ESAB B Series Installation and operating instructions

F15-800
November, 2003
Installation, Operation and Maintenance for the
PT-24 Precision Plasmarc System
Series “B”
411 South Ebenezer Road
Florence, SC 29501-0545

The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority is total
customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.
This manual is ESAB Part Number F15800
.
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
©ESAB Cutting Systems, 2003
Printed in U.S.A.

Table of Contents
1
SECTION TITLE PAGE
PARAGRAPH
SECTION 1
Safety ................................................................................................................................... 4
UNPACKING/HOISTING...................................................................................................... 18
1.1 Inspection ............................................................................................................................ 18
1.2 Hoisting................................................................................................................................ 18
SECTION 2 DESCRIPTION...................................................................................................................... 19
2.1 General................................................................................................................................. 19
2.2 Scope ................................................................................................................................... 19
2.3 Package Options Available ................................................................................................ 19
SECTION 3 INSTALLATION.................................................................................................................... 23
3.1 General................................................................................................................................. 23
3.2 Equipment Required........................................................................................................... 23
3.3 Location ............................................................................................................................... 23
3.4 Primary Electrical Input Connections............................................................................... 23
3.5 Interconnecting Lines......................................................................................................... 24
SECTION 4 OPERATION......................................................................................................................... 33
4.1 Power Source Controls/Indicators.................................................................................... 33
4.2 Operation ............................................................................................................................. 34
4.3 Sample Procedure for Setting O2Gas Flow Rates on Flow Control Box ..................... 35
4.4 Sample Procedure for Setting N2Gas Flow Rates on Flow Control Box ...................... 35
PROCESS DATA SHEETS .................................................................................................. 37
KERF .................................................................................................................................... 58
SECTION 5 CUTTING QUALITY ............................................................................................................. 71
5.1 Cut Angle ............................................................................................................................. 71
5.2 Voltage and Cut Quality ..................................................................................................... 72
5.3 Top Dross ............................................................................................................................ 74
5.4 Dross Formation ................................................................................................................. 74
5.5 Summary.............................................................................................................................. 75
SECTION 6 MAINTENANCE ................................................................................................................... 77
6.1 General................................................................................................................................. 77
6.2 Inspection and Cleaning .................................................................................................... 77
6.3 Torch Consumable Parts ................................................................................................... 77
6.4 Gas Pressure Switch .......................................................................................................... 77
6.5 PT-24 Torch Description and Maintenance...................................................................... 77
6.6 Torch Maintenance ............................................................................................................. 78
6.7 PT-24 Consumable Removal, Inspection and Installation.............................................. 78
SECTION 7 TROUBLESHOOTING ......................................................................................................... 81
7.1 Troubleshooting.................................................................................................................. 81
7.2 Process Troubleshooting................................................................................................... 81
7.3 Troubleshooting Procedures............................................................................................. 83
7.4 Schematics and Wiring ...................................................................................................... 88
SECTION 8 REPAIR PARTS ................................................................................................................... 97
8.1 General................................................................................................................................. 97
8.2 Ordering ............................................................................................................................... 97
REPLACEMENT PARTS LISTS .......................................................................................... 98

Table of Contents
2
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SECTION 1 SAFETY
1-1
1.1 Introduction
The process of cutting metals with plasma
equipment provides industry with a valuable and
versatile tool. ESAB cutting machines are
designed to provide both operation safety and
efficiency. However, as with any machine tool,
sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or
as an observer, compliance with established
precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious personnel injury
or severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the field
of cutting and welding apparatus, obtain and read
the publications listed in the Recommended
References.

SECTION 1 SAFETY
1-2
1.2 Safety Notations And Symbols The following words and symbols are used
throughout this manual. They indicate different
levels of required safety involvement.
!
ALERT or ATTENTION. Your safety is
involved or potential equipment failure exists.
Used with other symbols and information.
DANGER
!
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
WARNING
!
Used to call attention to potential hazards that
could result in personal injury or loss of life.
CAUTION
!
Used to call attention to hazards that could
result in minor personal injury or equipment
damage.
CAUTION
Used to call attention to minor hazards to
equipment.
NOTICE
Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.

SECTION 1 SAFETY
1-3
1.3 General Safety Information
WARNING
!
Machinery often starts automatically.
This equipment moves in various directions and
speeds.
• Moving machinery can crush.
• Only qualified personnel should operate or
service this power source.
• Keep all personnel, materials, and
equipment not involved in production
process clear of entire system area.
• Fence off entire work cell to prevent
personnel from passing through area or
standing in the working envelope of the
equipment.
• Post appropriate WARNING signs at every
work cell entrance.
• Follow lockout procedure before servicing
any equipment.
WARNING
!
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual
before using machine.
• Read entire procedure before operating or
performing any system maintenance.
• Special attention must be given to all hazard
warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
• All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
• Read all safety publications made available
by your company.

SECTION 1 SAFETY
1-4
WARNING
!
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety warning labels
on machine.
Refer to operator’s manual for additional safety
information.
1.4 Installation Precautions
WARNING
!
Improperly Installed Equipment Can
Cause Injury Or Death.
Follow these guidelines while installing machine:
• Contact your ESAB representative before
installation. He can suggest certain
precautions regarding piping installation and
machine lifting, etc. to ensure maximum
security.
• Never attempt any machine modifications or
apparatus additions without first consulting
a qualified ESAB representative.
• Observe machine clearance requirements
for proper operation and personnel safety.
• Always have qualified personnel perform
installation, troubleshooting and
maintenance of this equipment.
• Provide a wall mounted disconnect switch
with proper fuse sizes close to the power
supply.

SECTION 1 SAFETY
1-5
1.5 Electrical Grounding
Electrical grounding is imperative for proper
machine operation and SAFETY. Refer to this
manual’s Installation section for detailed grounding
instructions.
WARNING
!
Electric shock hazard.
Improper grounding can cause severe injury or
death.
Machine must be properly grounded before put
into service.
1.6 Operating A Plasma Cutting Machine
WARNING
!
Flying debris and loud noise
hazards.
• Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and
flying debris generated during operation.
• Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.
• Noise from plasma arc can damage hearing.
Wear correct ear protection when cutting
above water.
WARNING
!
Burn hazard.
Hot metal can burn.
• Do not touch metal plate or parts
immediately after cutting. Allow metal time
to cool, or douse with water.
• Do not touch plasma torch immediately after
cutting. Allow torch time to cool.

SECTION 1 SAFETY
1-6
WARNING
!
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
• Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
• Always turn power off to plasma power
supplies before servicing any system
component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Wear insulating gloves, shoes and clothing
to insulate yourself from workpiece and
electrical ground.
• Keep gloves, shoes, clothing, work area,
and equipment dry.
• Replace worn or damaged cables.
WARNING
!
Fume hazard.
Fumes and gases generated by the plasma
cutting process can be hazardous to your
health.
• Do NOT breathe fumes.
• Do not operate plasma torch without fume
removal system operating properly.
• Use additional ventilation to remove fumes if
necessary.
• Use approved respirator if ventilation is not
adequate.
• Provide positive mechanical ventilation when
cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe
these fumes.
• Do not operate near degreasing and
spraying operations. Heat or arc rays can react
with chlorinated hydrocarbon vapors to form
phosgene, a highly toxic gas and other irritant
gases.

SECTION 1 SAFETY
1-7
WARNING
!
Radiation hazard.
Arc rays can injure eyes and burn skin.
• Wear correct eye and body protection.
• Wear dark safety glasses or goggles with
side shields. Refer to following chart for
recommended lens shades for plasma cutting:
Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 Amps Shade No. 10
200-400 Amps Shade No. 12
Over 400 Amps Shade No. 14
• Replace glasses/goggles when lenses are
pitted or broken
• Warn others in area not to look directly at
the arc unless wearing appropriate safety
glasses.
• Prepare cutting area to reduce reflection
and transmission of ultraviolet light.
 Use special paint on walls to absorb
UV light.
 Install protective screens or curtains to
reduce ultraviolet transmission.

SECTION 1 SAFETY
1-8
WARNING
!
Burn Hazard.
Heat, spatter, and sparks cause fire and burns.
• Do not cut near combustible material.
• Do not have on your person any
combustibles (e.g. butane lighter).
• Pilot arc can cause burns. Keep torch
nozzle away from yourself and others when
activating plasma process.
• Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and hat.
• Wear flame-retardant clothing covering all
exposed areas.
• Wear cuffless trousers to prevent entry of
sparks and slag.
• Have fire extinguishing equipment available
for use.
WARNING
!
Explosion hazard.
• Certain molten aluminum-lithium (Al-Li)
alloys can cause explosions when plasma cut
OVER water.
 These alloys should only be dry cut on
a dry table.
 DO NOT dry cut over water.
 Contact your aluminum supplier for
additional safety information regarding
hazards associated with these alloys.
• Do not cut in atmospheres containing
explosive dust or vapors.
• Do not carry any combustibles on your
person (e.g. butane lighter)
• Do not cut containers that have held
combustibles.

SECTION 1 SAFETY
1-9
1.7 Service Precautions
WARNING
!
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
• Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
• Always turn power off to plasma power
supplies before removing covers or panels to
service any system component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Keep gloves, shoes, clothing, work area,
and equipment dry.
• Inspect power and ground leads cables for
wear or cracking. Replace worn or damaged
cables. Do not use if damaged.
• Never bypass safety interlocks.
• Follow lock-out procedures.
WARNING
!
Hot Torch can cause skin burns.
Allow torch to cool before servicing.

SECTION 1 SAFETY
1-10
DANGER
!
Danger of Electric Shock.
Torch may be electrically active.
Turn off Plasma Power Console before
servicing.
CAUTION
Establish and adhere to preventive
maintenance. A composite program can be
established from recommended schedules.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical
damage could occur to equipment or machine.
CAUTION
!
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter.
Integrated circuits are susceptible to over
voltage damage. Power off before using test
probes to prevent accidental shorting of
components.
All circuit boards securely seated in sockets, all
cables properly connected, all cabinets closed
and locked, all guards and covers replaced
before power is turned on.

SECTION 1 SAFETY
1-11
1.8 Safety References -- Regulations, Standards, Guidelines
The following recognized publications on safety in welding and cutting
operations are recommended. These publications have been prepared
to protect persons from injury or illness and to protect property from
damage, which could result from unsafe practices. Although some of
these publications are not related specifically to this type of industrial
cutting apparatus, the principles of safety apply equally.
1.8.1 USA
• “Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
• “Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
• “Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
• “Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
• “Safe Practices” - AWS SP, American Welding Society.
• “Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
• “Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
• "Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
• “Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.

SECTION 1 SAFETY
1-12
1.8.2 International
Accident Prevention
VBG- Unfallverhütungsvorshriften
General Provisions
VBG 1
Allgemeine Unfallverhütungsvorshriften
Electrical Equipment and operating Equipment
VBG 4
Elektrische Anlagen
Welding, Cutting and related working methods
VBG 15
Schweißen un Schneiden un verwandte Verfahren
Shot Blasting Works
VBG 48
Strahlarbeiten
Gases
VBG 61
Gase
Oxygen
VBG 62
Sauerstoff
Operating liquid jet cutting machines
VBG 87
Arbeiten mit Flüssigkeitsstrahlem
Laser beams, accident prevention and Electro-
technology
VBG 93
Laserstrahlung, Unfallverhütungs-vorschriften für
Feinmechnik und Elektrotechnik
Noise
VBG 121
Lärm

SECTION 1 SAFETY
1-13
VDE Regulations
VDE - Vorschriften
Erection of power installations with normal voltages up to
1000 volts
VDE 0100 Bestimmungen für das Errichten von Stakstromanlagen
mit Nennspannungen bis 1000 Volt
Electrical equipment of industrial machines
VDE0113
Elektrishe Ausrüstung von Industriemaschinen
Radiation safety of laser products; users guide (DIN EN
60825)
VDE 0837 Strahlungssicherheit von Lasereinrichtungen und
Benutzungsrichtlinen (DIN EN 60825)
Specification for laser guards
VDE 0837-
50 Anforderung an Lasershcutzwänden
TRAC Technical Rules for Acetylene and Carbide Stores
TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager
Acetylene lines
TRAC-204
Azetylenleitungen
Acetylene cylinder battery systems
TRAC-206
Azetylenflaschenbatterieanlagen
Safety devices
TRAC-207
Sicherheitseinrichtungen

SECTION 1 SAFETY
1-14
TRG Technical Rules for Pressure gases
TRG – Technische Regein für Druckgase
General regulations for pressure gases
TRG 100
Allgemeine Bestimmungen für Druckgase
Pressure gases
TRG 101
Druckgase
Technical gas mixtures
TRG 102
Technishe Gasgemische
Pressure gases; alterative use of compressed gas tanks
TRG 104 Druckgase, wahlweise Verwendung von
Druckgasbehältem

SECTION 1 SAFETY
1-15
TRGS – Technische Richtlinien für Gefahrstoffe
TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe
TRGS-402 Ermittlung u. Beurteilung der Konzentration gefährlicher
Stoffe in der Luft im Arbeitsbereich
TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)
TA TA-Luft un TA-Lärm (BLm SchV)
DIN Standards
DIN-Normen
DIN 2310
Part 1 Thermal cutting; terminology and nomenclature
Teil 1 Thermsiches Schneiden, Allgemeine Begriffe und
Bennungen
DIN 2310
Part 2 Thermal cutting; determination of quality of cut faces
Teil 2 Thermsiches Schneiden, Ermittein der Güte von
Schnittflächen
DIN 2310
Part 4
Thermal cutting; arc plasma cutting; process principles,
quality, dimensional tolerances
Teil 4 Thermsiches Schneiden, Plasmaschneiden,
Verfahrensgrundlagen, Güte, Maßtoleranzen
DIN 2310
Part 5
Thermal cutting; laser beam cutting of metallic materials;
process principles
Teil 5 Laserstrahlschneiden von metallischen Werkstoffen,
Verfahrensgrundlagen, Güte, Maßtoleranzen
DIN 2310
Part 6 Thermal cutting; Classification, processes
Teil 6 Einführung, Verfahren
DIN 4844
Part 1 Safety markings (DIN EN 7287)
Teil 1 Sicherheitskennzeichen (Siehe EN 7287)

SECTION 1 SAFETY
1-16
DIN EN ISO Harmonized Standards
DIN EN ISO-Harmonisierte Normen
Safety of machinery
DIN EN
292/1 and 2 Sicherheit von Maschinen, Geräten und Anlagen
Hoses for welding, cutting and allied processes
DIN EN 559 Schläuche für Schweißen, Schneiden und verwandte
Verfahren
Hose connections and hose couplings for equipment for
welding, cutting and allied processes
DIN EN 560 Schlauchanschlüsse und Schlauchverbindungen für
Geräte zum Schweißen, Schneiden und verwandte
Verfahren
Gas welding equipment hose couplings
DIN EN 561
Gasschweißgeräte, Kupplungen
Safety of machines, reduction of risks to health
DIN EN
626-1 Sichereit von Maschinen, Reduzierung des
Gesundheitsrisikos
Single spindle vertical milling machines
DIN EN
848-1 Fräsmaschine für einseitige Bearbeitung mit drehendem
Werkzeug
High pressure water jet machines
DIN EN
1829 Hochdruckwasserstrahlschneidmaschine
Thermal cutting, oxygen cutting, process principles,
dimensional tolerances
DIN EN
9013 Thermisches Schneiden, Autogenes Brennschneiden,
Verfahrensgrundlagen, Güte, Maßtoleranzen
Imperfections in oxy/fuel flame cuts, laser beam cuts and
plasma
DIN EN
12584 Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und
Plasmaschnitten
Laser processing machines
DIN EN
12626 Laserbearbeitungsmaschinen