PRECISION PLASMARC SYSTEM with Electronic Flow Control

Transcription

1 F E July, 2007 Installation, Operation and Maintenance Manual for the PRECISION PLASMARC SYSTEM with Electronic Flow Control CUTTING SYSTEMS 4 s. Ebenezer Road Florence, SC

2 The equipment described in this manual is potentially hazardous. Use caution when installing, operating and maintaining this equipment. Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting Systems has liability for personal injury or other damage arising out of the use of any product manufactured or sold be ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB s responsibilities and limitations on its liability. ESAB Cutting Systems first priority is total customer satisfaction. We constantly look for ways to improve our products, service and documentation. As a result, we make enhancements and/or design changes as required. ESAB makes every possible effort to ensure our documentation is current. We cant guarantee that each piece of documentation received by our customers reflects the latest design enhancements. Therefore, the information contained in this document is subject to change without tice. This manual is ESAB Part Number F5480 March-0 date reflects added cable part s. in Sect 2. Corrected Pressure in Section 6. Dec.-0 Replacement parts section updated This manual is for the convenience and use of the cutting machine purchaser. It is t a contract or other obligation on the part of ESAB Cutting Systems. ESAB Cutting Systems, 200 Printed in U.S.A.

3 Precision Plasma Electronic Flow Control Table of Contents Page Section Safety. Introduction....2 Safety Notations And Symbols....3 General Safety Information Installation Precautions Electrical Grounding Operating A Plasma Cutting Machine Service Precautions Safety References... 9 Section 2 Description 2. General Scope Package Options Available Technical Specifications Precision Plasma System Plasma Gas Start Gas Secondary Gas PT-24 Torch... 4 Section 3 Installation 3. General Equipment Required Location Primary Electrical Input Connections Interconnecting Lines... 4 Precision Plasmarc Component Interconnecting Diagram Torch Mounting Torch Coolant Inspection of Gas and Coolant Lines Replacement of EPROM in the Plasmarc Power Source Programmable Logic Controller (PLC)... 2 i

4 Precision Plasma Electronic Flow Control Table of Contents Section 4 Operation 4. Power Supply Controls 4.. Main Power Switch Pilot Arc Switch Fault Indicator Lights Meters Current Control Switch Cut Quality Introduction Cut Angle Cut Flatness Surface Finish Dross Dimensional Accuracy Influence of Gas Options on Cut Quality 4.3. Introduction Aluminum Carbon Steel Stainless Steel Process Data 4.4. Introduction Process Data Settings... 4 Plasma Marking Data Relationship of Kerf Width to Amperes and Material Thickness Aluminum Kerf Values Carbon Steel Kerf Values Stainless Steel Kerf Values O 2 /N 2 /O Stainless Steel Kerf Values Air/Air/CH Stainless Steel Kerf Values N 2 /N 2 /CH Stainless Steel Kerf Values N 2 /N Stainless Steel Kerf Values Air/Air ii

5 Precision Plasma Electronic Flow Control Table of Contents Section 5 Maintenance 5. General Inspection and Cleaning PT-24 Torch Description Torch Maintenance PT-24 Consumable Disassembly and Inspection PT-24 Torch Re-Assembly... 9 Section 6 Troubleshooting 6. General Safety Programmable Logic Controller (PLC) PLC LED Introduction PLC LED Functions Troubleshooting Guide 6.3. Reduced Consumable Life Poor Cut Quality No Pilot Arc No Arc Transfer No Preflow Torch Fails to Fire Nozzle Life Extremely Short Short Electrode Life Short Electrode AND Nozzle Life Flow Control Schematic Gas Flow Schematic Junction Box Wiring Diagram Junction Box Schematic Precision Plasma Power Module Wiring Diagram Power Module Schematic Power Source Wiring Diagrams Power Source Schematic iii

6 Precision Plasma Electronic Flow Control Table of Contents 6.2 Technical Guide to Using/Understanding the Operation of the EFC Precision Process Timers Process Timer Values Process Window Key Functions Proportional Valve Analog Values for PARAM.CUT and DEF.TEC Process Gas Selection Requirements EFC Process Gas Flow Chart Station On, Flush/Pressurize Cycle Timers Soleid/Proportional Valve Requirements and Gas Error Monitoring Carbon Steel PG-O 2, SG-O Carbon Steel PG-O 2, SG-N 2 /O Carbon Steel PG-O 2, Sg-O Stainless Steel PG-N 2, SG-N Stainless Steel PG-N 2, SG-N 2 /CH Stainless Steel PG-Air, SG-Air Stainless Steel PG-Air, SG-Air/CH Aluminum PG-N 2, SG- N Aluminum PG-N 2, SG-N 2 /CH Marking PG-Argon, SG-Air Section 7 Replacement Parts 7. General Ordering Plasmarc Power Source Exterior Components Plasmarc Power Source Internal Components Power Source Module EFC Junction Box Electronic Flow Control Box PT-24 Torch Assembly EFC Series A/M T Gas Shut-off Valve Assembly - Series A/M Torch PT-24 Torch Assembly Version Soleid Assembly - EFC Torch Version Interface Cables and Hoses Customer/Technical Information Resource Back Manual Cover iv

7 SECTION. Introduction SAFETY The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness. Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be accomplished. Failure to observe certain precautions could result in serious personnel injury or severe equipment damage. The following precautions are general guidelines applicable when working with cutting machines. More explicit precautions pertaining 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..2 Safety Notations And Symbols The following words and symbols are used throughout this manual. They indicate different levels of required safety involvement.!!!! DANGER WARNING CAUTION CAUTION NOTICE ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used in concurrence with other symbols and information. Used to call attention to immediate hazards which, if t avoided, will result in serious personal injury or loss of life. Used to call attention to potential hazards that could result in personal injury or loss of life. Used to call attention to hazards that could result in mir personal injury or equipment damage. Used to call attention to mir hazards to equipment. Used to call attention to important installation, operation or maintenance information t directly related to safety hazards. -

8 SECTION.3 General Safety Information SAFETY! WARNING Machine starts automatically. This equipment moves in various directions and speeds. Moving machinery can crush. Only qualified personnel should operate or service equipment. Keep all personnel, materials, and equipment t involved in production process clear of entire system area. Keep gear racks and rails clear of debris or obstructions, such as tools or clothing. Fence off entire work cell to prevent personnel from passing through area or standing in the working envelope of the equipment. Post appropriate WARNING signs at every work cell entrance. 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 using machine. Read entire procedure before operating or performing any system maintenance. Special attention must be given to all hazard warnings that provide essential information regarding personnel safety and/or possible equipment damage. All safety precautions relevant to electrical equipment and process operations must be strictly observed by all having system responsibility or access. Read all safety publications made available by your company. -2

9 SECTION! WARNING SAFETY Failure to follow safety warning label instructions could result in death or serious injury. Read and understand all safety warning labels on machine. Refer to operator s manual for additional safety information..4 Installation Precautions! WARNING Improperly installed equipment can cause injury or death. Follow these guidelines while installing machine: Do t connect a cylinder directly to machine inlet. An appropriate cylinder regulator must be installed on a fuel gas cylinder to reduce pressure to a reasonable inlet supply pressure. Machine regulator is then used to obtain pressure required by torches. Contact your ESAB representative before installation. He can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure maximum security. Never attempt any machine modifications or apparatus additions without first consulting a qualified ESAB representative. Observe machine clearance requirements for proper operation and personnel safety. -3

10 SECTION SAFETY.5 Electrical Grounding Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual s Installation section for detailed grounding instructions.! WARNING Electric shock hazard. Improper grounding can cause severe injury or death. Machine must be properly grounded before put into service.! WARNING Improper grounding can damage machine and electrical components. Machine must be properly grounded before put into service. Cutting table must be properly grounded to a good Earth ground rod..6 Operating A Plasma Cutting Machine! WARNING Flying debris and loud ise hazards. Hot spatter can burn and injure e. Wear goggles to protect e from burns and flying debris generated during operation. Chipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses. From plasma arc can damage hearing. Wear correct ear protection when cutting above water.! WARNING Burn hazard. Hot metal can burn. Do t touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with water. Do t touch plasma torch immediately after -4

11 SECTION cutting. Allow torch time to cool. SAFETY -5

12 SECTION SAFETY! WARNING Hazardous voltages. Electric shock can kill. Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process. Always turn power off to plasma power supplies before touching or servicing plasma torch. Always turn power off to plasma power supplies before opening or servicing plasma plumbing or flow control box. Do t touch live electrical parts. Keep all panels and covers in place when machine is connected to power source. Insulate yourself from workpiece and electrical ground: wear insulating gloves, shoes and clothing. Keep gloves, shoes, clothing, work area, and equipment dry.! WARNING Pinch hazard. Moving vertical slides can crush or pinch. Keep hands clear of torch and slide during operation.! WARNING Fume hazard. Fumes and gases generated by the plasma cutting process can be hazardous to your health. Do NOT breathe fumes. Do t operate plasma torch without fume removal system operating properly. Use additional ventilation to remove fumes if necessary. Use approved respirator if ventilation is t -6

13 SECTION adequate. SAFETY -7

14 SECTION! WARNING Radiation hazard. Arc rays can injure e and burn skin. SAFETY Wear correct eye and body protection. Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended lens shades for plasma cutting: Arc Current Lens Shade Up to 00 Amps Shade No Amps Shade No Amps Shade No. 2 Over 400 Amps Shade No. 4 Replace glasses/goggles when lenses are pitted or broken Warn others in area t to look directly at the arc unless wearing appropriate safety glasses. Prepare cutting area to reduce reflection and transmission of ultraviolet light. Paint walls and other surfaces with dark colors to reduce reflections. Install protective screens or curtains to reduce ultraviolet transmission.! WARNING Ruptured Gas Cylinders Can Kill Mishandling gas cylinders can rupture and violently release gas. Avoid rough handling of cylinders. Keep cylinder valves closed when t in use. Maintain hoses and fittings in good condition. Always secure cylinders in an upright position by chain or strap to a suitable stable object t part of an electrical circuit. Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder. Refer to CGA Standard P-, Precautions for Safe Handling of Compressed Gases in Cylinders, available from Compressed Gas Association. -8

15 SECTION SAFETY! WARNING Spark hazard. Heat, spatter, and sparks cause fire and burns. Do t cut near combustible material. Do t cut containers that have held combustibles. Do t have on your person any combustibles (e.g. butane lighter). Pilot arc can cause burns. Keep torch zzle away from yourself and others when activating plasma process. Wear correct eye and body protection. Wear gauntlet gloves, safety shoes and hat. Wear flame-retardant clothing that covers all exposed areas. Wear cuffless trousers to prevent entry of sparks and slag. CAUTION POOR PERFORMANCE WILL RESULT WHEN CUTTING ABOVE WATER. The PT-24 is designed to be a dry cutting process. Cutting above water may result in: reduced consumable life degradation of cut quality Cutting above water may result in poor cutting performance. Water vapor created when hot material or sparks contact liquid may cause arcing inside torch. When cutting on a water table, reduce the water level to provide maximum clearance between water and material. -9

16 SECTION SAFETY! WARNING Explosion hazard. Certain molten aluminum-lithium (Al-Li) alloys can cause explosions when plasma cut OVER water. Do t plasma cut the following Al-Li alloys with water: Alithlite (Alcoa) X892 (Alcoa) Alithally (Alcoa) Navalite (US Navy) 2090 Alloy (Alcoa) Lockalite (Lockheed) X8090A (Alcoa) Kalite (Kaiser) X8092 (Alcoa) 809 (Alcan) These alloys should only be dry cut on a dry table. DO NOT dry cut over water. Contact your aluminum supplier for additional safety information regarding hazards associated with these alloys..7 Service Precautions CAUTION Establish and adhere to preventive maintenance. A composite program can be established from recommended schedules in the instruction literature. Avoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage could occur to equipment or machine.! CAUTION Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage. Power off before using test probes to prevent accidental shorting of components. All circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all guards and covers replaced before power is turned on. Never plug or unplug a printed circuit board while machine power is on. Instantaneous surges of voltage and current can damage electronic components. -0

17 SECTION SAFETY.8 Safety References The following nationally recognized publications on safety in welding and cutting operations are recommended. These publications have been prepared to protect persons from injury or illness and to protect property from damage, which could result from unsafe practices. Although some of these publications are t related specifically to this type of industrial cutting apparatus, the principles of safety apply equally. Precautions and Safe Practices in Welding and Cutting with Oxygen-Fuel Gas Equipment, Form ESAB Cutting Systems. Precautions and Safe Practices for Electric Welding and Cutting, Form ESAB Cutting Systems. Safety in Welding and Cutting - ANSI Z 49., American Welding Society, 250 NW 7th Street, Miami, Florida, Recommended Safe Practices for Shielded Gases for Welding and Plasma Arc Cutting - AWS C5.0-94, American Welding Society. Recommended Practices for Plasma Arc Welding - AWS C5., 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 5B, National Fire Protection Association, 60 Batterymarch Street, Boston, Massachusetts, 020. Standard for Installation and Operation of Oxygen - Fuel Gas Systems for Welding and Cutting - NFPA 5, National Fire Protection Association. Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon Dioxide, Hydrogen, and Acetylene, Form ESAB Cutting Systems. Obtainable through your ESAB representative or local distributor. "Design and Installation of Oxygen Piping Systems," Form 50. ESAB Cutting Systems. Precautions for Safe Handling of Compressed Gases in Cylinders, CGA Standard P-, Compressed Gas Association. Literature applicable to safe practices in welding and cutting with gaseous materials is also available from the Compressed Gas Association, Inc., 500 Fifth Ave., New York, NY

18 SECTION SAFETY This page intentionally left blank. -2

19 SECTION 2 DESCRIPTION 2. General The Precision Plasmarc System consists of four separate components. The power source, the junction box, the flow control box, and the PT-24 torch. The power source provides power and coolant to the PT-24 torch via the junction box. 2.2 Scope The purpose of this manual is to provide the operator with all the information required to install and operate the Precision Plasmarc System. Technical reference material is also provided to assist in troubleshooting the cutting package. 2.3 Package Options Available Precision Plasmarc package options available through your ESAB dealer Precision Plasmarc Power Source (200/230/380/45/460/575) 3-phase 50/60 Hz P/N (required) Electronic Flow Control Box (required) P/N Junction Box (required) P/N PT-24 Torch Electronic Flow Series A/M (one required) Power Bundle (one required) Gas Line Bundle (one required) Control Lead Flow Console to Junction Box (one required) 4.5 ft. (.4 m) P/N ft. (4.4 m) P/N ft. (5.2 m) P/N ft. (3.6 m) P/N ft. (7.6 m) P/N ft. (2.2 m) P/N ft. (8 m) P/N ft. (24.4 m) P/N ft. (30 m) P/N ft. (3 m) P/N ft. (6 m) P/N ft. (9 m) P/N ft. (8 m) P/N ft. (30 m) P/N ft. (3 m) P/N ft. (6 m) P/N 298 Standard Cable 30 ft. (9 m) P/N 299 Flex cable (recommended for power track applications) 60 ft. (8 m) P/N ft. (30 m) P/N ft. (3 m) P/N ft. (6 m) P/N ft. (9 m) P/N ft. (2 m) P/N ft. (8 m) P/N ft. (30 m) P/N

20 SECTION 2 DESCRIPTION Control Lead Power Source to Cutting Machine I/O High Frequency Power Cable Power Supply to Junction Box or- Power Supply to Cutting Machine I/O, depending on configuration 30 ft. (9. m ) P/N ft. (5.2 m) P/N ft. (22.8 m ) P/N ft. (30.5 m) P/N ft. (48.8 m) P/N ft. (.9 m) P/N ft. (5.2 m) P/N ft. (22.8 m) P/N ft. (30.5 m) P/N ft. (38. m) P/N ft. (45.7 m) P/N ft. (53.3 m) P/N ft. (6 m) P/N Torch Coolant (one gallon (3.8 l) containers. four gallons (5 l) required) P/N 56F05 NOTES: Control lead from the power source to customer CNC is supplied based on customer order. Gas supply, hoses, work lead and input primary cable are all supplied by the customer. See Process Data Sheets for a list of torch consumable parts. 2.4 Precision Plasma Technical Specifications 2.4. System Input Voltage Input Current 200/230/380/45/460/575 V 3 phase 50/60 Hz 65/60/50/40/30/25 amps per phase Power Factor 0.95 Output Current Range Output Load Voltage 5-00 amps dc 20 V dc Duty Cycle 00% Open Circuit Voltage 35 V dc 2-2

21 NITROGEN AIR N2 AIR ARGON O2 N2 O2 OXYGEN AIR N2 NITROG EN METHANE HYDROGEN SECTION 2 DESCRIPTION JUNCTION BOX POWER SUPPLY 6.75" (7mm) CONTROL CURRENT PILOT ARC POWER 9.75" (502mm) 0.62" (270mm) RECISION PLASMARC WEIGHT = 26.5 lbs.(2 kg) 44" (8mm) 42" (067mm) ELECTRONIC FLOW CONTROL BOX 22" (559mm) WEIGHT = 560 lbs. (254 kg) 2.25" (3mm) PLASMA GAS NO. PLASMA GAS NO.2 AIR SHIELD GAS NO. OXYGEN NITROG EN METH H-35 SHIELD GAS NO.2 2" (305mm) 4.5" (8mm) WEIGHT = 5 lbs. (23 kg) 2-3

22 SECTION 2 DESCRIPTION Plasma Gas Technical Specifications Type Pressure Flow Purity Required* Recommended Liquid Cylinder Service Regulators Recommended Cylinder 2-Stage Regulators Recommended Heavy Duty Hi-flow Station or Pipeline Regulators Recommended High-capacity Station or Pipeline Regulators O 2, N 2, Air 25 psig (8.6 bars) 00 cfh (47 l/min) max. (varies with application) O % N % Air-clean, dry and oil free Oxygen: R LC (P/N 9777) Inert gas: R LC (P/N 9977) Oxygen: R (P/N Hydrogen/Methane:R (P/N ) Nitrogen: R (P/N ) Industrial Air: R-7750=590 (P/N ) Oxygen: R (P/N 95) R-6703 (P/N 22236) Gas Filter Required 25 micron w/bowl guard (P/N ) Start Gas Technical Specifications Type N 2, Air Pressure 25 psig (8.6 bar) Flow 60 cfh (28 l/min) max (varies with application) Minimum Purity Required % Secondary Gas Technical Specifications Type N 2, O 2, H-35, Methane, Air 00 psig (6.6 bar) H-35, Pressure Methane; 25 psig (8.6 bar) N 2, O 2, Air 60 cfh (28 l/min) max (varies Flow with application) Minimum Purity Required % Pt-24 Torch Technical Specifications Type Water-Cooled, Dual Gas Rating % duty cycle Dimensions See Package Options (2.3) 2-4

23 SECTION 3 3. General NOTICE INSTALLATION Proper installation can contribute materially to the satisfactory and trouble-free operation of the Precision Plasmarc System. It is suggested that each step in this section be studied and carefully followed. 3.2 Equipment Required Gas Supply and Hoses. Gas supply may be from a bulk source or from a bank of manifold cylinders and regulated to supply 25 psig (8.6 bar) to the Flow Control (gas flowing). Work Lead. No. 4 AWG cable is recommended for connecting workpiece to power source. Primary Input 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.! CAUTION Do Not Restrict Air Flow Restricting intake air with any type of filter on or around the power supply may void the warranty. 3-

24 SECTION 3 INSTALLATION 3.4 Primary Electrical Input Connections! DANGER Electric Shock Can Kill! Provide maximum protection against electrical shock. Before any connections are made inside the machine, open the line (wall) disconnect switch and unplug the power cord.! WARNING Input Power Configuration Machine must be properly configured for your input power. The machine is shipped from the factory configured for 575 V, 60 Hz input. Do NOT connect a power source of any other voltage unless machine is reconfigured. Damage to the machine will occur. Input Power Connection At Wall 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 Input requirements Input & ground Fuse ratings / conductor, Volts Phase Amps cu/awg/mm 2 phase, amps No No No No No No

25 SECTION 3 INSTALLATION The following procedure explains the proper installation steps for connecting primary electrical power to the power source. Ground Connection Input Power Cable (Customer supplied). Remove right side panel. 2. Ensure input power cable is disconnected from all electrical sources. 3. Route input power cable through the strain relief located at the rear panel. 4. Pull input power cable through the strain relief to allow cable wires sufficient length to connect to the main contactor. Tighten strain relief to ensure input power cable is secured. TB2 TB PHASE PHASE 2 PHASE 3 K Main Contactor 7 Position Terminal Block Auto Transformer Factory Wired for 575 volts 5. Connect input power cable ground wire to the ground lug provided on the base of the power source. 6. Connect three power leads of the input power cable to the terminals located atop the main contactor. Secure the leads by tightening 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 Ensure each input power jumper cable is connected to the correct input voltage on auto transformer. Factory wired for 575 V. 8. Connect jumper wire to the proper input voltage connector located on the 7-position terminal block. TB2 3-3

26 SECTION 3 INSTALLATION 3.5 Interconnecting Lines Black Red/Orange Yellow Blue. All interconnecting service lines supplied are numbered or color coded on each end with corresponding numbers/colors marked on the cabinets. Mounting Plate Gas Line Bundle Gas Bundle Installation 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 3-4

27 SECTION 3 INSTALLATION Power supply and EFC Connections to J-Box Power Supply Bundle Power Supply Negative Connection Pilot Arc Connection #6 Hose Connection (to power source) #7 Hose Connection (from power source) Gas Bundle Connections Control Lead Connection from EFC 3. Connect power and coolant lines in Power Supply Bundle from power source to junction box. Power bundle consists of #6 and # 7 coolant lines (with 5/8-8 L.H. fittings), power cable (#3 AWG) and yellow pilot arc cable (#6 AWG). Both coolant lines are stamped with a 6 or 7 on the fitting to assist in identification. 3-5

28 SECTION 3 INSTALLATION Torch Hose/Power Cable Connection Junction Box to Torch Torch Bundle Torch Soleid Electrical Connection Torch Pilot Arc Connection 4. Connect Torch Bundle Leads/Hoses to Junction box. (see Interconnecting Block Diagram) 3-6

29 SECTION 3 INSTALLATION Precision Plasmarc Component Interconnecting Diagram 25 micron Filters EFC Control Lead EFC/Junction Box ASIOB High N 2 O 2 CH 4 Air Frequency CNC 20VAC High Frequency 20VAC Ar Gas Line Bundle Junction Box Power Bundle Torch Cutting Table Work Lead Primary Power Cable Ground Rod Control Lead Power Supply to CNC 3-7

30 SECTION 3 INSTALLATION! CAUTION Gas Line Contamination Will Damage Proportional Valves Purge Gas Lines Before connecting gas delivery lines to the Electronic Flow Control, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your EFC. /4 NPT 5. Purge gas lines between supply and the EFC before connecting. Proportional valves in the EFC are very sensitive to dust and other foreign particles. 6. Connect Gas Delivery lines to Electronic Flow Control. Install 25 micron Gas filters in all delivery lines between gas source and EFC. 25 micron Gas Filter 25μ Filters N 2 O 2 CH 4 Air Ar 3-8

31 SECTION 3 INSTALLATION Pilot Arc Remove Access Cover Work Torch Pilot Arc 7. Remove panel from rear of console and attach the pilot-arc, torch and work lead. Work Torch Power Source 600 amp Bus Fuse CNC Control Lead Flow Control Lead Rating Label Serial Tag 8. Connect control lead between the console and the Electronic Flow Control. Connect coolant lines of the Power Bundle. Coolant In from Torch # 6 Connection Coolant Out to Torch # 7 Connection CONTROL LEAD 3-9

32 SECTION 3 INSTALLATION 3.6 Torch Mounting CAUTION Do Not Cover Vent Hole. When mounting, do t to cover the small vent hole in the side of the sleeve. This hole allows coolant to drain from inside the sleeve should a leak occur in a service line..82" (46mm) Diameter Collar 2.0" (5mm) Diameter Sleeve Vent Hole Torch Mounting Options. The torch is rmally mounted by the 2.0 inch diameter (5mm) sleeve. Do t cover vent hole. For custom alternative mounting, the torch can be mounted by the.82" (46 mm) dia collar shown. This insulated collar and its shoulder are machined relative to the zzle retainer thread on the torch body. Use only specified mounting surfaces 3-0

33 CONTROL CURRENT PILOT ARC POWER SECTION 3 INSTALLATION 3.7 Torch Coolant RECISION PLASMARC Remove coolant fill cap at front of console and fill coolant tank with 4 gallons (5 liters) of plasma coolant, P/N 56F05 (one gallon). Coolant Fill Cap Do t fill above maximum level Reinstall Cap.! CAUTION Commercial Antifreeze Will Cause Torch To Malfunction Use Special Torch Coolant! P/N56F05 Due to high electrical conductivity, DO NOT use tap water or commercial antifreeze for torch cooling. A specially formulated torch coolant is REQUIRED. This coolant also protects for freezing to 34 C. Operating the unit without coolant will cause permanent damage to the coolant pump. 3.8 Inspection of Gas and Coolant Lines To complete installation, it is necessary to inspect field assembled connections for leaks. Gas lines, use a standard soap solution. Pressurize the system from the control (SDP file) Coolant- check connections for signs of moisture at connections 3-

34 SECTION 3 INSTALLATION 3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic Controller (PLC) The Precision Plasmarc System may be shipped configured for a manual flow control (Series A ). If so, the EPROM in the Programmable Logic Controller must be replaced with an EFC EPROM. This EFC EPROM is shipped with the power source.!! CAUTION CAUTION Using the Wrong EPROM Could Result In Damaged System Components The Series A and the EFC EPROMs are programmed with different software. The EFC EPROM igres the process gas pressure switch inputs and does t include the process gas purge required for the Series A. Mishandling Can Damage Electronic Components. Handle electronic components with care. Do t drop Do t bend pins Do t touch circuit components- handle along edges when possible!! CAUTION WARNING Electronic Components Are Subject To Electro-Static-Discharge (ESD) Damage Integrated Circuit parts are sensitive to over voltages. The damage may t be seen immediately but show up as a premature failure. The EFC EPROM is shipped in an anti-static bag. Store EPROM in this bag. Wear a protective ground strap when handling sensitive electronic components. Electric shock Can Kill! Unplug power cable from wall to power source before any connections or adjustments are made inside power source. 3-2

35 CONTROL CURRENT PILOT ARC POWER SECTION 3 INSTALLATION RECISION PLASMARC Left Side Panel. 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 3-3

36 SECTION 3 CAUTION INSTALLATION Using An EPROM Puller Tool May Damage Socket Forcibly removing a clamped EPROM in the PLC may cause the socket/eprom to break. Special Zero Force EPROM Socket is used to eliminate the need for special tools. EPROM Locked In Place 4. Remove the EPROM from the socket. THIS DOES NOT REQUIRE 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 EPPSEFC= EFC EPROM, electronic flow control P/N EPROM Lock Released 3-4

37 SECTION 4 OPERATION 4. Power Supply Controls 4.. Main Power Switch EMERGENCY STOP LOW DONOTSWITCH WHILECUTING Main Power Switch Controls the input power to the fan, water cooler and the PC Board. Amber indicator light to the left of the switch 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. EMERGENCY STOP POWER ON WARNING Adjusting Pilot Arc While in Operation Could Damage Torch. Do t adjust pilot arc switch while in operation. Adjust before torch starts. Precision Plasma with Electronic Flow Control - 4-

38 SECTION 4 OPERATION 4..3 Fault Indicator Lights Fault Indicator Lights Coolant flow will show low coolant flow. When unit is turned on, the light will briefly show a fault and then go out. Plasma Gas Pressure fault indicator -- low Plasma Gas Pressure. Torch will t fire when indicated. Not used for the EFC. Start Gas Pressure fault indicator -- low start gas pressure. Torch will t fire when indicated. Not used for the EFC. P/S Temp fault indicator -- over temperature in the inverter power source. Power source will shut down. P/S Fault 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 t work Meters Cutting Current Meter (A) -- Displays actual cutting current in amperes. Cutting Voltage Meter (V) -- Displays actual cutting voltage. 4-2 Precision Plasma with Electronic Flow Control -

39 SECTION 4 OPERATION 4..5 Current Control Switch Control Remote/Panel Switch Panel Position Output current is set by the output current dial Output Current Dial sets the cutting current when current setting is made from the console front panel. Dial reads 0 to 99.9 amps amps shown. Remote Position output current is set by the CNC (or remote pot) with an analog dc signal 0-0 Vdc = 0-00 Adc Precision Plasma with Electronic Flow Control - 4-3

40 SECTION 4 OPERATION 4.2 Cut Quality 4.2. Introduction Causes affecting cut quality are interdependent. Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to different undesirable cutting results. To begin select the most prominent condition: Cut Angle, negative or positive Cut t flat, rounded or undercut Surface roughness Dross Usually the recommended cutting parameters will give optimal cut quality, occasionally conditions may vary eugh 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 settings/consumable part numbers listed in Process Data. 4-4 Precision Plasma with Electronic Flow Control -

41 SECTION 4 OPERATION Cut Angle Part Negative Cut Angle Top dimension is greater than the bottom. Drop Part Misaligned torch Bent or warped material Worn or damaged consumables Standoff low (arc voltage) Cutting speed slow (machine travel rate) Part Positive Cut Angle Top dimension is less than the bottom dimension. Drop Part Misaligned torch Bent or warped material Worn or damaged consumables High standoff High (arc voltage) Cutting speed fast Current high or low. (See Process Data for recommended current level for specific zzles). Precision Plasma with Electronic Flow Control - 4-5

42 SECTION 4 OPERATION 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). Drop Part Top Edge Undercut Standoff low (Arc Voltage) Drop Part 4-6 Precision Plasma with Electronic Flow Control -

43 SECTION 4 OPERATION Surface Finish Process Induced Roughness Cut face is consistently rough. May or may t be confined to one axis. Incorrect Shield Gas mixture (See Process Data) Top View Worn or damaged consumables Machine Induced Roughness Can be difficult to distinguish from Process Induced Roughness. Often confined to only one axis. Roughness is inconsistent. or Process Induced Roughness Machine Induced Roughness Dirty rails, wheels and/or drive rack/pinion. (Refer to Maintenance Section in machine owners manual). Carriage wheel adjustment Precision Plasma with Electronic Flow Control - 4-7

44 SECTION 4 OPERATION Dross Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data. Lag Lines Cut Face Roll over 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 Side view Lag Lines Cut Face Slow Speed Dross Forms as globules on bottom along kerf. Removes easily. Globules Cutting speed slow Side View 4-8 Precision Plasma with Electronic Flow Control -

45 SECTION 4 OPERATION Side View Splatter Top Dross Appears as splatter on top of material. Usually removes easily. Cut Face 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 Precision Plasma with Electronic Flow Control - 4-9

46 SECTION 4 OPERATION Dimensional Accuracy Generally using the slowest possible speed (within approved levels) will optimize part accuracy. Select consumables to allow a lower arc voltage and slower cutting speed. NOTICE Recommended cutting speed and arc voltage will give optimal 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 with the factory recommended settings/consumable part numbers listed in the Process Data. 4-0 Precision Plasma with Electronic Flow Control -

47 SECTION 4 OPERATION 4.3 Influence of Gas Options on Cut Quality 4.3. Introduction All gases are t suitable for all situations. Certain gases assist in cutting specific materials and thickness. The following explains why certain gases are selected and their influence on the finished part. Other influences such as arc voltage and gas flow/pressure are covered in the Process Data. NOTICE Refer to Cutting Process Data in this section for recommended flow/pressure settings Aluminum Material Thickness: Cut Qualities: All thickness between.062" to.625" (,6 mm to 5,9 mm) Smooth cut face Virtually dross Plasma Gas: Nitrogen Shield Gas: Nitrogen/Methane Discussion: Shield mixture is very important. Between 2 and 3 parts nitrogen, to part methane ratio is desired. Incorrect ratio results in heavy dross. Precision Plasma with Electronic Flow Control - 4-

48 SECTION 4 OPERATION NOTICE Refer to Cutting Process Data in the PT24 Manual for recommended flow/pressure settings Carbon Steel Material Thickness: Cut Qualities: Plasma Gas: Shield Gas: Discussion: 26 GA (.08") to 0 GA (.35") (0,5 mm to 3,4 mm) Smooth cut face Virtually dross Oxygen Oxygen/Nitrogen Shield gas is rmally nitrogen. A small amount of oxygen combined with nitrogen can effectively improve dross formation on thin material of 26 GA to 0 GA carbon steel. Also, an oxygen only shield may provide acceptable results on thinner materials. Material Thickness: Cut Qualities: Plasma Gas: Shield Gas: Discussion:.25" to.75" (3,2 mm to 9, mm) Smooth cut face Virtually dross Oxygen Nitrogen Cutting carbon steel with oxygen results in an exothermic reaction. This chemical reaction causes the carbon in the material to burn similar to when oxy-fuel cutting. This plus the electrical energy uses lower amperage levels without sacrificing cut speed. 4-2 Precision Plasma with Electronic Flow Control -

49 SECTION 4 OPERATION NOTICE Refer to Cutting Process Data in the PT24 Manual for recommended flow/pressure settings Stainless Steel Material Thickness: 22 GA (.028") to 6 GA (.062") (0,7 mm to,6 mm) Cut Qualities: Plasma Gas: Nitrogen Shield Gas: Nitrogen/Methane Discussion: Positive cut angle Excellent dross performance Shiny cut surface. Because of high cut speeds, a positive cut face angle is expected. Use a 70-amp zzle at 50 amps to allow more gas to exit the zzle. Material Thickness: 26 GA (.08") to 6 GA (.062") (0,5 mm to,6 mm) Cut Qualities: Plasma Gas: Oxygen Shield Gas: Oxygen/Nitrogen Discussion: Dark cut face Virtually dross free Improved cut squareness Low amperage cutting/slower speeds produce squarer cuts in thin materials. The oxygen allows for a lower arc voltage, improving cut squareness. The B zzle is used at 30 amps Material Thickness:.25" to.625" (3,2 mm to 5,9 mm) Cut Qualities: Plasma Gas: Air Cut edge dark good dross performance Good cut angle Shield Gas: Air When they are the same, the shield and plasma gases combine. This Discussion: combination has the effect of increasing the cut gas flow/pressure. This increased flow/pressure directly influences cut squareness. Precision Plasma with Electronic Flow Control - 4-3

50 SECTION 4 OPERATION NOTICE Refer to Cutting Process Data for recommended flow/pressure settings. Stainless Steel Material Thickness: Cut Qualities: Plasma Gas: Shield Gas: Discussion: Material Thickness: Cut Qualities: Plasma Gas: Shield Gas: Discussion:.25" to.625" (3,2 mm to 5,9 mm) Air Matted cut edge appearance Light gray color Much smoother finish Possible slight increase in cut angle Air/Methane Too much methane in the shield gas mixture can result in more dross formation. 4: ratio air to methane is recommended. Because methane is a fuel gas, possible slight increase in cut angles could be experienced..25" to.625" (3,2 mm to 5,9 mm) Dark cut face similar to air Excellent dross performance Good cut angle Nitrogen Nitrogen 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: Cut Qualities: Plasma Gas: Shield Gas: Discussion:.87" to.625" (4,7 mm to 5,9 mm) Shiny cut face Lip formation at the bottom Dross formation can be extensive and difficult to remove Nitrogen Nitrogen/Methane Because methane is a fuel gas, flow/pressure rates can affect the cut angle. High flow/pressure results in a negative cut angle, low flow/pressure results in a positive cut angle. Nitrogen to methane ratio is 0 to 4 parts N 2 / part CH 4. The lip formed on the cut face bottom is severe, making Nitrogen/Methane shield gas combination unsuitable for some finished part applications. 4-4 Precision Plasma with Electronic Flow Control -

51 SECTION 4 OPERATION 4.4 Process Data 4.4. Introduction The following information is a result of many hours of testing and is a general guide for setting up and cutting with a PT-24 Precision Plasmarc System. In most cases these settings will provide a quality cut. 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 consumable part numbers for current being used. Precision Plasma with Electronic Flow Control - 4-5

52 SECTION 4 OPERATION Process Data Material: Amperes: 30 Aluminum RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2536 (3 holes)! Nozzle P/N 254, "B" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-6 Precision Plasma with Electronic Flow Control -

53 SECTION 4 Process Data 30 Amperes Aluminum PG SG SG2 Material Thickness N 2 N 2 CH 4 OPERATION IN MM,6,9 2,3 3,2 4,7 6,4 Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc LOW. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-7

54 SECTION 4 OPERATION Material: Amperes: 55 Aluminum RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2542, "C" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-8 Precision Plasma with Electronic Flow Control -

55 SECTION 4 Process Data Aluminum 55 Amperes Aluminum PG SG SG2 Material Thickness N 2 N 2 CH 4 IN MM,6 3,2 4,7 6,4 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-9

56 SECTION 4 OPERATION Material: Amperes: 70 Aluminum RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2543, "D" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-20 Precision Plasma with Electronic Flow Control -

57 SECTION 4 Process Data 70 Amperes Aluminum PG SG SG2 Material Thickness N 2 N 2 CH 4 IN MM 4,7 6,4 9,5 2,7 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-2

58 SECTION 4 OPERATION Material: Amperes: 00 Aluminum RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-22 Precision Plasma with Electronic Flow Control -

59 SECTION 4 Process Data 00 Amperes Aluminum PG SG SG2 Material Thickness N 2 N 2 CH 4 IN MM 6,4 9,5 2,7 5,9 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

60 SECTION 4 OPERATION Material: Amperes: 6 Carbon Steel RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Oxygen (O 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Oxygen (O 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2852 (2 holes)! Nozzle P/N 2540, "A" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-24 Precision Plasma with Electronic Flow Control -

61 SECTION 4 Process Data 6 Amperes Carbon Steel PG SG SG2 Material Thickness O 2 N 2 O 2 OPERATION IN 20GA 8GA 6GA 4GA 2GA 0GA MM 0,9,2,6 2,0 2,7 3,4 Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc LOW. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

62 SECTION 4 Material: Amperes: 35 Carbon Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Oxygen (O 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Oxygen (O 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2536 (3 holes)! Nozzle P/N 254, "B" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-26 Precision Plasma with Electronic Flow Control -

63 SECTION 4 Process Data 35 Amperes Carbon Steel PG SG SG2 Material Thickness O 2 N 2 O 2 IN 4GA MM,9 3,2 3,4 4,7 6,4 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

64 SECTION 4 Material: Amperes: 45 Carbon Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Oxygen (O 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Oxygen (O 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2542, "C" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-28 Precision Plasma with Electronic Flow Control -

65 SECTION 4 Process Data 45 Amperes Carbon Steel PG SG SG2 Material Thickness O 2 N 2 O 2 IN MM 3,2 3,4 4,7 6,4 9,5 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

66 SECTION 4 Material: Amperes: 70 Carbon Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Oxygen (O 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Oxygen (O 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2543, "D" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-30 Precision Plasma with Electronic Flow Control -

67 SECTION 4 Process Data 70 Amperes Carbon Steel PG SG SG2 Material Thickness O 2 N 2 O 2 OPERATION IN MM 4,7 6,4 7,9 9,5 2,7 2,9 Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-3

68 SECTION 4 Material: Amperes: 00 Carbon Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Oxygen (O 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Oxygen (O 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-32 Precision Plasma with Electronic Flow Control -

69 SECTION 4 Process Data 00 Amperes Carbon Steel PG SG SG2 Material Thickness O 2 N 2 O 2 IN MM 7,9 9,5 2,9 5,9 9, OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

70 SECTION 4 OPERATION Material: Amperes: 30 Stainless Steel RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Oxygen (O 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Oxygen (O 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2536 (3 holes)! Nozzle P/N 254, "B" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-34 Precision Plasma with Electronic Flow Control -

71 SECTION 4 Process Data 30 Amperes Stainless Steel PG SG SG2 Material Thickness O 2 N 2 O 2 OPERATION IN 26GA 24GA 22GA 8GA 6GA MM 0,4 0,6 0,7,2,6 Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc LOW. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

72 SECTION 4 Material: Amperes: 50 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: 25 psi (8.6 bar) 25 psi (8.6 bar) 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2542, "C" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-36 Precision Plasma with Electronic Flow Control -

73 SECTION 4 Process Data 50 Amperes Stainless Steel PG SG SG2 Material Thickness Air Air Air IN MM 3,2 4,7 6,4 9,5 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

74 SECTION 4 Material: Amperes: 70 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: 25 psi (8.6 bar) 25 psi (8.6 bar) 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2543, "D" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-38 Precision Plasma with Electronic Flow Control -

75 SECTION 4 Process Data 70 Amperes Stainless Steel PG SG SG2 Material Thickness Air Air Air IN MM 4,7 6,4 9,5 2,7 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

76 SECTION 4 Material: Amperes: 00 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: 25 psi (8.6 bar) 25 psi (8.6 bar) 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-40 Precision Plasma with Electronic Flow Control -

77 SECTION 4 Process Data 00 Amperes Stainless Steel PG SG SG2 Material Thickness Air Air Air IN MM 6,4 9,5 2,7 5,9 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-4

78 SECTION 4 Material: Amperes: 70 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: 25 psi (8.6 bar) 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2543, "D" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-42 Precision Plasma with Electronic Flow Control -

79 SECTION 4 Process Data 70 Amperes Stainless Steel PG SG SG2 Material Thickness Air Air CH 4 IN MM 3,2 4,7 6,4 9,5 2,7 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

80 SECTION 4 Material: Amperes: 00 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: 25 psi (8.6 bar) 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-44 Precision Plasma with Electronic Flow Control -

81 SECTION 4 Process Data 00 Amperes Stainless Steel PG SG SG2 Material Thickness Air Air CH 4 IN MM 6,4 9,5 2,7 5,9 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

82 SECTION 4 Material: Amperes: 50 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2542, "C" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-46 Precision Plasma with Electronic Flow Control -

83 SECTION 4 Process Data 50 Amperes Stainless Steel PG SG SG2 Material Thickness N 2 N 2 IN MM 3,2 4,7 6,4 9,5 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

84 SECTION 4 Material: Amperes: 70 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2543, "D" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-48 Precision Plasma with Electronic Flow Control -

85 SECTION 4 Process Data 70 Amperes Stainless Steel PG SG SG2 Material Thickness N 2 N 2 IN MM 4,7 6,4 9,5 2,7 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

86 SECTION 4 Material: Amperes: 00 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-50 Precision Plasma with Electronic Flow Control -

87 SECTION 4 Process Data 00 Amperes Stainless Steel PG SG SG2 Material Thickness N 2 N 2 IN MM 6,4 9,5 2,7 5,9 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-5

88 SECTION 4 Material: Amperes: 70 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539! Swirl Baffle P/N 2692 (4 holes)! Nozzle P/N 2543, "D" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-52 Precision Plasma with Electronic Flow Control -

89 SECTION 4 Process Data 70 Amperes Stainless Steel PG SG SG2 Material Thickness N 2 N 2 CH 4 IN MM 4,7 6,4 9,5 2,7 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

90 SECTION 4 Material: Amperes: 00 Stainless Steel OPERATION RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: Shield Mix Gas: Nitrogen (N 2 25 psi (8.6 bar) Nitrogen (N 2 25 psi (8.6 bar) Methane (CH 4 00 psi (6.9 bar) Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-54 Precision Plasma with Electronic Flow Control -

91 SECTION 4 Process Data 00 Amperes Stainless Steel PG SG SG2 Material Thickness N 2 N 2 CH 4 IN MM 6,4 9,5 2,7 5,9 OPERATION Pierce Delay (SEC.) Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start SG- Cut SG2- Cut Flow Flow Reading Arc Voltage (standoff) Travel Speed IPM MM/MIN Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

92 SECTION 4 OPERATION Plasma Marking Amperes: 0 B Nozzle RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2536 (3 Holes)!Nozzle P/N 254 B Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-56 Precision Plasma with Electronic Flow Control -

93 SECTION 4 Plasma Marking Process Data B Nozzle 0 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 35 SG- Cut 35 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 200 MM/MIN 5080 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

94 SECTION 4 RECISION LASMARC PT-24 Torch Plasma Marking B Nozzle Amperes: 5 Plasma Gas: Shield Gas: OPERATION 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N holes!nozzle P/N 254 B Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-58 Precision Plasma with Electronic Flow Control -

95 SECTION 4 Plasma Marking Process Data B Nozzle 5 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 35 SG- Cut 35 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 300 MM/MIN 7620 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

96 SECTION 4 OPERATION Plasma Marking Amperes: 0 C Nozzle RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2542 C Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-60 Precision Plasma with Electronic Flow Control -

97 SECTION 4 Plasma Marking Process Data C Nozzle 0 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 37 SG- Cut 37 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 00 MM/MIN 2540 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-6

98 SECTION 4 OPERATION Plasma Marking C Nozzle Amperes: 5 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2542 C Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-62 Precision Plasma with Electronic Flow Control -

99 SECTION 4 Plasma Marking Process Data C Nozzle 5 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 35 SG- Cut 35 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 200 MM/MIN 5080 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

100 SECTION 4 OPERATION Plasma Marking D Nozzle Amperes: 0 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2543 D Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-64 Precision Plasma with Electronic Flow Control -

101 SECTION 4 Plasma Marking Process Data D Nozzle 0 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 00 SG- Cut 00 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 00 MM/MIN 2540 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

102 SECTION 4 OPERATION Plasma Marking D Nozzle Amperes: 5 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-66 Precision Plasma with Electronic Flow Control -

103 SECTION 4 Plasma Marking Process Data D Nozzle 5 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 37 SG- Cut 37 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 300 MM/MIN 7620 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

104 SECTION 4 OPERATION Plasma Marking Amperes: 20 D Nozzle RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2543 D Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-68 Precision Plasma with Electronic Flow Control -

105 SECTION 4 Plasma Marking Process Data D Nozzle 20 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 00 SG- Cut 00 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 200 MM/MIN 5080 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

106 SECTION 4 OPERATION Plasma Marking D Nozzle Amperes: 30 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2543 D Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-70 Precision Plasma with Electronic Flow Control -

107 SECTION 4 Plasma Marking Process Data D Nozzle 30 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 00 SG- Cut 00 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 500 MM/MIN 2700 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control - 4-7

108 SECTION 4 OPERATION Plasma Marking E Nozzle Amperes: 0 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-72 Precision Plasma with Electronic Flow Control -

109 SECTION 4 Plasma Marking Process Data E Nozzle 0 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 00 SG- Cut 00 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 00 MM/MIN 2540 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

110 SECTION 4 OPERATION Plasma Marking E Nozzle Amperes: 20 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-74 Precision Plasma with Electronic Flow Control -

111 SECTION 4 Plasma Marking Process Data E Nozzle 20 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 00 SG- Cut 00 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 300 MM/MIN 7620 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

112 SECTION 4 OPERATION Plasma Marking E Nozzle Amperes: 30 RECISION LASMARC PT-24 Torch Plasma Gas: Shield Gas: 25 PSI / 8.6 Bar 25 PSI/ 8.6 Bar Torch Body P/N 2758 Water Baffle P/N 2725 P/N P/N 86W62 P/N P/N 98W8 Electrode P/N 2539!Swirl Baffle P/N 2692 (4 holes)!nozzle P/N 2923, "E" Nozzle Retainer/Diffuser Shield Cup Insulator P/N 2200 Insulator Shield Retainer w/ - Shield Retainer. (Ref. P/N ) Cup shield w/retainer P/N 2253! Baffle and Nozzle are the only two replaceable torch front-end parts that may vary with amperage 4-76 Precision Plasma with Electronic Flow Control -

113 SECTION 4 Plasma Marking Process Data E Nozzle 30 Amperes OPERATION Setup Parameters (see tes) Plasma Start Gas Plasma Cut Gas Shield Gas (Flow Reading) SG-Start 00 SG- Cut 00 SG2- Cut Flow 0 Flow Reading Arc Voltage (standoff) 77 Travel Speed IPM 500 MM/MIN 2700 Notes:. Pilot Arc HIGH. 2. Cut and ALT gas mix in Flow Control. 3. Float Center of Ball Precision Plasma with Electronic Flow Control

114 SECTION 4 OPERATION Aluminum Kerf Values N 2 /N 2 /CH 4 Aluminum N 2 /N 2 /CH 4 30 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Aluminum N 2 /N 2 /CH 4 50 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Precision Plasma with Electronic Flow Control -

115 SECTION 4 OPERATION Aluminum N 2 /N 2 /CH 4 70 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches).270 Aluminum N 2 /N 2 /CH 4 00 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches).270 Precision Plasma with Electronic Flow Control

116 SECTION 4 OPERATION Carbon Steel Kerf Values O 2 /N 2 /O 2 Carbon Steel O 2 /N 2 /O 2 6 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Carbon Steel O 2 /N 2 /O 2 35 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Precision Plasma with Electronic Flow Control -

117 SECTION 4 OPERATION Carbon Steel O 2 /N 2 /O 2 45 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Carbon Steel O 2 /N 2 /O 2 70 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Precision Plasma with Electronic Flow Control - 4-8

118 SECTION 4 OPERATION Carbon Steel O 2 /N 2 /O 2 00 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Precision Plasma with Electronic Flow Control -

119 SECTION 4 OPERATION Stainless Steel Kerf Values O 2 /N 2 /O 2 Stainless Steel O 2 /N 2 /O 2 30 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) GA 24GA 22GA 8GA 6GA Material Thickness (inches) Precision Plasma with Electronic Flow Control

120 SECTION 4 OPERATION Stainless Steel Kerf Values Air/Air/CH 4 Stainless Steel Air/Air/CH 4 70 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Stainless Steel Air/Air/CH 4 00 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Precision Plasma with Electronic Flow Control -

121 SECTION 4 OPERATION Stainless Steel Kerf Values N 2 /N 2 /CH 4 Stainless Steel N 2 /N 2 /CH 4 70 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Stainless Steel N 2 /N 2 /CH 4 00 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches).270 Precision Plasma with Electronic Flow Control

122 SECTION 4 OPERATION Stainless Steel Kerf Values N 2 /N 2 Stainless Steel N 2 /N 2 50 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Stainless Steel N 2 /N 2 70 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Precision Plasma with Electronic Flow Control -

123 SECTION 4 OPERATION Stainless Steel N 2 /N 2 00 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches).270 Precision Plasma with Electronic Flow Control

124 SECTION 4 OPERATION Stainless Steel Kerf Values Air/Air Stainless Steel Air/Air 50 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) Stainless Steel Air/Air 70 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches) 4-88 Precision Plasma with Electronic Flow Control -

125 SECTION 4 OPERATION Stainless Steel Air/Air 00 Amperes Material Thickness (mm) Kerf (inches) Kerf (mm) Material Thickness (inches).270 Precision Plasma with Electronic Flow Control

126 SECTION 4 OPERATION Page intentionally left blank Precision Plasma with Electronic Flow Control -

127 SECTION 5 5. General Maintenance If this equipment does t operate properly, stop work immediately and investigate the cause. Qualified personnel must perform maintenance work. Do NOT permit untrained persons to inspect, clean or repair equipment. Use only recommended replacement parts. WARNING Electric Shock Can Kill! Before attempting any inspection or repair inside any of the components of the Precision Plasma, open wall disconnect or wall circuit breaker. 5.2 Inspection And Cleaning Frequent inspection and cleaning of the Precision Plasmarc System is recommended for safety and proper operation. Consider the following during inspection and cleaning: 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 zzle for wear daily. Ensure cable and hoses are t damaged or kinked. Location of pump filter Ensure all plugs, fittings, and ground connections are tight. Check screen filter in coolant pump located inside Power Source periodically and flush as required. CAUTION Flying Debris Hazard. Flying Debris Can Seriously Injure E Wear protective eyewear whenever cleaning with compressed air. PT-24 Precision Plasmarc with EFC 5-

128 SECTION 5 Maintenance CAUTION Avoid Potential Equipment Damage Water and/or oil can accumulate in compressed air lines. Be sure to direct the first air blast away from equipment to avoid damaging the junction box or flow control box. With all input power disconnected and with proper eye and face protection, blow out the inside of the power source, flow control, and junction box using low-pressure, clean/dry compressed air. Occasionally, bleed all water from the filter below the air filter-regulator. 5.3 PT-24 Torch Description.82" (46 mm) Diameter Collar 2.0" (5 mm) Diameter Sleeve Vent Hole Mounting. The torch can be mounted by the 2" (5 mm) dia. sleeve or by the.82" (46 mm) dia machined surface shown. This insulated surface and its shoulder are machined relative to the zzle retainer thread on the torch body. They are held concentric to the cutting zzle within a total indicator reading of 0.00" (0.25 mm) or the zzle bore is within 0.005" (0.27 mm) of any point on the.82" (46 mm) dia. When mounting, do t to cover the small vent hole in the side of the sleeve. This hole prevents coolant from building inside the sleeve if a leak occurs. Service Lines. 4.5 ft. (.4m), 2 ft. (3.7m), 7ft. (5.2m) and 20 ft. (6.m) lines are shielded and connect to the junction box by a friction fit grounded connection. 5-2 PT-24 Precision Plasmarc with EFC

129 SECTION 5 Maintenance Gas In from supply CH4 00 psi H35 00 psi N2 25 psi O2 25 psi Process Air Plasma Cut and Start Gas. These gases enter the torch through connections that house check valves within the torch body. The valves acting in conjunction with soleid valves control the back and forth switching of start and cut gases. Argon AIR- Ar N2- O2- PS METH N2-2 O2-2 AIR-2 Process Air Pressure Switch GAS FLOW SCHEMATIC N2-3 METH N2 O2 Air Ar Soleid Valve Pressure Switch PS5 PS4 PS3 PS2 Sentronic Valve Flow Meter Check Valve Interface Board VALVE 4 6-BAR SENTRONIC VALVE 3 6-BAR SENTRONIC VALVE 2 9-BAR SENTRONIC VALVE 9-BAR SENTRONIC Check Valve 2 Way Soleid Valve SG2 BLK SG ORG PG2 YEL PG BLU Gas Quick Coupling EFC J-Box SG2 SG PG2 PG Electronic Manifold Assembly PT-24 Torch Note: Shop air should t be used for process air. PT-24 Precision Plasmarc with EFC 5-3

130 SECTION 5 Maintenance Coolant Out via Pilot Arc Cable Coolant In via Power Cable Crossover Tube Shield Gas. Shield preflow, cut shield and postflow enter the torch through one connection. These gases pass through: the torch body, the shield gas diffuser, out the orifice in the shield cap surrounding the plasma jet. Power and Pilot Arc Lines. Coolant IN to the torch is through the power cable (-). Coolant OUT from the torch is through the pilot arc (+) line. Water Cooling.. Coolant enters the torch through the power cable (-), 2. circulates through the torch body and the electrode, 3. crosses over to the zzle (+) section of the torch body through nconductive crossover tubes, 4. travels back through the body and circulates between the zzle retainer and the zzle, 5. back through the torch body to the junction box via the pilot arc cable. Electrode Body Pilot Arc Body Water Baffle Nozzle Retainer Swirl Baffle Electrode Nozzle 5-4 PT-24 Precision Plasmarc with EFC

131 SECTION 5 Maintenance 5.4 Torch Maintenance WARNING Electric Shock Can Kill Before performing torch maintenance: Turn power switch on the console to the OFF position. Disconnect primary input power. Torch Body s Each day before starting operation, check O- rings on the torch body. Replace if damaged or worn. Apply a thin coat of silicone grease to O-rings before assembling to torch. Do t use Krytox. O-ring P/N O-ring P/N 86W62 The O-ring, P/N , inside the torch body that seals the zzle is especially critical. Damage or wear is t readily apparent because of its location, We recommend replacing this O-ring on a daily basis. O-ring P/N Be careful t 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 2725; however if the baffle is removed, always use a 3/6" (5 mm) hex wrench or nut driver. Torch Sleeve Vent Vent Hole Water leaks, moisture or coolant dripping from the sleeve vent hole indicates service line damage. If service lines must be replaced, always use two wrenches to avoid twisting the metal tubes. PT-24 Precision Plasmarc with EFC 5-5

132 SECTION 5 Maintenance Sleeve P/N Torch Sleeve The torch sleeve P/N is threaded onto the torch body. If the sleeve is too tight for hand removal, use a large adjustable wrench on the body flats or lightly tighten these flats in a vise. With the body secured, using two hands on the sleeve may break it free. If t, use a strap wrench. Before replacing sleeve, always check service line connections for leaks. CAUTION Damaged Or Incorrect Torch Check Valve Parts Will Affect Cutting Performance. Do t damaged the check valve seat, ball and spring when handling. Check Valve Body P/N 2739 Ball P/N 2740 Spring P/N 274 Do t substitute any other spring or ball. If they are lost, dropped, or damaged, they must be replaced with factory replacement parts. Using n-authorized or damaged torch check valve parts will affect set pressures and cause poor starting and piercing. CAUTION Improperly Seated Fittings Will Cause Leaks And Poor Performance. Keep threads and seat surfaces clean when re-assembling check valves. If dirt or foreign matter contaminates check valves, disassemble, clean or replace. 5-6 PT-24 Precision Plasmarc with EFC

133 SECTION 5 Maintenance 5.5 PT-24 Consumable Disassembly And Inspection WARNING Electric Shock Can Kill! Turn power switch on the console OFF. Disconnect primary input power. If the zzle retainer/diffuser is difficult to remove, the console may be on because of pressure inside the torch. PT-24 Front End NOTE: If the console is on, the pump will be running and coolant pressure behind the retainer will prevent it from turning freely. Check the console before attempting to remove the nut. Notice that a small amount of coolant is lost each time consumables are removed. This is rmal and the coolant will eventually have to be replaced. Check coolant before each operation.. Unscrew the cup shield/retainer. Inspect around orifice for damage. Replace orifice edge if nicked or damaged. A distorted orifice will t produce straight cuts. Shield Cup Insulator Insulator Shield Retainer 2. Unscrew and remove insulator shield Cup Shield w/retainer 3. The shield cup insulator is sandwiched between the cup and the zzle retainer/diffuser. It may remain attached to zzle retainer because of the very close fit between these members. PT-24 Precision Plasmarc with EFC 5-7

134 SECTION 5 Maintenance Nozzle 4. Unscrew the zzle retainer/diffuser. Inspect for damage, especially where the retainer contacts the zzle. The surface between the retainer and the zzle creates a metal to metal seal for the coolant. Any damage to this sealing surface will cause a leak resulting in poor cutting. Replace as necessary, but do t attempt to repair. Check small gas passages for blockages. Clear blockages with an air stream. Nozzle Retainer No damage to the contact area. Nozzle 5. Use the tool provided to remove the zzle. Place the slot around the zzle groove and pull it free. Electrode and Nozzle Tool P/N 2765 Electrode 6. Remove the swirl baffle from the zzle. 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 cant be cleared, replace baffle. Do NOT insert anything in these holes when trying to clear them. Distorting these holes will impair cutting performance. Swirl Baffle Nozzle 5-8 PT-24 Precision Plasmarc with EFC

135 SECTION 5 Maintenance 7. Use the electrode and zzle tool provided to unscrew the electrode. (P/N 2765). 5.6 PT-24 Torch Tip Re-assembly. Electrode Apply a thin film of silicone grease to the O-ring, just eugh to produce a shiny surface. Thread electrode in place and tighten snugly with tool provided. DO NOT OVER TIGHTEN. Nozzle Retainer Nozzle Small Amount of Krytox 2. Nozzle & Swirl Baffle Place swirl baffle into zzle with the grooved end of the baffle going inside zzle. When properly assembled, the small spherical tip of zzle makes a metal to metal coolant seal with the zzle retainer. Apply a small amount of Krytox (anti-seizing compound) on the small diameter of the zzle retainer as shown. This grease prevents possible galling/seizing between the zzle and retainer. It also facilitates a watertight seal. Do t put Krytox on zzle. 3. Nozzle Retainer/Diffuser Thread the zzle retainer onto torch and hand tighten. Water Seal PT-24 Precision Plasmarc with EFC 5-9

136 SECTION 5 Maintenance 4. Shield Cup Insulator Shield Cup Insulator Push the shield cup insulator on the zzle retainer. This component is a press fit and may remain assembled when the assembly was taken apart. Nozzle Retainer 5. Insulator Shield Retainer Apply a thin coat of silicone grease to the O-ring and thread insulator shield retainer on to Shield Cup. Hand tighten. NOTICE Do t attach insulator to the torch body first. Threading insulator on to torch body first will t allow shield gases to flow properly. Thread insulator onto the shield cup first and then attach both pieces onto the torch body. 6. Shield Cup And Retainer Screw this assembly (Insulator/Shield Cup and Retainer) onto the torch and hand tighten. CAUTION Inspection & Lubrication Inspect O-rings often for nicks and wear. Worn or damaged O-rings will affect starting and cut quality. Applying a thin coat of silicone grease to the torch tip O-rings during service assembly will facilitate future disassembly. Do t use Krytox on O-rings. Krytox is an anti-seize lubricant and will dissipate over time. Disassembly will be difficult. 5-0 PT-24 Precision Plasmarc with EFC

137 SECTION 6 TROUBLESHOOTING 6. General Safety WARNING WARNING Electric Shock Can Kill! Externally disconnect all primary power to the machine before servicing. Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside the power source. High Voltages Can Be Stored In Capacitors. Even when power is disconnected or unit is de-energized, capacitors can store high voltages. Assure power supply capacitors are grounded prior to performing maintenance. 6.2 Programmable Logic Controller (PLC) NOTICE All PT-24 Precision power consoles do t utilize a PLC. PLC functions were transferred to the Vision CNC and ceased to be necessary. Disregard information under this header (6.2) if t present in your console. 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 external devices. The signal exchange between the PLC and external devices are both time dependent and condition dependent. If a required signal is t received in the proper sequence, the PLC will discontinue the process and generate a fault signal to the CNC. 6-

138 SECTION 6 TROUBLESHOOTING 6.2. PLC LEDs (Light Emmiting Diode) OUTPUT CH POWER RUN ALARM ERROR INPUT 0 CH Highly reliable indicators. It is t likely that one will "burn out". However, if the technician is t confident that the LEDs are working, the presence of a signal can be confirmed by using a meter and taking a measurement on the appropriate pin. Refer to the schematic and wiring diagrams. This exchange of signals can be confirmed by observing the LEDs on the top of the PLC while troubleshooting. These indications are useful in isolating a system failure to the most likely device. The LEDs are divided into two groups; Input (0-5) light when the corresponding signal is detected by the PLC. Output (0-) light when the PLC issues a signal to an external device PLC LED Functions INPUT OUTPUT LED Function LED Function 0 Start/Stop 0 Not Used Not Used Hi-Frequency 2 Arc-On 2 Pilot Arc Relay 3 Not Used 3 Power Source 4 Not Used 4 Not Used 5 Fault 5 Fault Output 6 Not Used 6 Not Used 7 Not Used 7 Not Used 8 Not Used 8 Not Used 9 Not Used 9 Not Used 0 Not Used 0 Not Used Not Used Not Used 2 Not Used 3 Not Used 4 Not Used 5 Not Used 6-2

139 SECTION Troubleshooting Guide 6.3. Reduced Consumable Life Cutting Up Skeletons TROUBLESHOOTING Cutting skeletons (discarded material left after all pieces have been removed from a plate) to facilitate their removal from the table can adversely affect electrode life by: Causing the torch to run off the work. Continuous Pilot Arc edge starts Greatly increasing the frequency of starts. This is mainly a problem for O 2 cutting and can be alleviated by choosing a path with a minimum number of starts. Increase likelihood that the plate will spring up against the zzle causing a double arc. This can be mitigated by careful operator attention and by increasing standoff and reducing cutting speeds. If possible, use a gas torch for skeleton cutting. Height Control Problems Torch diving is usually caused by a change 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 Starting on edges with continuous pilot arc Work Flipping Catching on Pierce Spatter Pierce t complete before starting Increase pierce standoff Position torch more carefully or start on adjacent scrap material. The zzle may be damaged if the torch hits a flipped up part. Increase standoff or start with longer lead-in Increase initial delay time. 6-3

140 SECTION 6 TROUBLESHOOTING Poor Cut Quality See Cut Quality In Section No Pilot Arc Contaminated Electrode Insufficient spark gap setting in plumbing box. Pilot Arc Contactor (PAC) malfunctioning Clean or replace electrode Set spark gap to (.06 mm) Replace contactor No Arc Transfer Cutting current setting too low. Torch too high above workpiece Work lead t connect to cutting table Raise cutting current (see Process Data) Lower torch standoff (see Process Data) Ensure work lead is firmly connected to workpiece or cutting table No Preflow N 2 or O 2 check valve in torch body may be stuck open No start signal Emergency stop signal open See maintenance section for check valve repair. Check input 0 LED on PLC. Should be lit. This verifies a start command has been given Check for continuity between TB3-8 and TB3-9 Shorted, closed or jumpered out Cooling Water Flow Switch No Cooling Water Check cooling water LED on front panel. Should be lit. Check reservoir. Add coolant until full Torch Fails To Fire Start Gas Cooling water Flow Lower start gas flow Pump pressure too low. Should be 5psi. (7.9 bar) Faulty cooling water flow switch (CWFS) Obstruction in torch limiting cooling water flow Replace CWFS switch Coolant flow through torch should be greater than 0.5 gal/min (.5 l/min) 6-4

141 SECTION Nozzle Life Extremely Short Pilot Arc H/L switch in wrong position Refer to Process Data TROUBLESHOOTING Nozzle arcing inside bore Nitrogen quality too low. Requires % purity Start gas flow too low Check Process Data cutting parameters Short Electrode Life Insufficient cooling Start gas quality Cut gas quality Check pump for 5 psi (7.9 bar) output pressure Gas quality needs to be % purity minimum Oxygen gas needs to be 99.8 % purity Short Electrode And Nozzle Life Water leak on torch front-end Follow torch leak procedure 6-5

142 SECTION 6 TROUBLESHOOTING 6.4 Flow Control Schematic 5 PLASMA GAS PLASMA GAS 2 SHIELD GAS SHIELD GAS 2 COMMON amp VALVE SHIELD (SH) VALVE GND (GN) VALVE SET PT. (SP) VALVE +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 V (PR) VALVE 4 SHIELD (SH) VALVE 4 GND (GN) VALVE 4 SET PT. (SP) VALVE 4 +24V (PR) (SHIELD GAS 2) (SHIELD GAS ) (PLASMA GAS 2) (PLASMA GAS ) (PROCESS AIR) SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID SOLENOID amp amp amp amp amp amp amp amp amp { PS5 PS5 { PS4 PS4 { PS3 PS3 { PS2 PS2 { PS PS METH METH H-35 H-35 N-3 N-3 N-2 N-2 N- N- O-2 O-2 O- O- AIR-2 AIR-2 AIR- AIR- AR P5 RC RC2 RC3 RC4 RC5 RC6 RC7 RC8 RC9 RC0 JP JP2 JP3 JP4 JP P4 P P2 P3 PLASMA GAS PLASMA GAS 2 SHIELD GAS SHIELD GAS 2 COMMON 20 vac ( ne) A. C. COMMON CHASSIS FUSED 24vac TO CNC 24vac COMMON CHASSIS GROUND 24 vdc GROUND VALVE SET PT. VALVE + 24 VDC} PLASMA GAS VALVE 2 SET PT. VALVE VDC}PLASMA GAS 2 } VALVE 3 SET PT. SHIELD GAS VALVE VDC } VALVE 4 SET PT. SHIELD GAS 2 VALVE VDC PRES. SW. 5 V. SOURCE (SR) PRES. SW 24 V. SOURCE (SR2) PS5 (SHIELD GAS 2) PS4 (SHIELD GAS ) H.F. 20 V FROM POWER SUPPLY H.F. 20 V TO J-BOX PS3 (PLASMA GAS 2) H.F 20 V FROM POWER SUPPLY H.F. 20 V TO J-BOX PS2 (PLASMA GAS ) PS (PROCESS AIR) SELECTOR VALVE COMMON METHANE H-35 NOT USED N2-3 N2-2 N2- O2-2 O2- AIR-2 AIR- ARGON amp TB 6-6

143 SECTION 6 TROUBLESHOOTING 6.5 Gas Flow Schematic CH4 00 psi H35 00 psi N2 25 psi O2 25 psi Process Air 25 psi Argon 25 psi AIR- Ar N2- O2- PS AIR-2 METH N2-2 O2-2 N2-3 METH N2 O2 Air Ar Soleid Valve Pressure Switch PS5 PS4 PS3 PS2 Sentronic Valve Flow Meter Check Valve Interface Board VALVE 4 6-BAR SENTRONIC VALVE 3 6-BAR SENTRONIC VALVE 2 9-BAR SENTRONIC VALVE 9-BAR SENTRONIC Check Valve 2 Way Soleid Valve SG2 BLK SG ORG PG2 YEL PG BLU Gas Quick Coupling EFC Junction Box Electronic Manifold Assembly PT-24 Torch 6-7

144 SECTION 6 TROUBLESHOOTING 6.6 Junction Box Wiring Diagram Drawing

145 SECTION 6 TROUBLESHOOTING 6.7 Junction Box Schematic MANIFOLD EFC A/M CABLE CONNECTIONS TO CONSOLE TO FLOW CONTROL J2 TORCH CONNECTIONS SCHEMATIC DIAGRAM 6-9

146 SECTION 6 TROUBLESHOOTING 6.8 Power Module Wiring Diagram P4 P3 P3 P4 4 4 PCB P P2 P5 P PCB P-2(BLK) PCB P-(BLK) T-X9(BRN) T-X0(BRN) T-X5(BLU) T-X7(ORN) T-X8(ORN) J-3(ORN) 2 J-4(WHT) 3 T-X(YEL) 4 T-X2(YEL) 5 J-5(BLK) 2 J-6(WHT) T-X6(BLU) 5 SCR-G (YEL) 6 J-6(RED) 6 7 T2-X2(ORN) 6 SCR(+) (BRN) 7 7 PCB P2-4 (VIO) 8 T2-X(ORN) T-X3(WHT) * T-X4(WHT) J-4(BLK) PCB P-2(BLK) 0 SH (-) (BLK) 2 PCB P-(BLK) T-X(VIO) 2 J-5(RED) * SH(+) (RED) 2J-0(YEL) 2J-7 (BLU) * J-(YEL) 3 J-9(ORN) P 3 J-2(GRY) 4 J-8(BRN) J-3(GRY) P4 4T-X2(VIO) PCB2 P PCB P6-7(VIO) PCB3 P P5 P6 P5 PCB2 P PCB3 P C7 C6 PCB P3 PCB P4 NEXT PAGE GND P6 2 4 C4(-)(BLK) PCB L-H2 R2-(BLK) SCR(+)(WHT) * R2-2(RED) C4(+)(RED) P2 4 2 P P P2 SCR(+) (YEL) SCR(-) (YEL) J TS2-2(SPLICE)(VIO) 2 TS-(VIO) 3 PCB P5-(ORN) 4 PCB P5-2(WHT) 5 PCB P5-5(BLK) 6 PCB P5-6(RED) 7 PCB P6-2(BLU) 8 PCB P6-4(BRN) 9 PCB P6-3(ORN) 0PCB P2-2(YEL) PCB P2-2(YEL) 2PCB P2-3(GRY) 3PCB P2-3(GRY) 4PCB P6-0(BLK) 5PCB P6-(RED) 6 J 6 SEE NOTE 3 GND C3 C7 + - R2 PCB3 C5 J-2(VIO) TS2-(VIO) 2 + C4 - PCB2 C6 C2 2 2 H R 2 L H2 C9(+) BUSS (BLK) * * C4(-) BR-F 2 TS C R4 R J2 * * PCB P6-(RED) PCB P6-0(BLK) SH + - J2 8 J3 BUSS TO SH 0 * T3-X D C3 C2 R7 R6 * L2-X X2 Q2 D2 C5 C4 R9 R8 T3-X2 * C9 R3 C8 X Q T2 R5-2(BLK) *T3-H *T3-H2 H X2 X C4(+)(WHT) PCB P-8(ORN) PCB P-7(ORN) PCB P2-6(BRN) * * BLK R- (YEL) R-2 (YEL) SCR + G TS2 2 C TS-2(VIO) J-(SPLICE)(VIO) PCB P2-5(YEL) *L-H BR TB2-2(GRY) MOV2 MOV3 MOV * * H3 SEE NOTE 3 TB2-(RED) H J4 0 X L2 X2 T3 H2 T BOTTOM TB3 J3 J4-(BLK) 2 J4-2(WHT) 3 J4-3(RED) 4 J4-4(ORN) 5 J4-5(BLU) 6 J4-6(YEL) 7 J4-7(BRN) 8 J4-8(GRY) 9 J4-9(VIO) 0J4-0(BLK) *D/D2-2 BUSS D-3 D2-3 Q-C2E C9(+) BUSS * * * * PCB P-3(BRN) PCB P2-4(ORN) PCB P2-(ORN) PCB P-4(BRN) PCB P2-(VIO) PCB P2-4(VIO) T TOP PCB P-6(BLU) PCB P-5(BLU) PCB P-0(WHT) PCB P5-3(YEL) PCB P5-4(YEL) PCB P-9(WHT) 6-0

147 SECTION 6 TROUBLESHOOTING Power Module Wiring Diagram Part 2 Previous Page 2 2 *T-H3(GRY) TB2 2 * T-H(RED) * * BLK BLK M 2 T2 + G J4 0 J4 J3-(BLK) 2 J3-2(WHT) 3 J3-3(RED) 4 J3-4(ORN) 5 J3-5(BLU) 6 J3-6(YEL) 7 J3-7(BRN) 8 J3-8(GRY) 9 J3-9(VIO) 0J3-0(BLK) J4 H T3 H2 6 NOTES: - DENOTES SELF LEADS. 2- * DENOTES SPLICE 3- TP DENOTES TWISTED PAIR 4. SOLDERING AND CRIMPING WIRES AND TERMINALS ARE VERY IMPORTANT TO THE OPERATION AND RELIABILITY OF THIS POWER MODULE. ADDITIONAL INSPECTION MUST BE DONE. 6-

148 SECTION 6 TROUBLESHOOTING 6.9 Precision Plasma Power Module Schematic E2 E2 G2 Q(x) E G C C2E C(x) 4 DETAIL 6-2

149 SECTION 6 TROUBLESHOOTING 6.0 Power Module Schematic CE Version 6-3

150 SECTION 6 6. Power Module Wiring Diagram CE Version TROUBLESHOOTING Page 6-4

151 SECTION 6 TROUBLESHOOTING Power Module Wiring Diagram Page 2 6-5

152 SECTION 6 TROUBLESHOOTING 6.2 Precision Plasma Power Source Wiring Diagram Part drawing PCB P P2 P3 P4 P5 P7 P9 P0 2 P4-4(BRN) 2 P4-0(VIO) P4-9(VIO) 2 P4-(GRY) P4-2(BLU) 2 PLC P-(BRN) PLC P-2(GRY) 2 PLC P-5 (BLK) PLC P-6 (VIO) PLC P2-5(BLK) 2 MOD P-4(RED) 2 S3-5(VIO) 2 S3-2(RED) P4-3(RED) PCB P-6(BLK) PCB P-5(BLK) PLC P2-(WHT) PLC P2-2(ORN) PLC P2-3(GRY) P4-8(ORN) P4-7(ORN) P3-3(GRY) P3-4(RED) MOD P3-(RED) MOD P3-2(YEL) PLC P-3(YEL) PLC P-8(ORN) PLC P-3(YEL) 3 TB6-5(RED) 3 MOD P-5(BLK) 3 P3-7(BLK) 4 P3-6(WHT) 5 P3-8(WHT) 0 PLC P2-4(YEL) PCB P-2(BLK) 2 PCB P-(BLK) 3 MOD P-5 (BLK) 4 MOD P-6 (RED) 5 MOD P-2 (BLU) 6 MOD P- (VIO) 7 PCB P-8(BLK) 8 PCB P-7(BLK) 0 P3-5(GRY) P4-4(BRN) 2 P4-3(BRN) 3 P4-2(BLU) 4 P4-(BLU) 5 P3-(YEL) 6 P3-2(YEL) 0 2 MOD P-3(ORN) 3 MOD P-4(WHT) PCB-TB P-6(YEL) 8 MOD P-7(BLU) 0 PLC P-4(WHT) MOD P3-7(RED) 2 MOD P3-8(BLK) 3 MOD P3-9(VIO) 4 MOD P3-0(YEL) 5 MOD P3-3(BLU) 6 MOD P3-4(ORN) 7 8 J A GND2 (GRN) MOD P-7(BLU) S3- (BRN) R2-3(BLU) R2-2(BRN) PCB P0-2(RED) TB6-7(ORN) PCB P0-(VIO) TB6-8(GRY) S3,3 2 R2 2 3 S3-4 (BLU) VIEW OF R2 SEE VIEW OF R2 MOD P-9 (ORN) B C D E F G H J K L M PLC-008 (YEL) PLC J2-4 (ORN) PLC-COMM6 (BLU) PLC-009 (GRY) K5-A (BLK) PLC-00 (WHT) K6-A (YEL) PLC-0 (BRN) PLC-00 (VIO) P 8 4 P5 PCB4 3 P7 S2 4 P9 P P4 2 S K-L (BRN) P2 8 P3 K-L2 (BLU) F4- (YEL) MOD TB2- (RED) T3-H (RED) 6 L S2-5 (BLK) H2 K2-L3(BLU) H J-A (GRN) * M-GND (GRN) GND2 N P R S T U V A B C D E F G H I PLC J2-9 (GRY) J2 TB3-20 (BLU) TB3-2 (GRY) TB3-3 (ORN) TB3-23 (BLK) TB3-8 (VIO) TB3-9 (YEL) TB3-4 (WHT) TB3-4 (BRN) TB3-3 (ORN) J TB3-2 (VIO) L-H2 (BLK) K L TB3-22 (WHT) TB3- (RED) S2 BLK R7-2 (ORN) M N TB3-2 (GRY) TB3- (BRN) R-2 (BLK) J K2-L3 (BLU) J2 S-2(YEL) TB2-(BLU) CB- (BLK) TB2-3 (RED) M2-4 SPLICE (WHT) CB2- (BLK) M-2 (WHT) MOD TB2-2(GRY) F4 CB2 CB * M MOD TB2-(BLK) * * GND GND2 (GRN) 2 * CB- (WHT) NC RED * FSC BLK* NO ORN* J4-4(BRN) J4-3(RED) 6-6

153 SECTION 6 TROUBLESHOOTING Wiring Diagram Precision Plasma Power Source Part 2 MOD BR A MOVB MOVC MOV T2-AH2 T2-BH2 T2-CH2 S-5 (BRN) S- (BLU) F4-2(BLU) T3-H2(BLK) T3-H3(GRY) CB2-(RED) T3-H4(YEL) T3-H5(BRN) T3-H6(ORN) T3-H7(VIO) TB BLK J4-8(ORN) J4-7(ORN) X9 X0 J3-6(WHT) J3-7(RED) X X2 J3-8(WHT) X3 J3-3(GRY) X4 J3-4(BLK) J3-5(GRY) X5 X6 T TOP J4-0(VIO) J4-9(VIO) X H7 J4-4(BRN) J4-3(BRN) X2 X3 (VIO) (ORN) (BRN) X4 H6 H5 H4 J3-(YEL) J3-2(YEL) X5 X6 H3 H2 (YEL) T3-H3(GRY) (BLK) J4-2(BLU) J4-(BLU) X7 X8 H T3-H(GRY) T M2 SEE DETAIL SEE DETAIL MOD BR-A T3 MOD BR-B MOD BR-C J4-(GRY) SEE T3 DETAIL AH2 BH2 CH2 TB2 SEE L L2 L3 DETAIL ZD B A T T2 T3 K TB MOV BLK BLK MOV3 BLK MOV2 J4-2(BLU) T2 SPLICE GRN M MOD TB2-(RED) WHT (INTERNAL) RED (INTERNAL) CB2-2 (WHT) BRN (INTERNAL) TB2-4 (YEL) TB2-5 (BRN) H4 H5 H S-6 (RED) T-H (RED) SPLICE TB2-6 (ORN) H6 T3 H2 TB2-2 (BLK) TB2-7 (VIO) H7 H3 TB2-3 (GRY) T-H3 (GRY) 6-7

154 SECTION 6 TROUBLESHOOTING Wiring Diagram Precision Plasma Power Source Part 3 MOD TB2 CB-2(GRY) 2 MOD P4 M-(BLK) S-6(RED) M2- SPLICE (RED) MOD TB3-7(RED) TB3-8(YEL) TB3-9(BLU) TB3-0(ORN) TB3-(RED) TB3-2(VIO) F3-(RED) TB3-6(BLK) TB3-8(VIO) TB3-9(YEL) J3 T-X5(YEL) 2 T-X6(YEL) 3 T-X4(GRY) 4 T-X5(BLK) 5 T-X6(GRY) 6 T-X(WHT) 7 T-X2(RED) 8 T-X3(WHT) J4 T-X8(BLU) 2 T-X7(BLU) 3 T-X4(BRN) 4 T-X3(BRN) T-X0(ORN) SEE DETAIL TB2 MOD P4-7 (RED) 8 P4 0 J3 6 J4 2 TB3-5 (RED) F3 TB4 PA WORK TORCH TB3 TB PLC-0000 (BRN) J2-N (BRN) PLC(-24VDC) (GRY) J2-M (GRY) J2-I(ORN) PLC-COMM 2 (ORN) J2-G(WHT) PLC-000 (WHT) PLC J-5 (BLK) PLC J-6 (VIO) MOD P4-(RED) MOD P4-2(YEL) MOD P4-3(BLU) MOD P4-4(ORN) MOD P4-5(RED) J2-L(RED) MOD P4-6(VIO) J2-J(VIO) PCB2 P-2(ORN) J2-C(ORN) PCB2 P-3(BRN) J2-H(BRN) F3-2 (RED) MOD P4-8(BLK) MOD P4-9(VIO) J2-E(VIO) MOD P4-0(YEL) J2-F (YEL) K8-9 (BLU) J2-A (BLU) K8-6 (GRY) J2-B(GRY) K7-B (WHT) J2-K(WHT) K7-A (BLK) J2-D(BLK) 8 T-X9(ORN) 9 T-X2(VIO) 0 T-XVIO) K-A(GRY) 2 K-B(BLU) 3 FS-NO(RED) 4 FS-C(BRN) 5 6 REAR VIEW WITH REAR PANEL REMOVED 6-8

155 SECTION 6 TROUBLESHOOTING Wiring Diagram Precision Plasma Power Source Part 4 PLC MODULE PLC J J2 L TB4-(VIO) PLC-003(BRN) PLC-L2(BLK) MOD SH-2(BLK) MOD TB3-(BLK) TB5 PA WORK TORCH PCB2-PA(YEL) K2-T (YEL) PLC J2-5(RED) PCB2 P- (RED) PCB2 P-6 (BLK) PCB2 L2 000 COMM 2 00 COMM COMM COMM COMM COMM 7 PLC J2-(BLK) PLC-COMM(BLK) TB3-4 (WHT) TB3-3 (ORN) J-M (VIO) PLC J2-7 (BLU) PLC-COMM4 (BLU) PLC J2-0(RED) PLC-COMM3 (BLU) PLC J-(BRN) PLC J-2(GRY) K3-A (VIO) K4-A (WHT) K8-A (ORN) PLC-COMM 7 (BLU) J-D(BLU) J-B (YEL) J-F (GRY) J-J (WHT) J-L (BRN) PLC J2-3(BLU) PLC-COMM 6 (BLU) 2 PLC-COMM5(GRY) 3 TB4-(VIO) 4 PLC-0002(WHT) 5 TB3-5 (BLK) 6 TB3-6 (VIO) 7 8 PLC-0006(ORN) TB4- (VIO) 3 PLC-COMM7(BLU) 4 J-C(ORN) 5 TB5-WORK(RED) 6 7 PLC-COMM3 (BLU) 8 9 J-N(GRY) 0 PLC-002(RED) K3-6(WHT) 2 K3-9(ORN) 3 K4-9(GRY) 4 K4-6(YEL) 5 TB4-2(BRN) 6 VIEW F-F TB5-PA(YEL) PCB2 - P P- TB5-WORK(RED) P-2 TB3-3(ORN) P-3 TB3-4(BRN) P-6 TB5-TORCH(BLK) VIEW E-E HS COMM COMM +24VDC -24VDC TB3- (BRN) K7-4 (BLU) PLC-(+24VDC) (VIO) PLC J-4(WHT) K5-9 (YEL) K6-9 (RED) PLC J-8(ORN) PLC-L2(BLK) PLC-HS COMM (VIO) TB3-2 (GRY) K7-6 (GRY) E J PCB2 E L L2 000 COMM 2 00 COMM COMM COMM COMM COMM 7 MOD SH- (GRY) BLU 2 BLU 2 2 S2-6 (ORN) 2 S2-3 (BLK) 2 F TB HS COMM PLC COMM +24VDC -24VDC J2 BLU BLU BLU F R0 R9 R8 R7 R K B 7 A K7 3 A B K6 K A B A B K A B K A B TB4 PLC J2-2(VIO) PLC J2-5(BRN) PLC-L(VIO) K3-B(BRN) K5-6(VIO) K4-B(BRN) K6-6(VIO) 2 TB4 K5-B(BRN) T2 PLC J-3(VIO) K6-B(BRN) K8-B (BRN) K8 3 4 A B K7 K6 K5 K4 K A B A B A B A B A B PLC-006 (ORN) TB4-2(BRN) TB3-20 (BLU) TB3-2 (GRY) PLC-000 (BLU) TB3-23 (BLK) ZD3 TB3-22 (WHT) PLC-(-24VDC) (GRY) J-K (YEL) TB4-2(BRN) PLC-0004 (RED) TB4-(VIO) J-G (BLK) TB4-2(BRN) PLC-0003 (YEL) TB4-(VIO) PLC-005 (WHT) TB4-2(BRN) PLC J2-3(GRY) PLC J2-4(YEL) PLC-004 (VIO) TB4-2(BRN) PLC J2-2(ORN) PLC J2-(WHT) 6-9

156 SECTION 6 TROUBLESHOOTING Wiring Diagram Precision Plasma Power Source Part 5 MOD P3 P2 P SH PCB P4-3(RED) PCB P-6(VIO) R0- (GRY) 2 PCB P4-4(YEL) 2 2 PCB P-5(BLU) 2 TB5-WORK(BLK) 3 PCB P4-5(BLU) 3 3 PCB P3-2(ORN) 4 PCB P4-6(ORN) 4 4 PCB P3-3(WHT) 5 TB6-6(BRN) 5 5 PCB P-3(BLK) 6 TB6-8(GRY) 6 6 PCB P-4(RED) 7 PCB P4-(RED) 7 NOT USED 7 PCB P3-8(BLU) 8 PCB P4-2(BLK) 8 S3-4(BLU) 9 PCB P4-3(VIO) 8 PCB-TB P-(YEL) 0 PCB P4-4(YEL) R2-(ORN) 4 PCB P9-(RED) 5 PCB P9-3(BLK) 6 PCB P7-3(RED) MOD-TB3- (RED) R3 R4 TB R5 R6 MOD P3-6(GRY) S3-6(GRY) S3-3(ORN) MOD P3-5(BRN) P 8 MOD TB5-PA (YEL) C2- (YEL) WHT T T2 T3 K2 C2-2 (WHT) P ZD2 A L L2 L3 B TB SEE DETAIL K2-L3 (BLU) P3 PLC P2-9 (VIO) WHT C- (BLU) S2-2 (BLU) L-H (BLU) PLC P2-0 (RED) 6 P3 PCB P2-5(YEL) P PCB P4-(BRN) PCB P4-2(GRY) PCB P4-7(YEL) PCB P4-9(YEL) PCB P4-0(WHT) PCB P5- (BLK) PCB P5-2(VIO) PCB P4-8(ORN) PLC MODULE P2 P4-0(VIO) PLC P2-7 (VIO) 2 P4-9(VIO) PLC P2-9 (VIO) 3 P4-2(BLU) 4 P4-(BLU) PLC P2-5(BLU) 5 PCB P7-(BLK) 6 7 PLC P2- (VIO) 8 9 PLC P2-2 (VIO) K2-A (VIO) 0 K2-B(RED) PCB P-7(WHT) 2 PCB P-8(ORN) 3 PCB P-9(GRY) 4 PCB P-0(YEL) 5 PLC P2-4(BLU) 6 P2 6 PLC MOD TB6-2(RED) TB5-TORCH(BLK) R5-2 (RED) 0 C 2 R3 P3 P4 6 MOD TB3- (RED) R2 R 8 C2 SH K2-T(YEL) 2 K2-T3(WHT) R4- (GRY) D TB3 2 R5 2 R4 8 P2 D(-) GRY 2 PCB P2-6(YEL) 3 PCB P2-8(GRY) 4 PCB P2-9(RED) 5 PCB P2-0(GRY) 6 PCB P0-4(WHT) 7 PCB P0-3(BLK) 8 PCB P0-5(WHT) P4 PCB P2-4(BLU) PLC P2-4(BLU) 2 PCB P2-3(BLU) PLC P2-3(BLU) 3 PCB P2-2(BRN) 4 PCB P2-(BRN) PCB P2-5(ORN) 8 PCB P2-4(ORN) 9 PCB P2-2(VIO) PLC P2-2(VIO) 0 PCB P2-(VIO) PLC P2-(VIO) PCB P3-(GRY) 2 3 PCB P3-2(BLU) PCB P-3(RED) FRONT VIEW WITH FRONT PANEL REMOVED 4 PCB P-2(BRN)

157 SECTION 6 TROUBLESHOOTING This page intentionally left blank. 6-2

158 SECTION 6 TROUBLESHOOTING 6. Schematic- Precision Plasma Power Source Part Drawing rev C PUMP MOTOR M V 6 460V 5 45V 4 380V 3 230V 2 200V TB2 CB2 2 7A P3- P3-2 LED LED2 LED3 PCB ISOLATION AMPLIFIER AND FAULT SIGNAL PCB 3803 LED4 LED5 LED6 LED7 LED8 LED9 P-3 P-2 P-5 P-6 FNT PNL S ON/OFF 5 ZD,80V ØC VAC K A B L3 T3 2 M CB 3A 2 AM AMMETER T2 CH7 ØB ØA L2 T2 L T AH7 AH8 AH6 AUTO XFMR P3-8(-) P3-7(+) P9-3 P9- P-4 P-3 P3-3 P3-2 P-5 P-6 AH5 AH4 AH3 AH2 200V TB P8 AH + + P P2 J2 PLC PLC MODULE # 2 T3 H7 H6 H5 H4 H3 H2 H H7 H6 H5 H4 H3 H2 H T X3 X2 X X6 X5 X4 X6 X5 X8 X7 X4 X3 X0 X9 X2 X J3 P3 8 P0-5 8VAC 7 P0-3 8VAC 6 P0-4 5 P2-0 8VAC 4 P2-9 8VAC 3 P2-8 2 P2-6 24VAC P2-5 P2-4 24VAC P2-3 P2-2 24VAC P2- P2-7 P2-6 P2-5 2VAC P2-4 P2-2 20VAC P2- P7- P7-3 PLASMA GAS P-0 P-7 P-8 START GAS A B K3 TB TB F4 5A J4 P4 NC NO FS C P A B K4 6 A B K V 8 CH8 CH6 V VOLTMETER P4- P4-2 P4-7 P4-8 P4-9 P J A B K6 9 6 A B K MOV2 60V MOV3 MOV 60V 60V 460V 7 45V 6 380V 5 230V 4 200V 3 575V 2 460V 45V 0 380V 9 230V 8 200V 7 575V 6 CH5 CH4 CH3 CH2 CH BH7 BH8 BH6 BH5 BH4 BH3 BH2 BH PCB TRIM POT P4-0 P5- P-2 P5-2 P- P-8 P-7 P4-4 P4-3 P4-2 P4- P0- P0-2 P4-6 P4-5 P4-4 P V 5 45V 4 NOT USED ON PRECISION PLASMA CONSOLE J P V 3 230V 2 TB2-2 TB2- BR-A BR-B BR-C MOD POWER MODULE # 6-22

159 SECTION 6 TROUBLESHOOTING Schematic- Precision Plasma Power Source Part J 7 A B 8 C ZD3 80 VAC A B K VAC RELAY L L2 HS COMM Comm PLC COMM Comm VDC VDC Comm 7 Comm Comm Comm 5 START GAS 004 PLASMA GAS START GAS ON, NITROGEN CUT GAS ON, OXYGEN FULL SHIELD REGULATED SHIELD COMMON TB D E F G H J K L M N P R S T U V J2 N M I G ARC ON SIGNAL FROM P.S. TO CNC, TRANSISTOR START SIGNAL FROM CNC TO P.S., 20VAC TO FLOW CONTROL BOX J START SIGNAL FROM CNC TO P.S., RELAY CLOSING ARC ON SIGNAL FROM P.S. TO CNC, RELAY CLOSING PLC PLC MODULE # TB R3 4.99K 3 ZD2 80 VAC A B K2 L T L2 T2 L3 T3 20VAC RELAY P3 TB6-7 CURRENT SETTING POT R2 0K MIN MAX 3 R K 6 4 FRONT PNL CURRENT SETTING 2 5 LOCAL/REMOTE DPDT S3 P TB6-8 C2 20uf 400V R 0K 8W R6 39K 2W R5 39K 2W TB6-5 TB6-4 TB6-2 F3 2 A H2 L H R7 C 0K OHM 20uf 400V 8W D R7 0K OHM 8W R4 20 OHM 50W FRONT PNL PILOT ARC SELECTOR S2 6 5 HI 4 START SIGNAL FROM CNC TO P.S., 24VAC 3 R 2 LO P-2 P-3 L J C H D START UP PCB VDC REMOTE CURRENT SETTING FROM CNC TO P.S. VOLTAGE DIVIDER, (+) VOLTAGE DIVIDER, (-) E EMERGENCY STOP FROM CNC TO P.S. RELAY/CONTACTOR NORMALLY CLOSED F OPEN IN CASE OF EMERGENCY A FAULT SIGNAL FROM P.S. TO CNC B RELAY CLOSING, DRY CONTACT K 20 OHM 300W 20VAC PREFLOW SIGNAL FROM CNC TO P.S. P- P-6 R7 20 OHM 300W R8 20 OHM 300W R9 20 OHM 300W PA R0 3. OHM 300W TO CUTTING MACHINE CNC CONNECTOR CHASSIS GND SUPPLIED BY CUTTING MACHINE GROUP WORK PILOT ARC TORCH TO JUNCTION BOX J MOD POWER MODULE # R5 20 OHM 50W 2 SH-2 SH- TB3-6-23

160 SECTION 6 TROUBLESHOOTING 6.2 Technical Guide To Using And Understanding The Operation Of The Electronic Flow Control Introduction The following information is a guide for troubleshooting The Precision Plasma Electronic Flow Control. Kwledge of machine and control operation is required. 6-24

161 SECTION 6 TROUBLESHOOTING 6.2. Precision Process Timers Timer Plasma Preflow Time Line Purge Time Plasma Firing Time Plasma Pierce Time Plasma AHC Delay Plasma Arc Delay Master Up Analog Channel Disable Line Fill Time Plasma Postflow Line Vent Time Flow Control Vent Time Description The minimum interval of time between the receipt of a plasma process start signal and the issuance of the signal to turn the plasma power supply on. Plasma process start gas flows are in effect during this time. The interval of time allowed to purge the plasma process gas lines. Plasma process purge/fill gas flows are in effect during this time. The maximum interval of time allowed for receipt of an arc-on signal from the issuance of the signal to turn the plasma power supply on. Plasma process start gas flows are in effect during this time. The interval of time allowed for piercing the work piece after receipt of the arc-on signal. Plasma process cut gas flows are in effect during this time. (Torch stationary, AHC disabled, machine stationary). The interval of time allowed after expiration of the PLASMA PIERCE TIME timer before enabling AHC. Plasma process cut gas flows are in effect during this time. (Torch stationary, AHC disabled, machine moving). 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. The interval of time allowed to raise the plasma torch after receipt of a plasma process off signal. Plasma process start gas flows are in effect during this time. The interval of time allowed before enabling the plasma process idle flow analog values. Plasma process start gas flow analog values are in effect during this time. The interval of time allowed to fill the plasma process gas lines. Plasma process purge/fill gas flows are in effect during this time. The interval of time allowed for plasma process gases to flow after expiration of the MASTER UP timer. Plasma process start gas flows are in effect during this time. The interval of time allowed to vent the plasma process gas lines. Plasma process idle gas flows are in effect during this time. The interval of time allowed to vent the flow control gas lines. Plasma process purge/fill gas flows are in effect during this time. 6-25

162 SECTION 6 TROUBLESHOOTING Process Timer Values For Vision Cutting Record File PARAM.CUT Vision Interpretation Data File DEF.TEC PARAM.CUT DEF.TEC Wx (Preset Value) Ux (Lower Editing Limit) Qx (Upper Editing Limit) V (Hidden Flag) TIMERS V = Hidden Flag Enabled Plasma Preflow Time V Line Purge Time V Plasma Firing Time V Plasma Pierce Time Plasma Ahc Delay Plasma Arc Delay V Master Up Analog Channel Disable V Line Fill Time V Plasma Postflow V Line Vent Time / Flow Control Vent Time V 6-26

163 SECTION 6 TROUBLESHOOTING Process Window Key Functions Plasma AHC Allow Icon Key Function (F2 Push-Button) Description Icon permits the machine operator to allow or disallow plasma AHC. Icon does t turn plasma AHC on. Plasma AHC is allowed if the icon is highlighted (darkened). Plasma AHC is t allowed if the icon is t highlighted. Plasma AHC Icon (F3 Push-Button) Icon permits machine operator to manually turn plasma AHC on or off. Icon also permits the operator to perform a plasma IHS cycle if the plasma process is t active. The plasma AHC allow icon must be highlighted. Plasma Start Parameter Test Icon (F4 Push-Button) Icon permits 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 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 highlighted. Plasma Cut Parameter Test Icon (F6 Push-Button) Icon permits the machine operator to manually test/adjust the plasma process cut parameters. The plasma start parameter test icon must be highlighted. Plasma Start Icon (F6 Push-Button) Icon permits the machine operator to manually start or stop the plasma process. The plasma start parameter test icon must t be highlighted. 6-27

164 SECTION 6 TROUBLESHOOTING Proportional Valve Analog Flow Values For Param.Cut And Def.Tec PARAM.CUT DEF.TEC Wx (Preset Value) Ux (Lower Editing Limit) Qx (Upper Editing Limit) V (Hidden Flag) Xx (Lower Parameter Limit) Yy (Upper Parameter Limit) Ix (Lower Channel Limit) Jx (Upper Channel Limit) Analog Flow Values V = Hidden Flag Enabled Plasma Gas Start Flow Analog Out Plasma Gas Cut Flow Analog Out Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out Shield Gas Cut Flow Analog Out Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out V Plasma Gas Purge/Fill/Vent Flow Analog Out V Plasma Gas Idle Flow Analog Out V Plasma Gas 2 Soft Flow Analog Out V Plasma Gas 2 Purge/Fill/Vent Flow Analog Out V Plasma Gas 2 Idle Flow Analog Out V Shield Gas Soft Flow Analog Out V Shield Gas Purge/Fill/Vent Flow Analog Out V Shield Gas Idle Flow Analog Out V Shield Gas 2 Soft Flow Analog Out V Shield Gas 2 Purge/Fill/Vent Flow Analog Out V Shield Gas 2 Idle Flow Analog Out V

165 SECTION 6 TROUBLESHOOTING Process Gas Selection Requirements Plasma process gas selection is accomplished with activation of the appropriate SDP file. The correct CUTTING RECORD FLAG must be in each SDP file. Selection is keyed to the value in the CUTTING RECORD FLAG. Please refer to the ATAS description of the cutting package for a detailed explanation of The cutting record flag. Material Type Plasma Gas Shield Gas Abbreviation Cutting Record Flag Carbon steel O 2 N 2 CS-O 2 -N 2 M Carbon steel O 2 N 2 with O 2 mix CS 2 -O 2 -N 2 /O 2 M Carbon steel O 2 O 2 CS3-O 2 -O 2 M Stainless steel N 2 N 2 SS-N 2 -N 2 M Stainless steel N 2 N 2 with CH 4 mix SS 2 -N 2 -N 2 /CH 4 M Stainless steel Air Air SS 4 -Air-Air M Stainless steel Air Air with CH 4 mix SS5-Air-Air/CH 4 M Aluminum N 2 N 2 Al-N 2 -N 2 M Aluminum N 2 N 2 with CH 4 mix Al 2 -N 2 -N 2 /CH 4 M Plasma marking Argon Air PM-Argon-Air M

166 SECTION 6 TROUBLESHOOTING EFC Process Gas Flow Chart Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill 3 4 Plasma stop? Error condition? Station on? New SDP files selected? Plasma test? Station on? New SDP file selected? Station on? Plasma test cut? Plasma test? ready Station on? 5 Arc established? Process cut Plasma stop 7 0 Plasma test (start O 2 )? Test (start O 2 ) Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-30

167 SECTION 6 TROUBLESHOOTING Station On, Flush/Pressurize Cycle PG-N 2,O2 SG-N 2 Start 6 Milliseconds 2.0 Seconds.5 Seconds 0.5 Seconds.0 Second 0.5 Seconds Finish 6 Milliseconds SOLENOID VALVES X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, ANALOG VALUE = 0-0 VDC Plasma Gas Supply Soleid Valve N 2-2 X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 X X X X X Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - X X X X X X Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 X X X X X X Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X Shield Gas 2 Torch Soleid Valve X X X Analog Flow Values Plasma Gas Start Flow Analog Out Plasma Gas Cut Flow Analog Out Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out Shield Gas Cut Flow Analog Out Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog O Plasma t Gas Idle Flow Analog Out Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog O Plasma t Gas 2 Idle Flow Analog Out Shield Gas Soft Flow Analog Out X X X X X X X X X X X Shield Gas Purge/Fill/Vent Flow Analog Out X X X X X Shield Gas Idle Flow Analog Out Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog Out X X X X X Shield Gas 2 Idle Flow Analog Out X X 6-3

168 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Carbon Steel PG-O 2, SG-N Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Start) (O2) Test (Cut) Idle (Station On) Idle (Station Off) X = Open / Enabled, Blank = Closed / Disabled, SOLENOID VALVES Analog Value = 0-0 Vdc Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 X X X X X X X X X Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - X X X X X X X X X X Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 X Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X X X X X Plasma Gas 2 Torch Soleid Valve X X X X X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X X Plasma Gas Cut Flow Analog Out Plasma Gas 2 Start Flow Analog Out X X X X Plasma Gas 2 Cut Flow Analog Out X X Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog Out X X X Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog Out X X Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog Out X X X Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog Out X X Shield Gas 2 Idle Flow Analog Out X X X 6-32

169 SECTION 6 TROUBLESHOOTING Gas Error Monitoring Carbon Steel PG-O 2, SG-N Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Start) (O2) Test (Cut) Idle (Station On) Idle (Station Off) X = Monitored For Pressure Present, Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch O X X Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill 3 4 Plasma stop? Error condition? Station on? New SDP files selected? Plasma test? Station on? New SDP file selected? Station on? Plasma test cut? Plasma test? ready Station on? 5 Arc established? Process cut Plasma stop 7 0 Plasma test (start O 2 )? Test (start O 2 ) Plasma test cut? New SDP file selected? Station on? Plasma test? Error condition? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-33

170 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Carbon Steel PG-O 2, SG-N 2 /O Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Start) (O2) Test (Cut) Idle (Station On) Idle (Station Off) X = Open / Enabled, Blank = Closed / Disabled, SOLENOID VALVES Analog Value = 0-0 Vdc Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 X X X X X X X X X Shield Gas Supply Soleid Valve O 2 - X X X X X X X X X Shield Gas Supply Soleid Valve N 2 - Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 X X X X X X X X X X Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X X X X X Plasma Gas 2 Torch Soleid Valve X X X X X X Shield Gas Torch Soleid Valve X X X X X X Shield Gas 2 Torch Soleid Valve X X X X X X X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X X Plasma Gas Cut Flow Analog Out Plasma Gas 2 Start Flow Analog Out X X X X Plasma Gas 2 Cut Flow Analog Out X X Shield Gas Start Flow Analog Out Shield Gas Cut Flow Analog Out X X X X X Shield Gas 2 Start Flow Analog Out X X X X Shield Gas 2 Cut Flow Analog Out X X Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog Out X X X X Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog Out X X Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog Out X X X Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog Out X X X Shield Gas 2 Idle Flow Analog Out X X X 6-34

171 SECTION 6 TROUBLESHOOTING 6.2. Gas Error Monitoring Carbon Steel PG-O 2, SG-N 2 /O Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Start) (O2) Test (Cut) Idle (Station On) Idle (Station Off) X = Monitored For Pressure Present, Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch O X X Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O X X Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill 3 4 Plasma stop? Error condition? Station on? New SDP files selected? Plasma test? Station on? New SDP file selected? Station on? Plasma test cut? Plasma test? ready Station on? 5 Arc established? Process cut Plasma stop 7 0 Plasma test (start O 2 )? Test (start O 2 ) Plasma test cut? New SDP file selected? Station on? Plasma test? Error condition? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-35

172 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Carbon Steel PG-O 2, SG-O Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Start) (O2) Test (Cut) Idle (Station On) Idle (Station Off) SOLENOID VALVES X = Open / Enabled, Blank = Closed / Disabled,, Analog Value = 0-0 Vdc Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 X X X X X X X X X Shield Gas Supply Soleid Valve O 2 - X X X X X X X X X Shield Gas Supply Soleid Valve N 2 - Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 X X X X X X X X X X Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X X X X X Plasma Gas 2 Torch Soleid Valve X X X X X X Shield Gas Torch Soleid Valve X X X X X X Shield Gas 2 Torch Soleid Valve X X X X X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X X Plasma Gas Cut Flow Analog Out Plasma Gas 2 Start Flow Analog Out X X X X Plasma Gas 2 Cut Flow Analog Out X X Shield Gas Start Flow Analog Out Shield Gas Cut Flow Analog Out X X X X X Shield Gas 2 Start Flow Analog Out X X X X Shield Gas 2 Cut Flow Analog Out X X Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog Out X X X X Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog Out X X Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog Out X X X Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog Out X X X Shield Gas 2 Idle Flow Analog Out X X X 6-36

173 SECTION Gas Error Monitoring Carbon Steel PG-O 2, SG- O 2 TROUBLESHOOTING Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Start) (O2) Test (Cut) Idle (Station On) Idle (Station Off) X = Monitored For Pressure Present, Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch O X X Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O X X Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill 3 4 Plasma stop? Error condition? Station on? New SDP files selected? Plasma test? Station on? New SDP file selected? Station on? Plasma test cut? Plasma test? ready Station on? 5 Arc established? Process cut Plasma stop 7 0 Plasma test (start O 2 )? Test (start O 2 ) Plasma test cut? New SDP file selected? Station on? Plasma test? Error condition? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-37

174 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Stainless Steel PG-N 2, SG-N Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) Soleid Valves X = OPEN / ENABLED, BLANK = CLOSED / DISABLED, ANALOG VALUE = 0-0 VDC Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N2- X X X X X X X X X Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve CH 4 Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X O t Shield Gas 2 Idle Flow Analog Out X X X X 6-38

175 SECTION Gas Error Monitoring Stainless Steel PG-N 2, SG-N 2 TROUBLESHOOTING Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) X = Monitored For Pressure Present, Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O X X Vision Shift/Start Line vent Flow control vent 2 O Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-39

176 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Stainless Steel PG-N 2, SG-N 2 /CH Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) SOLENOID VALVES X = Open / Enabled, Blank = Closed / Disabled, Analog Value = 0-0 Vdc Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - X X X X X X X X X Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve CH 4 X X X X X X X X Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out X X X X X Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X X O t Shield Gas 2 Idle Flow Analog Out X X X X 6-40

177 SECTION 6 TROUBLESHOOTING Gas Error Monitoring Stainless Steel PG-N 2, SG-N 2 /CH Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station) Off) X = Monitored For Pressure Present, Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O X X Vision Shift/Start Line vent Flow control vent 2 O Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-4

178 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Stainless Steel PG-Air, SG-Air Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) Soleid Valves Plasma Gas Supply Soleid Valve N 2-2 X = Open / Enabled, Blank = Closed / Disabled, Analog Value = 0-0 Vdc X Plasma Gas Supply Soleid Valve Air-2 X X X X X X X X Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - Shield Gas Supply Soleid Valve Air- X X X X X X X X Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X O t Shield Gas 2 Idle Flow Analog Out X X X X X 6-42

179 SECTION Gas Error Monitoring Stainless Steel PG-Air, SG-Air TROUBLESHOOTING Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station) Off) X = Monitored For Pressure Present, Process Gas Pressure Switches O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O O Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-43

180 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Stainless Steel PG-Air, SG-Air/CH Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) Soleid Valves Plasma Gas Supply Soleid Valve N 2-2 X = Open / Enabled, Blank = Closed / Disabled, Analog Value = 0-0 Vdc X Plasma Gas Supply Soleid Valve Air-2 X X X X X X X X Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - X X X X X X X X X Shield Gas Supply Soleid Valve Air- X X X X X X X X Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve Ch 4 X X X X X X X X Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out X X X X X Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X X O t Shield Gas 2 Idle Flow Analog Out X X X X 6-44

181 SECTION Gas Error Monitoring Stainless Steel PG-Air, SG-Air/CH 4 TROUBLESHOOTING Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station) Off) Process Gas Pressure Switches X = Monitored For Pressure Present, O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O X X O Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-45

182 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Aluminum PG-N 2, SG-N Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) Soleid Valves X = Open / Enabled, Blank = Closed / Disabled, Analog Value = 0-0 Vdc Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - X X X X X X X X X Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out X Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X O t Shield Gas 2 Idle Flow Analog Out X X X X 6-46

183 SECTION Gas Error Monitoring Aluminum PG-N 2, SG-N 2 TROUBLESHOOTING Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station) Off) Process Gas Pressure Switches X = Monitored For Pressure Present, O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O O Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-47

184 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Aluminum PG-N 2, SG-N 2 /CH Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) Soleid Valves X = Open / Enabled, Blank = Closed / Disabled, Analog Value = 0-0 Vdc Plasma Gas Supply Soleid Valve N 2-2 X X X X X X X X X Plasma Gas Supply Soleid Valve Air-2 Plasma Gas Supply Soleid Valve Argon Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - X X X X X X X X X Shield Gas Supply Soleid Valve Air- Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve Ch 4 X X X X X X X X Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out X X X X X Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X X O t Shield Gas 2 Idle Flow Analog Out X X X X 6-48

185 SECTION 6 TROUBLESHOOTING Gas Error Monitoring Aluminum PG-N 2, SG-N 2 /CH Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station) Off) Process Gas Pressure Switches X = Monitored For Pressure Present, O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O X X O Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-49

186 SECTION 6 TROUBLESHOOTING Soleid And Proportional Valve Requirements Marking PG-Argon, SG-Air Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station Off) Soleid Valves Plasma Gas Supply Soleid Valve N 2-2 Plasma Gas Supply Soleid Valve Air-2 X = Open / Enabled, Blank = Closed / Disabled, Analog Value = 0-0 Vdc X Plasma Gas Supply Soleid Valve Argon X X X X X X X X Plasma Gas 2 Supply Soleid Valve O 2-2 Shield Gas Supply Soleid Valve O 2 - Shield Gas Supply Soleid Valve N 2 - Shield Gas Supply Soleid Valve Air- X X X X X X X X Shield Gas 2 Supply Soleid Valve N 2-3 Shield Gas 2 Supply Soleid Valve Ch 4 Plasma Gas Torch Soleid Valve X X X X X X X X X Plasma Gas 2 Torch Soleid Valve X X Shield Gas Torch Soleid Valve X X X X X X X X X Shield Gas 2 Torch Soleid Valve X X X Analog Flow Values Plasma Gas Start Flow Analog Out X X X X Plasma Gas Cut Flow Analog Out X X Plasma Gas 2 Start Flow Analog Out Plasma Gas 2 Cut Flow Analog Out Shield Gas Start Flow Analog Out X X X X Shield Gas Cut Flow Analog Out X X Shield Gas 2 Start Flow Analog Out Shield Gas 2 Cut Flow Analog Out Plasma Gas Soft Flow Analog Out Plasma Gas Purge/Fill/Vent Flow Analog X X X O t Plasma Gas Idle Flow Analog Out X X X Plasma Gas 2 Soft Flow Analog Out Plasma Gas 2 Purge/Fill/Vent Flow Analog X O t Plasma Gas 2 Idle Flow Analog Out X X X Shield Gas Soft Flow Analog Out Shield Gas Purge/Fill/Vent Flow Analog X X X O t Shield Gas Idle Flow Analog Out X X X Shield Gas 2 Soft Flow Analog Out Shield Gas 2 Purge/Fill/Vent Flow Analog X X O t Shield Gas 2 Idle Flow Analog Out X X X X X 6-50

187 SECTION 6 TROUBLESHOOTING Gas Error Monitoring --Marking PG-Argon, SG-Air Line Vent Flow Control Vent Line Purge Line Fill Ready Process Start Process Cut Process Post Flow Test (Start) Test (Cut) Idle (Station On) Idle (Station) Off) Process Gas Pressure Switches X = Monitored For Pressure Present, O = Monitored For Absence Of Pressure Plasma Gas Pressure Switch O X X Plasma Gas 2 Pressure Switch Shield Gas Pressure Switch O X X Shield Gas 2 Pressure Switch O O Vision Shift/Start Line vent Flow control vent 2 Numbers # correspond to columns on soleid/ proportional valve requirement charts and gas error monitoring charts Idle (Station off) 3 9 Section for details Station on? Station on Flush/ Pressure cycle Process start. 6 Test (start) Station on? Test (cut) Line Purge Station on? Line fill Station on? ready Station on? Plasma stop? Error condition? Station on? Arc established? Process cut Plasma stop 7 0 New SDP files selected? Plasma test? Plasma test cut? Plasma test (start O 2 )? Test (start O 2 ) Station on? New SDP file selected? Plasma test? Plasma test cut? New SDP file selected? Plasma test? Error condition? Station on? Station on? New SDP file selected? Plasma start? 8 Process Postflow Plasma test? 2 Analog disable timing? Idle (Station On) New SDP file selected? Station on? Plasma test cut? Plasma test (start O 2 )? Station on? New SDP file selected? Plasma test? Plasma start? 6-5

188 SECTION 6 TROUBLESHOOTING This page intentionally left blank. 6-52

189 SECTION 7 7. General REPLACEMENT PARTS Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 7.2 Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of n-esab parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor or from: ESAB Welding and Cutting Products ATTN: Customer Service Department PO Box Ebenezer Road Florence, SC USA Phone (843) (800) ESAB-23 ( ) ESAB Cutting Systems - Canada 600 Tomken Road Mississauga, Ontario, Canada L5T X9 Phone (905) Fax (905) ESAB Cutting Systems GMBH Robert-Bosch-Strasse 20 Postfach 28 D-684 Karben Phone Fax Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the last page of this manual for a list of customer service phone numbers. 7-

190 SECTION 7 REPLACEMENT PARTS 7.3 Plasmarc Power Source-Exterior Components

191 SECTION 7 REPLACEMENT PARTS Item Number Part Number 35925YL Symbol (Elec-Ay) Cover-Top Description YL 35923YL Label Warning-Exposed High Volt Label Warning Lens Clear Logo ESAB Clear Panel Right Side Panel Left Side Screw, HMH ¼-20 X.50 L 7-3

192 SECTION 7 REPLACEMENT PARTS See "TEE" Detail Page

193 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) S Description Switch Toggle 2PST 2 Pos 5A S2,3 Switch Toggle DPDT 2 Pos 5A AM,VM Meter LED 5VDC AM,VM Meter LED 5VDC S2,3 Switch Toggle DPDT 2 Pos 5A R2 POT 0K 0 Turn Overlay Precision Plasma GY Panel Front Gauge 200 PSI Spout Remote Filler w/cap 36346GY BRKT, Remote Filler 7-5

194 SECTION 7 REPLACEMENT PARTS

195 SECTION 7 REPLACEMENT PARTS Item Number Part Number 35928GY Symbol (Elec-Ay) Description Door Access Rear J Conn Box Recpt 9 FS SH J2 Conn Box Recpt 4 FS SH 4 97W6 3 Strain Relief Plug Hole.875 Dia..25 CT Nyl BK F4 Fuse 7A 600 VAC Fast Acting GY Panel Rear 8 58V75 Adaptor B/A-W F ¼ NPTM BKHD Label Rating Precision Plasma CB Circuit Breaker 3 AMP Strain Relief Plate, Serial CB2 Circuit Breaker 7 AMP 7-7

196 SECTION 7 REPLACEMENT PARTS 7.4 Plasmarc Power Source-Internal Components 8 7 Reference: PCB Isolation Amp Reference: Meter LED AM,VM

197 SECTION 7 REPLACEMENT PARTS Item Number Part Number 35920GY Symbol (Elec-Ay) Base, Precision Plasma Description TB4 Term Block 2 pos PCB PCB P9,7 PCB P0 PCB P,3,4 PCB P2 PCB P5 PCB Isolation AMP Housing Contact, Crimp 3 pin Standoff #6-32 X.88 L Plug 5 Pos Plug 8 Pos Plug 6 Pos Receptacle P/C 4 Pos GY Box PLC PLC PLC Controller PCB2 Board, PC Startup K3-6,8 Relay Enclosed DPDT 24VAC R,7,8,9 Resistor 300W 20ohm 0% K7 Relay Enclose DPDT 20VAC 20A Caster Fixed T2 XFMR Auto Tank, Water Caster Swivel Bushing, Snap.88 I.D. X.09 MH X.45 L Resistor, 300W 3.ohm 0% Spacer, LED Adhesive, SIRBR Clr 7-9

198 SECTION 7 REPLACEMENT PARTS

199 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) TB2 Terminal Block Description K Contactor 3 Pole 75A GY Shroud, Fan M Motor, Fan GY Shroud, Fan M2 Motor, Carb /3 Hp Pump, Carb w/strainer Tee, Pipe Branch ¼ Brs 9 0Z30 Adaptor, B/A-W M ¼ NPTM 0 82W82 Elbow 90 DEG. ¼ NPT Kit, Wire Primary BRKT, Water Tank T3 Auto XFMR GY BRKT, Auto XFMR 7-

200 SECTION 7 REPLACEMENT PARTS TEE Detail 0 X5 7-2

201 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) Description Hose, Assy Pump Outlet- Torch out FS 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 7 58V75 Adaptor, B/A-W F ¼ NPTM BKHD 8 82W82 Elbow 90 Deg. ¼ NPT 9 0Z30 Adaptor, B/A-W M ¼ NPTM Clamp, Hose W/D.50 Dia X.06 SS Tank, Water Spout, Remote Filler w/cap Tee, Plastic Pipe 7-3

202 SECTION 7 REPLACEMENT PARTS

203 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) Heat Exchanger Description Bushing, Snap Grommet, Rub.2 I.D. X.50 O.D. X.06 W TB3 Terminal Block 24 POS 5A TB5 Board, Terminal Output 6 96W0 Holder, Fuse 7 92W57 Grommet, Rub.63 I.D. X.88 O.D. X.06 W Bushing, Snap.88 I.D. X.09 MH X.45 L GY BRKT, Heat Exchanger Plug, 0 Pos 7-5

204 SECTION 7 REPLACEMENT PARTS

205 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) Bushing, Snap Description R,2 Res 20 ohm 50W GY Cover, Terminal Board C,2 Cap, Metpoly 20uf 400VDC K2 Contactor, Pilot Arc 3P 40A P4,MOD P,PLC P2 Plug, 6 Pos MOD P3, 4, PLC P Plug, 0 Pos J3 Receptacle, 8 Pos P,PLC P2 Plug, 6 Pos J4, PLC J2 Receptacle, 6 Pos TB6 Terminal Strip, 8 Pos L Choke Signal #Ch PCB-TB Printed Circuit Board Trim Pot 7-7

206 SECTION 7 REPLACEMENT PARTS 7.5 Power Source Power Module

207 SECTION 7 REPLACEMENT PARTS Item Number Part Number 3594GY Symbol (Elec-Ay) Base Power Module Description Bracket, PCB KYDEX Wire Kit, Power Module PCB P, 5 PCB P2, 6 Plug, Female 2 Position Plug, Female 4 Position 5 370GY Deck, Power Module Heat Sink L Inductor, Power Factor 7-9

208 SECTION 7 REPLACEMENT PARTS A A Section A-A 7-20

209 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) J3,4 Description Block Terminal 0 Position M Fan, Axial TB2 Terminal Strip 2 Position Bushing, Snap L Inductor, Power Factor R2 Resistor.5K OHM 00W L2 Inductor Assembly Output T3 Transformer Assembly, Main 7-2

210 SECTION 7 REPLACEMENT PARTS

211 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) J2 Description Block Terminal, 8 Position SH Shunt, Feedback J Block Terminal, 6 Position GY Baffle Heatsink Heatsink J3, 4 Block Terminal, 0 Position TB3 Adaptor 7-23

212 SECTION 7 REPLACEMENT PARTS

213 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) T Transformer Control Description BR Bridge Diode 3PH 30A Pad Thermal Bridge Busbar Input Bridge SCR SCR 90A Pad Thermal SCR Module Q,2 IGBT 300A 600V R4,5 Resistor 20OHM 50W NI Pad Thermal Power Resistor 50W Bushing Snap.3 I.D. X.5 MH.44 L Resistor 5OHM 50W C6,7 Capacitor uf 600VDC C4,5 Capacitor 3300 uf Busbar IGBT (-)/Capacitor Bushing Snap Busbar IGBT (+)/Capacitor Nomex Insulator Pad Thermal IGBT 200V Wire Kit Module Busbar Shunt Bushing Snap.875 I.D. X.093 MH R6,7,8,9 Resistor 20 OHM 25W NI D,2 Module Diode 00A 600V Bushing Snap.3 I.D. X.5 MH.44 L Busbar Capacitor/IGBT C8,9 Capacitor Film 40uf 400VDC Busbar Capacitor T2 Transformer, Current TS,2 Switch Thermal 94 Deg. F Busbar Jumper 7-25

214 SECTION 7 REPLACEMENT PARTS 7.6 Precision Plasma Junction Box Replacement Parts 2 A 2 REF A Section A-A 7-26

215 SECTION 7 REPLACEMENT PARTS Item Number Part Number 3755 Symbol (Elec-Ay) Description Wire Kit, Junction Box Precision Plasma PCB PCB Assembly Filter T2,3 XFMR H.F. Auto J2 Conn ( Pos BKHD A/A-W*F B/A-W*F BKHD A/A-W*F B/A-W*F C Cap Mica.002uf 0 KwV SG Spark Gap Assy 7-27

216 SECTION 7 REPLACEMENT PARTS 2 B 4 C 5 B C Section C-C Section B-B

217 SECTION 7 REPLACEMENT PARTS Item Number Part Number J Symbol (Elec-Ay) Description Conn Box Recpt 4 MP Shell Base Kydex J Box Cover Kydex J Box 4 Ref PCB Ref Ref Ref Torch Cable Conn Reference Torch Conn NEG Reference Pilot Arc Torch Reference 8 Ref J2 7-29

218 SECTION 7 REPLACEMENT PARTS

219 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) Name Plate Description Torch Conn Shield Locknut, Conduit 2NPT Label Warning High Volt Symbol Coupling, Quick Disconn F 4 Hose Grommet RBR 2.2 I.D. X 2.50 O.D. X.06W 7-3

220 SECTION 7 REPLACEMENT PARTS RC9 RC5 RC4 RC6 PR V4 P5 RC3 RC2 RC 7.7 Electronic Flow Control Box 3 ℵ P/N R P/N SR SR2 SR SR2 SR SR2 SR SR2 SR SR2 AR AIR AIR2 O- O-2 N- N-2 N-3 SP P2 P3 P4 H35 TB METH 4 7 JP3 JP2 JP SH GN PR V3 SP GN SH PS5 JP5 JP4 P PS4 RC0 PS3 PS2 PR RC8 V2 SP GN SH RC7 V PR PS SP SH GN ASSY P/N I P/N Process Air Argon Air N2 Argon Air-2 Air- Air Argon Oxygen Nitrogen O2 Air O2 N2 Argon O2-2 O2- Oxygen H-35 Methane Meth H-35 N2 N2-3 N2-2 N2- H-35 Methane Nitrogen H-35 Methane 7-32 P/N P/N P/N 95295

221 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) Description Switch, Pressure 50 PSI Non-Adj PCB Prec Flow Control Interface Board Valve Sol 2-Way Manifold Assembly Complete Prec Flow XMFR Control 5/230V 50/60 HZ Lamp Pilot 28V Green Manifold Assembly w/check Valves ONLY 7-33

222 SECTION 7 REPLACEMENT PARTS Plasma Gas Plasma Gas Shield Gas Shield Gas 2 Valve Valve 2 Valve 3 Valve 4 Vent Vent 2 Vent 3 Vent IR P/Ns 95299,95298, 95296,

223 SECTION 7 REPLACEMENT PARTS Item Number Part Number Purchase Locally Symbol (Elec-Ay) Description Fuse, Glass Body, Slow Acting 3AG 4A Valve, Analog 0-6 Bar 0-0 VDC Valve 4 SG Valve, Analog 0-6 Bar 0-0 VDC Valve 3 SG Valve, Analog 0-9 Bar 0-0 VDC Valve 2 PG Valve, Analog 0-9 Bar 0-0 VDC Valve PG Flow Meter Tube ONLY SG, SG2 ¼-33-G-5 PG2, Flow Meter Tube ONLY ¼ -5-G-5 PG 7-35

224 SECTION 7 REPLACEMENT PARTS 7.8 PT-24 Torch Assembly EFC Series A/M P/N Notes: * = Plasma 2 in Yellow 2* = Plasma 2 Out Yellow 3* = Plasma in Blue 4* = Plasma Out Blue 5* = Shield 2 In Black 6* = Shield 2 Out Black 7* = Shield In Orange/Red 8* = Shield Out Orange/Red * 6* 5* 8 4* 3* 6 2* * /8-8 L.H. (Ref) /8-24 L.H. (Ref) Not Shown 7-36

225 SECTION 7 Item Number Part Number See Process Data See Process Data , , , , , , , 86W , REPLACEMENT PARTS Description Body & Tube 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 T Gas Shutoff VLV Assembly EFC Protector Gortiflex Sensor 7LG Tool Electrode & Nozzle (NOT Shown) Quick Disconnect 90 Deg. Elbow.8 L LUB Grease DOW DC- (NOT Shown) Clamp, Worm Drive Clamp, Hose PT-24 Cable Bundle Assembly 4.5 Ft. PT-24 Cable Bundle Assembly 2 Ft. PT-24 Cable Bundle Assembly 7 Ft. Check Valve Body Ball Spring PT-24 Start-up Kit (Quantity of each) Nozzle A (2); Nozzle B (2); Nozzle C (2); Nozzle D (2); Nozzle E (2); Swirl Baffle 5A(); Swirl Baffle 30A(); Swirl Baffle 50/70A(); Lubricant(); Electrode and Nozzle Tool(); Shield Insulator Cup(); O-ring.239 x 0.07(); O-ring 0.64 X 0.07(), O-ring.498 X 0.07(); Electrode(5) Torch Spare Parts Kit (Quantity of each) Swirl Baffle(2), Oxy Electrode(5) Nozzle B (5), Nozzle C (5) Nozzle D (5), Swirl Baffle 50/70A(2) Retainer Shield Cup(), Water Baffle() Electrode and Nozzle Tool(), Nozzle E (3) Retainer diffuser Nozzle(), Shield Insulator Cup(3) Shield(6), O-ring.239 x 0.07(3) O-ring 0.64 X 0.07(3), O-ring.498 X 0.07(3) 7-37

226 SECTION 7 REPLACEMENT PARTS 7.9 T Gas Shut-off Valve Assembly EFC Series A/M Plasma & 2 Common Shield & 2 Common Shield Shield 2 Plasma 2 Plasma 7-38

227 SECTION 7 REPLACEMENT PARTS Item Number Part Number Symbol (Elec-Ay) Description Flange Way Soleid Valves

228 SECTION 7 REPLACEMENT PARTS 7.0 PT-24 Torch EFC Version Detail Torch Front End Not Shown