m3 plasma-shield gas boxes 0558005487

Precision Plasmarc Plasma Gas Box & Shield Gas Box

Instruction Manual

0558005487 10 / 2008

Plasma Gas Box

Shield Gas Box

This equipment will perform in conformity with the description thereof contained in this manual and accompa-nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-vice facility designated by the manufacturer.

Be sure thIs InforMatIon reaches the operator.You can get extra copIes through Your supplIer.

these InstructIons are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “precautions and safe practices for arc Welding, cutting, and gouging,” form 52-529. Do not permit untrained persons to install, operate, or maintain this equipment. Do not attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the safety precautions be-fore installing or operating this equipment.

cautIon

user responsIBIlItY

reaD anD unDerstanD the InstructIon Manual Before InstallIng or operatIng.

protect Yourself anD others!

taBle of contents

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 2.1 System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 2.3 System Gas Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.4 Plasma Gas Box Water Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.5 Plasma Gas Box Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.6 Shield Gas Box Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.7 System Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.8 Plasma Gas Box Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 2.9 Shield Gas Box Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.1 Plasma Gas Box Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.2 Plasma Gas Box Mounting (Bottom View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 3.3 Plasma Gas Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.4 Plasma Gas Box Nomex Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 3.5 Plasma Gas Box Gas Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 3.6 Shield Gas Box Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 3.7 Shield Gas Box Mounting (Bottom View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 3.8 Shield Gas Box Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 3.9 Component Relationship Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 4.1 Plasma Gas Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 4.2 Plasma Gas Box Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 4.3 Plasma Gas Box Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 4.4 Shield Gas Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 4.5 Shield Gas Box Air Regulator for Air Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 4.6 Shield Gas Box Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

section / title page

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taBle of contents

5.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 5.1 Plasma Gas Box Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 5.2 Plasma Gas Box Schematic (Plumbing Schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 5.3 Plasma Gas Box Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 5.4 Spark Gap Of the Arc Starter Box (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 5.5 Spark Adjustment Procedure (Plasma Gas Box). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 5.6 Cooling Water Circuit (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 5.7 Plasma Gas Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 5.8 Voltage Divider Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 5.9 Voltage Divider Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 5.10 Shield Gas Box Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.11 Shield Gas Box Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 5.12 Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 5.13 Mass Flow Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 5.14 Gas Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 5.15 Fluid Schematic – m3 Plasma System Plasma Gas Box and Shield Gas Box . . . . . . . . . . . . . . . . . . . . . . . .60

6.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 6.3 Plasma Gas Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 6.4 Start Gas Manifold (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 6.5 Buss Bar Manifold (Plasma Gas Box). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 6.6 Shield Gas Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 6.7 Shield Gas Manifold (Shield Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

5

sectIon 1 safetY precautIons

1.0 safety precautions 1.1 safety - english

WarnIng: These Safety Precautions are for your protection. They summarize pre-cautionary information from the references listed in Additional Safety Information sec-

tion. Before performing any installation or operating procedures, be sure to read and follow the safety precau-tions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

protect Yourself anD others -- some welding, cutting, and gouging processes are noisy and require ear protection. the arc, like the sun, emits ultraviolet (uV) and other radiation

and can injure skin and eyes. hot metal can cause burns. training in the proper use of the processes and equipment is essential to prevent accidents. therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protec-tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses.

fIres anD explosIons -- heat from flames and arcs can start fires. hot slag or sparks can also cause fires and explosions. therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protec-tive non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hid-den smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For ex-ample, overloaded welding cable can overheat and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protec-tion Association, Batterymarch Park, Quincy, MA 02269.

electrIcal shocK -- contact with live electrical parts and ground can cause severe injury or death. Do not use ac welding current in damp areas, if movement is confined, or if there is danger of falling.

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1. Be sure the power source frame (chassis) is con-nected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

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

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommenda-tions. Do not mistake the work lead for a ground cable.

electrIc anD MagnetIc fIelDs — May be dangerous. electric cur-rent flowing through any conduc-tor causes localized electric and Magnetic fields (eMf). Welding and

cutting current creates eMf around welding cables and welding machines. therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together. Secure them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as possible to the area being welded.

E. Keep welding power source and cables as far away from your body as possible.

fuMes anD gases -- fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. shield-ing gases can cause asphyxiation.

therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stain-less steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-ritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discom-fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.

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5. WarnIng: this product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the state of california to cause birth defects and, in some cases, cancer. (california health & safety code §25249.5 et seq.)

cYlInDer hanDlIng -- cylinders, if mishandled, can rupture and vio-lently release gas. sudden rupture of cylinder, valve, or relief device can injure or kill. therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instruc-tions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercar-riages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

eQuIpMent MaIntenance -- faulty or improperly maintained equipment can cause injury or death. therefore:

1. Always have qualified personnel perform the instal-lation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

aDDItIonal safetY InforMatIon -- for more information on safe practices for electric arc welding and cutting equip-ment, ask your supplier for a copy of "precautions and safe practices for arc Welding, cutting and gouging", form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

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

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

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

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

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5. AWS C5.5 - "Recommended Practices for Gas Tung-sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc Welding"“

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

8. ANSI/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances."

MeanIng of sYMBols - as used throughout this manual: Means atten-tion! Be alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in im-mediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

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sectIon 1 segurIDaD1.2 safety - spanish

aDVertencIa: Estas Precauciones de Se-guridad son para su protección. Ellas hacen resumen de información proveniente de las

referencias listadas en la sección "Información Adi-cional Sobre La Seguridad". Antes de hacer cualquier instalación o procedimiento de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación así como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. El no observar las Precauciones de Seguridad puede resultar en daño a la persona o muerte.

proteJase usteD Y a los DeMas-- algunos procesos de soldadura, corte y ranurado son ruidosos y requiren protección para los oídos. el arco, como el sol , emite rayos ultravioleta

(uV) y otras radiaciones que pueden dañar la piel y los ojos. el metal caliente causa quemaduras. el entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes. por lo tanto:

1. Utilice gafas de seguridad con protección a los lados siempre que esté en el área de trabajo, aún cuando esté usando careta de soldar, protector para su cara u otro tipo de protección.

2. Use una careta que tenga el filtro correcto y lente para proteger sus ojos, cara, cuello, y oídos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las per-sonas cercanas de no mirar el arco y no exponerse a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa pesada de mangas largas, pantalón de ruedo liso, zapato alto al tobillo, y careta de soldar con capucha para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es necesario para protegerse del calor radiado y las chispas.

4. Chispas y partículas de metal caliente puede alojarse en las mangas enrolladas de la camisa , el ruedo del pantalón o los bolsillos. Mangas y cuellos deberán mantenerse abotonados, bolsillos al frente de la camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-pas calientes con una cortina adecuada no-flamable como división.

6. Use careta protectora además de sus gafas de segu-ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y dEPPrenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora.

fuego Y explosIones -- el calor de las flamas y el arco pueden ocacionar fuegos. escoria caliente y las chispas pueden causar fuegos y explosiones. por lo tanto:

1. Remueva todo material combustible lejos del área de trabajo o cubra los materiales con una cobija a prueba de fuego. Materiales combustibles incluyen madera, ropa, líquidos y gases flamables, solventes, pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o EPPacios. Asegúrese de que toda grieta y agujero esté cubierto para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté to-talmente limpia y libre de substancias que puedan producir gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar si contienen vapores inflamables.

4. Tenga siempre a la mano equipo extintor de fu-ego para uso instantáneo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, o extintor portátil. Asegúrese que usted esta entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego.

6. DEPPués de termirar la operación del equipo, inspec-cione el área de trabajo para cerciorarse de que las chispas o metal caliente ocasionen un fuego más tarde. Tenga personal asignado para vigilar si es necesario.

7. Para información adicional , haga referencia a la publicación NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible a través de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

choQue electrIco -- el contacto con las partes eléctricas energizadas y tierra puede causar daño severo o muerte. no use soldadura de corri-ente alterna (ac) en áreas húmedas,

de movimiento confinado en lugares estrechos o si hay posibilidad de caer al suelo.

10

sectIon 1 segurIDaD

1. Asegúrese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario.

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

3. Conecte el cable de retorno a la pieza de trabajo. Cables y conductores expuestos o con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi-ciones. Reemplaze cables rotos, dañados o con conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de trabajo, los cables, antorchas, pinza del electrodo, y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien-tras trabaja en lugares estrechos o áreas húmedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma.

8. Use guantes secos y sin agujeros antes de energizar el equipo.

9. Apage el equipo antes de quitarse sus guantes. 10. Use como referencia la publicación ANSI/ASC

Standard Z49.1 (listado en la próxima página) para recomendaciones EPPecíficas de como conectar el equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra.

caMpos electrIcos Y MagnetI-cos - son peligrosos. la corriente eléctrica fluye através de cualquier conductor causando a nivel local campos eléctricos y Magnéticos

(eMf). las corrientes en el área de corte y soldadura, crean eMf alrrededor de los cables de soldar y las maquinas. por lo tanto: 1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced-imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Asegúrelos uno junto al otro con cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar lo más lejos posible de su cuerpo.

huMo Y gases -- el humo y los gases, pueden causar malestar o daño, particularmente en eppacios sin ventilación. no inhale el humo o gases. el gas de protección puede

causar falta de oxígeno. por lo tanto:

1. Siempre provea ventilación adecuada en el área de trabajo por medio natural o mecánico. No solde, corte, o ranure materiales con hierro galvanizado, acero inoxidable, cobre, zinc, plomo, berílio, o cad-mio a menos que provea ventilación mecánica positiva . No rEPPire los gases producidos por estos materiales.

2. No opere cerca de lugares donde se aplique sub-stancias químicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formar un fosfógeno, o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de ojos, nariz o garganta mientras est á operando, es indicación de que la ventilación no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilación en el área de trabajo. No continúe operando si el malestar físico per-siste.

4. Haga referencia a la publicación ANSI/ASC Standard Z49.1 (Vea la lista a continuación) para recomen-daciones EPPecíficas en la ventilación.

11

sectIon 1 segurIDaD

5. aDVertencIa-- este producto cuando se uti-liza para soldaduras o cortes, produce humos o gases, los cuales contienen químicos conocidos por el estado de cali-fornia de causar defectos en el nacimiento, o en algunos casos, cancer. (california health & safety code §25249.5 et seq.)

ManeJo De cIlInDros-- los cilindros, si no son manejados correctamente, pueden romp-erse y liberar violentamente gases. rotura repentina del cilindro, válvula, o válvula de escape puede causar daño o muerte. por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize un regulador diseñado para operar y reducir la presión del cilindro de gas . No utilice adapta-dores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operación del manufacturero para montar el regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical y amárrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tablil-leros, paredes, postes, o armazón. Nunca asegure los cilindros a la mesa de trabajo o las piezas que son parte del circuito de soldadura . Este puede ser parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la válvula del cilindro cerrada. Ponga el capote de protección sobre la válvula si el regulador no está conectado. Asegure y mueva los cilindros utilizando un carro o transporte adecuado. Evite el manejo brusco de los

MantenIMIento Del eQuIpo -- equipo defectuoso o mal mantenido puede causar daño o muerte. por lo tanto:

1. Siempre tenga personal cualificado para efec-tuar l a instalación, diagnóstico, y mantenimiento del equipo. No ejecute ningún trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo.

2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones, cable primario, y cualquier otra fuente de poder en buen estado operacional. No opere ningún equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga el equipo lejos de cosas que generen calor como hornos, también lugares húmedos como charcos de agua , aceite o grasa, atmósferas corrosivas y las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y coverturas del equipo en su posición y en buenas condiciones.

6. Use el equipo sólo para el propósito que fue diseñado. No modifique el equipo en ninguna manera.

InforMacIon aDIcIonal De segurI-DaD -- para más información sobre las prácticas de seguridad de los equipos de arco eléctrico para soldar y cortar, pregunte a su suplidor por una copia de "precautions and safe practices for arc Welding, cutting and gouging-form 52-529.

Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted:

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

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

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

4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting"

12

sectIon 1 segurIDaD

sIgnIfIcaDo De los sIMBolos -- según usted avanza en la lectura de este folleto: los símbolos sig-nifican ¡atención! ¡esté alerta! se trata de su seguridad.

significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daño personal o la muerte.

significa el riesgo de un peligro potencial que puede resultar en serio daño personal o la muerte.

significa el posible riesgo que puede resultar en menores daños a la persona.

13

sectIon 1 sÉcurItÉ1.3 safety - french IncenDIes et explosIons -- la

chaleur provenant des flammes ou de l'arc peut provoquer un incendie. le laitier incandescent ou les étincelles peuvent également provoquer un

incendie ou une explosion. par conséquent :

1. Éloignez suffisamment tous les matériaux combus-tibles de l'aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vête-ments, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incan-descent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l'étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra-vail à chaud avant d'avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu'il n'ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N'exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction d'incendie est disponible et prêt à servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'être bien instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un in-cendie.

6. Une fois les opérations terminées, inspectez l'aire de travail pour assurer qu'aucune étincelle ou projec-tion de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d'incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

choc ÉlectrIQue -- le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mor-telles. ne pas utiliser un courant de

soudage c.a. dans un endroit humide, en eppace restreint ou si un danger de chute se pose.

aVertIsseMent : Ces règles de sécurité ont pour but d'assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section

des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les fiches d'information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d'observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

protÉgeZ-Vous -- les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et

exige l'emploi d'une protection auditive. l'arc, tout comme le soleil, émet des rayons ultraviolets en plus d'autre rayons qui peuvent causer des blessures à la peau et les yeux. le métal incandescent peut causer des brûlures. une formation reliée à l'usage des processus et de l'équipement est essentielle pour prévenir les accidents. par conséquent: 1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l'arc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas re-garder l'arc et de ne pas s'exposer aux rayons de l'arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l'arc, des étincelles et du métal incandescent, en plus d'un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous proté-ger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recom-mandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l'arc à l'aide d'un rideau ou d'une cloison ininflammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d'écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent égale-ment porter des lunettes étanches par dessus leur lunettes de sécurité.

14

sectIon 1 sÉcurItÉ

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l'exposition aux champs électriques et magnétiques :

A. Acheminez l'électrode et les câbles de masse ensemble. Fixez-les à l'aide d'une bande adhésive lorsque possible.

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

C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le soudage et les câbles à une distance appropriée de votre corps.

les Vapeurs et les gaZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les eppaces restreints. ne rep-pirez pas les vapeurs et les gaz. le gaz de protection risque de causer l'asphyxie. par conséquent :

1. Assurez en permanence une ventilation adéquate dans l'aire de travail en maintenant une ventila-tion naturelle ou à l'aide de moyens mécanique. N'effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l'absence de moyens mécaniques de ventilation efficaces. Ne rEPPirez pas les vapeurs de ces matériaux.

2. N'effectuez jamais de travaux à proximité d'une opération de dégraissage ou de pulvérisation. Lor-sque la chaleur

ou le rayonnement de l'arc entre en contact avec les vapeurs d'hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d'autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d'une opération indique que la ven-tilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l'aire de travail. Ne poursuivez pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.

1. Assurez-vous que le châssis de la source d'alimentation est branché au système de mise à la terre de l'alimentation d'entrée.

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

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d'éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endom-magés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l'aire de travail, les câbles, le porte-électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez effectuer votre travail dans un EPPace restreint ou humide, ne tenez vous pas directe-ment sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez vos mains avec des gants secs et sans trous.

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

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

chaMps ÉlectrIQues et MagnÉ-tIQues — comportent un risque de danger. le courant électrique qui passe dans n'importe quel conduc-teur produit des champs électriques

et magnétiques localisés. le soudage et le cou-rant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l'équipement. par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour cer-tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-tiques peut avoir des effets néfastes inconnus pour la santé.

15


1. Efforcez-vous de toujours confier les tâches d'installation, de dépannage et d'entretien à un personnel qualifié. N'effectuez aucune réparation électrique à moins d'être qualifié à cet effet.

2. Avant de procéder à une tâche d'entretien à l'intérieur de la source d'alimentation, débranchez l'alimentation électrique.

3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d'alimentation et la source d'alimentation en bon état. N'utilisez ja-mais un équipement s'il présente une défectuosité quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez l'équipement à l'écart de toute source de chaleur, notamment des fours, de l'humidité, des flaques d'eau, de l'huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l'équipement conformément à son usage prévu et n'effectuez aucune modification.

InforMatIons supplÉMentaIres rela-tIVes À la sÉcurItÉ -- pour obtenir de l'information supplémentaire sur les règles de sécurité à observer pour l'équipement de soudage à l'arc électrique et le coupage, demandez un exemplaire du livret "precau-tions and safe practices for arc Welding, cutting and gouging", form 52-529.

Les publications suivantes sont également recomman-dées et mises à votre disposition par l'American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126 :1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"2. AWS C5.1 - "Recommended Practices for Plasma Arc

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

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

Arc Gouging and Cutting"

5. aVertIsseMent : ce produit, lorsqu'il est utilisé dans une opération de soudage ou de coupage, dégage des vapeurs ou des gaz contenant des chimiques consid-éres par l'état de la californie comme étant une cause des malformations congénitales et dans certains cas, du cancer. (california health & safety code §25249.5 et seq.)

ManIpulatIon Des cYlInDres -- la manipulation d'un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz.

une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des bles-sures graves ou mortelles. par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l'aide d'une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n'est pas bran-ché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis à votre dis-position par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

entretIen De l'ÉQuIpeMent -- un équipe-ment entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. par conséquent :

16


sIgnIfIcatIon Des sYMBolesce symbole, utilisé partout dans ce manuel, signifie "attention" ! soyez vigilant ! Votre sécurité est en jeu.

signifie un danger immédiat. la situation peut entraîner des blessures graves ou mortelles.

signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

signifie un danger qui peut entraîner des blessures corporelles mineures.

Danger

aVertIsseMent

attentIon

17

sectIon 2 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. •

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.

plasma gas Box shield gas Box

2.0 Description

18


2.3 system gas requirementsargon 125 PSI (8,6 bar) with 0.25” NPT, 99.995% purity, Filtered to 25 microns

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

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

h-35 (argon/hydrogen) 75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns

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

compressed air (process)

80 PSI (5,5 bar) with 0.25” NPT, clean, dry, oil-free and filtered to 25 microns

compressed air (air curtain )

80 PSI @ 1200cfh (5,5 bar @ 35 m3h) filtered to 25 micronsDIN Quality ISO 8573-1Oil quality mg/m3 = 0.1 class 2Particle Size 0.1um class 1Temparature +3 C class 4

2.4 plasma gas Box Water supply requirementscooling 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 +24 VDC for proportional valves, mfc

+15 VDC for pressure switch

Voltage signals 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

Adapter Coolant EPP-200 ..............................................................................................0558006162

Speedloader assembly, handheld ..............................................................................0558006164

Speedloader assembly, 5 fixtures ...............................................................................0558006165

Coolant Hose Adapter Kit ............................................................................................. 0558006698

19


2.8 plasma gas Box Dimensions

11.28”286.5 mm

7.25”184.2 mm

17.13”435.1 mm

20


2.9 shield gas Box Dimensions

20.00”508.0 mm

12.00”304.8 mm

8.00”203.2 mm

21

sectIon 3 InstallatIon

3.1 plasma gas Box Introduction

electrIcItY can KIll!Before perforMIng anY MaIntenance or asseMBlY of thIs eQuIpMent, ensure the poWer source (epp) Is turneD off anD DIsconnecteD.

WarnIng

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 rela-tionship of hole pattern to gauges and cable clamp.

.75”19.1 mm

4.50”114.3 mm

2.00”50.8 mm

11.00”279.4 mm

4.13”104.9 mm

2.00”50.8 mm

3.0 Installation

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22

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 in the Strain Relief / Clamp Block, only one power

source cable is used in picture below.

Pilot Arc Cable

Power Source Cable

23

3.3.1 plasma gas Box starter Box connections

TB1 – Pilot arc cable from the plasma power source.

TB4 – Connected to buss bar (lower back right hand corner).

TB2 – Pilot Arc Torch cable from the torch leads.

Black Lead - 120 vdc input


View from underneath the arc starter Box

TB1 TB4 TB2 Black Lead

Arc Starter Box

Pilot Arc Cable Buss Bar

24


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 connections1 - Female old-style air water nut for Shield Gas connection2 - B-IG fittings for Plasma Start gas and Plasma Cut gas. Ei-

ther 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 tip7 - Torch Grounding Stud (for CE units only).

6

2

1

53

34

2

1

5

7

25

3.3.3 plasma gas Box torch cooling Water connections


coolant connections to and from power source

When packaged with a torch and power supply at the factory, connections are labeled. Additional labels are available if re-labeling becomes necessary. Tracing the Plasma Gas boxes in-terior lines can identify the proper connections. Flow switch is located on the “IN” line.

coolant connections to and from torch

Note arrows on fittings indicating coolant flow direction.Coolant Out has right-hand threads.Coolant In has left-hand threads.

plasma gas Box rear View

H2O IN

H2O OUT

note:Coolant hoses connect as shown from the

water cooler to the Plasma Gas box.

plasma gas Box rear View

26

3.3.4 power source to plasma gas Box Buss connection

1. Strip 4/0 (95 mm2) insulation, approximately 38 mm.2. Insert 4/0 (95 mm2) 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 mm2) - 400 amps(2) 4/0 (95 mm2) - 800 amps(3) 4/0 (95 mm2) - 1000 amps

careful attention while stripping insulation will make installation of the 4/0 (95 mm2) cable in the buss easier. Do not spread or flare the copper conductors.

notIce


Buss Block

Pilot Arc Cable

Power Source Cable

X1-10 - +24 vdc Input

X1-9 - Sensor Input

X1-2 - Common / Chassis Ground

X4 - Torch Tip / Electrical soft touch wire

PE - Chassis Ground

note:For more detailed information, refer to PC

board schematic next page.

3.3.5 plasma gas Box pc Board connections

27


pc B

oard

sch

emat

ic

25.0

7.20

05 1

2:51

:42

C:\P

rogr

amm

e\EA

GLE

_V4-

11\p

roje

cts\

2256

510\

2256

510.

sch

(She

et: 1

/1)

28

3.4 plasma gas Box 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 Plas-ma Gas Box.


Nomex Insulation

29


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.

unfiltered gas Will clog proportional ValvescautIonDirt 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 service-able parts. replace valve assembly with factory parts.

plasma gas Box front gas connections

plasma gas Box rear gas connections

30

gas line contamination Will Damage proportional Valves. purge gas lines.

cautIon Before connecting gas delivery lines to the m3 plasma system plas-ma gas Box, purge all lines thoroughly. residue from the hose man-ufacturing process may clog/damage the proportional valves in your m3 plasma system plasma gas Box.


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.

1 PG1

2 PG2

3 Air Curtain

4 PG2 Out

5 PG1 Out

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

14 H2O IN

15 Shield

16 Air Curtain

17 Cut Gas Selection (O2 N2 AIR)

18 H2O OUT

19 LED Volt Meter

20 Torch Cable Grounding Stud(for CE units only)

4

1

2

3

5

6

7

8

911

10

13

15

12

14

17

18 16

19

20

31


3.6 shield gas Box Introduction

electrIcItY can KIll!Before perforMIng anY MaIntenance or asseMBlY of thIs eQuIpMent, ensure the poWer source (epp) Is turneD off anD DIsconnecteD.

WarnIng

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 pro-portional 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 rela-tionship of hole pattern to gauges and cable clamp.

.75”19.1 mm

6.50”165.1 mm

.75”19.1 mm

16.00”406.4 mm

1.50”38.1 mm

2.50”63.5 mm

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32

3.8 shield gas Box connections


All connections are made on the exterior of the box. See diagrams and chart below.

3.8.1 shield gas Box front connections

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

gas line contamination Will Damage Internal components. purge gas lines.

cautIon Before connecting gas delivery lines to the m3 plasma system shield gas Box, purge all lines thoroughly. residue from the hose manufac-turing process may clog/damage the valves in your m3 plasma sys-tem shield gas Box.

View from inside showing connections of Items 4, 5 & 6

4

1

23

5

6

7

8

9

4

5

6

10

11

33

3.8.2 shield gas Box rear connections


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

1

2

3

5

6

7

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

34

3.9 component relationship Block Diagram

25 M

icro

n fil

ters

CNC Pilo

t Arc

Ca

ble

Encoder / Voltage Height Control

Earth Ground

3-phase w/ ground

O2 H-35N2 CH4Air(plasma shield supply

DIN Qual-ity ISO 8573-1)

Argon

Pow

er C

able

PS

& W

C Co

ntro

l Cab

les

Pilo

t Arc

Cab

le

Pow

er C

able

Cabl

e 4

Twis

ted

Pair

Cabl

e 4c

Torc

h Le

ad

4

21

3

6

5

10

8

17

15a = 10 Pin15b = 14 Pin

13

14

16

11

12

79

3a

Workpiece

Work Table


LED Volt Meter

Air(clean,

dry, oil-free shop air for Air Curtain supply)

note: Air Curtain or Bubble Muffler can

be used here. See torch manual for conditions.

35


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’)







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’)

5 0558004400 Coolant Circulator PCC-10

0558007515 Coolant Circulator PCC-11

36


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’)


37


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’)


0558006865 Hose, Air Curtain, 6.1m (20’)
















38


10 0558004841 Air Curtain Hose 1.4m (4.5’)

0558004842 Air Curtain Hose 1.8m (6’)





0558005915 Fixture Assy SpeedLoader

0558005916 Nozzle Retainer SpeedLoader

0558005917 Tool Preassembly

11 0560941536 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











39


15b 0560940144 Cable, PGC-B3, 14p, 1.4m (4.5’) - 2 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 0558003849 Plasma Torch PT-36, 1.4m (4.5’)

0558003850 Plasma Torch PT-36, 1.8m (6’)

0558003852 Plasma Torch PT-36, 3.6m (12’)

0558005741 Plasma Torch PT-36, 4.3m (14’)

0558003853 Plasma Torch PT-36, 4.6m (15’)

0558003854 Plasma Torch PT-36, 5.2m (17’)

0558003856 Plasma Torch PT-36, 7.6m (25’)


40


41

4.1 plasma gas Box operation

sectIon 4 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. Man-agement 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.

see cut Data Manual, p/n 0558006163 for cutting parameter set-tings for using the m3 plasma system plasma gas Box.notIce

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

Cut Gas

(PG1)

(PG2)

note:PG1 & PG2 are referred to as Start & Cut gas most of the time. Certain cutting conditions

require PG1 conditions only.

4.0 operation

42

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.

Gas Pressure Switch

Plasma Gas Box

43

4.4 shield gas Box operation

sectIon 4 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. Man-agement is accomplished either with manual inputs on the Vision cutting parameter screen or using the ESAB system of Process Parameter Files.

see cut Data Manual, p/n 0558006163 for cutting parameter set-tings for using the m3 plasma system shield gas Box.notIce

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.

44

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 (2.8 bar) while flowing.

sectIon 4 operatIon

45

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)

46

sectIon 4 operatIon

47

5.1 plasma gas Box Maintenance

sectIon 5 MaIntenance

electrIc shocK can KIll!alWaYs DIsconnect poWer froM the epp poWer source anD the cuttIng MachIne Before openIng or serVIcIng the m3 plasMa sYsteM plasMa gas Box.

WarnIng

only Qualified Maintenance personnel should repair and Maintain this equipment.cautIon

Argon

N2/O2/Air

H35-1

Air Curtain To AIr Curtain

N2/O2/Air

PS 1

PS 2

Shield IN Shield to Torch

5.2 plasma gas Box schematic (plumbing schematic)

The m3 Plasma System Plasma Gas Box has proven to be a very reliable product. Regular maintenance is impor-tant for many years of trouble free use. This section contains a brief description of the most common problems, schematics, and technical diagnostic tools.

5.0 Maintenance

Spark Arrestor

48


5.3 plasma gas Box pressure switches

gas pressure switch monitors the pressure of plasma gas supply to the Plasma Gas box. One switch monitors both O2. The other switch is used for monitoring alternate gas, either H-35, Air or N2.

note:H-35 is an industry name for a mixture of 65 % argon and 35% hydrogen.

secondary shield switch monitors the pressure of the secondary shield gas in the shield box. These switches are wired as an input to the CNC. Logic codes in the control look for a change of state (low/high) of the input signals, therefore these switches cannot be jumpered out of the circuit. Both pressure switches are factory set and non-adjustable to close at 50 PSI (3.45 Bar). They contain no serviceable parts. Replacement P/N 952920.

Gas Pressure Switch

Plasma Gas Box

49

Decreased spark gap from 0.040” (1 mm):• NegativeEffect-startingreliabilityisdecreased• PositiveEffect–smallerriskofhighfrequencyinterference

Increased spark gap from 0.040” (1 mm):• NegativeEffect–increaseddamageriskfromhighfrequency

interference• PositiveEffect-startingreliabilityincreased(toapointwhereit

doesn’t work at all).

high frequency Interference can Damage Machine electronic com-ponents. potentially damaging high frequency interference may re-sult from increasing the spark gap beyond recommendation. this electrical interference may find its’ way to pc boards in the electron-ics cabinet or Vision control. the result will be failure of some por-tion of machine function. Do not set spark gap beyond recommend-ed distance of 0.040” (1,0 mm).

cautIon

HIGH

Risk

of

Hig

h Fr

eque

ncy

Inte

rfer

ence

Dam

age

LOW

Spark Gap

0 .040"(1 mm)

Starting Reliability

The m3 Plasma System Plasma Gas Box uses a high frequency arc starter to initiate the plasma arc within the cut-ting torch. The arc starter box is mounted in the upper right corner of the Plasma Gas box. The arc starter box contains an adjustable spark gap.

The recommended spark gap setting is 0.040” (1,0 mm).

5.4 spark gap of the arc starter Box (plasma gas Box)


arc starter Box

50

WarnIng


electrIc shocK can KIll!alWaYs turn poWer off Before openIng anD serVIcIng the m3 plasMa sYsteM plasMa gas Box.

5.5 spark adjustment procedure (plasma gas Box)

1. Disconnect input power to plasma power source (EPP) and cutting machine.

2. Remove access cover from the arc starter box.

3. Use a 0.040” (1 mm) feeler gauge or shim to measure the spark gap setting.

4. Adjust as required. When correctly adjusted, there should be slight pressure felt when a back and forth mo-tion is applied to the shim.

5. Replace cover.

51

5.6 cooling Water circuit (plasma gas Box)

The cooling water circuit consists of two reverse flow check valves and a flow switch. It is a closed loop re-circu-lating system which cools the electrode and torch body of the PT-36 torch. The PT-36 torch has an electrode, nozzle, nozzle retaining cup, and torch body cooled by this sys-tem. The primary concern of the cooling water system is the flow rate. Insufficient cooling flow can result in severe damage to the consumables and torch body. The cool-ing water flow switch is calibrated to close at or above a flow rate of 1 gallon (3.8 liters) per minute. If the flow rate drops below this rate, a signal is sent to the CNC and the plasma system is shut down.

1 Torch

2 To torch check valve

3 Flow Switch (In water cooler and/or power supply

4 Return coolant check valve

5 Water cooler

1 Buss Block

2 Coolant line – to torch (from cooler)

3 Coolant line – from torch (to cooler)

4 Flow Switch (In water cooler and/or power supply

5 Check Valve – from torch

6 Check Valve – to torch

2 1

36

5

123

45


52

5.7 plasma gas schematic

Plasma gases are controlled with proportional valves mounted on the manifold.


Torch PG 1

N2/O2/Air

H35-1

Air CurtainTo AIr Curtain

N2/O2/Air

PS 1

PS 2

Shield To Torch

Plasma Gas Box

Spark Arrestor

Shield To Torch

Argon

N2/O2/Air

Air Curtain - optional for under water cutting only

Torch PG 2

0-9 barPV - PG1

0-10 m3/hMFC - PG1

PG to Torch

53


Procedure:

To adjust the VDR for cutting, place ohm meter leads between TB1-11 and chassis ground. With VDR hooked up and in place as shown, the reading should be approximately 690 ohms.

To adjust the VDR for marking, place ohm meter leads between TB1-11 and chassis ground. With VDR hooked up and in place as shown, the reading should be approximately 900 ohms.

To obtain a more accurate cut or mark, turn the pot adjustment screw and make a test cut. Adjust and test until desired cut or mark is achieved. Ohm meter readings can vary according to cable lengths. Test cuts will have to be made to fine tune the quality.

5.8 Voltage Divider adjustment procedure

The Voltage Dividers or VDR’s can be adjusted to provide optimum cut and marking capability. Follow the pro-cedure below to start tuning the cut and mark VDR. Once this range has been obtained more precise cuts can be tuned in by adjusting the pot and making test cuts to gauge accuracy.

VDR (marking)

VDR (cutting)

TB1-11 will be located here

VDR Adjustment Pot

54


5.9 Voltage Divider schematic

cutting Board - 56997963 Marking Board - 0560940947

2K

55

5.11 shield gas Box schematic


5.10 shield gas Box Maintenance

The m3 Plasma System Shield Gas Box has proven to be a very reliable product. Regular maintenance is impor-tant for many years of trouble free use. Only trained personnel should perform maintenance on this equipment. This section contains a brief description of the most common problems and schematics.

electrIc shocK can KIll!alWaYs DIsconnect poWer froM the epp poWer source anD the cuttIng MachIne Before openIng or serVIcIng the m3 plasMa sYsteM shIelD gas Box.

WarnIng

only Qualified Maintenance personnel should repair and Maintain this equipment.cautIon

Fuel Check Valve

O2/N2/Air

AirTo AIr Curtain

PS 4

PS 3

Shield Gas Box

Shield To Torch

N2/O2/Air

Air Curtain

0-10 m3/hMFC - SG2

0-10 m3/hMFC - SG1

Air-3

N2-3

O2-3

Air-2

N2-2

O2-2

CH4

O2-1

N2-1

Air-1

CH4

O2

N2

Air

56


5.12 solenoid replacement

Procedure:

To replace a solenoid on the shield gas assembly, unscrew solenoid nut on the faulty solenoid.

Remove solenoid assembly and unplug the attached wires on the output board (make note of the red and white wire connections).

Replace solenoid assembly, plug in the wires and re-place nut on assembly.

Shield Gas Assembly

Solenoid Nut

Solenoid Coil

Common Problems:

Coil has malfunctioned, no flow to the •MFC.

Shorted output.•

Solenoid Valve

electrIc shocK can KIll!alWaYs DIsconnect poWer froM the epp poWer source anD the cuttIng MachIne Before openIng or serVIcIng the m3 plasMa sYsteM shIelD gas Box.

WarnIng

Output Boards

57


5.13 Mass flow controller replacement

Procedure:

1. Check LED indicator on top of MFC for power.

2. Ensure gas is flowing to the MFC. Refer to sche-matic for input flow setting. If no flow is present, check gas and gas lines.

3. Check for gas passage through the MFC. When gas is on and power is on MFC, gas should flow through.

4. If no gas flows through, replace MFC. Replace by unscrewing (4) four screws in bottom of MFC. Remove cable and hose connections. Take note of placement for reassembly.

5. Replace MFC and reconnect hoses and cables.

Common Problems:

No flow through • Mass Flow Controller (MFC).

LED Power Indicator

Mass Flow Controllers

Mass Flow Controller

58


5.14 gas filters

unfiltered gas Will clog proportional Valves

gas filters must be installed in the gas supply lines in front of the gas regulator panel. a 25 micron filter is required, p/n 56998133. replacement filter element p/n 0560988406.cautIonall gases supplied to the m3 plasma system plasma gas Box must be filtered to 25 microns. small orifices in proportional valves will be-come clogged if filters are neglected or bypassed. Do not attempt to clean. replacement of manifold assembly may be necessary. re-placement of proportional valves only is possible. thoroughly flush manifold and gas lines with n2 before reassembly. Because pro-portional valves contain the smallest gas passages, replacement or cleaning of check valves is not recommended. avoid any potential problems by appropriately filtering plasma and shield gases.

59


60


5.15 fluid schematic – m3 plasma system plasma gas Box and shield gas Box

Fuel Check Valve

O2/N2/Air

AirTo AIr Curtain

PS 4

PS 3

Shield Gas Box

Shield To Torch

N2/O2/Air

Air Curtain

0-10 m3/hMFC - SG2

0-10 m3/hMFC - SG1

Air-3

N2-3

O2-3

Air-2

N2-2

O2-2

CH4

O2-1

N2-1

Air-1

CH4

O2

N2

Air

Water Cooler PCC-10

61


Torch PG 1

N2/O2/Air

H35-1

Air CurtainTo AIr Curtain

N2/O2/Air

PS 1

PS 2

Shield To Torch

Plasma Gas Box

Spark Arrestor

Shield To Torch

Argon

N2/O2/Air

Air Curtain - optional for under water cutting only

Torch PG 2

0-9 barPV - PG1

0-10 m3/hMFC - PG1

PG to Torch

62


63

sectIon 6 replaceMent parts

6.1 general

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

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

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

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

6.2 ordering

Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources.

note

6.0 replacement parts

64

6.3 plasma gas Box


V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 1 : 1

A

A

B

1 7 . 1 3

4 8

2 2

4 5

1 1 . 2 8

7 . 5 0

3 6

3 5

5 25 35 46 1

4 04 14 34 21 1 1 0 ( N O T E 5 )

3 1

4 4

3 1

2 5 2 6

( 2 X )

1 1 . 0 0 1 . 7 5

4 . 5 00 . 7 50 . 3 8 R E F .

8 2

8 3

8 5

( N O T E 8 )

3

( N O T E 1 )

4

V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 1 : 1

A

A

B

1 7 . 1 3

4 8

2 2

4 5

1 1 . 2 8

7 . 5 0

3 6

3 5

5 25 35 46 1

4 04 14 34 21 1 1 0 ( N O T E 5 )

3 1

4 4

3 1

2 5 2 6

( 2 X )

1 1 . 0 0 1 . 7 5

4 . 5 00 . 7 50 . 3 8 R E F .

8 2

8 3

8 5

( N O T E 8 )

3

( N O T E 1 )

4

65


V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 1 : 1

A

A

B

1 7 . 1 3

4 8

2 2

4 5

1 1 . 2 8

7 . 5 0

3 6

3 5

5 25 35 46 1

4 04 14 34 21 1 1 0 ( N O T E 5 )

3 1

4 4

3 1

2 5 2 6

( 2 X )

1 1 . 0 0 1 . 7 5

4 . 5 00 . 7 50 . 3 8 R E F .

8 2

8 3

8 5

( N O T E 8 )

3

( N O T E 1 )

4

V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 1 : 1

A

A

B

1 7 . 1 3

4 8

2 2

4 5

1 1 . 2 8

7 . 5 0

3 6

3 5

5 25 35 46 1

4 04 14 34 21 1 1 0 ( N O T E 5 )

3 1

4 4

3 1

2 5 2 6

( 2 X )

1 1 . 0 0 1 . 7 5

4 . 5 00 . 7 50 . 3 8 R E F .

8 2

8 3

8 5

( N O T E 8 )

3

( N O T E 1 )

4

66


D

1 3

1

5 6 6 6 8

1 7 8 8

1 1 1 05 12 95 0

1 4 1 9 6 4 3 9

1 7

3

5 5

6

5 6 1 7

3 98 8

3 88 8

1 78 8

3 9

1 6

5 92 52 6

1 8

6 06 26 1

2 7 8 9

6 3

( N O T E 2 )

5 8 6 5 3 9

( N O T E 3 )

4 6 9 7 0 6 8

1 7

1 1 2 1 1 0

4 8

3 76 66 72 4

1 4 1 9 2 0 9 0

7 16 66 72 4

( N O T E 7 )

( N O T E 7 )

7 32 77 4

7 26 66 72 4

7 7

8 0

8 1

( 2 X )

1

3 8 8 83 8

3 9

1 3

8 6

8 9

3

9 1 4

D E T A I L D

S C A L E 1 : 1

1 6 8 8

8 8

1 5

3 0

1 48 7

1 6

( 2 X )

1

8 8

2

4

9 24

29

50 51

67


D

1 3

1

5 6 6 6 8

1 7 8 8

1 1 1 05 12 95 0

1 4 1 9 6 4 3 9

1 7

3

5 5

6

5 6 1 7

3 98 8

3 88 8

1 78 8

3 9

1 6

5 92 52 6

1 8

6 06 26 1

2 7 8 9

6 3

( N O T E 2 )

5 8 6 5 3 9

( N O T E 3 )

4 6 9 7 0 6 8

1 7

1 1 2 1 1 0

4 8

3 76 66 72 4

1 4 1 9 2 0 9 0

7 16 66 72 4

( N O T E 7 )

( N O T E 7 )

7 32 77 4

7 26 66 72 4

7 7

8 0

8 1

( 2 X )

1

3 8 8 83 8

3 9

1 3

8 6

8 9

3

9 1 4

D E T A I L D

S C A L E 1 : 1

1 6 8 8

8 8

1 5

3 0

1 48 7

1 6

( 2 X )

1

8 8

2

4

9 24

D

1 3

1

5 6 6 6 8

1 7 8 8

1 1 1 05 12 95 0

1 4 1 9 6 4 3 9

1 7

3

5 5

6

5 6 1 7

3 98 8

3 88 8

1 78 8

3 9

1 6

5 92 52 6

1 8

6 06 26 1

2 7 8 9

6 3

( N O T E 2 )

5 8 6 5 3 9

( N O T E 3 )

4 6 9 7 0 6 8

1 7

1 1 2 1 1 0

4 8

3 76 66 72 4

1 4 1 9 2 0 9 0

7 16 66 72 4

( N O T E 7 )

( N O T E 7 )

7 32 77 4

7 26 66 72 4

7 7

8 0

8 1

( 2 X )

1

3 8 8 83 8

3 9

1 3

8 6

8 9

3

9 1 4

D E T A I L D

S C A L E 1 : 1

1 6 8 8

8 8

1 5

3 0

1 48 7

1 6

( 2 X )

1

8 8

2

4

9 24

99

Item #99 attached to in-side of enclosure cover

68


plasma gas Box parts list

IteM QtY part nuMBer DescrIptIon

1 1 0558001055 ENCLOSURE HIGH FREQ BOX

2 1 0560940776 ASSY BUSS BAR m3 FLOW CONTRO L

3 1 0560940808 MASS FLOW PROPORTIONAL VALVE

4a 1 56997963 ASSY VOLTAGE DIVIDER BOARD - CUTTING

4b 1 0560940947 ASSY VOLTAGE DIVIDER BOARD - MARKING

5 1 0002256510 BOARD TOOL TOUCH

6 2 0560940875 CLAMP, PANEL GAGE MOUNT

7 2 Helical Spring Lock Washer ASME B 18.21 . 1 - 1/4 Regular. Carbon Steel

8 2 Washer A ANSI B 18.22. 1 - 1/4 - narrow - Type A

9 2 Hex Nut ANSI B 18.2.2 - 1/4 - 20

10 13 Spring Washer DIN 127 - A4

11 12 Hexagon Socket Button Head Screw ISO 7380 - M4 x 8

12

13 1 33053 STRAIN RELIEF 2” TORCH

14 3 2236750 TEE, STREET 1/4 NPTF x 1/4 NPTM

15 2 3390 ADAPTER 1/4 NPT - ’B’ FG

16 3 3389 ADAPTER 1/4 NPT - ’B’ OXY

17 7 10Z30 FITTING 1/4 NPT TO “B” A/W

18 2 0560940876 FITTING 1/4 NPTF TO 1/4 TUBE

19 2 2233664 FITTING 90 X 1/4 NPTM X 1/4 TU

20 1 44151500 COUPLING 1/4 NPT F-F

21 4 Plain Washer ANSI B 18.22 M - 4N

22 2 950167 GROMMET, RUBBER 1-1 /2 X 1-1/8




26 6 Hexagon Socket Button Head Screw ISO 7380 - M6 x 10STD-000037

27 2 Cylinder Head Cap Screw DIN 912 - M6 x 16


29 8 Hex Nut DIN 934 - M6 STD-000024

30 1 952920 SWITCH PRESSURE NON-ADJUSTING

69




31 2 2234485 END CLAMP

32

33

34 2 Washer DIN 125 - A 6.4

35 15 2237993 TERMINAL BLOCK MINI DBL LEVEL

36 1 2237994 END COVER MINI DBL LEVEL

37 1 636692 CONNECTOR AMPHEN MS3102A-18-19S

38 3 11N16 ADAPTER 1/4 NPTTO ‘B’ FEMALE

39 4 74S76 ADAPTER 1/4 NPT TO ‘B’ FEMALE

40 4 5700062900 WIRE TIE CRADLE

41 2 Slotted Cheese Head Screw DIN 84 - M5 x 8

42


44 1 0560940865 DIN RAIL MOUNTING

45 2 0560940862 FASTNER 1/4 TURN RECEPTACLE

46 2 0560940863 STUD 1/4 TURN SLOTTED HEAD

47 2 0560940864 RING RETAINER FOR 1/4 TURN FSTR

48 1 0560940779 ENCLOSURE WLDMT m3 FLOW CTRL

49 2 Slotted Cheese Head Screw DIN 84 - M5 x 10

50 8 Toothed Lock Washer DIN 6797 - A 6.4

51 2 0560940873 STUD, M6 - 1.0 X 1” PLATED

52 1 634220 CLIP GROUND

53 1 Recessed Pan Head Screw ISO 7045 - M4 x 8 - 4.8 - H

54

55 2 0560940874 GAGE, 2-1/2” PANEL MTG. 0-100

56 1 0560940879 CHECK VALVE 1/4 M IN 1/4 F OUT

57

58 1 2135688 NIPPLE 1/4 NPT M-M

59 ♥ 0560940761 ASSY START GAS MANIFOLD

70




60 1 0560938404 FILTER RFI POWER 2VB3 CORCOM

61 1 Toothed Lock Washer DIN 6797 - A 4.3 STD-000452

62 2 Recessed Pan Head Screw ISO 7045 - M4 x 5 - 4.8 - H STD-000453

63 1 0560940916 SHIELD, ELECTRICAL, BUSS BAR

64 1 33501007 ELBOW STREET 45 DEG 1/4 N P T

65 1 44251100 ELBOW 90° 1/4 NPT BRONZE

66 12 Cylinder Head Cap Screw DIN 912 - M3 x 12 STD-000457

67 12 Hex Nut DIN 934 - M3

68 8 Spring Washer DIN 127 - A 3.5

69 4 0560940922 STANDOFF, M3.5 - 0.6 X 22mm

70 8 Recessed Pan Head Screw JIS B 1111 - AM 3.5 x 6 - H

71 1 2062307 CONNECTOR AMPHEN DMS 3102A-22-23S

72 1 636665 CONNECTOR AMPHEN MS 3102A-20-27S

73 1 0560940777 CABLE CLAMP, m3 FLOW CONTROL

74 1 0560940778 CABLE CRADLE

75 1 0560940919 m3 HOSE ASSY SHIELD GAS

76 1 0560940920 m3 HOSE ASSY AIR CURTAIN

77 1 0560940918 m3 HOSE ASSY PLASMA GAS 1

78 2 0560940917 m3 HOSE ASSY COOLING WATER

79

80 1 57001682 HOSE MANIFOLD TO GAGE

81 1 57001682 HOSE MFC TO GAGE

82 1 0560941602 ASSY, RELAY

83 1 0560941603 MODULE, SIGNAL RELAY

84 1 0560940921 m3 HOSE ASSY MFC IN

85 1 954075 NAMEPLATE 2.30 X 3.38

86 1 951188 Lock Nut

87 1 44052550 Bushing 1/8 to 1/4 Brass

88 8 0560941905 Adpt. Blkhd 1/4 NPT w/ Flats

89 1 527376 Strain Relief 1/2”

90 1 67101075 Nipple 1/4 NPT Close

91 1 674969 FILTER BOARD

92 1 20373 FLASHBACK ARRESTOR

94 8 0560943621 22mm Nylon Standoff

99 1 0560945880 Shield, Electrical, Enclosure Cover

71


6.4 start gas Manifold (plasma gas Box)

1 1 0 5 6 0 9 4 0 7 6 0 M A N IF O L D , S T A R T G A S

2 1 9 5 2 9 2 0 S W IT C H P R E S S U R E N O N -A D J U S T IN G

3 3 9 5 2 9 2 1 V A L V E S O L E N O ID 2 -W A Y M A N . M T .

4 1 0 5 6 0 9 3 9 5 0 8 0 0 V A L V E , P R O P O R T IO N A L 8 3 3 -3 5 4 N 0 3 0 1 0

5 1 4 4 4 0 1 6 7 5 0 0 P L U G P IP E 1 /8 N P T

6 1 5 6 7 5 9 6 M U F F L E R 1 /8 " N P T B R A S S

8 1 8 3 3 9 0 A D A P T E R 1 /4 N P T - 'B ' F G

9 1 8 1 0 Z 3 0 F IT T IN G 1 /4 N P T T O "B " A /W

1 0 3 0 5 6 0 9 4 0 7 6 3 "O " R IN G 1 1 /1 6 X 1 3 /1 6 X .0 7 V IT O N

1 1 2 D IN 9 1 2 - M 4 x 4 0 C y lin d e r H e a d C a p S c re w

1 2 3 9 5 0 6 5 4 B A L L 1 /2 " D IA R U B B E R

1 3 3 6 3 9 6 7 8 T U B E

1 4 3 6 3 9 6 6 9 S P R IN G 0 .4 7 x 0 .4 3 1 L

1 5 3 3 6 3 5 8 P L U G M A N IF O L D

1 6 1 6 8 1 0 0 1 2 6 R E D U C E R H E X 3 /8 N P T X 1 /4 N P T

1 8 3 0 5 6 0 9 4 0 7 6 2 S T A N D O F F M A N IF O L D M O U N T IN G

1 9 1 4 4 4 0 1 9 0 0 P L U G 1 /4 N P T S Q R H D B R S

2 0 2 0 5 5 8 0 0 1 2 8 2 O -R IN G ..P R O P O R T IO N A L V A L V E 5 m m X

1 m m

2 1 1 0 5 5 8 0 0 1 2 8 3 O -R IN G ..P R O P O R T IO N A L V A L V E 4 m m X

1 m m

2 3 1 4 4 0 5 2 5 5 0 R E D U C E R H E X 1 /4 N P T X 1 /8 N P T

2 4 1 6 3 1 4 7 5 F IT T IN G , "A " T O I-G T O 1 /8 N P T

P a r ts L is t

IT E M Q T Y P A R T N U M B E R D E S C R IP T IO N

See View B-BView B-B

8

9

1

2

4 20 216

2423

19

10 12 13 14 15

3

3

72


start gas Manifold (plasma gas Box) parts list


1 1 0560940760 MANIFOLD, START GAS


3 3 952921 VALVE SOLENOID 2-WAY MAN.MT.

4 1 0560939508 VALVE, PROPORTIONAL 833-354N03010

5 1 4440167500 PLUG PIPE 1/8 NPT

6 1 567596 MUFFLER 1/8 NPT BRASS

8 1 3390 ADAPTER 1/4 NPT -’B’ FG

9 1 10Z30 FITTING 1/4 NPT TO “B” A/W

10 3 0560940763 “O” RING 11/16 X 13/16 X .07 VITON

11 2 Cylinder Head Cap Screw DIN 912 - M4 x 40

12 3 950654 BALL 1/2” DIA RUBBER

13 3 639678 TUBE

14 3 639669 SPRING 0.47 x 0.43 1 L

15 3 36358 PLUG MANIFOLD

16 1 68100126 REDUCER HEX 3/8 NPT X 1/4 NPT

18 3 0560940762 STANDOFF MANIFOLD MOUNTING

19 1 44401900 PLUG 1/4 NPT SQR HD BRS

20 2 0558001282 “O” RING PROPORTIONAL VALVE 5mm X 1mm

21 1 0558001283 “O” RING PROPORTIONAL VALVE 4mm X 1mm


24 1 631475 FITTING, “A” TO I-G TO 1/8 NPT

73


6.5 Buss Bar Manifold (plasma gas Box)

12, 3

4

5

6, 7

8

4

74


Buss Bar Manifold (plasma gas Box) parts list


1 1 0560940772 BUSS BAR SOLDERED ASSY.

2 2 672225 STANDOFF, FIBERGLASS 1.25 LG.

3 4 0560940774 STUD (BUSS BAR INSUL)

4 2 10Z30 FIT TING 1/4 NPT TO “B” A / W

5 3 0560940775 SET SCR 5/8-18 X 1/2 OVAL PNT

6 1 Ex ternal Tooth Lock Washer Type AASME B18.21.1 - No. 10. Carbon Steel

7 1 Cross Recessed Fill ister Head Machine Screw - Type IAANSI B18.6.3 - No. 10. - 32 - 3/8

8 1 0560940879 CHECK VALVE 1/4 F IN 1/4 M OUT

75

6.6 shield gas Box


V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5

L U G T O O U T S I D E

O F E N C L O S U R E .

1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5



1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5



1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5



1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

76


V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5



1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5



1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

77


D E T A I L D

S C A L E 1 : 1

D

7

5 2

5 1

3 1

5 0

4 9

4 8

4 1 8 3 7 3 8

43 93 4

4 25 55 45 6

1 92 12 72 5

3 6 3 7

2 0

2 1

6 9

6 8

2 1

7 0 7 2 7 1

6 4

2 1

3 0 8 4

2 7 8 4

2 1 8 4

8 0

2 4

6 7 5 8 5 7

21 21 37 67 57 75 3

2 4

2

6 4

1 7

2

2

8 2

3

6 3

1 3 83

1 3 9

3

78


D E T A I L D

S C A L E 1 : 1

D

7

5 2

5 1

3 1

5 0

4 9

4 8

4 1 8 3 7 3 8

43 93 4

4 25 55 45 6

1 92 12 72 5

3 6 3 7

2 0

2 1

6 9

6 8

2 1

7 0 7 2 7 1

6 4

2 1

3 0 8 4

2 7 8 4

2 1 8 4

8 0

2 4

6 7 5 8 5 7

21 21 37 67 57 75 3

2 4

2

6 4

1 7

2

2

8 2

3

6 3

1 3 83

1 3 9

3

24

146

79


V I E W A - A

S C A L E 1 / 2

D E T A I L B

S C A L E 3 / 4

D E T A I L C

S C A L E 1 : 1

D E T A I L E

S C A L E 1 : 1

A

A

B

C

E

4 5

4 6

4 5

1 6 . 0 01 . 5 0

2 0 . 0 0

6 . 5 00 . 7 5

1 2 . 0 0

0 . 3 8

13 1 5 1 6 1 4

4 3 5 9 5 7 5 8 9

2 0

1 91 82 52 6

52 94 01 12 06 66 36 3

8 . 0 0

4 0 2 1 6 3

1 61 41 5

( N O T E 2 )( N O T E 5 )

( N O T E 6 )

6 3 4 0 2 1

7 3 7 8

2 31 41 51 6

4 4

7 9

( N O T E 6 )

2 0

4 7

7 4

1

6 5



1

8 4 8 4

8 5

2

2

2

3

3

1 3 7 5 9



3

80


shield gas Box parts list


1 1 0560940923 Enclosure, SF3 Flow Control

2 1 2237924 MB03 MAIN BOARD ASSEMBLY

3 2 0560940808 MASS FLOW CONTROL VALVE

4 1 0560941466 TRANSFORMER ASSY

5 1 522368 REGULATOR AIR WITH GAGE

6

7 1 0560940926 ASSY, SHIELD GAS MANIFOLD SF3

8 3 2236432 CLIP, STIRRUP .32 - .47 DIA .

9 1 0560938111 CONN ASIOB FEMALE 5 PIN

10

11 1 950249 VALVE, 2-WAY 1/4 NPT 24V 60/50HZ

12 1 2237927 ANALOG CARD ASSEMBLY

13 2 0002256475 RELAY OUTPUT CARD ASSY

14 8 Washer DIN 125 - A 4.3

15 8 Spring Washer DIN 127 - A 4

16 8 Hexagon Socket Button Head Screw IS0 7380-M4 x 8

17 1 0560995891 ELBOW STREET 90 1/4 NPTF x 1/4 NPTM

18 1 3390 ADAPTER 1/4 NPT - ’B’ FG

19 3 2236750 TEE, STREET 1/4 NPTF x 1/4 NPTM

20 4 10Z30 FITTING 1/4 NPT TO “B-A/W

21 7 3389 ADAPTER 1/4 NPT -’B’OXY

22

23 1 0560941465 DIN RAIL

24 2 527376 STRAIN RELIEF 1/2” (1/4-3/8” Insert)




28

29 1 44352230 NIPPLE, PIPE 1/4 X 2 BRASS

30 1 11N16 ADAPTER 1/4 NPT TO ‘B’ FEMALE

81




31 2 950167 GROMMET,RUBBER 1-1/2 X 1-1/8

32

33


35

36 4 Hexagon Socket Button Head Screw ISO 7380 - M6 x 10 STD-000037




40 3 4425110000 ELBOW 1/4 NPT BRONZE

41 1 0560940925 RAIL, GROUND CLAMP

42 1 0560940912 Switch , VoItage Select Slide

43 1 0560938112 CONN FLANGE ASIOB

44 1 0 2237993 TERMINAL BLOCK MINI DBL LEVEL

45 2 2234485 END CLAMP

46 2 2234477 FUSE HOLDER

47 1 5 2237987 TERM BLOCK DBL LEVEL W/COMB

48 1 0560941463 ASSY, HOSE, PLASMA GAS 1

49 1 0560941461 ASSY, HOSE, AIR CURTAIN

50 1 0560941462 ASSY, HOSE, PLASMA GAS 2

51 1 0560941459 ASSY, HOSE, SHIELD GAS 1


53 4 Hexagon Socket Button Head Screw IS0 7380 - M3 x 6


55 2 Hexagon SocketButton Head Screw ISO 7380 - M3 x 10

56 2 Hex Nut DIN 934 - M 3

57 6 Hex Nut DIN 934 - M 2.5

58 6 Spring Washer DIN 127 - A 2.5

59 6 Cylinder Head Cap Screw DIN 912 - M 2.5 x 8

82




60

61

62

63 1 639501 NIPPLE 1/4“ HEX BRASS

64 2 639110 VALVE CHECK OXYGEN

65 1 2237994 END COVER MINIDBL LEVEL

66 6 950906 TERM INLINE FML .25 X 18-22 AWG

67 1 0560942023 ASSY MALE CONN PWR



70 1 0560940873 STUD, GND. 1/4 - 20 X 1” PLATED

71 4 Toothed Lock Washer DIN 6797 -J 6.4 STD-000483

72 4 Hex Nut DIN 934 - M6 STD-000024

73 4 0560941602 ASSY, RELAY

74 20 2213249 3 PIN CONNECTOR

75 4 56997679 BL 3.5/2/S N 2 PIN PLUG

76 6 56995340 BL 3.5/3/180 3 PIN PLUG

77 3 56995341 BL 3.5/4/180 4 PIN PLUG

78 4 0560941604 MODULE, POWER RELAY

79 1 954075 NAMEPLATE 2.30 X 3.38

80 1 2010560 STRAIN RELIEF 3/4”

81

82 1 0560942026 ASSY FEMALE CONN PWR

83

84 5 0560941905 ADPT BLKHD 1/4 NPT W/ FLATS

85 1 2770891 PHOENIX END COVER

137 1 0560942021 COVER PLT SHIELD GAS BOX M3 PLASMA

138 1 2059603 TEE 1/4 NPT FFF

139 1 0560985522 CHECK VALVE FUEL GAS

140 ref 0560988032 5 A SLOW BLOW

141 ref 0560939203 1.0 AMP SLOW BLOW

142 ref 0560943657 0.5 A SLOW BLOW

146 1 526651 STRAIN RELIEF, 1/2 (3/8-1/2” INSERT)

83


6.7 shield gas Manifold (shield gas Box)

2

4, typ. 13 plcs

7, Nitrogen

8, Air

9, Oxygen1012

12

10, Methane

9 97

1

3

5

6

11

See

View

A-A

View A-A

84


shield gas Manifold (shield gas Box) parts list

ITEM QTY PART NUMBER DESCRIPTION

1 10 0560940763 “O” RING 11/16 X 13/16 X .07 VITON

2 1 0560940899 SHIELD MANIFOLD

3 10 36358 PLUG MANIFOLD

4 13 4 4 40167500 PLUG PIPE 1/8 NPT

5 10 639669 SPRING 0.47x0.43 1 L

6 10 639678 TUBE


8 1 10Z30 FIT TING 1/4 NPT TO “B” A / W

9 3 3389 ADAPTER 1/4 NPT - ‘B ’ OXY

10 2 3390 ADAPTER 1/4 NPT - ‘B ’ FG

11 10 950654 BALL 1/2” DIA RUBBER

12 10 952921 VALVE SOLENOID 2-WAY MAN. MT.

85

notes

86

notes

87

reVIsIon hIstorY

1. Original release - 05/2006

2. 06/2006 - Changes made through out the manual: updated flip-top covers, gas filters, added hose fittings kit, various editorial changes, updated bom’s, added previously uncompleted information.

3. 12/2006 - Changes per cutting systems CN #064113. Changes made to various pictures of the shield gas and plasma gas boxes. New pictures show new handle, strain relief & power cable connector for shield gas box. Plasma gas box has new strain relief connector. Added P/N 20373, Flash Arrestor to the m3 Gas Fittings Kit, P/N 0558005229. Added LED Volt Meter to the component block diagram. Updated schematics to show check valve & spark arrestor placement. Updated 2.3 system gas requirements to show new information and match torch manual.

4. 06/2007 - Removed ground wires from illustration page 24, chgd item 1 p/n’s page 35, chgd item 17 p/n’s page 39, revised note to call for correct cut data manual page 41 & 43, del note from page 52.

5. 02/2008 - Added second Voltage Divider Board (0560940947) to Pages 54 and 68 per e-mail request.

6. 10/2008 - Added chassis grounding stud and updated replacement parts / schematics.

0558005487 10 / 2008

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m3 plasma-shield gas boxes 0558005487

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plasma gas box operation

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plasma gas box introduction21

shield gas box connections

shield gas box mounting