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Model 3710 Plasma Control Console

Operator’s

Manual

_____________________________________________________________________________________________________________________

Issued: 01/02

Page

3

1.3.3 Hazardous

Materials

Toxic Wastes

Preparations for thermal spraying, the process itself, or subsequent
finishing operations may generate toxic materials. Dispose of them
according to the

EPA Resource Conservation and Recovery Act

(RCRA).

Flammable Solvents and Sealer Bases

Certain de-greasing solvents and sealer bases are flammable and require
special use, handling, and storage precautions in and around the thermal
spray area.

Metal Dusts and Powders

Treat airborne metal dusts, finely divided solids, or accumulations as
explosives. Minimize the danger from dust explosions by providing
adequate ventilation in spray booths. Install a cartridge-type dry dust
collection system to collect spray dust.

1.4

Safe Operating Conditions

1.4.1

Compressed Gas Cylinders

Always comply with local, state, municipal and federal regulations
regarding compressed gas cylinder storage and follow recommendations
in

ANSI/AWS Z49.1, Safety in Welding and Cutting; CGA Pamphlet

P-1, Safe Handling of Compressed Gases; NFPA 55, Compressed &
Liquefied Gases in Portable Cylinders; NFPA 51, Oxygen-Fuel Gas
Systems in Welding and Cutting; and NFPA 51B Standard for Fire
Prevention in the Use of Cutting & Welding Processes

. Improper

storage, handling, and use of gas cylinders

Creates A Safety Hazard

. If

the site plan includes manifolding cylinders to permit longer spray times
before changeover, follow

ANSI/AWS Z49.1

recommendations in

designing the plan.

NEVER

use oil or grease on oxygen equipment. Use

ONLY

special

oxidation- resistant lubricants. Consult the equipment manufacturers or a
qualified dealer for more information.

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Summary of Contents for 3710

Page 1: ...buy your excess underutilized and idle equipment along with credit for buybacks and trade ins Custom engineering so your equipment works exactly as you specify Critical and expedited services Leasing Rentals Demos In stock Ready to ship TAR certified secure asset solutions Expert team I Trust guarantee I 100 satisfaction All trademarks brand names and brands appearing herein are the property of th...

Page 2: ...Revision E Issued 03 11 Model 3710 Plasma Control Console Operator s Manual Manual Part Number 5008575 ...

Page 3: ...other document s Applied Directive s Low Voltage 2006 95 EC EMC 2004 108 EC Standard s EN 60204 1 EN 61000 6 4 EN 61000 6 2 Equipment Thermal Spray Control Console Brand Name Praxair Surface Technologies Model 3710 We hereby declare that the equipment specified above conforms to the above directive s and standard s Signature Full Name Stephen Ford Position Engineering Manager Praxair Surface Techn...

Page 4: ... the manual Praxair Surface Technologies reserves the right to make improvements and or changes to the product s and or programs described in this manual at any time and without notice Illustrations are meant to be representative of but not exact duplicates of existing equipment BUSINESS CONFIDENTIAL THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION OF PRAXAIR SURFACE TECHNOLOGIES THIS...

Page 5: ...ving safe practices Be safe Learn the recommended procedures and standards Failure to follow recommended procedures and standards can result in severe injury to people and damage to equipment Who should use Thermal Spray Equipment Use the equipment only if you have been trained fully in safely using it Do not allow untrained persons to install operate or maintain the equipment Understand what to d...

Page 6: ...ribed in section 1 and in highlighted paragraphs throughout this guide Operating instructions see section 4 z Technical bulletins included with or referred to in this manual This includes industry publications that contain standards that may apply to your work See page vi of this guide for a list of industry publications z Labels tags other instructions and warnings that come with or are attached ...

Page 7: ...s and words have the following meaning Praxair Surface Technologies RECOMMENDS A procedure or setting that will produce optimum results Information that can help to operate the equipment more effectively Refer to the manual before doing any maintenance Wear respirator Risk of eye injury Eye protection required Wear opaque eye protection Wear protective clothing gloves Wear hearing protection Press...

Page 8: ... determine what devices may not be classified as ignition sources USE THIS DEVICE ONLY IN A WELL VENTILATED AREA WARNING PERSONAL INJURY HAZARD Use caution when handling the powder feeder feed lines and fittings There is a possibility of static electricity discharge from the powder feed system which could result in significant discomfort or injury HAZARD Hazards that can result in minor or major d...

Page 9: ...970 84 Stat 1943 cover safe handling of compressed gases More recently the Resource Conservation and Recovery Act RCRA dealing with the disposal of toxic wastes potentially affects the thermal spray industry Occupational Safety and Health Act Standards 29CFR 1910 available from the Superintendent of Documents U S Government Printing Office Ventilation Control of Grinding Polishing and Buffing of M...

Page 10: ...ractices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances ANSI AWS F3 1 available from the American Welding Society Safety Release Device Standards Cylinders for Compressed Gases CGA Pamphlet S1 1 available from the Compressed Gas Association Standard for Gaseous Hydrogen at Consumer Sites CGA Pamphlet G5 1 available from the Compress Gas Association Po...

Page 11: ... 5 1 4 5 Plasma and Arc Spray Equipment 6 1 4 6 Abrasive Blast Machine 7 1 4 7 Handling and Manipulating Equipment 7 1 5 Protecting Workers 8 1 5 1 Eye Protection 8 1 5 2 Respiratory Protection 9 1 5 3 Noise Protection 10 1 5 3 1 Noise and Noise Level 10 1 5 3 2 Noise Duration 11 1 5 3 3 Hearing Protection 12 1 5 4 Protective Clothing 14 1 5 5 Confined Spaces 15 1 5 5 1 Rapid Emergency Exit 15 1 5...

Page 12: ...Console 38 4 4 System Safety Operation 40 4 5 Plasma Spray System Checkout 43 4 6 Sequence of Operation 43 4 7 Spray Procedure 45 4 8 Shutdown Procedure 46 4 9 Gas Purge System 46 Section 5 Maintenance Troubleshooting 49 5 1 Maintenance 49 A Leak Test Procedure 50 5 2 Troubleshooting Chart 57 5 3 Gas Schematic 58 5 4 Electrical Schematic 59 5 5 E Stop Electrical Schematic 62 Section 6 Parts List 6...

Page 13: ...handling Relevant safety standards 1 1 Reminder Safety First Thermal spraying equipment is very powerful Do not use equipment carelessly or without observing safe practices Be safe Learn the recommended procedures and standards Failure to follow recommended procedures and standards can result in severe damage to equipment and injury to people Use the equipment only if you have been trained fully i...

Page 14: ...troubleshooting of thermal spray equipment requires practices and procedures that ensure personal safety and the safety of others Therefore this equipment is to be installed operated and maintained by qualified persons as specified in this manual and in accordance with all applicable codes such as but not limited to those listed in section 1 and the corresponding sections of the manual You should ...

Page 15: ...ntilation in spray booths Install a cartridge type dry dust collection system to collect spray dust 1 4 Safe Operating Conditions 1 4 1 Compressed Gas Cylinders Always comply with local state municipal and federal regulations regarding compressed gas cylinder storage and follow recommendations in ANSI AWS Z49 1 Safety in Welding and Cutting CGA Pamphlet P 1 Safe Handling of Compressed Gases NFPA 5...

Page 16: ...ons and ensure proper flame balance by installing backflow prevention devices in conjunction with the flow meters Place a protective shield on flow meters with glass tubes Install and use hose and hose connections according to ANSI AWS Z49 1 and the Specification for Rubber Welding Hose published by the Rubber Manufacturer s Association and the CGA Handle hoses carefully to avoid damage Use hoses ...

Page 17: ...ment and correct the condition before restarting the system EXPLOSION HAZARD Acetylene pressures exceeding 15 psig 1 03 bar may cause the gas to detonate If this pressure of 15 psig 1 03 bar is insufficient use another fuel gas 1 4 3 Compressed Air Always refer to gases by their proper names to avoid confusion Never use compressed air oxygen or fuel gas to clean clothing For thermal spraying or bl...

Page 18: ...sent an electrical hazard Train operators how to use the equipment safely before they actually use it Specifically ensure that operators know and understand all the operating and safety recommendations in the operator manuals Always observe standard safety precautions for electrical equipment and operate in accordance with ANSI AWS Z49 1 Frequently clean arc guns and power supplies to prevent meta...

Page 19: ...r that can lead to a blowout at those points If hoses must be curved around an object use long radius curves Store blast hoses in cool dry areas Be sure blast hose controls function properly They should require continuous pressure on the activating lever for operation Releasing the lever should cause the system to shut off dead man control PERSONAL INJURY NEVER point a blast nozzle at a person Mos...

Page 20: ...ors with suitable eye protection as well Equip the eye protection with a suitable filter plate to protect against ultraviolet infrared and intense visible light radiation see Table 1 1 Table 1 1 Eye Protection Operation Required Type of Eye Protection Wire Flame Spraying except Molybdenum Shades 2 4 Molybdenum Wire Spraying Shades 3 6 Flame Spraying of Metal Powder Shades 3 6 Flame Spraying of Exo...

Page 21: ...om rebounding abrasive material Minimum air flow to the respirator should be 4 cfm 11 2 L minute at the face piece and 6cfm 19 6 L minute entering the helmet or hood Fresh air blowers are preferred to compressed air as an air source of respirator air If adequate ventilation is not provided use an in line vortex cooler when possible for operator comfort Filter the air supply line to remove objectio...

Page 22: ...itions OSHA also requires employees to comply with all rules regulations and orders that apply to their actions and conduct OSHA does not provide thermal spraying specific rules but establishes general rules for the control of unsafe and unhealthy elements 1 5 3 1 Noise and Noise Level Noise is an unneeded and objectionable sound Excess noise reduces productivity slows reaction times and causes te...

Page 23: ...apacity Acetylene w spray booth w spray both airjet cooling 94 111 Wire Combustion Guns 1 8 3 16 inch 3 2 4 8 mm Acetylene Propane Propane nonload hardware Methylacetylene propadiene gas 114 118 125 118 Plasma gun Nitrogen 600 A Nitrogen Hydrogen 600 A Argon 1000 A Argon Hydrogen 600 A Argon Helium 600 A Argon Nitrogen 1000 A 134 133 128 133 127 131 HVOF Oxygen plus kerosene 126 Grit blasting Equi...

Page 24: ...9 1 5 3 3 Hearing Protection If noise at your site exceeds the limits established by OSHA in paragraph 1910 95 entitled Occupational Noise Exposure of the Occupational Safety and Health Standards you should provide ear and or other protection to everyone near thermal spray operations to bring the exposure within OSHA permissible tolerable noise levels Limit workers exposure to noise according to f...

Page 25: ...controls are being established Mufflers on thermal spray equipment are impractical and ineffective Simple baffles between the gun and nearby personnel are not effective because noise scatters around the baffle Specially designed sound absorbing materials provide a 5 dB reduction to adjacent areas Sound absorbing materials on walls and hanging baffles can reduce nearby levels but do not solve the p...

Page 26: ...to keep the exposure of any one person within limits Spraying outside of regular plant hours can control exposure of persons near the operation Also rotate personnel assignments in the vicinity of the thermal spraying operation to control exposure 1 5 4 Protective Clothing When working in confined spaces wear flame resistant clothing and leather or rubber gauntlet gloves Clothing should fit snugly...

Page 27: ...erred to in Compressed Gas Cylinders in section 1 4 1 of this manual for ventilation requirements When you are thermal spraying in any confined space keep the gas cylinders out of the work space 1 5 5 1 Rapid Emergency Exit If operators must enter a confined space through a small opening provide the means for rapid emergency exit If operators are using safety belts and life lines for this purpose ...

Page 28: ...n system does not preclude the need for respiratory protection devices See Respiratory Protection section 1 5 2 for recommendations on protective devices and filtration systems When thermal spraying on a machine tool such as a lathe mount an exhaust hood at the end of the carriage so that it travels with the gun exhausting dust and fumes into the dust collector Aim the gun so the sprayed material ...

Page 29: ...lasting and thermal spraying will require their own independent dust collectors Although dry cartridge type dust collectors are suitable for use in both the grit blast and thermal spray environments it is suggested to refer to Industrial Ventilation a manual of recommended practice with a compilation of research data and information on design maintenance and evaluation of industrial exhaust ventil...

Page 30: ...ting the health of spray equipment operators vary according to the type of material being sprayed 1 6 1 Beryllium and Lead Praxair Surface Technologies does not recommend spraying beryllium lead or their compounds because they are highly toxic and hazardous 1 6 2 Cadmium Cadmium is highly toxic and hazardous Use respiratory protective equipment such as fume respirators approved by the U S Bureau o...

Page 31: ...on of some solvent vapors into noxious and toxic gases even at considerable distance from the arc Slow extraction of the part from the solvent cleaning tank can reduce this problem When spraying vapor degreased parts take extra care to see that all solvent vapors or liquid films or drops of solvent caught by pockets and crevices is removed prior to thermal spraying The ultraviolet radiation from p...

Page 32: ...___________________________________ Issued 01 02 Page 20 concentration is sufficiently high to cause operator discomfort even when the appropriate TLV is not exceeded 1 7 Safety Standards In addition to the contents of this chapter a variety of industry publications contain safety standards See the related publications list on page vi ...

Page 33: ...m Depth 15 5 in 394 mm Height 37 in 940 mm Electrical Input 115 VAC 1 phase 50 60 Hz 20 amps Air Gas Orifice Pressure Flow Purge Air Input N A 80 psi 550 kPa minimum Argon primary gas 56 71 3 430 SCFH 33 5 202 l min at 30 200 psi 207 1380 kPa Helium secondary gas 80 15 92 6 SCFH 7 1 43 5 l min at 30 200 psi 207 1380 kPa Hydrogen secondary gas 97 4 3 26 4 SCFH 2 12 4 l min at 30 200 psi 207 1380 kP...

Page 34: ...re adding small percentages of helium or other secondary gases to the arc gas If the plasma does not melt the powder completely adding a small percentage of helium or another secondary gas to the primary arc gas increases the heat level However adding these gases WILL CHANGE OPERATING CHARACTERISTICS Consult with your gas supplier to determine appropriate facilities for your expected spray operati...

Page 35: ...o powder feeder control one at a time for top coat bond coat applications and an auxiliary power circuit that can be used for actuating part cooling etc Like its predecessor the 3710 is an economically priced plasma spray process controller designed for production environments Easy to understand controls coupled with a compact cabinet design make the 3710 an ideal control console for any plasma sp...

Page 36: ...with audio visual alarm 24 V DC purge circuit Remote E stop box Stainless steel flammable gas plumbing Safety interlocks Power Control The Model 3710 operates with the Model PS 1000 60 kW or HPS 100 100 kW three phase constant current DC plasma power supplies The PC 100 Control Module integral to the 3710 console regulates power from the either power supply and allows the user to set plasma curren...

Page 37: ...easured at the plasma spray gun or the system voltage measured at the input terminals of the high frequency starter As the water cooled power cables deteriorate with use their increasing resistance to current flow can seriously affect the system performance The 3621 remote pendant not shown allows the operator to switch between monitoring of the system and gun voltage displayed on the PC 100 power...

Page 38: ...____________________________________________________ Issued 03 11 Page 26 Figure 2 2 Typical 3710 System Layout Voltage Switch Box Refrigerated Heat Exchanger Powder Feeders Gun Manipulator Gun Manipulator Control Console Plasma Control Console Turntable High Frequency Starter Power Supply Acoustical Room Spray Booth ...

Page 39: ...fully inspect for any shipping damage Purchaser must file any claims for loss or damage incurred in transit with the carrier The manufacturer will supply a copy of the bill of lading on request if occasion to file a claim arises When requesting information about this equipment it is essential that Model Description and Serial Number of the equipment be supplied 4 Use the cart or two wheel hand dol...

Page 40: ... drilled holes 7 On the opposite side of the wall from the console Place a flat washer of sufficient size and strength to prevent bolt from tearing out of wall material a lock washer and a hex nut on each bolt Tighten both nuts until secure The two workers can then release the console Above instructions are for the recommended mounting method If unable to drill through wall cement block or other m...

Page 41: ...d with dash and a number telling cable length in feet example 5005224 25 is a 25 ft cable Since cable and hose lengths may vary we do not reference actual lengths unless they are not variable Standard cable and hose lengths are listed in Section 6 Symbols shown on the left refer to the connection symbols used on the 3710 control console Be sure to use good wiring practices when routing wires and c...

Page 42: ...t system operation without the booth exhaust system in operation The dust collection system must be on before the console can be energized An air flow switch in duct work connected to the console DUST COLLECTOR INTERLOCK connector is one of the means to satisfy this safety requirement For more information on this feature contact our service department Console will not power up if interlock is not ...

Page 43: ...ach hose 7 P N 985 2 to console ARC GAS OUT fitting on manifold then to plasma spray gun arc gas fitting E Powder Feeder Connections 1 Attach hose 13 P N 5005135 to console POWDER GAS 1 out fitting and then to Powder Feeder 1 2 If using a second Powder Feeder attach the second hose 13 to console POWDER GAS 2 out fitting then to the 2 Powder Feeder 2 3 Attach control cable P N 5005293 to console PO...

Page 44: ...fy that the Power Supply and the High Frequency Unit is locked out from any input power source 1 A For PS 1000 Power Supply only attach cable P N 5008637 to the console PS100 connector then to the Junction Box B For HPS 100 Power Supply only attach cable P N 610402 25 to the console PS100 connector then to the HPS 100 Power Supply 2 Attach cable 9 P N 5005224 to console HIGH FREQUENCY POWER connec...

Page 45: ...rce I Auxiliary Optional Equipment Connections 1 Connect cable 3 P N 5008540 to console AUXILIARY POWER OUTPUT connector then to a user defined auxiliary device 2 Connect a user supplied cable from a switch closure to USER DEFINED INTERLOCK connector located on the E stop box User defined interlock is designed to allow the user to prevent system operation before certain conditions or states are sa...

Page 46: ...0 Plasma Control Console Operator s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 34 Figure 3 2 Cable Hose Layout ...

Page 47: ...S HAZARD A plasma gun creates electro magnetic fields which could adversely affect the operation of electronic instruments in its vicinity Persons with heart pacemakers should avoid proximity to the plasma gun while it is operating HIGH TEMPERATURE HAZARD The temperature of the plasma gun reaches up to 20 000 C The plasma plume radiates much of this heat and therefore can heat objects e g spray ro...

Page 48: ...ogen Secondary Gas Gauge Arc Start Button Secondary Gas ON OFF Hydrogen Control Power Source ON OFF Button Primary Gas ON OFF Cooling Water Start Button E Stop Reset button Spray Booth Exhaust Interlock Light Hopper Controls Carrier Gas START STOP Powder Feed OFF ON E Stop Button Water Blowout Button Carrier Gas Gauge Carrier Gas Control Primary Gas Control Secondary Gas Control Auxiliary Power ON...

Page 49: ...nput power and employ lockout tagging procedures on power source before making any gun connections Lockout tagging procedures consist of padlocking line disconnect switch in open position removing fuses from fuse box or shutting off and red tagging circuit breaker or other disconnecting device SHORT CIRCUIT or improper connections can damage equipment Ammeter deflection shows a short circuit or im...

Page 50: ...ter Blowout Button Momentarily pressing the WATER BLOWOUT button injects compressed air into the cooling water circuit at the heat exchanger to remove any in line water from the system before disassembling the gun Button illuminates when blowback process is started D Cooling Water Button Pressing the COOLING WATER button starts the heat exchanger circulating cooling water through the gun circuit E...

Page 51: ... illuminates button Pressing POWDER FEED ON 2 button feeds powder from hopper 2 through system and illuminates button Press POWDER FEED button again to stop the process Select ONLY ONE powder feeder at a time The Model 3710 Console controls EITHER feeder 1 OR feeder 2 but not both simultaneously K Emergency Stop E Stop Button Pressing EMERGENCY STOP stops the entire plasma spray system Press the R...

Page 52: ...ed start secondary gas by pressing SECONDARY GAS button P Secondary Gas Regulator Hydrogen With the SECONDARY GAS SELECTOR SWITCH in HYDROGEN position the HYDROGEN SECONDARY GAS SUPPLY PRESSURE CONTROL located on the far right side of the console regulates hydrogen pressure Turn knob CLOCKWISE to increase hydrogen pressure or COUNTERCLOCKWISE to decrease pressure When secondary gas amperage setpoi...

Page 53: ...oved from the console except the purge air circuit B Restarting after Emergency Shutdown Before resetting the system make sure that the system is back to safe operating condition and that the event causing the shutdown has been identified and corrected 1 Twist and pull out all E STOPS 2 Press the 3710 console E STOP RESET button 3 If all E STOPS are satisfied E STOP RESET button illuminates and th...

Page 54: ...a Control Console Operator s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 42 Figure 4 2 Orifice Flow Chart 5003935 rev D ...

Page 55: ...n plasma gun as specified by the gun instruction manual 2 Place SECONDARY GAS SELECTOR SWITCH in HYDROGEN or HELIUM position according to the parameter used 3 Adjust powder feeder RPM as recommended in powder feeder manual Switch MODE SELECTOR to FEED 4 Put the specified powder in the powder feeder canister and secure lid 5 Place a properly prepared piece of material or coupon on the work area 4 6...

Page 56: ...dicates energized console 10 Press COOLING WATER switch Switch illuminates Recheck system for leaks Verify water flow rate is AT LEAST 6 0 gpm 22 8 l m 11 Press the PRIMARY GAS switch and adjust primary gas to the recommended pressure for the parameter used The Critical Orifice Flow Rate graph Figure 4 2 shows flowrates of various critical orifices 12 Press the CARRIER GAS switch for the powder fe...

Page 57: ...l ammeter LCD displays desired drop in amperage Normally the auxiliary gas start setting is 30 of the Main Amps setting 20 Momentarily three seconds or less press ARC START switch Plasma arc initiates 21 Monitor the ramping process on the PC 100 and verify that the Secondary Gas is automatically energized at the setpoint 22 Press the FEED ON button for the powder feeder desired Button illuminates ...

Page 58: ... 1 Press console POWDER FEED switches to OFF 2 Press console POWER SOURCE switch to OFF 3 Press console POWDER GAS switches to OFF 4 Wait 7 10 seconds This interval with arc gases and water running cools the electrodes and protects the O ring seals from overheating 5 Turn OFF water supply Shut off water supply and close the gas regulators at the source if the system will not be used for several ho...

Page 59: ...ceplate to pink side and rotate dial numbers so that 10 minutes shows as the maximum b Set DIP switch fully to the right c Set digital switch to 7 d Re install faceplate with pink side up e Turn timer knob to 8 5 minutes 3 The pressure switch is factory set to trigger a visual alarm if the internal cabinet pressure drops below the required 0 25 in water To verify its operation a With console close...

Page 60: ...steps c through f 4 The purge air exhaust vent is factory set to provide an internal air pressure of 0 25 in water Purging system power is independent of other console circuits To allow purge system operation when console main power is off press the AUXILIARY POWER switch ON then press the red section of the MAIN POWER switch to de energize the main console Purging and hopper circuits remain energ...

Page 61: ...rocedure When Due Performed By Check water flow through gun refer to spray gun manual for recommended flow levels Each startup Operator Check gas cylinders for adequate pressure Each startup Operator Check for water leaks Each startup Operator Inspect all hoses for cuts cracks or abrasion replace as required Weekly Operator Wipe off excessive dirt dust As Needed Operator Perform console leak test ...

Page 62: ... vent until purging light illuminates The pressure shown on the water column gauge should read at least 0 2 in water If the gauge reads less than 0 2 inches water adjust the pressure switch see A1 3 A1 3 Set pressure switch for 0 2 in water minimum a With console closed and power ON reduce purge air pressure by opening the purge pressure control vent until low purge pressure alarm is triggered b C...

Page 63: ...ogen gas are acceptable if helium is not available These tests are to be performed by qualified personnel only EXPLOSION HAZARD Air purge system must be connected and operating properly to avoid possible accumulation of flammable gases Purge system for at least five minutes before starting procedure Test ONLY with inert gases helium argon or nitrogen DO NOT test with combustible or oxidizing gases...

Page 64: ...ondary and Carrier Gas regulator clockwise two turns to open the internal diaphragms Press COOLING WATER PRIMARY GAS SECONDARY GAS CARRIER GAS and POWER SUPPLY buttons in order The power supply will be live at this point After gases are bled off press POWER SUPPLY button to turn power supply OFF A3 2 Using a test manifold connect a regulated 0 150 psi 0 1035 kPa inert gas supply to the arc gas aux...

Page 65: ...sole power to keep solenoid valves open during testing Note the pressure indicated on the tester and observe the pressure reading periodically over a 15 minute period A3 9 A pressure decrease of 0 3 psi or more at any time in the 15 minute time period indicates a leak Refer to section 4 locate and correct the leak A pressure drop on both gauges indicates a leak in the primary gas circuit A pressur...

Page 66: ...her items used during the test procedure A5 2 Reconnect all cables and hoses to the console Inspect sup ply hose connections for leaks before resuming operations A5 3 Consider testing complete ONLY if these conditions are met No leaks were found in the gas circuits Any leaks found were corrected see section A 6 A 6 Corrective Action Locate and Correct Leak This section outlines the procedure to be...

Page 67: ...ctrical contacts or wiring A6 6 When the leak is located disassemble and inspect the affected components Replace any worn or defective items A6 7 Reassemble the unit using Loctite 242 or equivalent thread locking compound on all threaded components DO NOT use Teflon tape as a sealant Replace any leaking hose or tubing components as they cannot safely be repaired A6 8 Disconnect and lock tagout con...

Page 68: ...evelop in this console Use this table and circuit diagram to perform troubleshooting If the problem is not remedied after performing these procedures contact the Praxair Thermal Spray Systems Service Department at 603 224 9585 In cases of equipment malfunction the manufacturer s recommendations must be strictly followed ELECTRIC SHOCK HAZARD Do not touch live electrical parts Shut down unit discon...

Page 69: ...itch Arc Gas Pressure Switch Replace Arc Gas Pressure Switch Arc Gas Pressure Too Low Increase Arc Gas Pressure Low Water Flow Condition Increase Water Pressure Water Pressure Switch Replace Water Pressure Switch No Arc Power Arc Gas Solenoid Replace Arc Gas Solenoid Master Push Button Fails to Light When Activated Light Bulb Replace Light Bulb Voltmeter Replace Voltmeter No Voltmeter Readouts Cab...

Page 70: ...el 3710 Plasma Control Console Operator s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 58 5 3 Gas Schematic ...

Page 71: ...RELAY 3PDT 115VAC K10 RELAY DPDT ONE SHOT 115VAC L1 L4 VALVE SOLENOID 2 WAY 115VAC L5 VALVE SOLENOID 3 WAY 115VAC PS1 POWER SUPPLY 24VDC 0 6A S1 SWITCH DIFFERENTIAL PRESSURE S2 S4 S11 S16 SWITCH MOMENTARILY LIGHTED S5 S10 S5 10 S16 SWITCH ALTERNATE LIGHTED S15 SWITCH TOGGLE S3 SWITCH E STOP RED MUSHROOM CONNECTORS CABLES J1 MAIN POWER CONNECT USER SUPPLIED J2 HEAT EXCHANGER CONNECT HX Dependant J3...

Page 72: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 60 ...

Page 73: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 61 ...

Page 74: ... Plasma Control Console Operator s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 62 5 5 E Stop Electrical Schematic ...

Page 75: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 63 Section 6 Parts List 6 1 3710 Console Figure 6 1 Model 3710 Assembly Key Drawing 610343 Rev M S1 ...

Page 76: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 64 Figure 6 2 Model 3710 Console Assembly 610343 Rev M S2 ...

Page 77: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 65 Figure 6 3 Model 3710 Console Assembly 610343 Rev M S3 ...

Page 78: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 66 Figure 6 4 Model 3710 Console Assembly 610343 Rev M S4 ...

Page 79: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 67 Figure 6 5 Model 3710 Console Assembly 610343 Rev M S5 ...

Page 80: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 68 Figure 6 6 Model 3710 Console Assembly 610343 Rev M S6 ...

Page 81: ...Model 3710 Plasma Control Console Operator s Manual Issued 03 11 Page 69 Figure 6 7 Model 3710 Console Assembly 610343 Rev M S7 ...

Page 82: ...S 1 EA 251105 13 PLATE LEGEND E STOP YELLOW 1 EA 5007950 14 BULB LIGHT 2 EA 250124 15 SOCKET LAMP 120 VAC 3 EA 251230 16 MODULE LED WHITE 120 VAC 12 EA 5003014 17 LENS WHITE FLAT BEZEL 3 EA 5007972 18 PANEL 3710 MANIFOLD LEXAN 1 EA 5001679 19 WIREWAY COVER WIRING DUCT 0 83 FT 5001677 20 WIREWAY DUCT SLOTTED 0 83 FT 5007909 21 CONN TUBE SWAGE SS 4 EA 5000555 22 CONN TUBE SWAGE BR 3 EA 5001071 24 AD...

Page 83: ...ET RELAY 1 EA 5000299 52 HOSE BULK GAS RED 2 FT 5000172 53 TIE DOWN WIRE TIE HOLDER 8 EA 10290 54 RELAY 3PDT 120 VAC 1 EA 5007951 55 RELAY 2PDT 24VDC TIME DELAY 1 EA 5006096 56 SOCKET RELAY SPDT 3 EA 5006095 57 RELAY 1PDT 120 VAC 3 EA 5002983 58 RELAY 2PDT 120 VAC 2 EA 5002982 59 SOCKET RELAY 5 EA 5004586 60 RELAY TIE DOWN 16 EA 240557 61 BLOCK END END BARRIER FOR 240556 2 EA 240556 62 BLOCK TERMI...

Page 84: ...SAME AS 210025 3 EA 5004428 94 AMP CAP SEALING 3 EA 5004339 95 AMP RECP 16 PIN SAME AS 240488 2 EA 7000517 96 SCREW BTN HD HEX SKT 20 EA 7000363 97 WASHER LOCK INT TOOTH 20 EA 5008395 98 MANIFOLD 3710 CSL 1 EA 5001905 99 CONN TUBE FLARE BRASS 9 EA 5003817 100 CONN HOSE BR 2 EA 5000402 101 ADAPTOR GAS BR R H OXY 4 EA 5008394 102 CONN MACH BR R H MALE 1 EA 5000221 103 COUPLING PIPE BR SAME AS 210454...

Page 85: ...ASHER FLAT SAME AS 200479 10 EA 5007763 159 PANEL COVER 3702 HYDROGEN 1 EA 7000182 160 WASHER FLAT 4 EA 200243 161 SCREW BHSCS SAME AS 7000612 4 EA 5004612 162 RELAY 2PDT 24 VDC 3 EA 5007721 163 VENTILATOR PLATE PURGE AIR 1 EA 5007722 164 GUARD VENTILATING PURGE AIR 1 EA 5006388 166 TIE CABLE INTERMED 1 EA 5004703 167 AMP RECP 14 SKT 2 EA 5004403 168 AMP KEYING PLUG 3 EA 240509 169 CONN RECPT 7 PI...

Page 86: ...EA 270126 201 WIREWAY W COVER 63 50 IN 5004442 202 AMP PLUG 7 PIN 1 EA 5004471 203 AMP BOOT HT SHRK 1 EA 5008098 204 AMP PIN 2 EA 5000473 206 BUSHING PIPE BR 1 EA 250051 209 DIODE 4 EA 5008463 211 DRAWING 3710 HOSE CABLE CONN 1 EA 200202 214 SCREW PHMS S 30 EA 200125 215 WASHER FLAT 30 EA 200800 216 WASHER LOCK SPLIT 6 EA 5001559 217 TERM FORK SPRING SPADE 18 EA 610346 218 JUMPER E STOP 14 PIN PIN...

Page 87: ...ge 75 PART ITEM DESCRIPTION QTY UM 210423 237 FITTING ELBOW 2 EA 210083 238 REDUCER MALE TO FEMALE SAME 5000548 1 EA 620306 242 SPACER MOUNT FOR TUBE CLAMP 1 EA 540277 243 LABEL LEXAN PLASMA GAS OUT 1 EA 210994 244 FITTING TUBE SS ADAPTER 1 EA 200281 245 SCREW BHSCS 6 EA 220659 246 WRAP WIRE SPIRAL 120 IN 540244 247 LABEL WARNING DUST BY PRODUCT 1 EA 201080 248 NUT JAM 20 STL ZNC 2 EA ...

Page 88: ...tor s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 76 6 2 Hoses and Cables Figure 6 8 Standard 3710 System Diagram Customer supplied power cord ...

Page 89: ... 3 7 987 8 12 1 CABLE WATER COOLED POS HF 2210 SG100 12 3 7 610370 L 1 CABLE POWER TO 115V 8 2 4 800782 PS 1000 POWER SUPPLY CONFIGURATION 5008632 25 1 CABLE PS 1000 TO JUNCTION BOX 25 3 0 5008637 25 1 CABLE CTRL CNSL AMP TO JUNCTION BOX for PS 1000 25 7 6 984 18 8 2 CABLE POWER 4 0 PWR SPLY TO H FRQ POSITIVE For PS 1000 60 kW Power Supply 8 2 4 984 33 8 2 CABLE POWER 4 0 PWR SPLY TO H FRQ NEGATIV...

Page 90: ...a Control Console Operator s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 78 6 3 E Stop Box Figure 6 9 E STOP Controller ...

Page 91: ... Control Console Operator s Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 79 Figure 6 10 E STOP Controller Internal Layout ...

Page 92: ...Manual _____________________________________________________________________________________________________________________ Issued 03 11 Page 80 Figure 6 11 E STOP Controller Connection Panel Figure 6 12 E STOP Controller Connector and Terminator ...

Page 93: ...BUTTON 1 18 5007132 LEGEND YELLOW BLANK 1 19 5007128 BUTTON GREEN LIGHTED 1 20 5007129 CONTACT ASM FOR GREEN BUTTON 1 21 5001675 DIODE 3 22 5003864 AMP RECP 1 23 10137 SWITCH ASSY SELECTOR 1 24 5007844 LABEL MASTER E STOP BOX KIT 5 LABELS 1 25 7000634 SCREW BTN HD 10 26 5004586 RELAY TIE DOWN 3 27 7000438 SCREW BTN HD 2 28 7000199 WASHER LOCK 2 29 5004700 AMP PLUG 1 30 5003171 CAP PLASTIC 1 31 500...

Page 94: ...___________________________ Issued 03 11 Page 82 ITEM PART DESCRIPTION QTY 45 7000062 NUT HEX 2 46 5004696 AMP SEAL PERIPHERAL 1 47 5004694 AMP SEAL PERIPHERAL 1 48 5002196 AMP PLUG 1 49 6002017 SUPPLY PACKAGE CAP THREADED PLASTIC 1 50 5007088 LABEL PROTECTIVE EARTH SYMBOL 2 51 5004237 TERM RECP 6 52 5003382 TERM RING 6 53 5001478 TERM RING 2 ...

Page 95: ...TAFA Incorporated A Praxair Surface Technologies Company 146 Pembroke Road Concord NH 03301 www praxairsurfacetechnologies com psti info praxair com Telephone 1 603 224 9585 Fax 1 603 225 4342 ...

Page 96: ...quipment Have surplus equipment taking up shelf space We ll give it a new home Learn more Visit us at artisantg com for more info on price quotes drivers technical specifications manuals and documentation Artisan Scientific Corporation dba Artisan Technology Group is not an affiliate representative or authorized distributor for any manufacturer listed herein We re here to make your life easier How...

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