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.

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control - 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.
WARNING
!
Improper Grounding Can Damage
Machine And Electrical Components.
· Machine must be properly grounded before put
into service.
· Cutting table must be properly grounded to a good
Earth ground rod.

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control -
1-6
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
Precision Plasma with Integrated Flow Control - 1-7
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
Precision Plasma with Integrated Flow Control -
1-8
WARNING
!
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 AmpsShade No. 10
200-400 AmpsShade 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.
§ Paint walls and other surfaces with dark
colors to reduce reflections.
§ Install protective screens or curtains to
reduce ultraviolet transmission.
Ruptured Gas Cylinders Can Kill
Mishandling gas cylinders can rupture and violently
release gas.
· Avoid rough handling of cylinders.
· Keep cylinder valves closed when not in use.
· Maintain hoses and fittings in good condition.
· Always secure cylinders in an upright position by
chain or strap to a suitable stable object not part of
an electrical circuit.
· Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
· Use approved pressure reducing regulator for the
specific gas.
· Refer to CGA Standard P-1, “Precautions for Safe
Handling of Compressed Gases in Cylinders”,
available from Compressed Gas Association.

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control - 1-9
CAUTION
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 cuff-less trousers to prevent entry of sparks
and slag.
· Have fire extinguishing equipment available for use.
Poor Performance Will Result When
Cutting Above Water.
The PT-24 is designed to be a dry cutting
process.
Cutting above water may result in:
· reduced consumable life
· degradation of cut quality
Cutting above water may result in poor cutting
performance. Water vapor created when hot material
or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level
to provide maximum clearance between water and
material.

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control -
1-10
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.
WARNING
!Pinch hazard.
Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during operation.

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control - 1-11
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.
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
Precision Plasma with Integrated Flow Control -
1-12
1.8 Safety References
The following nationally recognized publications on
safety in welding and cutting operations are
recommended. These publications have been
prepared to protect persons from injury or illness and
to protect property from damage, which could result
from unsafe practices. Although some of these
publications are not related specifically to this type of
industrial cutting apparatus, the principles of safety
apply equally.
Domestic
· “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
Precision Plasma with Integrated Flow Control - 1-13
International
Accident Prevention
VBG 1 General Provisions
VBG 4 Electrical Equipment and operating
Equipment
VBG 15 Welding, Cutting and related working
methods
VBG 48 Shot Blasting Works
VBG 61 Gases
VBG 62 Oxygen
VBG 87 Operating liquid jet cutting machines
VBG 93 Laser beams, accident prevention and
Electro-technology
VBG 121 Noise
VDE Regulations
VDE 0100 Erection of power installations with normal
voltages up to 1000 volts
VDE0113 Electrical equipment of industrial machines
VDE 0837 Radiation safety of laser products; users
guide (DIN EN 60825)
VDE 0837-
50 Specification for laser guards
TRAC Technical Rules for Acetylene and Carbide Stores
TRAC-204 Acetylene lines
TRAC-206 Acetylene cylinder battery systems
TRAC-207 Safety devices
TRG Technical Rules for Pressure gases TRG 100 General regulations for pressure gases
TRG 101 Pressure gases
TRG 102 Technical gas mixtures
TRG 104 Pressure gases; alterative use of
compressed gas tanks

SECTION 1 SAFETY
Precision Plasma with Integrated Flow Control -
1-14
DIN Standards
DIN 2310
Part 1 Thermal cutting; terminology and nomenclature
DIN 2310
Part 2 Thermal cutting; determination of quality of cut faces
DIN 2310
Part 4 Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances
DIN 2310
Part 5 Thermal cutting; laser beam cutting of metallic materials; process principles
DIN 4844
Part 1 Safety markings (DIN EN 7287)
DIN EN ISO Harmonized Standards
DIN EN
292/1 and 2 Safety of machinery
DIN EN 559 Hoses for welding, cutting and allied
processes
DIN EN 560 Hose connections and hose couplings for
equipment for welding, cutting and allied
processes
DIN EN 561 Gas welding equipment hose couplings
DIN EN
626-1 Safety of machines, reduction of risks to health
DIN EN
848-1 Single spindle vertical milling machines
DIN EN
1829 High pressure water jet machines
DIN EN
9013 Thermal cutting, oxygen cutting, process principles, dimensional tolerances
DIN EN
12584 Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma
DIN EN
12626 Laser processing machines
DIN EN
28206 Acceptance testing for oxygen cutting machines
DIN EN
31252 Laser Equipment
DIN EN
31553 Laser and laser related equipment
DIN EN
60204-1 Electrical equipment of machines
DIN EN
60825 Radiation safety of laser products
DIN EN 999 Arrangement of protection devices
VDI Guidelines
VDI 2906 Quality of cut faces on metallic workpieces;
abrasive water jet cutting and arc plasma
cutting
VDI 2084 Room air; Technical systems for welding
workshops