ESAB Precision Plasmarc IEFC-S PT-24 General instructions

F-15-652
November, 2003
Installation, Operation and Maintenance Manual for the
Precision PLASMARCCutting
and High Speed Marking SYSTEM
with Integrated Flow Control
411 s. 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 by 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 F15-652
Rev A indicates new IFC Schematic, installation
instructions (p13-14) and fluid schematic mod.
December: Updated Torch solenoid wiring, updated
parts section
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, 2001
Printed in U.S.A.

Precision Plasma Integrated Flow Control - CE Table of Contents
i
Page
Section 1 Safety
1.1 Introduction ........................................................................................ 1
1.2 Safety Notations And Symbols ............................................................ 1
1.3 General Safety Information .................................................................. 2
1.4 Installation Precautions........................................................................ 3
1.5 Electrical Grounding ............................................................................ 4
1.6 Operating A Plasma Cutting Machine .................................................. 4-9
1.7 Service Precautions............................................................................. 9
1.8 Safety References ............................................................................... 10
Section 2 Description
2.1 General............................................................................................... 1
2.2 Scope................................................................................................. 1
2.3 Package Options Available .................................................................. 1
2.4 Technical Specifications
2.4.1 Precision Plasma System ........................................................... 2
2.4.2 Plasma Gas ............................................................................... 3
2.4.3 Start Gas ................................................................................... 3
2.4.4 Secondary Gas .......................................................................... 3
2.4.5 Cut Gas ..................................................................................... 3
2.4.5 PT-24 Torch ............................................................................... 4
Section 3 Installation
3.1 General............................................................................................... 1
3.2 Equipment Required ........................................................................... 1
3.3 Location.............................................................................................. 1
3.4 Primary Electrical Input Connections.................................................... 2-3
3.5 Alternate Connection Locations for IFC................................................ 4
3.6 IFC Basic Component Identification ..................................................... 4
3.7 Interconnecting Lines .......................................................................... 5-10
3.8 Precision Plasmarc Component Interconnecting Diagram .................... 7
3.9 Torch Mounting................................................................................... 11
3.10 Torch Coolant .................................................................................... 12
3.11 Inspection Of Gas And Coolant Lines.................................................. 12
3.12 Using the 5 Solenoid Torch Manifold.................................................. 13
3.13 Adapting to use a 4 Solenoid Torch Manifold ..................................... 14

Precision Plasma Integrated Flow Control - CE Table of Contents
ii
Page
Section 4 Operation
4.1 Power Supply Controls
4.1.1 Main Power Switch ..................................................................... 1
4.1.2 Pilot Arc Switch .......................................................................... 1
4.1.3 Fault Indicator Lights................................................................... 2
4.1.4 Meters........................................................................................ 2
4.1.5 Current Control Switch................................................................ 2
4.2 Cut Quality .........................................................................................
4.2.1 Introduction ................................................................................ 3
4.2.2 Cut Angle ................................................................................... 3
4.2.3 Cut Flatness ............................................................................... 4
4.2.4 Surface Finish ............................................................................. 5
4.2.5 Dross ......................................................................................... 6-7
4.2.6 Dimensional Accuracy................................................................. 8
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction ................................................................................ 9
4.3.2 Aluminum ................................................................................... 9
4.3.3 Carbon Steel .............................................................................. 10
4.3.4 Stainless Steel ............................................................................ 11
4.4 Process Data
4.4.1 Introduction ................................................................................ 13
4.4.2 Process Data Settings................................................................. 14-55
Aluminum ............................................................................ 14-21
Carbon Steel........................................................................ 22-31
Stainless Steel ..................................................................... 32-55
4.4.3 Relationship of Kerf Width to Amperes and Material Thickness..... 56
4.4.3.1 Aluminum Kerf Values ......................................................... 56
4.4.3.2 Carbon Steel Kerf Values..................................................... 58
4.4.3.3 Stainless Steel Kerf Values O2/N2/O2................................... 61
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4................................ 62
4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4................................. 63
4.4.3.6 Stainless Steel Kerf Values N2/N2........................................ 64
4.4.3.7 Stainless Steel Kerf Values Air/Air ....................................... 66
Plasma Marking Data .......................................................... 68

Precision Plasma Integrated Flow Control - CE Table of Contents
iii
Page
Section 5 Maintenance
5.1 General............................................................................................... 1
5.2 Inspection and Cleaning ...................................................................... 1
5.3 PT-24 Torch Description ..................................................................... 2-4
5.4 IFC Fluid Schematic ............................................................................ 3
5.4 Torch Maintenance ............................................................................. 5-6
5.5 PT-24 Consumable Disassembly and Inspection.................................. 7-10
5.6 PT-24 Torch Re-Assembly .................................................................. 10-11
5.7 Flow Control ....................................................................................... 12
5.8 Proportional Valve Removal................................................................. 13
Section 6 Troubleshooting
6.1 General Safety .................................................................................... 1
6.2 Troubleshooting Guide ........................................................................ 1
6.2.1 Reduced Consumable Life........................................................... 2
6.2.2 Poor Cut Quality.......................................................................... 2
6.2.3 No Pilot Arc................................................................................. 3
6.2.4 No Arc Transfer........................................................................... 3
6.2.5 No Preflow .................................................................................. 3
6.2.6 Torch Fails to Fire........................................................................ 3
6.2.7 Nozzle Life Extremely Short ......................................................... 4
6.2.8 Short Electrode Life..................................................................... 4
6.2.9 Short Electrode AND Nozzle Life.................................................. 4
6.3 IFC Fluid Schematic ............................................................................ 5
IFC Manifold Valve Identification................................................... 5
6.4 IFC Electrical Schematic...................................................................... 6-7
6.5 Precision Plasma Power Source Electrical Schematic........................... 8-9
6.6 Precision Plasma Power Source Wiring Diagram (includes CE Version) 10-14
6.7 Power Module Schematic – CE Version ............................................... 15
6.8 Precision Plasma Power Module Wiring Diagram – CE Version............. 16-17
6.9 Torch Manifold .................................................................................... 18

Precision Plasma Integrated Flow Control - CE Table of Contents
iv
Page
Section 7 Replacement Parts
7.1 General .............................................................................................. 1
7.2 Ordering............................................................................................. 1
7.3 Plasmarc Power Source – Exterior Components.................................. 2-7
7.4 Plasmarc Power Source – Internal Components .................................. 8-17
7.5 Power Source Module ........................................................................ 18-25
7.6 IFC ..................................................................................................... 26-27
7.7 IFC Manifold ....................................................................................... 28-29
7.8 PT-24 Torch Assembly IFC Series with Marking.................................. 30-31
7.9 Torch Manifold with marking ............................................................... 32-33
7.10 Interface Cables and Hoses .............................................................. 34-35
Customer/Technical Information Back Manual Cover

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control - 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
Precision Plasma with Integrated Flow Control -
1-2
DANGER
!
WARNING
!
CAUTION
!
CAUTION
NOTICE
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.
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
Used to call attention to potential hazards that
could result in personal injury or loss of life.
Used to call attention to hazards that could result
in minor personal injury or equipment damage.
Used to call attention to minor hazards to
equipment.
Used to call attention to important installation,
operation or maintenance information not
directly related to safety hazards.

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

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control -
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:
· Do not connect a cylinder directly to machine inlet.
An appropriate cylinder regulator must be installed
on a fuel gas cylinder to reduce pressure to a
reasonable inlet supply pressure. Machine
regulator is then used to obtain pressure required
by torches.
· Contact your ESAB representative before
installation. He can suggest certain precautions
regarding piping installation and machine lifting,
etc. to ensure maximum security.
· Never attempt any machine modifications or
apparatus additions without first consulting a
qualified ESAB representative.
· Observe machine clearance requirements for
proper operation and personnel safety.
· 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.