Precision Plasmarc Plasma Gas Box & Shield Gas Box Shield Gas Box Plasma Gas Box Instruction Manual (EN) 0558007535
Be sure this information reaches the operator. You can get extra copies through your supplier. caution These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, Precautions and Safe Practices for Arc Welding, Cutting, and Gouging, Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased. This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 114
table of contents Section / Title Page 1.0 Safety Precautions...117 2.0 Description...119 2.1 System Introduction...119 2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36...119 2.3 System Gas Requirements... 120 2.4 Plasma Gas Box Water Supply Requirements... 120 2.5 Plasma Gas Box Electrical Input Requirements... 120 2.6 Shield Gas Box Electrical Input Requirements... 120 2.7 System Accessories... 120 2.8 Plasma Gas Box Dimensions...121 2.9 Shield Gas Box Dimensions... 122 3.0 Installation... 123 3.1 Plasma Gas Box Introduction... 123 3.2 Plasma Gas Box Mounting (Bottom View)... 123 3.3 Plasma Gas Box Connections... 124 3.4 Plasma Gas Box Nomex Insulation... 130 3.5 Plasma Gas Box Gas Connections...131 3.6 Shield Gas Box Introduction... 133 3.7 Shield Gas Box Mounting (Bottom View)... 133 3.8 Shield Gas Box Connections... 134 3.9 Component Relationship Block Diagram... 136 4.0 Operation........................................................................................... 143 4.1 Plasma Gas Box Operation... 143 4.2 Plasma Gas Box Pressure Gauges... 143 4.3 Plasma Gas Box Pressure Switches... 144 4.4 Shield Gas Box Operation... 145 4.5 Shield Gas Box Air Regulator for Air Curtain... 146 4.6 Shield Gas Box Check Valves... 147 115
table of contents 116
section 1 safety precautions 1.0 Safety Precautions Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace. All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in injury to the operator and damage to the equipment. 1. Anyone who uses welding or plasma cutting equipment must be familiar with: - its operation - location of emergency stops - its function - relevant safety precautions - welding and / or plasma cutting 2. The operator must ensure that: - no unauthorized person stationed within the working area of the equipment when it is started up. - no one is unprotected when the arc is struck. 3. The workplace must: - be suitable for the purpose - be free from drafts 4. Personal safety equipment: - Always wear recommended personal safety equipment, such as safety glasses, flame proof clothing, safety gloves. - Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become trapped or cause burns. 5. General precautions: - Make sure the return cable is connected securely. - Work on high voltage equipment may only be carried out by a qualified electrician. - Appropriate fire extinquishing equipment must be clearly marked and close at hand. - Lubrication and maintenance must not be carried out on the equipment during operation. 117
section 1 safety precautions WARNING WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA. ELECTRIC SHOCK - Can kill. - Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards. - Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing. - Insulate yourself from earth and the workpiece. - Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health. - Keep your head out of the fumes. - Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone and the general area. ARC RAYS - Can injure eyes and burn skin. - Protect your eyes and body. Use the correct welding / plasma cutting screen and filter lens and wear protective clothing. - Protect bystanders with suitable screens or curtains. FIRE HAZARD - Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby. NOISE - Excessive noise can damage hearing. - Protect your ears. Use earmuffs or other hearing protection. - Warn bystanders of the risk. MALFUNCTION - Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! 118
section 2 DEscription 2.0 Description 2.1 System Introduction The m3 Plasma System is a streamlined, high performance-cutting package designed for use exclusively with the ESAB CNC. This advanced technology integrates gas and water control into the machine CNC. Using a system of electronic valves driven by CNC outputs, this system: dramatically reduces the amount of Plasma Gas hardware necessary to control the plasma torch. reduced purge time/increased part throughput. simplified operation with gas and water flow rates are controlled by the ESAB CNC process parameter screen. allows for programmed/automated control of fluid and water flow rates using SDP Files (SchneidDaten- Paket = Cutting Data Package, see Vision control and programming manuals for details on SDP Files. Data used to generate SDP files can be found in your model specific torch manual.) SDP files can also be referred to as TDF files (Technology Data Files). to be used with the PT-36 cutting torch. Plasma Gas Box Shield Gas Box 2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36 The complete m3 cutting system requires a variety of components. See section 3.9, Component Relationship Block Diagram for components and hook-up. 119
section 2 DEscription 2.3 System Gas Requirements Argon Nitrogen Oxygen 125 PSI (8,6 bar) with 0.25 NPT, 99.995% purity, Filtered to 25 microns 125 PSI (8,6 bar) with 0.25 NPT, 99.99% purity, Filtered to 25 microns 125 PSI (8,6 bar) with 0.25 NPT, 99.5% purity, Filtered to 25 microns H-35 (Argon/Hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns Methane Compressed Air (Air Curtain ) Compressed Air (Process) 75 PSI (5,2 bar) with 0.25 NPT, 93% purity, Filtered to 25 microns 80 PSI (5,5 bar) with 0.25 NPT, clean, dry, oil-free and filtered to 25 microns 80 PSI @ 1200cfh (5,5 bar @ 35 m 3 h) filtered to 25 microns DIN Quality ISO 8573-1 Oil quality mg/m3 = 0.1 class 2 Particle Size 0.1um class 1 Temparature +3 C class 4 2.4 Plasma Gas Box Water Supply Requirements Cooling Water... 175 PSI (12,1 bar), 1.5 gallons per minute (5.68 liters/minute) 2.5 Plasma Gas Box Electrical Input Requirements Voltage Supply Voltage Signals +24 VDC for proportional valves, mfc +15 VDC for pressure switch 24 VAC input to start gas solenoid valve 120 VAC input to arc starter 0-10 VDC input to proportional valves 0-10 VDC for mass flow valve 2.6 Shield Gas Box Electrical Input Requirements Voltage Supply +24 VDC for 120/230 transformer and I/O board +24 VDC for proportional valves and mfc s 2.7 System Accessories Coolant Hose Adaptor Kit... 0558006698 Adapter Coolant EPP-200...0558006162 120
section 2 DEscription 2.8 Plasma Gas Box Dimensions 11.28 286.5 mm 17.13 435.1 mm 7.25 184.2 mm 121
section 2 DEscription 2.9 Shield Gas Box Dimensions 12.00 304.8 mm 8.00 203.2 mm 20.00 508.0 mm 122
section 3 INstallation 3.0 Installation WARNING Electricity Can Kill! Before performing any maintenance or assembly of this equipment, ensure the power source (EPP) is turned off and disconnected. 3.1 Plasma Gas Box Introduction The m3 Plasma System Plasma Gas Box interfaces with the ESAB Vision machine controls and the EPP product line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control electronic valves. The result is CNC management of gas or shield gas delivery to the plasma torch. Analog signal feedback is sent back to the CNC, creating a control loop. 3.2 Plasma Gas Box Mounting (Bottom View) If mounting the box is required: The box has four (1.10 ) 28 mm threaded mounting holes in a pattern offset from longitudinal center. Note relationship of hole pattern to gauges and cable clamp..75 19.1 mm back front 4.50 114.3 mm 2.00 50.8 mm 4.13 104.9 mm 11.00 279.4 mm 2.00 50.8 mm 123
section 3 INstallation 3.3 Plasma Gas Box Connections 1. To access the inside of the box: remove or unlock screws and lift the box cover off to expose internal components. 2. Disassemble the strain relief/clamp block. (When apart, this strain relief will allow placement of cables and hoses without removing plugs and fittings.) A. Remove two screws holding block together. B. Insert cables for making connections inside box. C. Reattach block. Strain Relief / Clamp Block Note: Wires can be inserted in any of the three holes, only one cable is used in picture below. Pilot Arc Cable Power Source Cable 124
section 3 INstallation 3.3.1 Plasma Gas Box Starter Box Connections Arc Starter Box TB1 TB4 TB2 Pilot arc cable from the plasma power source. Connected to buss bar (lower back right hand corner). Pilot Arc Torch cable from the torch leads. Black Lead - 120 vdc input TB1 TB4 TB2 Black Lead Pilot Arc Cable Buss Bar View from underneath the Arc Starter Box 125
section 3 installation 3.3.2 Plasma Gas Box Torch Connections To connect the torch see the following illustrations. Hook-up requires connection of the cut and start gas hoses, shield gas hose, coolant hoses, air curtain hose, the pilot arc cable (TB2) and the Torch Tip / Electrical soft touch wire on the PC board X4 terminal. Torch Bundle Hose Connections 1 - Female old-style air water nut for Shield Gas connection 2 - B-IG fittings for Plasma Start gas and Plasma Cut gas. Either hose can be attached in either location. 3 - Cooling Water Connections. 4 - Pilot Arc Cable - connects to TB2 underneath Arc Starter Box. 5 - Torch Tip / Electrical soft touch wire - connects to PC board at X4 terminal. 6 - Air Curtain Hose - to air curtain at torch tip 7 - Ground Wires (yellow/green) - to be connected to ground stud beneath torch connection inside box. 2 5 4 3 7 1 2 1 6 5 3 126
section 3 installation 3.3.3 Plasma Gas Box Torch Cooling Water Connections Coolant Connections To and From Power Source H2O OUT When packaged with a torch and power supply at the factory, connections are labeled. Additional labels are available if relabeling becomes necessary. Tracing the Plasma Gas boxes interior lines can identify the proper connections. Flow switch is located on the IN line. H2O IN Coolant Connections To And From Torch Plasma Gas Box Rear View Note arrows on fittings indicating coolant flow direction. Coolant Out has right-hand threads. Coolant In has left-hand threads. Note: Coolant hoses connect as shown from the water cooler to the Plasma Gas box. Plasma Gas Box Rear View 127
section 3 INstallation 3.3.4 Power Source To Plasma Gas Box Buss Connection 1. Strip 4/0 (95 mm 2 ) insulation, approximately 38 mm. 2. Insert 4/0 (95 mm 2 ) cable in buss bar hole until copper extends to the edge of the buss block. 3. Tighten locking screw(s) on cable. Note: The buss will accommodate these cables. (1) 4/0 (95 mm 2 ) - 400 amps (2) 4/0 (95 mm 2 ) - 800 amps (3) 4/0 (95 mm 2 ) - 1000 amps Pilot Arc Cable Buss Block Power Source Cable notice Careful attention while stripping insulation will make installation of the power source cable in the buss easier. Do not spread or flare the copper conductors. 3.3.5 Plasma Gas Box PC Board Connections X1-10 - +24 vdc Input X1-9 - Sensor Input X1-2 - Common / Chassis Ground X4 - PE - Torch Tip / Electrical soft touch wire Chassis Ground Note: For more detailed information, refer to PC board schematic next page. 128
section 3 INstallation 129 25.07.2005 12:51:42 C:\Programme\EAGLE_V4-11\projects\2256510\2256510.sch (Sheet: 1/1) PC Board Schematic
section 3 INstallation 3.4 Plasma Gas Box Nomex Insulation Nomex Insulation 1. To access the inside of the box: remove or unlock screws and lift the box cover off to expose internal components. 2. Position Nomex insulation to prevent any possible arcing between the buss and arc start box terminals. 3. Replace enclosure of m3 Plasma System Plasma Gas Box. 130
section 3 INstallation 3.5 Plasma Gas Box Gas Connections Gas Connections are made on the exterior of the box. Gas lines are connected to the back of the plasma gas box from supply sources. Gas lines are connected to the front of the plasma gas box from the torch. caution Unfiltered Gas Will Clog Proportional Valves Dirt particles will clog small orifices in proportional valves. All gas supplies must have a 25 micron filter installed between supply and gas regulator panel. ESAB Filter P/N 56998133 (replacement filter element P/N 0560988406). Proportional valves contain no serviceable parts. Replace valve assembly with factory parts. Plasma Gas Box Rear Gas Connections Plasma Gas Box Front Gas Connections 131
section 3 INstallation caution Gas Line Contamination Will Damage Proportional Valves. Purge Gas Lines. Before connecting gas delivery lines to the m3 Plasma System Plasma Gas Box, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your m3 Plasma System Plasma Gas Box. 1 2 5 6 1. Purge gas and air lines completely before connecting to 25 micron gas filters. 2. Connect oxygen, H-35, nitrogen and air lines to gas filters. 3. Purge gas/air lines between shield gas box and m3 Plasma System Plasma Gas Box. 4. Connect gas/air lines to back of Plasma Gas box. 4 7 1 PG1 2 PG2 20 3 Air Curtain 4 PG2 Out 5 PG1 Out 3 8 10 6 Shield 7 Torch 8 14 Pin To B3 Lifter 9 8 Pin to Shield Box 10 10 Pin To B3 Lifter 11 H-35 12 Start Gas Selection (O2 N2 AIR) 13 Argon 12 14 H 2 O IN 15 Shield 9 19 11 13 15 16 Air Curtain 17 Cut Gas Selection (O2 N2 AIR) 18 H 2 O OUT 19 LED Volt Meter 20 Torch Cable Leads Grounding stud 14 18 16 17 132
section 3 WARNING INstallation Electricity Can Kill! Before performing any maintenance or assembly of this equipment, ensure the power source (EPP) is turned off and disconnected. 3.6 Shield Gas Box Introduction The m3 Plasma System Shield Gas Box interfaces with the ESAB Vision machine controls and the EPP product line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control proportional and solenoid valves. The result is CNC management of gas or shield gas delivery to the plasma torch. Analog signal feedback is sent back to the CNC, creating a control loop. 3.7 Shield Gas Box Mounting (Bottom View) If mounting the box is required: The box has four (1.10 ) 28 mm threaded mounting holes in a pattern offset from longitudinal center. Note relationship of hole pattern to gauges and cable clamp..75 19.1 mm back front 6.50 165.1 mm.75 19.1 mm 1.50 38.1 mm 16.00 406.4 mm 2.50 63.5 mm 133
section 3 INstallation 3.8 Shield Gas Box Connections All connections are made on the exterior of the box. See diagrams and chart below. caution Gas Line Contamination Will Damage Internal Components. Purge Gas Lines. Before connecting gas delivery lines to the m3 Plasma System Shield Gas Box, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the valves in your m3 Plasma System Shield Gas Box. 3.8.1 Shield Gas Box front connections 13 10 4 12 5 1 6 2 11 1 Power Cable 2 Ground Connection 3 Buss Connection Communication 4 CNC Out to Power Source 5 To Plasma Gas Box 6 Spare 7 To Air Curtain 8 To Plasma Gas 2 9 To Plasma gas 1 10 Spare 11 Power Cable Connector 12 X100 Female Plug 13 Bracket 3 7 8 4 9 5 6 134 View from inside showing connections of Items 4, 5 & 6
section 3 INstallation 3.8.2 Shield Gas Box rear connections 1 2 3 7 1 Shield Gas Out 2 Air Curtain Inlet 3 Oxygen Inlet 4 N2 Inlet 5 Air Inlet 6 Check Valves (typical) 7 CH4 Inlet 4 5 6 m3 Gas Fittings Kit (0558005229, included w/ m3 system) Consists of the following: P/N Description Quantity 36Z40 NUT HOSE B-A/W.63-18F RH 2 136Z08 NUT HOSE B-I/G.63-18M RH 1 3380 NUT HOSE B-OXY.56-18F RH 1 3381 NUT HOSE B/ACET.56-18F LH 2 136Z07 NUT HOSE A-I/G.38-24M RH 1 2064114 NPL PUSH A/A-W 3/16 ID HOSE 1 03Z74 NPL PUSH B/SIZE 3/8 HOSE 5 347995 NPL PUSH B/A-W 3/8 ID HOSE 1 0558006336 m3 PLASMA FILTER ASSEMBLY 1 20373 Flash Arrestor Assembly 1 135
section 3 3.9 Component Relationship Block Diagram INstallation 3-phase w/ ground 5 3 2 3a 1 4 Air (clean, dry, oilfree shop air for Air Curtain supply) N 2 Air (plasma CH 4 O 2 Argon H-35 shield supply DIN Quality ISO 8573-1) PS & WC Control Cables Cable 4c CNC Cable 4 Twisted Pair Power Cable Power Cable 13 Pilot Arc Cable Pilot Arc Cable 11 25 Micron filters 9 8 7 6 16 12 LED Volt Meter Note: Air Curtain or Bubble Muffler can be used here. See torch manual for conditions. 10 14 Torch Lead 17 15a = 10 Pin 15b = 14 Pin Encoder / Voltage Height Control Workpiece Work Table Earth Ground 136
section 3 INstallation ITEM NUMBER PART NUMBER DESCRIPTION 1 0558004315 EPP-200, 200,230,380,415,460,575V 0558006470 EPP-400 400V, 50/60Hz CE 0558006471 EPP-400 460V, 60Hz 0558006472 EPP-400 575V, 60Hz 0558006473 EPP-600 400V, 50/60Hz CE 0558006474 EPP-600 460V, 60Hz 0558006475 EPP-600 575V, 60Hz 0558007800 EPP-201, 380/400V, 50/60Hz, CCC/CE 0558007801 EPP-201, 460V, 60Hz 0558007802 EPP-201, 575V, 60Hz 0558007831 EPP-360, 380/400V, 50/60Hz, CCC/CE 0558006832 EPP-360, 460V, 60Hz 0558006833 EPP-360, 575V, 60Hz 0558007730 EPP-401/450, 380/400V, 50/60Hz CE 0558007731 EPP-450, 460V, 60Hz 0558007732 EPP-450, 575V, 60Hz 0558007733 EPP-601, 380/400V, 50/60Hz, CCC/CE 0558007734 EPP-601, 460V, 60Hz 0558007735 EPP-601, 575V, 60Hz 2 0558006086 Junction Box, PS & WC 3 0558004837 Cable Control, WC, 5m (16 ) 0558004838 Cable Control, WC, 10m (33 ) 0558004839 Cable Control, WC, 20m (66 ) 3a 0558004849 Cable Control, PS & WC, 5m (16 ) 0558004850 Cable Control, PS & WC, 10m (33 ) 0558004851 Cable Control, PS & WC, 20m (66 ) 0558004852 Cable Control, PS & WC, 40m (131 ) 0558004853 Cable Control, PS & WC, 50m (164 ) 0558004854 Cable Control, PS & WC, 60m (196 ) 0558005237 Cable Control, PS & WC, 15m (49 ) 0558005238 Cable Control, PS & WC, 30m (98 ) 4 0558005246 Coolant Hose, 5m (16 ) 0558005563 Coolant Hose, 10m (33 ) 0558005564 Coolant Hose, 15m (49 ) 0558005565 Coolant Hose, 20m (66 ) 0558005247 Coolant Hose, 30m (98 ) 0558005248 Coolant Hose, 40m (131 ) 0558005567 Coolant Hose, 50m (164 ) 0558005249 Coolant Hose, 60m (196 ) 137
section 3 INstallation ITEM NUMBER PART NUMBER DESCRIPTION 5 0558004400 Coolant Circulator PCC-10 0558007515 Coolant Circulator PCC-11 6 0558006089 Hose, Plasma Gas #1, 1.5m (5 ) 0558006090 Hose, Plasma Gas #1, 5m (16 ) 0558006091 Hose, Plasma Gas #1, 6m (19 ) 0558006092 Hose, Plasma Gas #1, 7m (23 ) 0558006093 Hose, Plasma Gas #1, 8m (26 ) 0558006094 Hose, Plasma Gas #1, 9m (30 ) 0558006095 Hose, Plasma Gas #1, 10m (33 ) 0558006096 Hose, Plasma Gas #1, 11m (36 ) 0558006097 Hose, Plasma Gas #1, 12m (39 ) 0558006098 Hose, Plasma Gas #1, 13m (43 ) 0558006099 Hose, Plasma Gas #1, 14m (46 ) 0558006100 Hose, Plasma Gas #1, 15m (49 ) 0558006101 Hose, Plasma Gas #1, 16m (52 ) 0558006102 Hose, Plasma Gas #1, 17m (56 ) 0558006103 Hose, Plasma Gas #1, 18m (59 ) 0558006104 Hose, Plasma Gas #1, 19m (62 ) 0558006105 Hose, Plasma Gas #1, 20m (66 ) 7 0558006106 Hose, Plasma Gas #2, 1.5m (5 ) 0558006107 Hose, Plasma Gas #2, 5m (16 ) 0558006108 Hose, Plasma Gas #2, 6m (19 ) 0558006109 Hose, Plasma Gas #2, 7m (23 ) 0558006110 Hose, Plasma Gas #2, 8m (26 ) 0558006111 Hose, Plasma Gas #2, 9m (30 ) 0558006112 Hose, Plasma Gas #2, 10m (33 ) 0558006113 Hose, Plasma Gas #2, 11m (36 ) 0558006114 Hose, Plasma Gas #2, 12m (39 ) 0558006115 Hose, Plasma Gas #2, 13m (43 ) 0558006116 Hose, Plasma Gas #2, 14m (46 ) 0558006117 Hose, Plasma Gas #2, 15m (49 ) 0558006118 Hose, Plasma Gas #2, 16m (52 ) 0558006119 Hose, Plasma Gas #2, 17m (56 ) 0558006120 Hose, Plasma Gas #2, 18m (59 ) 0558006121 Hose, Plasma Gas #2, 19m (62 ) 0558006122 Hose, Plasma Gas #2, 20m (66 ) 138
section 3 INstallation ITEM NUMBER PART NUMBER DESCRIPTION 8 0558006200 Hose, Shield Gas, 1.5m (5 ) 0558006201 Hose, Shield Gas, 5m (16 ) 0558006202 Hose, Shield Gas, 6m (19 ) 0558006203 Hose, Shield Gas, 7m (23 ) 0558006204 Hose, Shield Gas, 8m (26 ) 0558006205 Hose, Shield Gas, 9m (30 ) 0558006206 Hose, Shield Gas, 10m (33 ) 0558006207 Hose, Shield Gas, 11m (36 ) 0558006208 Hose, Shield Gas, 12m (39 ) 0558006209 Hose, Shield Gas, 13m (43 ) 0558006210 Hose, Shield Gas, 14m (46 ) 0558006211 Hose, Shield Gas, 15m (49 ) 0558006212 Hose, Shield Gas, 16m (52 ) 0558006213 Hose, Shield Gas, 17m (56 ) 0558006214 Hose, Shield Gas, 18m (59 ) 0558006215 Hose, Shield Gas, 19m (62 ) 0558006216 Hose, Shield Gas, 20m (66 ) 9 0558006217 Hose, Air Curtain, 1.5m (5 ) 0558006218 Hose, Air Curtain, 5m (16 ) 0558006219 Hose, Air Curtain, 6m (19 ) 0558006865 Hose, Air Curtain, 6.1m (20 ) 0558006220 Hose, Air Curtain, 7m (23 ) 0558006221 Hose, Air Curtain, 8m (26 ) 0558006222 Hose, Air Curtain, 9m (30 ) 0558006223 Hose, Air Curtain, 10m (33 ) 0558006224 Hose, Air Curtain, 11m (36 ) 0558006225 Hose, Air Curtain, 12m (39 ) 0558006226 Hose, Air Curtain, 13m (43 ) 0558006227 Hose, Air Curtain, 14m (46 ) 0558006228 Hose, Air Curtain, 15m (49 ) 0558006229 Hose, Air Curtain, 16m (52 ) 0558006230 Hose, Air Curtain, 17m (56 ) 0558006231 Hose, Air Curtain, 18m (59 ) 0558006232 Hose, Air Curtain, 19m (62 ) 0558006233 Hose, Air Curtain, 20m (66 ) 139
section 3 INstallation ITEM NUMBER PART NUMBER DESCRIPTION 10 0558004841 Air Curtain Hose 1.4m (4.5 ) 0558004842 Air Curtain Hose 1.8m (6 ) 0558004843 Air Curtain Hose 3.6m (12 ) 0558004844 Air Curtain Hose 4.6m (15 ) 0558004845 Air Curtain Hose 5.2m (17 ) 0558004846 Air Curtain Hose 7.6m (25 ) 11 0560942312 Shield Gas Box 12 0560941491 Plasma Gas Box 13 2239606 Power Junction Box 14 37440 Air Curtain Assembly 37439 Bubble Muffler 15a 0560940129 Cable, PGC-B3, 10p, 1.4m (4.5 ) - 2 Plug 0560941700 Cable, PGC-B3, 10p, 1.8m (6 ) - 2 Plug 0560940135 Cable, PGC-B3, 10p, 3.6m (12 ) - 2 Plug 0560941701 Cable, PGC-B3, 10p, 4.6m (15 ) - 2 Plug 0560940138 Cable, PGC-B3, 10p, 5.2m (17 ) - 2 Plug 0560940141 Cable, PGC-B3, 10p, 7.6m (25 ) - 2 Plug 0560940142 Cable, PGC-B3, 10p, 10.7m (35 ) - 2 Plug 0560941482 Cable, PGC-B3, 10p, 7.6m (25 ) - 1 Plug 0560941483 Cable, PGC-B3, 10p, 10.7m (35 ) - 1 Plug 0560941484 Cable, PGC-B3, 10p, 13.7m (45 ) - 1 Plug 0560941485 Cable, PGC-B3, 10p, 16.8m (55 ) - 1 Plug 140
section 3 INstallation ITEM NUMBER PART NUMBER DESCRIPTION 15b 0560940144 Cable, PGC-B3, 14p, 1.4m (4.5 ) - 2 Plug 0560941702 Cable, PGC-B3, 14p, 1.8m (6 ) - 2 Plug 0560940147 Cable, PGC-B3, 14p, 3.6m (12 ) - 2 Plug 0560941703 Cable, PGC-B3, 14p, 4.6m (15 ) - 2 Plug 0560940148 Cable, PGC-B3, 14p, 5.2m (17 ) - 2 Plug 0560940149 Cable, PGC-B3, 14p, 7.6m (25 ) - 2 Plug 0560940152 Cable, PGC-B3, 14p, 10.7m (35 ) - 2 Plug 0560941487 Cable, PGC-B3, 14p, 7.6m (25 ) - 1 Plug 0560941488 Cable, PGC-B3, 14p, 10.7m (35 ) - 1 Plug 0560941489 Cable, PGC-B3, 14p, 13.7m (45 ) - 1 Plug 0560941490 Cable, PGC-B3, 14p, 16.8m (55 ) - 1 Plug 16 0560939938 Cable, GS-PGC, 8p, 1.8m (6 ) 0560939939 Cable, GS-PGC, 8p, 7.6m (25 ) 0560939940 Cable, GS-PGC, 8p, 10.7m (35 ) 0560939941 Cable, GS-PGC, 8p, 13.7m (45 ) 0560939942 Cable, GS-PGC, 8p, 16.8m (55 ) 17 0558006745 Plasma Torch PT-36, 1.4m (4.5 ) 0558006746 Plasma Torch PT-36, 1.8m (6 ) 0558006747 Plasma Torch PT-36, 3.6m (12 ) 0558006748 Plasma Torch PT-36 4.3m (14 ) 0558006749 Plasma Torch PT-36, 4.6m (15 ) 0558006750 Plasma Torch PT-36, 5.2m (17 ) 0558006779 Plasma Torch PT-36, 6.1m (20 ) 0558006751 Plasma Torch PT-36, 7.6m (25 ) 141
section 3 INstallation 142
section 4 operation 4.0 Operation 4.1 Plasma Gas Box Operation A major advantage of the m3 Plasma System Plasma Gas Box is that operating parameters are managed by the machine CNC. There are no operating procedures necessary with the m3 Plasma System Plasma Gas Box. Management is accomplished either with manual inputs on the Vision cutting parameter screen or using the ESAB system of Process Parameter Files. Note: Process Parameter Files (known by the acronyms SDP or TDF) are files stored in the machine control memory containing all necessary information for cutting a thickness and a material type. It is specific to material, thickness, torch model, gas and material type. The information used to create the files can be found in your torch manual. Refer to ESAB CNC Part Programming manual for more detail on the creation and use of parameter files. notice See CUT DATA MANUAL, P/N 0558006263 for cutting parameter settings for using the m3 Plasma System Plasma Gas Box. 4.2 Plasma Gas Box Pressure Gauges Pressure gauges display actual pressure to the torch. They provide visual feedback to the operator, and can be helpful in spotting torch problems. Start Gas (PG1) Note: PG1 & PG2 are referred to as Start & Cut gas most of the time. Certain cutting conditions require PG1 conditions only. Cut Gas (PG2) 143
section 4 operation 4.3 Plasma Gas Box Pressure Switches Pressure switches monitor line pressure and provide inputs to the CNC. If the pressure drops below 50 psi, the CNC can shut the process down. Switches are in-line between the solenoid and the proportional valve for shield gas 1 & 2, start gas and cut gas. Plasma Gas Box Gas Pressure Switch 144
section 4 operation 4.4 Shield Gas Box Operation A major advantage of the m3 Plasma System Shield Gas Box is that operating parameters are managed by the machine CNC. There are no operating procedures necessary with the m3 Plasma System Shield Gas Box. Management is accomplished either with manual inputs on the Vision cutting parameter screen or using the ESAB system of Process Parameter Files. Note: Process Parameter Files (known by the acronyms SDP or TDF) are files stored in the machine control memory containing all necessary information for cutting a thickness and a material type. It is specific to material, thickness, torch model, gas and material type. The information used to create the files can be found in your torch manual. Refer to ESAB CNC Part Programming manual for more detail on the creation and use of parameter files. notice See CUT DATA MANUAL, P/N 0558006263 for cutting parameter settings for using the m3 Plasma System Shield Gas Box. 145
section 4 operation 4.5 Shield Gas Box Air Regulator for Air Curtain The Air Regulator displays actual air pressure to the torch. It provides visual feedback to the operator, and can be helpful in spotting torch problems. To access the Air Regulator: 1. Remove the cover. No adjustment should be necessary to the regulator. Regulator is factory set to 40 psi while flowing. 146
section 4 operation 4.6 Shield Gas Box Check Valves Check Valves stop backflow between gas selections. Periodic purging of check valves is necessary to clear gas lines. To purge lines simply unscrew caps on check valves to bleed the gas pressure. Check Valves (9 typical) 147
section 4 operation 148