2 3 N2 2 N2 1 H 35 Methane Process Air Argon Oxygen Nitrogen Methane H 35 1 2 3 4 5 6 7 7 Electronic Flow Control Box P N 953914 P N 952913 P N 952915 P N 952868 P N 952921 P N 952920 P N 9529...

Page 213: ...ion 1 2 3 4 5 6 7 952920 952686 952921 952913 952915 952922 952914 Switch Pressure 50 PSI Non Adj PCB Prec Flow Control Interface Board Valve Sol 2 Way 02 Manifold Assembly Complete Prec Flow XMFR Control 115 230V 50 60 HZ Lamp Pilot 28V Green Manifold Assembly w Check Valves ONLY ...

Page 214: ...SECTION 7 REPLACEMENT PARTS 7 34 Plasma Gas 1 Plasma Gas 2 Shield Gas 1 Shield Gas 2 Vent 1 Vent 2 Vent 3 Vent 4 Valve 1 Valve 2 Valve 3 Valve 4 1 5 4 3 2 6 P Ns 952916 952917 952918 952919 7 ...

Page 215: ...952916 952917 952918 952919 639571 0558002392 Fuse Glass Body Slow Acting 3AG 4A Valve Analog 0 6 Bar 0 10 VDC Valve4 SG2 Valve Analog 0 6 Bar 0 10 VDC Valve3 SG1 Valve Analog 0 9 Bar 0 10 VDC Valve2 PG2 Valve Analog 0 9 Bar 0 10 VDC Valve 1 PG1 Flow Meter Tube ONLY 33 G 5 PG1 Flow Meter Tube ONLY 15 G 5 PG2 SG1 SG2 ...

Page 216: ...5 4 3 2 1 Notes 1 Plasma 2 in Yellow 2 Plasma 2 Out Yellow 3 Plasma 1 in Blue 4 Plasma 1 Out Blue 5 Shield 2 In Black 6 Shield 2 Out Black 7 Shield 1 In Orange Red 8 Shield 1 Out Orange Red 5 8 18 L H Ref 3 8 24 L H Ref 7 8 PT 24 Torch Assembly EFC Series A M P N 0558001462 21 22 23 ...

Page 217: ...embly PT 24 Torch Sleeve Torch PT 24 Gas Line Start Blue Gas Line Cut Yellow Gas Line Shield Orange Red Swirl Baffle See Process Data Nozzle see Process Data Retainer Diffuser Insulator Shield Cup Insulator Shield Retainer Electrode Cup Shield w Retainer T Gas Shutoff VLV Assembly EFC Protector Gortiflex Sensor 7LG Tool Electrode Nozzle NOT Shown Quick Disconnect 90 Deg Elbow 1 18 L LUB Grease DOW...

Page 218: ...SECTION 7 REPLACEMENT PARTS 7 38 Plasma 1 2 Common Shield 1 2 Common Shield 1 Shield 2 Plasma 2 Plasma 1 1 2 3 4 5 6 3 2 1 7 9 T Gas Shut off Valve Assembly EFC Series A M ...

Page 219: ...SECTION 7 REPLACEMENT PARTS 7 39 Item Number Part Number Symbol Elec Ay Description 1 2 3 0558001502 8952921 593985 Flange 2 Way Solenoid Valves O Ring ...

Page 220: ...SECTION 7 REPLACEMENT PARTS 7 40 9 8 7 12 11 6 10 14 19 2 18 1 3 4 5 13 16 Detail Torch Front End 15 17 Not Shown 20 21 7 10 PT 24 Torch EFC Version 1 22 23 24 ...

Page 221: ...ube Assembly PT 24 Torch Sleeve Torch PT 24 Gas Line Start Blue Gas Line Cut Yellow Gas Line Shield Orange Red Swirl Baffle See Process Data Nozzle see Process Data Retainer Diffuser Insulator Shield Cup Insulator Shield Retainer Electrode Cup Shield w Retainer Solenoid Assembly Electronic Flow Control V1 Protector Gortiflex Sensor 7LG Tool Electrode Nozzle NOT Shown Clamp Band it LUB Grease DOW D...

Page 222: ...SECTION 7 REPLACEMENT PARTS 7 42 7 11 Solenoid Assembly Torch Electronic Flow Control Version 1 COM COM COM COM Shield 2 Shield 1 Plasma 2 Plasma 1 1 2 3 6 7 6 8 8 7 5 9 9 10 5 4 ...

Page 223: ...31 22421 952703 22367 952697 22366 22365 22364 Solenoid Assembly Electronic Flow Version 1 O Ring 1 42 X 103 NEOP 70A Plug Block 6 Pos Bracket Solenoid EFC Solenoid 2 Way Quick Disconnect Connector Yellow Solenoid 3 Way Quick Disconnect Connector Blue Quick Disconnect Connector Orange Red Quick Disconnect Connector Silver ...

Page 224: ...SECTION 7 REPLACEMENT PARTS 7 44 Notes ...

Page 225: ......

Page 226: ...45 http www esab com ESAB Cutting Systems Canada 6010 Tomken Road Mississauga Ontario Canada L5T 1X9 Phone 905 670 0220 Fax 905 670 4879 ESAB Hancock GmbH Cutting Technologies P O Box 1128 D 61174 Karben Robert Bosch Strasse 20 D 61184 Karben Phone 49 60 39 40 0 Fax 49 60 39 40 301_302 http www esab com esab_info compuserve com Printed in U S A ...

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