SmartFlow II Plasma System Plumbing Box - ESAB equipment... · 2015-11-17 · SmartFlow II Plasma System Plumbing Box . The equipment described in this manual is ... 3.8 System Component

F-15-487 July, 2001

Installation, Operation, and Maintenance for the

SmartFlow II Plasma System Plumbing Box

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 toESAB Cutting Systems first priority is toESAB Cutting Systems first priority is toESAB Cutting Systems first priority is total customer tal customer tal customer tal customer satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to improve our products, service and documentation. improve our products, service and documentation. improve our products, service and documentation. improve our products, service and documentation. As a result, we make eAs a result, we make eAs a result, we make eAs a result, we make ennnnhancements and/or design hancements and/or design hancements and/or design hancements and/or design changes as rchanges as rchanges as rchanges as reeeequired. ESAB makes every possible quired. ESAB makes every possible quired. ESAB makes every possible quired. ESAB makes every possible effort to ensure our documentation is current. We effort to ensure our documentation is current. We effort to ensure our documentation is current. We effort to ensure our documentation is current. We cannot guarantee that each piece of documecannot guarantee that each piece of documecannot guarantee that each piece of documecannot guarantee that each piece of documennnntation tation tation tation received by our customers reflects the latest design received by our customers reflects the latest design received by our customers reflects the latest design received by our customers reflects the latest design enhancements. Therefore, the information enhancements. Therefore, the information enhancements. Therefore, the information enhancements. Therefore, the information contained in this document is subject to change contained in this document is subject to change contained in this document is subject to change contained in this document is subject to change without nwithout nwithout nwithout nooootice.tice.tice.tice.

This manual is ESAB Part Number F15487This manual is ESAB Part Number F15487This manual is ESAB Part Number F15487This manual is ESAB Part Number F15487 Date reflects rewritten and updated.

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.

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 Service Precautions............................................................................. 8

1.7 Safety References ............................................................................... 10

Section 2 Description 2.1 Introduction......................................................................................... 1

2.2 SmartFlow II and PT-15XL Plasma Torch ............................................. 1

2.3 SmartFlow II and PT-19XLS/PT-600 Plasma Torch .............................. 2

2.4 SmartFlow II Options ........................................................................... 2

2.5 Gas Requirements................................................................................ 2

2.6 Water Supply Requirements ................................................................ 3

2.7 Electrical Input Requirements............................................................... 3

2.8 Physical Dimensions............................................................................ 4

Section 3 Installation

3.1 Introduction......................................................................................... 1

3.2 Mounting............................................................................................. 1

3.3 Hose and Cable Connections .............................................................. 2

3.3.1 Starter Box Connections.............................................................. 3

3.3.2 PC Board Connections ................................................................ 3

3.3.3 Torch Cooling Water Connections................................................ 4

3.3.4 Power Source (ESP) to SmartFlow II Buss Connections................ 4

3.4 Nomex Insulation................................................................................. 5

3.5 Gas Connections................................................................................. 5

3.5.1 Gas Lines From Supply................................................................ 5

3.5.2 Gas Pressure Setup..................................................................... 7

3.6 Cutwater Setup (PT-15XL only) ............................................................ 7

3.7 Secondary Shield Gas Setup (PT-19XLS and PT-600)......................... 7

3.8 System Component Block Diagram ..................................................... 8

3.9 Fluid Schematic – SF II ........................................................................ 9

Table of Contents

ii

Page

Section 4 Operation 4.1 Introduction ........................................................................................ 1

4.2 Pressure Gages .................................................................................. 1

4.3 Pressure Switches .............................................................................. 1

Section 5 Maintenance

5.1 Introduction ........................................................................................ 1

5.2 Pressure Switches .............................................................................. 2

5.3 Arc Starter Spark Gap......................................................................... 3

5.4 Spark Gap Adjustment Procedure ....................................................... 4

5.5 Gas Proportional Valves ...................................................................... 5

5.6 Cutwater/ Secondary Shield Proportional Valve ................................... 5

5.7 Cooling Water Flow Switch.................................................................. 6

5.8 Gas Filters .......................................................................................... 7

Section 6 Troubleshooting 6.1 Introduction ........................................................................................ 1

6.2 Cooling Water Circuit .......................................................................... 2

6.3 Cutwater and Auxiliary Cutwater.......................................................... 3

6.4 Plasma Gas Circuit ............................................................................. 4

6.5 Secondary Shield................................................................................ 5

6.6 Arc Start

6.6.1 Setting the Spark Gap................................................................. 6

6.6.2 Spark Gap Size Attributes ........................................................... 7

6.6.3 Spark Viewing............................................................................. 8

6.7 Fluid Schematic .................................................................................. 9

6.8 SM II Interface PCB Schematic............................................................ 10

6.9 Technical Guide to SmartFlow II Process Diagnostics 6.9.1 Plasma Process Timer Values for Vision Cutting Record File PARAM.CUT and Interpretation Data File DEF.TEC................................ 11

6.9.2 Vision Keyboard Functions for Plasma System Test ..................... 12 6.9.3 Proportional Valve Analog Flow Values for Vision Cutting Record File PARAM.CUT and Interpretation File DEF.TEC .................................. 13

6.9.4 Gas Selection Requirements ....................................................... 13 6.9.5 Plasma Process Gas Flowchart ................................................... 14

6.9.6 Solenoid and Proportional Valve Requirements – Station ON Flush Cycle ........................................................................................... 15

Table of Contents

iii

6.9.7 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas N2, Cut Gas N2.......................................... 16

Error Monitoring Requirements SFII— N2— N2..................................... 16 6.9.8 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas H-35, Cut Gas H-35 ................................. 18

Error Monitoring Requirements SFII— H-35— H-35 ............................ 18 6.9.9 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas N2, Cut Gas H-35...................................... 20

Error Monitoring Requirements SFII— N2— H-35 ................................ 20 6.9.10 Solenoid and Proportional Valve Requirements – PT-19XLS/PT-600 Start Gas N2, Cut Gas O2.......................................... 22

Error Monitoring Requirements SFII— N2— O2 .................................... 22 6.9.11 Solenoid and Proportional Valve Requirements – PT-15XL Start Gas N2, Cut Gas N2....................................................... 24 Error Monitoring Requirements SFII— N2— N2..................................... 24

6.9.12 Solenoid and Proportional Valve Requirements – PT-15XL Start Gas N2, Cut Gas O2 ...................................................... 26 Error Monitoring Requirements SFII— N2— O2 .................................... 26 6.9.13 Solenoid and Proportional Valve Requirements – PT-15XL Start Gas H-35, Cut Gas H-35 .............................................. 28 Error Monitoring Requirements SFII— H-35— H-35 ............................ 28 6.9.14 Solenoid and Proportional Valve Requirements – PT-15XL Start Gas N2, Cut Gas H-35 .................................................. 30 Error Monitoring Requirements SFII— N2— H-35 ................................ 30

6.9.15 SmartFlow II Test Files............................................................... 32

6.10 Secondary Shield Proportional Valve Calibration Procedure................ 38

Section 7 Replacement Parts

7.1 General............................................................................................... 1

7.2 Ordering ............................................................................................. 1

7.3 Right Inside without H-35 Option......................................................... 2

7.4 Right Inside with H-35 Option.............................................................. 4

7.5 Front Outside...................................................................................... 6

7.6 Left Inside ........................................................................................... 8

7.7 Back Outside ...................................................................................... 10

Customer/Technical Information Back Manual Cover

Table of Contents

iv

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SECTION 1 SAFETY

Smart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting SystemSmart Flow II Plasma Cutting System 1-1

DANGER!

WARNING!

CAUTION!

CAUTION

NOTICE

1.1 Introduction

ESAB cutting machines are designed to provide both operational safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary. Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be carried out. Failure to observe warnings/ precautions could result in death/serious personal injury or severe equipment damage. The following are general guidelines applicable when working with cutting machines. Additional precautions pertaining to this equipment are found throughout this literature. For a wide scope of safety information on the field of cutting and welding, obtain and read the publications listed in the Recommended References at the end of this section.

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


1.3 General Safety Information

WARNING!

Failure to follow operating instructions could result in death or serious injury.

Read and understand this operator’s manual before Read and understand this operator’s manual before Read and understand this operator’s manual before Read and understand this operator’s manual before using machine.using machine.using machine.using machine.

• Read entire pRead entire pRead entire pRead entire procedure before operating or rocedure before operating or rocedure before operating or rocedure before operating or performing any system maintenance. performing any system maintenance. performing any system maintenance. performing any system maintenance.

• Special attention must be given to all hazard Special attention must be given to all hazard Special attention must be given to all hazard Special attention must be given to all hazard warnings that provide essential information warnings that provide essential information warnings that provide essential information warnings that provide essential information regarding personnel safety and/or possible regarding personnel safety and/or possible regarding personnel safety and/or possible regarding personnel safety and/or possible equipment damage.equipment damage.equipment damage.equipment damage.

• All safety precautions relevant to electAll safety precautions relevant to electAll safety precautions relevant to electAll safety precautions relevant to electrical rical rical rical equipment and process operations must be equipment and process operations must be equipment and process operations must be equipment and process operations must be strictly observed by all having system strictly observed by all having system strictly observed by all having system strictly observed by all having system responsibility or access. responsibility or access. responsibility or access. responsibility or access.

• Read all safety publications made available by Read all safety publications made available by Read all safety publications made available by Read all safety publications made available by your company.your company.your company.your company.

WARNING!

Failure to follow safety warning label instructions could result in death or serious injury.

Read and understand all safety warning labels on Read and understand all safety warning labels on Read and understand all safety warning labels on Read and understand all safety warning labels on machine.machine.machine.machine.

Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety information.information.information.information.

SECTION 1 SAFETY


1.4 Installation Precautions

WARNING! Improperly Installed Equipment Can Cause Injury Or Death.

Follow these guidelines while installing machine:Follow these guidelines while installing machine:Follow these guidelines while installing machine:Follow these guidelines while installing machine:

• Do not connect a cylinder directlDo not connect a cylinder directlDo not connect a cylinder directlDo not connect a cylinder directly to machine inlet. y to machine inlet. y to machine inlet. y to machine inlet. An appropriate cylinder regulator must be installed An appropriate cylinder regulator must be installed An appropriate cylinder regulator must be installed An appropriate cylinder regulator must be installed on a fuel gas cylinder to reduce pressure to a on a fuel gas cylinder to reduce pressure to a on a fuel gas cylinder to reduce pressure to a on a fuel gas cylinder to reduce pressure to a reasonable inlet supply pressure. Machine reasonable inlet supply pressure. Machine reasonable inlet supply pressure. Machine reasonable inlet supply pressure. Machine regulator is then used to obtain pressure required regulator is then used to obtain pressure required regulator is then used to obtain pressure required regulator is then used to obtain pressure required by torches.by torches.by torches.by torches.

• Contact your ESAB representatiContact your ESAB representatiContact your ESAB representatiContact your ESAB representative before ve before ve before ve before installation. He can suggest certain precautions installation. He can suggest certain precautions installation. He can suggest certain precautions installation. He can suggest certain precautions regarding piping installation and machine lifting, regarding piping installation and machine lifting, regarding piping installation and machine lifting, regarding piping installation and machine lifting, etc. to ensure maximum security.etc. to ensure maximum security.etc. to ensure maximum security.etc. to ensure maximum security.

• Never attempt any machine modifications or Never attempt any machine modifications or Never attempt any machine modifications or Never attempt any machine modifications or apparatus additions without first consulting a apparatus additions without first consulting a apparatus additions without first consulting a apparatus additions without first consulting a qualified ESAB represequalified ESAB represequalified ESAB represequalified ESAB representative.ntative.ntative.ntative.

• Observe machine clearance requirements for Observe machine clearance requirements for Observe machine clearance requirements for Observe machine clearance requirements for proper operation and personnel safety. proper operation and personnel safety. proper operation and personnel safety. proper operation and personnel safety.

• Always have qualified personnel perform Always have qualified personnel perform Always have qualified personnel perform Always have qualified personnel perform installation, troubleshooting and maintenance of installation, troubleshooting and maintenance of installation, troubleshooting and maintenance of installation, troubleshooting and maintenance of this equipment.this equipment.this equipment.this equipment.

• Provide a wall mounted disconnect switch with Provide a wall mounted disconnect switch with Provide a wall mounted disconnect switch with Provide a wall mounted disconnect switch with proper fuse sproper fuse sproper fuse sproper fuse sizes close to the power supply.izes close to the power supply.izes close to the power supply.izes close to the power supply.

SECTION 1 SAFETY


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.Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into Machine must be properly grounded before put into Machine must be properly grounded before put into Machine must be properly grounded before put into servservservservice.ice.ice.ice.

WARNING!

Improper Grounding Can Damage Machine And Electrical Components.

• Machine must be properly grMachine must be properly grMachine must be properly grMachine must be properly grounded before put ounded before put ounded before put ounded before put into service. into service. into service. into service.

• Cutting table must be properly grounded toCutting table must be properly grounded toCutting table must be properly grounded toCutting table must be properly grounded to a good a good a good a good Earth ground rod.Earth ground rod.Earth ground rod.Earth ground rod.

1.6 Operating A Plasma Cutting Machine

WARNING!

Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying debris generated during operation.debris generated during operation.debris generated during operation.debris generated during operation.

• Chipped slag may be hot and fly far. BystandChipped slag may be hot and fly far. BystandChipped slag may be hot and fly far. BystandChipped slag may be hot and fly far. Bystanders ers ers ers should also wear goggles and safety glasses.should also wear goggles and safety glasses.should also wear goggles and safety glasses.should also wear goggles and safety glasses.

• Noise from plasma arc can damage hearing. Wear Noise from plasma arc can damage hearing. Wear Noise from plasma arc can damage hearing. Wear Noise from plasma arc can damage hearing. Wear correct ear protection when cutting above water. correct ear protection when cutting above water. correct ear protection when cutting above water. correct ear protection when cutting above water.

SECTION 1 SAFETY


WARNING! Burn hazard.

Hot metal can burn.Hot metal can burn.Hot metal can burn.Hot metal can burn.

• Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with water.water.water.water.

• Do not touch plasma torch immediately after Do not touch plasma torch immediately after Do not touch plasma torch immediately after Do not touch plasma torch immediately after cutting. Allow torch ticutting. Allow torch ticutting. Allow torch ticutting. Allow torch time to cool.me to cool.me to cool.me to cool.

WARNING! Hazardous voltages. Electric shock can kill.

• Do NOT touch plasma torch, cutting table oDo NOT touch plasma torch, cutting table oDo NOT touch plasma torch, cutting table oDo NOT touch plasma torch, cutting table or cable r cable r cable r cable connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.

• Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies before touching or servicing plasma torch. before touching or servicing plasma torch. before touching or servicing plasma torch. before touching or servicing plasma torch.

• Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies before servicing any system component.before servicing any system component.before servicing any system component.before servicing any system component.

• Do not touch live electricaDo not touch live electricaDo not touch live electricaDo not touch live electrical parts.l parts.l parts.l parts.

• Keep all panels and covers in place when machine Keep all panels and covers in place when machine Keep all panels and covers in place when machine Keep all panels and covers in place when machine is connected to power source.is connected to power source.is connected to power source.is connected to power source.

• Wear insulating gloves, shoes and clothing to Wear insulating gloves, shoes and clothing to Wear insulating gloves, shoes and clothing to Wear insulating gloves, shoes and clothing to insulate yourself from workpiece and electrical insulate yourself from workpiece and electrical insulate yourself from workpiece and electrical insulate yourself from workpiece and electrical ground.ground.ground.ground.

• Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and equipment dry.equipment dry.equipment dry.equipment dry.

• ReplacReplacReplacReplace worn or damaged cables.e worn or damaged cables.e worn or damaged cables.e worn or damaged cables.

SECTION 1 SAFETY


WARNING!Fume hazard.

Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting process caprocess caprocess caprocess can be hazardous to your health.n be hazardous to your health.n be hazardous to your health.n be hazardous to your health.

• Do NOT breathe fumes.Do NOT breathe fumes.Do NOT breathe fumes.Do NOT breathe fumes.

• Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal system operating properly. system operating properly. system operating properly. system operating properly.

• Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if necessary.necessary.necessary.necessary.

• Use approved respirator if ventilation is not Use approved respirator if ventilation is not Use approved respirator if ventilation is not Use approved respirator if ventilation is not adequate.adequate.adequate.adequate.

• Provide positProvide positProvide positProvide positive mechanical ventilation when ive mechanical ventilation when ive mechanical ventilation when ive mechanical ventilation when cutting galvanized steel, stainless steel, copper, cutting galvanized steel, stainless steel, copper, cutting galvanized steel, stainless steel, copper, cutting galvanized steel, stainless steel, copper, zinc, beryllium, or cadmium. Do not breathe these zinc, beryllium, or cadmium. Do not breathe these zinc, beryllium, or cadmium. Do not breathe these zinc, beryllium, or cadmium. Do not breathe these fumes.fumes.fumes.fumes.

• Do not operate near degreasing and spraying Do not operate near degreasing and spraying Do not operate near degreasing and spraying Do not operate near degreasing and spraying operations. Heat or arc rays can react with operations. Heat or arc rays can react with operations. Heat or arc rays can react with operations. Heat or arc rays can react with chlorinated hydrocarbon vchlorinated hydrocarbon vchlorinated hydrocarbon vchlorinated hydrocarbon vapors to form phosgene, apors to form phosgene, apors to form phosgene, apors to form phosgene, a highly toxic gas and other irritant gases. a highly toxic gas and other irritant gases. a highly toxic gas and other irritant gases. a highly toxic gas and other irritant gases.

SECTION 1 SAFETY


WARNING! Radiation hazard.

Arc rays Arc rays Arc rays Arc rays can injure eyes and burn skin.can injure eyes and burn skin.can injure eyes and burn skin.can injure eyes and burn skin.

• Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.

• Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended shields. Refer to following chart for recommended shields. Refer to following chart for recommended shields. Refer to following chart for recommended lens shades for plasma cutting:lens shades for plasma cutting:lens shades for plasma cutting:lens shades for plasma cutting:

Arc CurrentArc CurrentArc CurrentArc Current Lens Shade Lens Shade Lens Shade Lens Shade Up to 100 AmpsUp to 100 AmpsUp to 100 AmpsUp to 100 Amps Shade NShade NShade NShade No. 8o. 8o. 8o. 8 100100100100----200 Amps200 Amps200 Amps200 Amps Shade No. 10Shade No. 10Shade No. 10Shade No. 10 200200200200----400 Amps400 Amps400 Amps400 Amps Shade No. 12Shade No. 12Shade No. 12Shade No. 12 Over 400 AmpsOver 400 AmpsOver 400 AmpsOver 400 Amps Shade No. 14Shade No. 14Shade No. 14Shade No. 14

• Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or brokenbrokenbrokenbroken

• Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.

• Prepare cutting aPrepare cutting aPrepare cutting aPrepare cutting area to reduce reflection and rea to reduce reflection and rea to reduce reflection and rea to reduce reflection and transmission of ultraviolet light.transmission of ultraviolet light.transmission of ultraviolet light.transmission of ultraviolet light.

�� Paint walls and other surfaces with dark Paint walls and other surfaces with dark Paint walls and other surfaces with dark Paint walls and other surfaces with dark colors to reduce reflections.colors to reduce reflections.colors to reduce reflections.colors to reduce reflections.

��Install protective screens or curtains to Install protective screens or curtains to Install protective screens or curtains to Install protective screens or curtains to reduce ultraviolet transmission.reduce ultraviolet transmission.reduce ultraviolet transmission.reduce ultraviolet transmission.

SECTION 1 SAFETY


WARNING! Ruptured Gas Cylinders Can Kill

MishandlMishandlMishandlMishandling gas cylinders can rupture and violently ing gas cylinders can rupture and violently ing gas cylinders can rupture and violently ing gas cylinders can rupture and violently release gas. release gas. release gas. release gas.

• Avoid rough handling of cylinders.Avoid rough handling of cylinders.Avoid rough handling of cylinders.Avoid rough handling of cylinders.

• Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.

• Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.

• Always secure cylinders in an upright position by Always secure cylinders in an upright position by Always secure cylinders in an upright position by Always secure cylinders in an upright position by chain or strap to a chain or strap to a chain or strap to a chain or strap to a suitable stable object not part of suitable stable object not part of suitable stable object not part of suitable stable object not part of an electrical circuit.an electrical circuit.an electrical circuit.an electrical circuit.

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

• Use approved pressure reducing regulator for the Use approved pressure reducing regulator for the Use approved pressure reducing regulator for the Use approved pressure reducing regulator for the specific gas.specific gas.specific gas.specific gas.

• Refer to CGA Standard PRefer to CGA Standard PRefer to CGA Standard PRefer to CGA Standard P----1, “Precautions for Saf1, “Precautions for Saf1, “Precautions for Saf1, “Precautions for Safe e e e Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”, available from Compressed Gas Association.available from Compressed Gas Association.available from Compressed Gas Association.available from Compressed Gas Association.

WARNING! Explosion hazard.

• Certain molten aluminumCertain molten aluminumCertain molten aluminumCertain molten aluminum----lithium (Allithium (Allithium (Allithium (Al----Li) alloys can Li) alloys can Li) alloys can Li) alloys can cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water. cause explosions when plasma cut OVER water.

�� These alloys should only be dry cut on a dry These alloys should only be dry cut on a dry These alloys should only be dry cut on a dry These alloys should only be dry cut on a dry table.table.table.table.

�� DO NOT dry cut over water.DO NOT dry cut over water.DO NOT dry cut over water.DO NOT dry cut over water. ��Contact your aluminum supplier for Contact your aluminum supplier for Contact your aluminum supplier for Contact your aluminum supplier for

additional safety information regaadditional safety information regaadditional safety information regaadditional safety information regarding rding rding rding hazards associated with these alloyshazards associated with these alloyshazards associated with these alloyshazards associated with these alloys.

• Do not cut in atmospheres containing explosive Do not cut in atmospheres containing explosive Do not cut in atmospheres containing explosive Do not cut in atmospheres containing explosive dust or vapors.dust or vapors.dust or vapors.dust or vapors.

• Do not carry any combustibles on your person Do not carry any combustibles on your person Do not carry any combustibles on your person Do not carry any combustibles on your person (e.g. butane lighter)(e.g. butane lighter)(e.g. butane lighter)(e.g. butane lighter)

• Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.

SECTION 1 SAFETY


WARNING! Burn Hazard.

Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.Do not cut near combustible material.Do not cut near combustible material.Do not cut near combustible material.

• Do not have on your person aDo not have on your person aDo not have on your person aDo not have on your person any combustibles (e.g. ny combustibles (e.g. ny combustibles (e.g. ny combustibles (e.g. butane lighter).butane lighter).butane lighter).butane lighter).

• Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle away from yourself and others when activating away from yourself and others when activating away from yourself and others when activating away from yourself and others when activating plasma process.plasma process.plasma process.plasma process.

• Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

• Wear flameWear flameWear flameWear flame----retardant clothiretardant clothiretardant clothiretardant clothing covering all exposed ng covering all exposed ng covering all exposed ng covering all exposed areas.areas.areas.areas.

• Wear cuffWear cuffWear cuffWear cuff----less trousers to prevent entry of sparks less trousers to prevent entry of sparks less trousers to prevent entry of sparks less trousers to prevent entry of sparks and slag.and slag.and slag.and slag.

• Have fire extinguishing equipment available for use.Have fire extinguishing equipment available for use.Have fire extinguishing equipment available for use.Have fire extinguishing equipment available for use.

SECTION 1 SAFETY


1.6 Service Precautions

WARNING!

Hazardous voltages. Electric shock can kill.

• Do NOT touch plasma torch, cuttiDo NOT touch plasma torch, cuttiDo NOT touch plasma torch, cuttiDo NOT touch plasma torch, cutting table or cable ng table or cable ng table or cable ng table or cable connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.

• Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies before touching or servicing plasma torch. before touching or servicing plasma torch. before touching or servicing plasma torch. before touching or servicing plasma torch.

• Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies before removing covers or panels to service any before removing covers or panels to service any before removing covers or panels to service any before removing covers or panels to service any system csystem csystem csystem component.omponent.omponent.omponent.

• Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.

• Keep all panels and covers in place when machine Keep all panels and covers in place when machine Keep all panels and covers in place when machine Keep all panels and covers in place when machine is connected to power source.is connected to power source.is connected to power source.is connected to power source.

• Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and equipment dry.equipment dry.equipment dry.equipment dry.

• Inspect power and ground leads cables for wear or Inspect power and ground leads cables for wear or Inspect power and ground leads cables for wear or Inspect power and ground leads cables for wear or cracking. Replace worcracking. Replace worcracking. Replace worcracking. Replace worn or damaged cables. Do n or damaged cables. Do n or damaged cables. Do n or damaged cables. Do not use if damaged.not use if damaged.not use if damaged.not use if damaged.

• Never bypass safety interlocks.Never bypass safety interlocks.Never bypass safety interlocks.Never bypass safety interlocks.

• Follow lockFollow lockFollow lockFollow lock----out procedures.out procedures.out procedures.out procedures.

CAUTION Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A composite program can be established from composite program can be established from composite program can be established from composite program can be established from recommended schedules.recommended schedules.recommended schedules.recommended schedules.

Avoid leaving test equipment Avoid leaving test equipment Avoid leaving test equipment Avoid leaving test equipment or hand tools on or hand tools on or hand tools on or hand tools on machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage could occur to equipment or machine.could occur to equipment or machine.could occur to equipment or machine.could occur to equipment or machine.

SECTION 1 SAFETY


CAUTION! Extreme caution should be used when probing Extreme caution should be used when probing Extreme caution should be used when probing Extreme caution should be used when probing circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damagcircuits are susceptible to over voltage damagcircuits are susceptible to over voltage damagcircuits are susceptible to over voltage damage. e. e. e. Power off before using test probes to prevent Power off before using test probes to prevent Power off before using test probes to prevent Power off before using test probes to prevent accidental shorting of components.accidental shorting of components.accidental shorting of components.accidental shorting of components.

All circuit boards securely seated in sockets, all cables All circuit boards securely seated in sockets, all cables All circuit boards securely seated in sockets, all cables All circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all guards and covers replaced before power is turned guards and covers replaced before power is turned guards and covers replaced before power is turned guards and covers replaced before power is turned on.on.on.on.

1.9 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.

• “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.

Continued next page

SECTION 1 SAFETY


• “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 2 DESCRIPTION

SmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting SystemSmartFlow II Plasma Cutting System 2-1

2.1 Introduction The SmartFlow II Cutting System is a streamlined,

high performance-cutting package designed for use exclusively with the ESAB Vision CNC. This advanced technology integrates gas and water control into the machine CNC. Using a system of proportional valves driven by CNC outputs, this system:

• dramatically reduces the amount of plumbing hardware necessary to control the plasma torch

• reduced purge time/increased part throughput

• simplified operation with gas and water flow rates manually controlled at the Vision CNC process parameter screen

• allows for programmed/automated control of gas and water flow rates using SDP Files (SSSSchneidDDDDatenPPPPaket = 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.)

• can be used with either a PT-15XL water injection torch or a PT-600/PT-19XLS dry cutting torch with secondary shield gas. (The PT-600 and the PT-19XLS are both dry cutting torches of similar design.)

2.2 SmartFlow II and PT-15XL When the PT-15XL water injection torch is used, the

complete cutting system also requires the following components:

• PT-15XL plasma torch

• a plasma power supply

• a recirculating water cooler

• coolant pump

• cut water pump

• air curtain regulator

• Vision CNC.



2.3 SmartFlow II and PT-19XLS/PT-600

When a dry torch (no water injection) is used, the SmartFlow II water injection components are used to control the secondary shield pressure. The components of The SmartFlow II Cutting System with dry torch requires the following components:

• Vision CNC,

• PT-19XLS or PT-600 plasma torch,

• power supply,

• a recirculating water cooler,

• and coolant pump.

2.4 SmartFlow II Options

SmartFlow II with H-35 capability (H-35 is industry accepted nomenclature for a gas

mixture of 65% argon and 35% hydrogen)

SmartFlow II without H-35 capability

P/N 37538P/N 37538P/N 37538P/N 37538 P/N 37540P/N 37540P/N 37540P/N 37540

2.5 Gas Requirements

Nitrogen

• 125 PSI (8,63 bar) with 0.5” NPT

• 99.999% purity

• Filtered to 25 microns

Oxygen

• 125 PSI (8,63 bar) with 0.5” NPT

• 99.999% purity


Compressed Air • 100 PSI (6,9 bar) with 0.5” NPT

• Clean, dry and filtered to 25 microns

H-35 (argon/hydrogen)

• 150 PSI (10,4 bar)




2.6 Water Supply Requirements

Cooling Water • 120 PSI (8,28 bar)

• 1.5 gallons per minute (5.68 liters/minute)

Deionized Water (PT-15XL only)

• 35 PSI (2,42 bar)

• >200,000 ohms (resistance)

• .5 gallons/minute (1,89 liters/minute) for up to 600A cutting

• 1.5 gallons/minute (5,68 liters/minute) for 600A to 1000A cutting

2.7 Electrical Input Requirements

Voltage Supply • +24 VDC for proportional valves, flow and

pressure switches

• +15 VDC for pressure switch

Voltage Signals

• 120 VAC input to start gas solenoid valve

• 120 VAC input to cut gas solenoid valve

• 120 VAC input to arc starter

• 0-10 VDC input to proportional valves



2.8 Dimensions

12.12" (308mm)

15.62" (396.8mm)

7.5 " (190,5mm)

SECTION 3 INSTALLATION

SmartFlow IISmartFlow IISmartFlow IISmartFlow II 3-1

WARNING!

Electricity Can Kill! Before performing any maintenance or assembly of this equipment, ensure the power source (ESP) is turned off and disconnected.

3.1 Introduction

The SmartFlow II is a plumbing box that interfaces with the ESAB Vision machine controls and the ESP product line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control proportional and solenoid valves. The result is CNC management of gas and cutwater or shield gas delivery to the plasma torch. Analog signal feedback is sent back to the CNC, creating a control loop. The SmartFlow II can be used with the PT-15 water injection plasma torch or both the dry cutting PT-19XLS and PT-600 plasma torches with secondary shield gas.

3.2 Box Mounting

2.015"51.2 mm6.515"

165.5 mm7.25"

184.2 mm

2.125"54 mm

13.125"333.4 mm

15.125"384.2 mm

If mounting the box is required: The box has four 6 mm threaded mounting holes in a pattern offset from longitudinal center. Note relationship of hole pattern to gauges and cable clamp.

Bottom View Gauges

Cable Clamp

front

rear



3.3 Hose and Cable Connections

1. Remove left side panel of the SmartFlow II box. Rotate ¼ turn fasteners counterclockwise.

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 six screws holding block to back of the

SM box.

B. Remove four side clamping screws.

3. Place cables in block.

4. Replace four side clamp screws. Do not tighten.

5. Reattach block using three mount screws along a vertical line.

6. Adjust cable length and tighten the four side clamp screws.

7. Finish attaching the block to the box with the other three mount screws.

8. Tighten all screws.

Control Cable Clamp/Strain Relief

Left side panel removed

Control Cables

Pilot Arc Cable

Power Source Leads (4/0 cable)



3.3.1 Starter Box Connections

TB1TB1TB1TB1 – Pilot arc ground cable from the plasma power source (ESP).

TB4TB4TB4TB4 – Connected to buss bar (brass block just below starter box) inside the SmartFlow box.

TB2TB2TB2TB2 – Pilot Arc Torch cable from the torch leads.

3.3.2 PC Board Connections P1 P1 P1 P1 – 12 pin connector, CNC control lead (valves)

P2P2P2P2 – 8 pin connector, CNC control lead (cutwater/ secondary shield)

P3P3P3P3 – 10 pin connector, CNC control lead (cut gas)

P6P6P6P6 – Cooling water flow switch

P8P8P8P8 – High frequency arc start AC power

P9P9P9P9 – Voltage divider

Reverse side (not shown)

P4P4P4P4 – 10 pin connector, valve control lead (valves)

P5P5P5P5 – 8 pin connector, manifold control lead (cutwater/ secondary shield)

P7P7P7P7 – 12 pin connector, manifold control lead (cut gas)

Note:Note:Note:Note:

For more detailed information, refer to PC board For more detailed information, refer to PC board For more detailed information, refer to PC board For more detailed information, refer to PC board schematic in Section 6.schematic in Section 6.schematic in Section 6.schematic in Section 6.

P1

P3

P2 P9

P8

P6

To arc start buss

TB4/Buss connection point



AIRCOOLING WATEROUT IN

CUT WATER

SERIALNUMBER

IN

OUT

3.3.3 Torch Cooling Water Connections

Coolant Connections To and From Power SourceCoolant Connections To and From Power SourceCoolant Connections To and From Power SourceCoolant 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 Smart Flow II interior lines can identify the proper connections. Flow switch is located on the “ IN” line.

Coolant

OUT (from torch)

Left Side Panel Removed Coolant

IN (to torch)

Coolant Connections To And From TorchCoolant Connections To And From TorchCoolant Connections To And From TorchCoolant Connections To And From Torch

Note arrows on fittings indicating coolant flow direction.

Coolant OutCoolant OutCoolant OutCoolant Out has right-hand threads.

Coolant InCoolant InCoolant InCoolant In has left-hand threads

3.3.4 Power Source To SMF II Buss Connection

1. Strip 4/0 insulation, approximately 1½” (38 mm).

2. Insert 4/0 cable in buss hole until copper extends to the edge of the buss block.

3. Tighten locking screw(s) on cable.

Note:

The buss will accommodate three cables.

(1) 4/0 – 400 amps

(2) 4/0 – 750 amps

(3) 4/0 – 1000 amps

NOTICE

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

4/0 power source cable

Buss



3.4 Nomex Insulation

Position Nomex insulation to prevent any possible arcing between the buss and arc start box terminals. Replace side panels of SmartFlow II enclosure.

3.5 Gas Connections Gas Connections are made on the exterior of the

SM box. Gas lines are connected to the back from supply sources and the front for the torch.

3.5.1 Gas Lines From Supply.

CAUTIONUnfiltered Gas Will Clog Proportional Valves Dirt particles will clog small orifices in proportional valves.

All gas supplies must have a 25 micron filter installed between supply and gas regulator panel. EASB Filter P/N 56998133 (replacement filter element P/N 0560988406)

When using the PT-19XLS or PT-600 torch with a secondary shield, air supply must be filtered and dry using a minimum 25 micron filter.

Proportional valves contain no serviceable parts. Replace valve assembly with factory parts.

Nomex Insulation

Buss

High Frequency Cable from ESP Power Source

Arc Start Box



CAUTION

Gas Line Contamination Will Damage Proportional Valves Purge Gas Lines Before connecting gas delivery lines to the SmartFlow II, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your SmartFlow II.

AIR

H-35

COOLING WATEROUT IN

NITROGEN

OXYGEN

CUT WATER

SERIALNUMBER

1

2

3

4

5

Back of SM II Plumbing Box

1. Purge gas and air lines completely before connecting to 25 micron gas filters.

2. Connect oxygen, H-35, nitrogen and airlines to gas filters.

3. Purge gas/air lines between regulator panel and SmartFlow II plumbing box.

4. Connect gas/air lines to back of plumbing box.

1 Nitrogen (N2) 2 Oxygen (O2) 3 H-35 (65%Argon, 35% Hydrogen) Optional 4 Torch Air 5 Secondary Shield or Cutwater (depends on torch



3.5.2 Gas Pressure Setup Adjust pressure at the regulator panel while gas is

flowing.

Gas Type Pressure

Oxygen 125 PSI (8,63 Bar) Nitrogen 125 PSI (8,63 Bar) H-35 150 PSI (10,4 Bar) 3.6 Cut Water Setup (PT-15XL)

See system requirements for description of cutwater.

A supply of deionized water is required for the installation of cutwater when using the PT-15XL. A minimum regulated pressure of 30 psi (2,07 bar) supply is required to prevent cavitation in the cutwater pump.

Pressure from the cutwater pump to the SmartFlow should be adjusted to 120 psi (8,28 bar). Refer to the cutwater pump manual for this procedure.

3.7 Secondary Shield Gas Setup (PT-19XLS/PT-600) Secondary shield gas (air or N2) must be dry and

filtered to a minimum of 25 microns and regulated to 60 PSI (4,14 bar). Excess moisture in shield gas may cause arcing inside the torch and/or poor consumable life. This gas supply (pre-filtered) uses the same fitting as the cutwater hose in back of the plumbing box.

Secondary shield gas regulator Air regulator



3.8 A Component Relationship Block Diagram

ESP Front viewESP

Back view

N2 O2 Air H-35

SmartFlow

II

Pilot Arc

Torch (-)

On/OffControl

Remote toCNC

Cooling WaterTo Torch

Cooling WaterFrom Torch

Work (+)

Earth Ground

Plasma TorchBundle and

Torch

3 phasew/ground

CNC I/O toSmart Flow II

WC-7WaterCooler

VoltageHeightControl

CNC

Cut WaterPump

(for PT-15)

RegulatorPanel

25 micronfilters



PS

PS

PS

PS

3.9 Fluid Schematic – SmartFlow II

Gauge

Proportional Valve

Flow Switch

2 Way Solenoid Valve

Check Valve

Pressure Switch

Flow Restriction Orifice

Aux. Cut Water

Secondary Shield/ Cutwater IN

H-35 IN

Oxygen IN

PS2

PS3

PS1

0-100 PSI (6,9 Bar)

Valve 3

Valve 2

Valve 1

0-100 PSI (6,9 Bar)

0-50 PSI (3,45 Bar)

Vent

Vent

Cutwater/ Secondary Shield

Plasma Gas

Air Curtain

To Torch

Cooling Water IN

Cooling Water OUT

N2 Purge Orifice

IN OUT

Nitrogen IN

Air IN



This page intentionally left blank.

SECTION 4 OPERATION

SmSmSmSmart Flow IIart Flow IIart Flow IIart Flow II 4-1

4.1 Operation Introduction

A major advantage of the SmartFlow II is that operating parameters are managed by the machine CNC. There are no operating procedures necessary with the SmartFlow II. Management is accomplished either with manual inputs on the Vision cutting parameter screen or using the ESAB system of Process Parameter Files.

Note:

Process Parameter Files (know by the acronym … SDPSDPSDPSDP for SSSSchneidDDDDatkenPPPPaket) are files stored in the Vision 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 SDP files can be found in your torch manual under Cutting Data, Operation, Section 4. Refer to Vision CNC Part Programming manual for more detail on the creation and use of SDP files.

NOTICE

See your specific torch manual for cutting parameter settings for using the SmartFlow II Plumbing Box. These settings can be found in the form of cutting data charts located in the operation section of the torch manual.

4.2 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.

4.3 Pressure Switches.

Pressure switches monitor line pressure and provide inputs to the CNC. If the pressure drops below a preset level, the CNC can shut the process down. Switches are in-line between the solenoid and the proportional valve for cut water (or secondary shield), H-35, and oxygen/nitrogen lines.

SECTION 4 OPERATION

SmSmSmSmart Flow IIart Flow IIart Flow IIart Flow II 4-2


SECTION 5 Maintenance

Smart Flow IISmart Flow IISmart Flow IISmart Flow II 5-1

5.1 SmartFlow II Maintenance Introduction This section provides adjustment or replacement

procedures for those serviceable parts inside the SmartFlow II plumbing box. Only trained personnel should perform maintenance on this equipment.

WARNING!Electric Shock Can Kill! Always disconnect power from the ESP power source and the cutting machine before opening or servicing the SmartFlow II plumbing box.

CAUTION!Only Qualified Maintenance Personnel Should Repair And Maintain This Equipment.



P5 P71

2

3

4

5 6

5.2 Pressure Switches Gas Pressure SwitchGas Pressure SwitchGas Pressure SwitchGas Pressure Switch monitors the pressure of

plasma gas supply to the plumbing box. One switch monitors both O2 and N2 gases. An additional switch is used for monitoring the H-35 option.

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

Cut Water/Secondary Shield SwitchCut Water/Secondary Shield SwitchCut Water/Secondary Shield SwitchCut Water/Secondary Shield Switch monitors the pressure of either cutwater or secondary shield gas, depending on the torch application.

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.

1 H-35 (Argon/Hydrogen) Pressure Switch 2 Plasma Gas Pressure Gauge Tap 3 O2/N2 Plasma Gas Pressure Switch 4 Air Curtain Pressure Gauge Tap 5 Cut Water/Secondary Shield Pressure Switch 6 Cut Water Pressure Gauge Tap



0 .040"(1 mm)

5.3 Spark Gap Of the Arc Starter

The SmartFlow II uses a high frequency arc starter to initiate the plasma arc within the cutting torch. The arc starter box is mounted in the upper right corner of the plumbing box. The arc starter box contains an adjustable spark gap.

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

Decreased Spark Gap from 0.040” (1 mm):Decreased Spark Gap from 0.040” (1 mm):Decreased Spark Gap from 0.040” (1 mm):Decreased Spark Gap from 0.040” (1 mm):

• Negative Effect- starting reliability is decreased

• Positive Effect – smaller risk of high frequency interference

Increased Spark Gap from 0.040” (1 mm):Increased Spark Gap from 0.040” (1 mm):Increased Spark Gap from 0.040” (1 mm):Increased Spark Gap from 0.040” (1 mm):

• Negative Effect – increased damage risk from high frequency interference

• Positive Effect - starting reliability increased (to a point where it doesn’t work at all).

CAUTION High Frequency Interference Can Damage Machine Electronic Components

Potentially damaging high frequency interference may result from increasing the spark gap beyond recommendation. This electrical interference may find its’ way to pc boards in the electronics cabinet or Vision control. The result will be failure of some portion of machine function.

Do not set spark gap beyond recommended distance of 0.040”””” (1,0 mm)

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Hig

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Inte

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nce

Dam

age

Inte

rfere

nce

Dam

age

Inte

rfere

nce

Dam

age

HIGH

LOW

Spark GapSpark GapSpark GapSpark Gap

Starting Reliability



WARNING!

Electric Shock Can Kill! Always turn power off before opening and servicing the SmartFlow II plumbing box.

5.4 Spark Adjustment Procedure

1

2

3

ARC Starter Box

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

2. Remove left and right side covers from the SmartFlow II. Mounting screws for the arc starter box are accessed from the manifold side (right side) of the SM II.

3. Disconnect fiber optic cable from arc starter box.

4. Remove arc starter box. Mounting screws are accessed from the opposite side of the SM II. Removal of gauge(s) may be necessary to see some screws.

5. Remove access cover from the arc starter.

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

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

8. Replace access cover and remount arc starter box.

9. Replace side panels.

1111 Spark Gap Access 2222 Fiber Optic Cable 3333 Spark Gap of 0.040” (1 mm)



5.5 Gas Proportional Valves

P/N 0558001068 N2/O2 Proportional Valve Gas proportional valves contain no user serviceable parts. In case of failure, the valve must be replaced.

P/N 0558001065 H-35 Proportional Valve Easily distinguishable with nickel-plated valve body. Gas proportional valves contain no user serviceable parts. In case of failure, the valve must be replaced.

5.6 Cutwater/Secondary Shield Proportional Valve

P/N 56997044 This proportional valve contains no user serviceable parts. The valve must be replaced in case of failure. This is the only valve that can be calibrated if necessary. See troubleshooting section for calibration procedure.



1

2

3

4

1

2

5.7 Cooling Water Flow Switch

P/N 636383 The cooling water circuit uses a 1.0 gallon (3.8 liters) flow switch to monitor cooling water flow. It measures actual flow through the torch in the cooling water return line. The switch is wired as an input to the CNC. The control looks for a change of state of the input signal when the plasma station is turned on. This switch cannot be jumpered out of the circuit. Type of cooling water problems: • Insufficient flow due to a restriction in the

cooling water circuit. The switch may be disassembled and cleaned if found to have a restriction. • Sufficient flow but no flow closure. If measurement of the actual cooling water flow rate indicates more than 1.0 gallon (3.8 liters) per minute, but the switch does not close, the switch may be damaged or clogged. Clean or replace as necessary.

1 Retainer Ring 2 Flow Switch 3 Spring 4 Piston



5.8 Gas Filters

Nitrogen, oxygen, and secondary shield gases must be filtered before entering the SmartFlow II. Check these filters regularly (dependent on usage and cleanliness of supply). Replace filter as required.

CAUTION 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




SECTION 6 TROUBLESHOOTING


WARNING!

Electric Shock Can Kill! Disconnect power before removing side panels.

6.1 Troubleshooting Introduction The SmartFlow II has proven to be a very reliable

product. Regular maintenance is important for many years of trouble free use. This section contains a brief description of the most common problems, schematics, and technical diagnostic tools.

• Cooling Water Circuit • Cut Water • Plasma Gas • Secondary Shield • Spark • Process Diagnostics

The SmartFlow II is designed to support the PT-15XL, PT-19XLS and PT-600 plasma torches.

• The PT-15XL torch uses cutwater.

• PT-19XLS and PT-600 torches introduce a secondary gas shield. Secondary shield utilizes the same solenoid and proportional valve used for the cutwater on the PT-15XL.

CAUTION

All gases supplied to the SmartFlow II must be filtered to 25 microns. Small orifices in proportional valves will become clogged if filters are neglected or bypassed. Do Not Attempt to Clean. Replacement of manifold assembly may be necessary. Replacement of proportional valves only is possible. Thoroughly flush manifold and gas lines with N2 before reassembly. Because proportional 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.



6.2 Cooling Water Circuit

123

45

1 Torch 2 To torch check valve 3 Flow Switch 4 Return coolant check valve 5 Water cooler

The cooling water circuit consists of two reverse flow check valves and a flow switch. It is a closed loop re-circulating system which cools the electrode

and torch body of the PT-15XL torch. The PT-19XLS and PT-600 torches have electrode, nozzle, nozzle retaining cup, and torch body cooled by this system.

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 cooling 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 Buss Block 2 Coolant line – to torch (from cooler) 3 Coolant line – from torch (to cooler) 4 Flow switch 5 Check Valve – from torch 6 Check Valve – to torch

12

3

4

5

6



6.3 Cut Water and Auxiliary Cut Water SmartFlow II ManifoldSmartFlow II ManifoldSmartFlow II ManifoldSmartFlow II Manifold

1 De-ionized cutwater supply connection

2 Cutwater solenoid

3 Aux. Cutwater solenoid

4 Cutwater pressure tap

5 Cutwater Pressure switch

6 Aux cutwater supply hose

7 Cutwater hose manifold to proportional valve

8 Cutwater proportional valve

9 Cutwater torch connection

10 Check valve

11 Cutwater Gage

12 Aux. Cutwater Restriction Orifice

• Cutwater is used with the PT-15 XL torch.

• Deionized water is supplied ➀➀➀➀ to the plumbing box cutwater solenoid valve ➁➁➁➁.

• Check valves built into the manifold are positioned to prevent back flow to the solenoids. See Schematic below.

• A port inside the manifold re-routes additional cutwater to the auxiliary cutwater solenoid ➂➂➂➂. This option is used when cutting with Ar/H2 (H-35) to provide additional cutwater flow. Maximum water flow, with auxiliary water solenoid open and the cutwater proportional valve set to maximum, is 1.5 gpm.

• Back pressure thru the auxiliary cutwater hose ➅➅➅➅ provides pressure to the cutwater pressure tap ➃➃➃➃ and line to the cutwater gauge.

• Cutwater pressure switch �� is preset and nonadjustable to 50 psi. If pressure drops below 50 psi, a signal is sent to the machine control and process is shut down.

• Cutwater proportional valve ➇➇➇➇ provides a means of controlling flow at the CNC. This value is automatically set if using SDP files to control cutting parameters. (SDP SSSSchneidDDDDatenPPPPaket = cutting data package contain all the same information that can be individually adjusted on the Vision control process parameter screen. See Vision Programming Manual.)

PS

1

2

3

4

58

9

10

11 12

Cutwater Flow Schematic

1

2

3456789



6.4 Plasma Gas Plasma gases are controlled with proportional

valves mounted on the manifold.

PS

PS

1

2

3

4

5678

910111213

14

15

1 H-35 connection (used only on P/N 37538) 2 Oxygen supply connection 3 Nitrogen supply connection 4 Air curtain supply connection 5 Solenoids 6 Check valves 7 Nitrogen purge orifice 8 Air gage 0-50 psi 9 Nitrogen/oxygen pressure switch 10 H-35 pressure switch (used only on P/N 37538) 11 H-35 proportional valve (used only on P/N 37538) 12 Nitrogen/oxygen proportional valve 13 Plasma gas gage 0-100 psi 14 Plasma gas 15 Air curtain

Note:Note:Note:Note:

Part number 37538, SmartFlow II with H-35, includes all of the components listed at left.

Part number 37540, SmartFlow II without H-35 capabilities, does not include items 1, 10, and 11. The auxiliary water is not removed because of improved piercing of thicker materials when using PT-19 and PT-600. Squarer cuts in thicker materials are also possible using the auxiliary cutwater path for additional shield gas flow.



6.5 Secondary Shield

SmartFlow II ManifoldSmartFlow II ManifoldSmartFlow II ManifoldSmartFlow II Manifold

1 Shield Gas Supply Connection

2 Secondary Shield Gas Solenoid

3 Auxiliary Shield Gas Solenoid

4 Secondary Shield Pressure Tap

5 Secondary Shield Pressure Switch

6 Secondary Shield Supply Hose

7 Shield Gas Hose To Proportional Valve

8 Secondary Shield Gas Proportional Valve

9 Shield Gas Torch Connection

10 Check Valve

11 Shield Gas Gage

• Secondary shield gas is used with the PT-19XLS and PT-600 torches (dry torches)

• Shield gas (nitrogen or air) is supplied ➀➀➀➀ to the shield gas solenoid valve ➁➁➁➁.

• Check valves built into the manifold are positioned to prevent back flow to the solenoids. See Schematic below.

• A port inside the manifold re-routes additional shield gas to the secondary shield gas solenoid ➂➂➂➂. This option is used when piercing may require an addition “blast”.

• Back flow thru the secondary shield gas hose ➅➅➅➅ provides pressure to the shield gas pressure tap ➃➃➃➃.

• Secondary Shield pressure switch �� is preset and nonadjustable to 50 psi. If pressure drops below 50 psi, a signal is sent to the machine control and process is shut down.

• Shield gas proportional valve ➇➇➇➇ provides a means of controlling flow at the CNC. This value will be automatically set if using SDP files to control cutting parameters. (SDP SSSSchneidDDDDatenPPPPaket = cutting data package contain all the same information that can be individually adjusted on the Vision control process parameter screen. See Vision Programming Manual.

PS

1

2

3

4

58

9

10

11 12

Shield Gas Fluid Schematic

1

2

3456789



6.6 Arc Start

Electric Shock Can Kill Disconnect Power before attempting any repairs, Disconnect Power before attempting any repairs, Disconnect Power before attempting any repairs, Disconnect Power before attempting any repairs, disassembly or adjustments.disassembly or adjustments.disassembly or adjustments.disassembly or adjustments.

6.6.1 Setting the Spark Gap

The Arc Spark Gap inside the spark box should be set to 0.040".

1

2

3

ARC Starter Box

Note: Evidence of a spark can be confirmed at the Note: Evidence of a spark can be confirmed at the Note: Evidence of a spark can be confirmed at the Note: Evidence of a spark can be confirmed at the front of the plumbing box during normal operations. front of the plumbing box during normal operations. front of the plumbing box during normal operations. front of the plumbing box during normal operations. See 6.6.3.See 6.6.3.See 6.6.3.See 6.6.3.

ProcedureProcedureProcedureProcedure

1. Disconnect electricity to plasma power source (ESP) and cutting machine.

2. Remove left and right side covers from the SmartFlow II. Mounting screws for the arc starter box are accessed from the manifold side (right side) of the SM II.

3. Remove arc starter box, being careful not to damage the fiber optic cable.

4. Remove access cover from the arc starter.

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

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

7. Replace access cover and remount arc starter box.

8. Replace side panels.

1 Spark Gap Access 2 Fiber Optic Cable 3 Spark Gap of 0.040"""" (1 mm)

WARNING!



0 .040"(1 mm)

6.6.2 Spark Gap Size Attributes

Decreased Spark Gap of 0.040" (1 mm):Decreased Spark Gap of 0.040" (1 mm):Decreased Spark Gap of 0.040" (1 mm):Decreased Spark Gap of 0.040" (1 mm):

• Negative Effect- starting reliability is decreased

• Positive Effect – smaller risk of high frequency interference

Increased Spark Gap of 0.040" (1 mm):Increased Spark Gap of 0.040" (1 mm):Increased Spark Gap of 0.040" (1 mm):Increased Spark Gap of 0.040" (1 mm):

• Negative Effect – increased risk of damage from high frequency interference

• Positive Effect - starting reliability increased (to a point where it doesn’t work at all).

CAUTION High Frequency Interference Can Damage Machine Electronic Components

Potentially damaging high frequency interference may result from increasing the spark gap beyond recommendation. This electrical interference may find its way to pc boards in the electronics cabinet or Vision control. The result can be failure of some portion of machine function.

Do not set spark gap beyond recommended distance of 0.040"""" (1,0 mm)

Ris

k of

Hig

h Fr

eque

ncy

Ris

k of

Hig

h Fr

eque

ncy

Ris

k of

Hig

h Fr

eque

ncy

Ris

k of

Hig

h Fr

eque

ncy

Inte

rfere

nce

Dam

age

Inte

rfere

nce

Dam

age

Inte

rfere

nce

Dam

age

Inte

rfere

nce

Dam

age

HIGH

LOW

Spark GapSpark GapSpark GapSpark Gap

Starting Reliability



6.6.3 Spark Viewing

The spark can be seen from the front of the plumbing box without removing any covers. An optical cable is connected from the arc start box to a view port on the bottom left front corner of the plumbing box

60

100

100

AIR CURTAIN

CUT GAS

CUT WATER

AIR CURTAIN

CUT GAS

CUT WATER

To Pilot ArcStart Box

SparkView Port



PS

PS

PS

PS

6.7 Fluid Schematic

Gauge

Proportional Valve

Flow Switch

2 Way Solenoid Valve

Check Valve

Pressure Switch

Flow Restriction Orifice

Aux. Cut Water

Cutwater/ Secondary Shield Gas IN

H-35 IN

Oxygen IN

PS2

PS3

PS1

0-100 PSI (6,9 Bar)

Valve 3

Valve 2

Valve 1

0-100 PSI (6,9 Bar)

0-50 PSI (3,45 Bar)

Vent

Vent

Cutwater/ Secondary Shield Gas

Plasma Gas

Air Curtain

To Torch

Cooling Water IN

Cooling Water OUT

N2 Purge Orifice

IN OUT

Nitrogen IN

Air IN



6.8 SmartFlow II Interface PCB Schematic

AIRRC1

RC2

RC3

RC4

RC5

RC6

CHASSIS GROUND

1

2

3

4

5

6

7

8

9

10

11

12

P1

P21

2

4

5

6

3

1

2

3

4

5

6

VALVE 1 SET PT.

VALVE 1 +24 VDC

VALVE 2 SET PT.

VALVE 3 SET PT.

PS1 (N2 /O2)

PS2 (CUT H2O)

PS3 (H-35)

PRES. SW. 15 V. SOURCE (SR1)

SELECTOR VALVE COMMON

AIR

JP1

JP2

JP3

JP4

PRES. SW. 24 V. SOURCE (SR2)

24 VDC GROUND

VALVE 2 +24 VDC

VALVE 3 +24 VDC

O2 / N2 GAS

CUT H2O

H-35

PS1

PS1

PS2

PS2

PS3

PS3

FS2

FS2(COOLING H2O)

(H-35)

(CUT H2O)

(O2 / N2)

ALL SELECTOR VALVES120 VAC 50/60 HZ. 7 WATTS

AIR

N2

O2

CUT H2O

CUT H2O AUX

H-35

N2

N2

O2

O2

CUT H2O

CUT H2O

CUT H2O AUX

CUT H2O AUX

H-35

H-35 7

FS1 (COOLING H2O)

8

9

7

8

ARC START AC PWR

ARC START AC PWR

V-DIVIDE WORK

V-DIVIDE ARC VOLTS

24 VDC GROUND

1

2

6

4

3

5

1

2

1

2

C10.1MFDR1

1K 0.5W

R215K 8W

BUSS BAR

P3

P5

P6

P7

P8

VALVE 1 P-SENSOR

VALVE 2 P-SENSOR

7

8

9

10

CUT WATER P-SENSOR +

CUT WATER P-SENSOR -

N.C.

CUT WATER P-SENSOR -

CUT WATER P-SENSOR +

10N.C.

CW

ARC START AC PWR

ARC START AC PWR

V2P

WR

V1P

WR

RC7

source file:135c001c.dxf

2

1

P9New wiring

configuration01/28/01

Jumpers JP1 -- JP4select either 24 vdc or

15 vdc inputrequirements

PROVISIONAL PROVISIONAL

PROVISIONAL

PROVISIONAL

6

1

2

5

11

9

10

7

3

4

8

12

P4

1

2

10

7

6

9

4

8

5

3

VALVE 3 SET PT.

VALVE 3 +24 VOLTS

VALVE 2 +24 VOLTS

VALVE 2 SET PT.

VALVE SHIELDS

VALVE 1 SET PT.

VALVE GNDS

VALVE 1 +24 VOLTS

VALVE 1 P-SENSOR

VALVE 2 P-SENSOR

(GREEN)

(WHITE)

(RED)

(GREEN)

(WHITE)

(RED)

(WHITE)

(RED)

(BLACK)

VALVE 1

HARNESS

VALVE 2

HARNESS

VALVE 3

HARNESS

1

2

3

6

1

3

6

1

3

Old wiringconfiguration



6.9 Technical Guide To SmartFlow II Process Diagnostics

6.9.1 Plasma Process Timer Values For Vision Cutting Record File PARAM.CUT Vision Interpretation Data File DEF.TEC Please refer to the description of the cutting

package in the Vision manual for a detailed explanation of the PARAM.CUT and DEF.TEC

PARAM.CUTPARAM.CUTPARAM.CUTPARAM.CUT DEF.TECDEF.TECDEF.TECDEF.TEC

TimersTimersTimersTimers

WxWxWxWx Preset Preset Preset Preset valuevaluevaluevalue

UxUxUxUx Lower Lower Lower Lower

editing limitediting limitediting limitediting limit

QxQxQxQx Upper Upper Upper Upper

editing limitediting limitediting limitediting limit

VVVV Hidden Hidden Hidden Hidden

flagflagflagflag V= V= V= V= Hidden Flag EnabledHidden Flag EnabledHidden Flag EnabledHidden Flag Enabled

Plasma Preflow/purge/firing/vent timePlasma Preflow/purge/firing/vent timePlasma Preflow/purge/firing/vent timePlasma Preflow/purge/firing/vent time 2.02.02.02.0 2.02.02.02.0 2.02.02.02.0 VVVV High voltageHigh voltageHigh voltageHigh voltage 0.50.50.50.5 0.50.50.50.5 0.50.50.50.5 VVVV

Plasma PrePlasma PrePlasma PrePlasma Pre----Switch timeSwitch timeSwitch timeSwitch time .01.01.01.01 0.00.00.00.0 0.30.30.30.3 Plasma Rise on Pierce TimePlasma Rise on Pierce TimePlasma Rise on Pierce TimePlasma Rise on Pierce Time 0.00.00.00.0 0.00.00.00.0 50.050.050.050.0

Plasma Pierce TimePlasma Pierce TimePlasma Pierce TimePlasma Pierce Time 0.00.00.00.0 0.00.00.00.0 50.050.050.050.0 Plasma Travel DelayPlasma Travel DelayPlasma Travel DelayPlasma Travel Delay 0.00.00.00.0 0.00.00.00.0 50.050.050.050.0 PlasmaPlasmaPlasmaPlasma AHC Delay AHC Delay AHC Delay AHC Delay 0.00.00.00.0 0.00.00.00.0 50.050.050.050.0

Master UpMaster UpMaster UpMaster Up 2.02.02.02.0 0.00.00.00.0 50.050.050.050.0 Plasma PostflowPlasma PostflowPlasma PostflowPlasma Postflow 5.05.05.05.0 5.05.05.05.0 50.050.050.050.0 VVVV



6.9.2 Vision Keyboard Functions for Plasma System Test

Key Function Description

Plasma AHC Allow Icon

(F2 Push(F2 Push(F2 Push(F2 Push----Button)Button)Button)Button)

• Icon permits the machine operator to allow or disallow plasma AHC.

• Icon does not turn plasma AHC on.Icon does not turn plasma AHC on.Icon does not turn plasma AHC on.Icon does not turn plasma AHC on. • Plasma AHC is allowed if the icon is highlighted

(darkened). • Plasma AHC is not allowed if the icon is not

highlighted.

Plasma AHC Icon


• Icon permits machine operator to manually turn plasma AHC on or off.

• Icon also permits the operator to perform a plasma IHS cycle if the plasma process is not active.

• The plasma AHC allow icon must be highlightedplasma AHC allow icon must be highlightedplasma AHC allow icon must be highlightedplasma AHC allow icon must be highlighted.

Plasma Start Parameter Test Icon


• Icon permits the machine operator to manually test/adjust the plasma process start parameters with the exception of the plasma gas 2 start flow.

Plasma Gas 2 Test Icon


• Icon permits the machine operator to manually test/adjust the plasma gas 2 start flow.

• The plasma start parameter test icon must be plasma start parameter test icon must be plasma start parameter test icon must be plasma start parameter test icon must be highlightedhighlightedhighlightedhighlighted.

Plasma Cut Parameter Test Icon


• Icon permits the machine operator to manually test/adjust the plasma process cut parameters.

• The plasma start parameter test icon must be plasma start parameter test icon must be plasma start parameter test icon must be plasma start parameter test icon must be highlightedhighlightedhighlightedhighlighted.

Plasma Start Icon


• Icon permits the machine operator to manually start or stop the plasma process.

• The plasma start parameter test icon must not be must not be must not be must not be highlightedhighlightedhighlightedhighlighted.



6.9.3 Plasma Process Proportional valve Analog Flow Values For Vision Cutting Record File PARAM.CUT and Vision Interpretation File DEF.TEC

Please refer to the ATAS description of the cutting package for a detailed explanation of PARAM.CUT and DEF.TEC

PARAM.CUT DEF.TEC

Wx Preset Value

Ux Lower editing

limit

Qx Upper editing

limit

V Hidden

flag

Xx Lower

parameter limit

Yy Upper

parameter limit

Ix Lower

channel limit

Jx Upper

Channel limit

Analog Output ValuesAnalog Output ValuesAnalog Output ValuesAnalog Output Values V = Hidden Flag EnabledV = Hidden Flag EnabledV = Hidden Flag EnabledV = Hidden Flag Enabled Plasma Gas Start… NPlasma Gas Start… NPlasma Gas Start… NPlasma Gas Start… N2222/O/O/O/O2222 25.0 0.0 100.0 0.0 100.0 0.0 255.0

Plasma Gas Cut… NPlasma Gas Cut… NPlasma Gas Cut… NPlasma Gas Cut… N2222/O/O/O/O2222 25.0 0.0 100.0 0.0 100.0 0.0 255.0

Plasma Cut Water/Shield Gas StartPlasma Cut Water/Shield Gas StartPlasma Cut Water/Shield Gas StartPlasma Cut Water/Shield Gas Start 25.0 0.0 100.0 0.0 100.0 0.0 255.0

Plasma Cut Water/Plasma Cut Water/Plasma Cut Water/Plasma Cut Water/Shield Gas CutShield Gas CutShield Gas CutShield Gas Cut 25.0 0.0 100.0 0.0 100.0 0.0 255.0

Plasma Gas Start… HPlasma Gas Start… HPlasma Gas Start… HPlasma Gas Start… H----35353535 25.0 0.0 100.0 0.0 100.0 0.0 255.0

Plasma Gas Cut… NPlasma Gas Cut… NPlasma Gas Cut… NPlasma Gas Cut… N2222/O/O/O/O2222 25.0 0.0 100.0 0.0 100.0 0.0 255.0 Plasma Gas PurgePlasma Gas PurgePlasma Gas PurgePlasma Gas Purge 100.0 100.0 100.0 V 0.0 100.0 0.0 255.0

Plasma Cut Water/ShPlasma Cut Water/ShPlasma Cut Water/ShPlasma Cut Water/Shield Gas Purgeield Gas Purgeield Gas Purgeield Gas Purge 100.0 100.0 100.0 V 0.0 100.0 0.0 255.0 6.9.4 Plasma Process Gas Selection Requirements

Plasma process gas selection is accomplished with activation of the appropriate SDP file.

The correct Cutting Record Flag must be in each SDP file. Plasma process gas selection is keyed to the value in the Cutting Record Flag.

Please refer to the ATAS description of the cutting package for a detailed explanation of the cutting record flag.

Plasma Start Gas Plasma Cut Gas Abbreviation Cutting Record Flag

N2 O2 SF-N2-O2 M1000000000000000

N2 N2 SF-N2-N2 M0100000000000000

H-35 H-35 SF-H35-H35 M0010000000000000

N2 H-35 SF-N2-H35 M0001000000000000



6.9.5 Plasma Process Gas Flowchart

Visionshift/start

Station off

Station on?

Station onflush cycle

Station on?

Flush cyclecomplete?

Ready

Station on?

Flush cyclerequired?

Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?

Process highvolt delay

Plasma stop?

Error condition?

Station on?

High volt delaycomplete?

Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?

Process highfrequency

Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes



6.9.6 Plasma Process Solenoid and Proportional valve Requirements Station On Flush Cycle

This cycle will be initiated each time a SmartFlow II station is manually

selected

Start 0.096

seconds 3.0 seconds 1.0 seconds 2.0 seconds 1.0 seconds 1.0 seconds

Finish 0.016 seconds

Solenoid Valves X= open/enabled, Blank = Closed/Disabled, Analog value = 0 - 10 VDC

Plasma Gas N2 X X X

Plasma Gas O2

Plasma Gas H-35

Cutwater/Shield Gas

Cutwater/Shield Gas Auxiliary

Plasma Torch Cooling Water Pump X X X X X X X

Analog Output Values

Plasma Gas Start (N2/O2)

Plasma Gas Cut (N2/O2)

Cutwater/Shield Gas Start

Cutwater/Shield Gas Cut

Plasma Gas Start (H-35)

Plasma Gas Cut (H-35)

Plasma Gas Purge (N2/O2) X X X X X

Cutwater/Shield Gas Purge

Note: 0.016 seconds is the minimum timing interval allowed by the system software.



6.9.7 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-N2, N2 Plasma Start Gas N2, Plasma Cut Gas N2

Flow Chart Reference:Flow Chart Reference:Flow Chart Reference:Flow Chart Reference: A B C D E F G H J K L M N

Note: Plasma process gas selection is accomplished with activation of the

appropriate SDP file.

Station Off Ready

Line Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5

Process Pierce Note 6

Process Cut

Note 9

Process Post Flow

Flow Control

Vent

Solenoid ValvesSolenoid ValvesSolenoid ValvesSolenoid Valves X = open/Enabled, BlaX = open/Enabled, BlaX = open/Enabled, BlaX = open/Enabled, Blank = Closed/Disabled, Analog Value = 0nk = Closed/Disabled, Analog Value = 0nk = Closed/Disabled, Analog Value = 0nk = Closed/Disabled, Analog Value = 0----10 VDC10 VDC10 VDC10 VDC Plasma Gas N Plasma Gas N Plasma Gas N Plasma Gas N2222

X X X X X Plasma Gas O Plasma Gas O Plasma Gas O Plasma Gas O2222

X X X X X Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Note 8 Note 8 Note 9

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump X X X X X X X X X X X Note 7

Analog Values (output)Analog Values (output)Analog Values (output)Analog Values (output) Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– N N N N2222

/O/O/O/O2222 X X X X X X

Plasma Gas Cut Plasma Gas Cut Plasma Gas Cut Plasma Gas Cut –––– N N N N2222/O/O/O/O2222

X X X Plasma Cut Water/Shield G Plasma Cut Water/Shield G Plasma Cut Water/Shield G Plasma Cut Water/Shield Gas Startas Startas Startas Start X X X X Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X

Plasma Gas Purge Plasma Gas Purge Plasma Gas Purge Plasma Gas Purge –––– N N N N2222/O/O/O/O2222

X X Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge X

Note 1: LINE PURGELINE PURGELINE PURGELINE PURGE will be initiated after the first Station On Flush CycleStation On Flush CycleStation On Flush CycleStation On Flush Cycle after a Vision Shift/StartVision Shift/StartVision Shift/StartVision Shift/Start. Line PurgeLine PurgeLine PurgeLine Purge will also be initiated each time SDP file selection specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line PurgeLine PurgeLine PurgeLine Purge is initiated.

Note 2: Plasma PreflowPlasma PreflowPlasma PreflowPlasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process PostflowProcess PostflowProcess PostflowProcess Postflow and Plasma Postflow Plasma Postflow Plasma Postflow Plasma Postflow was active for a minimum period of 3 seconds.

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection.Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1MKON 1MKON 1MKON 1 (MIP constant 57 is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58 is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59 is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKONMKONMKONMKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0. Note 6: Machine motion will be allowed and MIP OVERRIDEOVERRIDEOVERRIDEOVERRIDE 1 (MIP constant 35) will be enabled if MKON 5MKON 5MKON 5MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to

0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVMIP OVMIP OVMIP OVERRIDE 3ERRIDE 3ERRIDE 3ERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Plasma Process Error Monitoring Requirements, SF--N2--N2 Plasma Start Gas – N2 Plasma Cut Gas – N2


Station

Off Ready

Line Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control

Vent

Process Pressure Switches X = monitored for pressure present, 0 = monitored for absence of preX = monitored for pressure present, 0 = monitored for absence of preX = monitored for pressure present, 0 = monitored for absence of preX = monitored for pressure present, 0 = monitored for absence of pressuressuressuressure CSF = monitored for status of change of state flag (see notes 11, 12, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 14)

Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 Note 12 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 0 0 0 0 0

Plasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Note 14 X,CSF X,CSF X,CSF X,CSF X,CSF PlaPlaPlaPlasma Torch Cooling Watersma Torch Cooling Watersma Torch Cooling Watersma Torch Cooling Water Note 11 CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

Note 11: The appropriate Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

start of the Station Station Station Station On Flush CycleOn Flush CycleOn Flush CycleOn Flush Cycle. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring. Note 12: The appropriate Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (NPlasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N2222

/O/O/O/O2222)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring. Note 13: The appropriate Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (HPlasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H----35)35)35)35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring. Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

beginning of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.



SmartFlow II Plasma Flow Chart Note: Circled letters reference columns in process valve and gas error requirement charts

Visionshift/start

Station off

Station on?

Station on flushcycle

Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.8 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-H-35, H-35 Plasma Start Gas H-35, Plasma Cut Gas H-35




Station Off Ready

Line Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent

Solenoid ValvesSolenoid ValvesSolenoid ValvesSolenoid Valves X = open/Enabled, Blank = Closed/DisableX = open/Enabled, Blank = Closed/DisableX = open/Enabled, Blank = Closed/DisableX = open/Enabled, Blank = Closed/Disabled, Analog Value = 0d, Analog Value = 0d, Analog Value = 0d, Analog Value = 0----10 VDC10 VDC10 VDC10 VDC Plasma Gas N Plasma Gas N Plasma Gas N Plasma Gas N2222

X Plasma Gas O Plasma Gas O Plasma Gas O Plasma Gas O2222

Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 X X X X X X X X X Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Note 8 Note 8 Note 9



/O/O/O/O2222


Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X X Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 X X X X X X Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X X X X



Note 1: LINE PURLINE PURLINE PURLINE PURGEGEGEGE will be initiated after the first Station On Flush CycleStation On Flush CycleStation On Flush CycleStation On Flush Cycle after a Vision Shift/StartVision Shift/StartVision Shift/StartVision Shift/Start. Line PurgeLine PurgeLine PurgeLine Purge will also be initiated each time SDP file selection specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line PurgeLine PurgeLine PurgeLine Purge is initiated.


Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1MKON 1MKON 1MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0),once for 0.080

seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59) is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKONMKONMKONMKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0. Note 6: Machine motion will be allowed and MIP OVERRIDEOVERRIDEOVERRIDEOVERRIDE 1 (MIP constant 35) will be enabled if MKON 5MKON 5MKON 5MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKOMKOMKOMKON 8N 8N 8N 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Plasma Process Error Monitoring Requirements SF-- H-35 -- H-35 Plasma Start Gas – H-35 Plasma Cut Gas – H-35


Station Off

Ready Line

Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control Vent

Process Pressure Switches X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure CSF = monitored for status of change of state flag (see notes 11, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 13, 14)

Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 0 0 0 0 0 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 Note 13 X,CSF X,CSF X,CSF X,CSF X,CSF 0

Plasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Note 14 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Plasma Plasma Plasma Torch Cooling WaterTorch Cooling WaterTorch Cooling WaterTorch Cooling Water Note 11 CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

Note 11: The appropriate Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the start of the Station On FStation On FStation On FStation On Flush Cyclelush Cyclelush Cyclelush Cycle. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.

Note 12: The appropriate Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (NPlasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N2222/O/O/O/O2222

)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.

Note 13: The appropriate Plasma Gas Pressure Switches (HPlasma Gas Pressure Switches (HPlasma Gas Pressure Switches (HPlasma Gas Pressure Switches (H----35)35)35)35) for the selected stations will be checked for absence of pressure (normally open) at the beginning of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.

Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the beginning of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.




Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.9 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-N2, H-35 Plasma Start Gas N2, Plasma Cut Gas H-35




Station Off

Ready Line

Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent

Solenoid ValvesSolenoid ValvesSolenoid ValvesSolenoid Valves X = open/Enabled, Blank = Closed/Disabled, Analog X = open/Enabled, Blank = Closed/Disabled, Analog X = open/Enabled, Blank = Closed/Disabled, Analog X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0Value = 0Value = 0Value = 0----10 VDC10 VDC10 VDC10 VDC Plasma Gas N Plasma Gas N Plasma Gas N Plasma Gas N2222

X X X X Plasma Gas O Plasma Gas O Plasma Gas O Plasma Gas O2222

Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 X X X X X Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Note 8 Note 8 Note 9

P P P Plasma Torch Cooling Water pumplasma Torch Cooling Water pumplasma Torch Cooling Water pumplasma Torch Cooling Water pump X X X X X X X X X X X Note 7


/O/O/O/O2222 X X X


Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X Plasma C Plasma C Plasma C Plasma Cut Water/Shield Gas Cutut Water/Shield Gas Cutut Water/Shield Gas Cutut Water/Shield Gas Cut X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 Note 10 Note 10 Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X X X X



Note 1: LINE PURLINE PURLINE PURLINE PURGEGEGEGE will be initiated after the first Station On Flush CycleStation On Flush CycleStation On Flush CycleStation On Flush Cycle after a Vision Shift/StartVision Shift/StartVision Shift/StartVision Shift/Start. Line PurgeLine PurgeLine PurgeLine Purge will also be initiated each time SDP file selection specifies a change of plasma process gases. A torch consumable inquiry message will be displayed each time Line PurgeLine PurgeLine PurgeLine Purge is initiated.


Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection.Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1MKON 1MKON 1MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0)., once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59) is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection.


0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0).

Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKOMKOMKOMKON 8N 8N 8N 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Error Monitoring Requirements SF--N2--H -35 Plasma Start Gas – N2 Plasma Cut Gas – H-35


Station Off Ready

Line Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control

Vent

Process Pressure Switches X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure

CSF = monitored for stCSF = monitored for stCSF = monitored for stCSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)atus of change of state flag (see notes 11, 12, 13, 14)atus of change of state flag (see notes 11, 12, 13, 14)atus of change of state flag (see notes 11, 12, 13, 14) Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 Note 12 X,CSF X,CSF X,CSF 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 Note 13 X,CSF X,CSF 0

Plasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Note 14 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Torch Cooling WaPlasma Torch Cooling WaPlasma Torch Cooling WaPlasma Torch Cooling Waterterterter Note 11 CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

Note 11: The appropriate Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the start of the Station On Flush CycleStation On Flush CycleStation On Flush CycleStation On Flush Cycle. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.








Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.10 Plasma Process Solenoid and Proportional Valve Requirements PT-19XLS/PT-600 – SF-N2, O2 Plasma Start Gas N2, Plasma Cut Gas O2

FlowFlowFlowFlow Chart Reference: Chart Reference: Chart Reference: Chart Reference: A B C D E F G H J K L M N

Note: Plasma process gas selection is accomplished with

activation of the appropriate SDP file.

Station Off Ready Line

Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent

Solenoid ValvesSolenoid ValvesSolenoid ValvesSolenoid Valves X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0X = open/Enabled, Blank = Closed/Disabled, Analog Value = 0----10 VDC10 VDC10 VDC10 VDC Plasma Gas N Plasma Gas N Plasma Gas N Plasma Gas N2222


X X X X X Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Note 8 Note 8 Note 9

Plasma Torch Cooli Plasma Torch Cooli Plasma Torch Cooli Plasma Torch Cooling Water pumpng Water pumpng Water pumpng Water pump X X X X X X X X X X X Note 7




X X X Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X X Plasma Cut Water/S Plasma Cut Water/S Plasma Cut Water/S Plasma Cut Water/Shield Gas Cuthield Gas Cuthield Gas Cuthield Gas Cut X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X




Note 2: Plasma PreflowPlasma PreflowPlasma PreflowPlasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process PostflowProcess PostflowProcess PostflowProcess Postflow and Plasma Plasma Plasma Plasma Postflow Postflow Postflow Postflow was active for a minimum period of 3 seconds.

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1MKON 1MKON 1MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080 seconds

if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59) is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), pulsed continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection. Plasma high frequency will not be pulsed if MKONMKONMKONMKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

Note 6: Machine motion will be allowed and MIP OVERRIDEOVERRIDEOVERRIDEOVERRIDE 1 (MIP constant 35) will be enabled if MKON 5MKON 5MKON 5MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Plasma Process Error Monitoring Requirements SF--N2--O2 Plasma Start Gas – N2, Plasma Cut Gas – O2


Station Off

Ready Line

Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control

Vent

Process Pressure Switches X = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressureX = monitored for pressure present, 0 = monitored for absence of pressure CSF = monitored for status of cCSF = monitored for status of cCSF = monitored for status of cCSF = monitored for status of change of state flag (see notes 11, 12, 14)hange of state flag (see notes 11, 12, 14)hange of state flag (see notes 11, 12, 14)hange of state flag (see notes 11, 12, 14)

Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 Note 12 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 0 0 0 0 0 0

Plasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Note 14 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Torch Cooling WaterPlasma Torch Cooling WaterPlasma Torch Cooling WaterPlasma Torch Cooling Water Note 11 CSF X,CSF X,CSF X,CSF X,CSF X,CSF X









Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.11 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-N2, N2

Plasma Start Gas N2, Plasma Cut Gas N2




Station Off Ready

Line Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent


X X X X X X X X X X Plasma Gas O Plasma Gas O Plasma Gas O Plasma Gas O2222

Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary





X X X Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut X X X X X X Plas Plas Plas Plasma Gas Start ma Gas Start ma Gas Start ma Gas Start –––– H H H H----35353535 Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X





Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection.Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1MKON 1MKON 1MKON 1 (MIP constant 57) is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59) is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60) is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection. Plasma high frequency will not be pulsed if MKONMKONMKONMKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0.

Note 6: Machine motion will be allowed and MIP OVERRIDEOVERRIDEOVERRIDEOVERRIDE 1 (MIP constant 35) will be enabled if MKON 5MKON 5MKON 5MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0).

Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Plasma Process Error Monitoring Requirements SF--N2--N2 Plasma Start Gas – N2 Plasma Cut Gas – N2


Station Off

Ready Line

Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control

Vent


Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 Note 12 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 0 0 0 0 0

Plasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Note 14 X,CSF X,CSF X,CSF X,CSF X,CSF Plasma Torch Cooling WaterPlasma Torch Cooling WaterPlasma Torch Cooling WaterPlasma Torch Cooling Water Note 11 CSF X,CSF X,CSF X,CSF X,CSF X,CSF X









Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.12 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-N2, O2 Plasma Start Gas N2, Plasma Cut Gas O2




Station Off Ready

Line Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent


X X X X X X X X X Plasma Gas O Plasma Gas O Plasma Gas O Plasma Gas O2222

X P P P Plasma Gas Hlasma Gas Hlasma Gas Hlasma Gas H----35353535 Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary





X X X Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut X X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X




Note 2: Plasma PreflowPlasma PreflowPlasma PreflowPlasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process PostflowProcess PostflowProcess PostflowProcess Postflow and Plasma Plasma Plasma Plasma Postflow Postflow Postflow Postflow was active for a minimum period of 3 seconds.

Note 3: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active the first time the plasma is fired after manual station selection. Note 4: Plasma gas pre-switching and plasma cut water/shield gas pre-switching will not be active if the plasma high frequency is not pulsed. Note 5: Plasma high frequency will be pulsed once for 0.064 seconds if MKON 1MKON 1MKON 1MKON 1 (MIP constant 57 is set to 1. (set MKON 2, 3, and 4 to 0), once for 0.080

seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59 is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0) continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection.

Plasma high frequency will not be pulsed if MKONMKONMKONMKON 1 thru 4 (MIP constants 57, 58, 59, 60) are all set to 0. Note 6: Machine motion will be allowed and MIP OVERRIDEOVERRIDEOVERRIDEOVERRIDE 1 (MIP constant 35) will be enabled if MKON 5MKON 5MKON 5MKON 5 (MIP constant 61) is set to 1 (set MKON 6 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Plasma Process Error Monitoring Requirements SF--N2--O2 Plasma Start Gas – N2, Plasma Cut Gas – O2

Flow Chart RefFlow Chart RefFlow Chart RefFlow Chart Reference:erence:erence:erence: A B C D E F G H J K L M N

Station Off

Ready Line

Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control

Vent


Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 Note 12 X,CSF X,CSF X,CSF X,CSF X,CSF 0

Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 0 0 0 0 0 0 Plasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield GasPlasma Cutwater/Shield Gas Note 14 X,CSF X,CSF X,CSF X,CSF X,CSF 0 Plasma Torch Cooling WaterPlasma Torch Cooling WaterPlasma Torch Cooling WaterPlasma Torch Cooling Water Note 11 CSF X,CSF X,CSF X,CSF X,CSF X,CSF X

Note 11: The appropriate Plasma Torch Cooling Water PressuPlasma Torch Cooling Water PressuPlasma Torch Cooling Water PressuPlasma Torch Cooling Water Pressure Switchesre Switchesre Switchesre Switches for the selected stations will be checked for absence of pressure (normally open) at the start of the Station On Flush CycleStation On Flush CycleStation On Flush CycleStation On Flush Cycle. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.








Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.13 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-H-35, H-35 Plasma Start Gas N2, Plasma Cut Gas N2




Station Off Ready

Line Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent


X Plasma Gas O Plasma Gas O Plasma Gas O Plasma Gas O2222

Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 X X X X X X X X X Plasma Cutwater/Sh Plasma Cutwater/Sh Plasma Cutwater/Sh Plasma Cutwater/Shield Gas ield Gas ield Gas ield Gas X X X X X X X X X Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary Plasma Cutwater/Shield Gas Auxiliary X X X X

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump X X X X X X X X X X X NOTE 7


/O/O/O/O2222


Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut X X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 X X X X X X Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X X X X

Plasma Plasma Plasma Plasma Gas Purge Gas Purge Gas Purge Gas Purge –––– N N N N2222/O/O/O/O2222 X X

Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge Plasma Cut Water/Shield Gas Purge X


Note 2: Plasma PreflowPlasma PreflowPlasma PreflowPlasma Preflow will be by-passed under the following conditions: Plasma process start signal received from M-Code during Process PProcess PProcess PProcess Postflowostflowostflowostflow and Plasma Postflow Plasma Postflow Plasma Postflow Plasma Postflow was active for a minimum period of 3 seconds.


seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58) is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59 is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0) continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection.


0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Error Monitoring Requirements SF-- H-35 -- H-35 Plasma Start Gas – H-35 Plasma Cut Gas – H-35


Station

Off Ready Line

Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control

Vent


Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 0 0 0 0 0 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 Note 13 X,CSF X,CSF X,CSF X,CSF X,CSF 0


Note 11: The appropriate Plasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure SwitchesPlasma Torch Cooling Water Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

start of the Station On Flush CycleStation On Flush CycleStation On Flush CycleStation On Flush Cycle. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring. Note 12: The appropriate Plasma Gas Pressure Switches (NPlasma Gas Pressure Switches (NPlasma Gas Pressure Switches (NPlasma Gas Pressure Switches (N2222

/O/O/O/O2222)))) for the selected stations will be checked for absence of pressure (normally open) at the beginning

of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring. Note 13: The appropriate Plasma Gas Pressure SwPlasma Gas Pressure SwPlasma Gas Pressure SwPlasma Gas Pressure Switches (Hitches (Hitches (Hitches (H----35)35)35)35) for the selected stations will be checked for absence of pressure (normally open) at the beginning

of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostflowProcess PostflowProcess PostflowProcess Postflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring. Note 14: The appropriate Plasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure SwitchesPlasma Cutwater/Shield Gas Pressure Switches for the selected stations will be checked for absence of pressure (normally open) at the

beginning of Process StartProcess StartProcess StartProcess Start if the plasma start signal is not originated during Process PostProcess PostProcess PostProcess Postflowflowflowflow. Switch status is flagged to provide Change of StateChange of StateChange of StateChange of State error monitoring.




Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.14 Plasma Process Solenoid and Proportional Valve Requirements PT-15XL – SF-N2, H-35 Plasma Start Gas N2, Plasma Cut Gas H-35




Station Off Ready

Line Purge Note 1

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow Note 2

Process High Volt

Delay

Process Pre-

Switch Note 3, 4

Process High Freq.

Note 5


Process Cut

Note 9

Process Post Flow

Flow Control

Vent



Plasma Gas H Plasma Gas H Plasma Gas H Plasma Gas H----35353535 X X X X X Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas Plasma Cutwater/Shield Gas X X X X X X X X X Plasma Cut Plasma Cut Plasma Cut Plasma Cutwater/Shield Gas Auxiliary water/Shield Gas Auxiliary water/Shield Gas Auxiliary water/Shield Gas Auxiliary X X X X

Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump Plasma Torch Cooling Water pump X X X X X X X X X X X NOTE 7


/O/O/O/O2222 X X X


Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start Plasma Cut Water/Shield Gas Start X X X Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut Plasma Cut Water/Shield Gas Cut X X X X X X Plasma Gas Start Plasma Gas Start Plasma Gas Start Plasma Gas Start –––– H H H H----35353535 NOTE 10 NOTE 10 Plasma Gas cut Plasma Gas cut Plasma Gas cut Plasma Gas cut –––– H H H H----35353535 X X X X






seconds if MKON 2MKON 2MKON 2MKON 2 (MIP constant 58 is set to 1. (set MKON 1, 3, and 4 to 0), once for 0.096 seconds if MKON 3MKON 3MKON 3MKON 3 (MIP constant 59 is set to 1. (set MKON 1, 2, and 4 to 0), once for 0.112 seconds if MKON 4MKON 4MKON 4MKON 4 (MIP constant 60 is set to 1. (set MKON 1, 2, and 3 to 0), continuously as specified with 0.032 second off intervals the first time the plasma is fired after manual station selection.


0). Machine motion will be allowed and MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2MIP OVERRIDE 2 (MIP constant 36) will be enabled if MKON 6MKON 6MKON 6MKON 6 (MIP constant 62) is set to 1 (set MKON 5 and 7 to 0). Machine motion will be allowed and MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3MIP OVERRIDE 3 (MIP constant 37) will be enabled if MKON 7MKON 7MKON 7MKON 7 (MIP constant 63) is set to 1 (set MKON 5 and 6 to 0). Note 7: The plasma torch cooling water will not be on during FLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENTFLOW CONTROL VENT if the SmartFlow II stations were de-selected. Note 8: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1 and pre-switching is active. Note 9: The auxiliary valve will be opened only if MKON 8MKON 8MKON 8MKON 8 (MIP constant 64) is set to 1. Note 10: Plasma Gas Start – Analog Output H-35 must be set it the same value as Plasma Gas Start – Analog Output N2/O2

Error Monitoring Requirements SF--N2--H -35 Plasma Start Gas – N2 Plasma Cut Gas – H-35


Station Off Ready

Line Purge

Plasma Test

(Start)

Plasma Test (Cut)

Process Start

Preflow

Process High Volt

Delay

Process Pre-

Switch

Process High Freq.

Process Pierce

Process Cut

Process Post Flow

Flow Control Vent

Process Pressure Switches X = monitored for pressure preX = monitored for pressure preX = monitored for pressure preX = monitored for pressure present, 0 = monitored for absence of pressuresent, 0 = monitored for absence of pressuresent, 0 = monitored for absence of pressuresent, 0 = monitored for absence of pressure

CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14)CSF = monitored for status of change of state flag (see notes 11, 12, 13, 14) Plasma gas NPlasma gas NPlasma gas NPlasma gas N2222/O/O/O/O2222 Note 12 X,CSF X,CSF X,CSF 0 Plasma Gas HPlasma Gas HPlasma Gas HPlasma Gas H----35353535 Note 13 X,CSF X,CSF 0










Visionshift/start

Station off

Station on?


Station on?


Ready

Station on?


Line purgerequired?

Plasma test?

Plasma start?

Process start

Plasma stop?

Error condition?

Station on?

Preflowcomplete?


Plasma stop?

Error condition?

Station on?


Processpre-switch

Plasma stop?

Error condition?

Station on?

Pre-switchcomplete?


Plasma stop?

Error condition?

Station on?

Arc established?

Process pierce

Plasma stop?

Error condition?

Station on?

Pierce complete?

Process cut

Plasma stop?

Error condition?

Station on?

Line purge

Station on?


Line purgecomplete?

Plasma test?

Plasma Test(start)

Station on?


Line purgerequired?

Plasma test (cut)?

Plasma test(cut)

Station on?


Line purgerequired?

Plasma test?

Plasma test?

Plasma test (cut)?

ProcessPostflow

Line purgerequired?

Station on?

Plasma start?

Postflowcomplete?

Flow controlvent

Station on?

Plasma start?

Vent complete?

Vent timecomplete?

Station on?

Error condition?

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

No

Yes

Yes

Yes

Yes

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

Yes

A

B

C

D

E

F

G

H

J

K

L

M

N



6.9.15 SmartFlow II Test Files 3 SP_BEGINN ; SF1.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - O2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 1. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THIS TEST FILE DOES NOT MODIFY ANY OF THE CUTTING PACKAGE PROCESS ; PARAMETERS. N1 ; Plasma Process (SF-N2-O2) ; DESIGNATION LINE 1. (NO PARAMETER ALTERATION) ; DESIGNATION LINE 2. M1000000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 SP_ENDE 4



3 SP_BEGINN ; SF2.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - N2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 2. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THIS TEST FILE DOES NOT MODIFY ANY OF THE CUTTING PACKAGE PROCESS ; PARAMETERS. N1 ; Plasma Process (SF-N2-N2) ; DESIGNATION LINE 1. (NO PARAMETER ALTERATION) ; DESIGNATION LINE 2. M0100000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 SP_ENDE 4



3 SP_BEGINN ; SF3.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - H35, PLASMA CUT GAS - H35. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 3. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THIS TEST FILE DOES NOT MODIFY ANY OF THE CUTTING PACKAGE PROCESS ; PARAMETERS. N1 ; Plasma Process (SF-H35-H35) ; DESIGNATION LINE 1. (NO PARAMETER ALTERATION) ; DESIGNATION LINE 2. M0010000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 SP_ENDE 4



3 SP_BEGINN ; SF1ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - O2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 1. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO. N1 ; Plasma Process (SF-N2-O2) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2. M1000000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 ; NA = NOT APPLICABLE TO THIS MATERIAL. P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME SP_ENDE 4



3 SP_BEGINN ; SF2ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - N2. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 2. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO. N1 ; Plasma Process (SF-N2-N2) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2. M0100000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 ; NA = NOT APPLICABLE TO THIS MATERIAL. P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME SP_ENDE 4



3 SP_BEGINN ; SF3ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - H35, PLASMA CUT GAS - H35. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 3. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO. N1 ; Plasma Process (SF-H35-H35) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2. M0010000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 ; NA = NOT APPLICABLE TO THIS MATERIAL. P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME SP_ENDE 4



3 SP_BEGINN ; SF4ZERO.SDP ; SMART FLOW II SDP TEST FILE. ; VERSION OF 25 JANUARY 1999. ; PLASMA START GAS - N2, PLASMA CUT GAS - H35. ; THE CUTTING RECORD FLAG (Mb) MUST HAVE A 1 IN POSITION 4. ; THIS TEST SDP FILE IS FOR PROCESS GAS SELECTION ONLY. ; THE CUTTING PACKAGE PROCESS PARAMETERS SPECIFIED IN THIS TEST ; FILE ARE MODIFIED TO A VALUE OF ZERO. N1 ; Plasma Process (SF-N2-H35) ; DESIGNATION LINE 1. (PARAMETER ALTERATION TO ZERO) ; DESIGNATION LINE 2. M0001000000000000 ;CUTTING RECORD FLAG (PROCESS GAS SELECTION). ;1234567891111111 ; 0123456 ; NA = NOT APPLICABLE TO THIS MATERIAL. P100 W0.0 U66 Q200 ; STANDOFF P101 W0.0 U0 Q100 ; INITIAL HEIGHT P105 W0.0 U0.0 Q255.0 ; SMART FLOW REMOTE CURRENT P102 W0.0 U0.0 Q100.0 ; START GAS P103 W0.0 U0.0 Q100.0 ; CUT GAS P104 W0.0 U0.0 Q100.0 ; START WATER OR SHIELD GAS P106 W0.0 U0.0 Q100.0 ; CUT WATER OR SHIELD GAS P132 W0.0 U0.0 Q100.0 ; START H35 GAS P133 W0.0 U0.0 Q100.0 ; CUT H35 GAS T1 W0.0 U0.0 Q50.0 ; PLASMA RISE ON PIERCE TIME T14 W0.0 U0.0 Q50.0 ; PLASMA PIERCE TIME T2 W0.0 U0.0 Q50.0 ; PLASMA TRAVEL DELAY TIME T23 W0.0 U0.0 Q50.0 ; PLASMA AHC DELAY TIME T5 W0.0 U0.0 Q50.0 ; MASTER UP TIME SP_ENDE 4



6.10 SmartFlow II Secondary Shield Gas Proportional Valve Calibration Procedure

NOTICE

The Secondary Shield Gas (and Cutwater) The Secondary Shield Gas (and Cutwater) The Secondary Shield Gas (and Cutwater) The Secondary Shield Gas (and Cutwater) Proportional valve is the only proportional valve Proportional valve is the only proportional valve Proportional valve is the only proportional valve Proportional valve is the only proportional valve that can be calibrated. that can be calibrated. that can be calibrated. that can be calibrated.

Plasma Gas proportional valves aPlasma Gas proportional valves aPlasma Gas proportional valves aPlasma Gas proportional valves are calibrated re calibrated re calibrated re calibrated by the valve manufacturer to ESAB by the valve manufacturer to ESAB by the valve manufacturer to ESAB by the valve manufacturer to ESAB specifications. Do not attempt to calibrate.specifications. Do not attempt to calibrate.specifications. Do not attempt to calibrate.specifications. Do not attempt to calibrate.

P3 P4

P1

S1, S2, S3, S4

Cutwater/Secondary Shield Proportional

Valve

P2

Pin3

Pin2

Pin4

Pin1

The following instructions are for calibrating single or multiple station machines to ensure a consistent value for the Cut Water/Shield proportional valve. This calibration procedure will ensure the SDP files developed in the factory conform to the same screen values and output pressures as factory settings.

These instructions are tested for PT19XLS and These instructions are tested for PT19XLS and These instructions are tested for PT19XLS and These instructions are tested for PT19XLS and PTPTPTPT----600 Secondary Shield only.600 Secondary Shield only.600 Secondary Shield only.600 Secondary Shield only.

1. Calibrate the frequency of the proportional valve using Pin2 to Pin3 for 300 Hz for gas and water using P4 (potentiometer).

2. Check voltage on Pin2 to Pin3 on Cutwater/Shield proportional valve. At 100 on Vision Parameter Window for "Cut Water or Shield" the voltage should be approximately 10 VDC.

3. Set shield gas regulator to 80 psi on the back of the plumbing box with screen value for "Cutwater/Shield" set to 100.

4. Check shield gas gauge (on front of plumbing box) for max output pressure equal to about 32 psi. Adjust P3 (potentiometer) on proportional valve board to maximum value by turning clockwise until the pressure peaks out. Then turn counterclockwise until the pressure begins to drop. This will insure the valve is at the maximum opening for the voltage.

5. Recheck shield input gas regulator is at 80 psi at 100 on screen. Reset to 80 psi if necessary and recheck for maximum output pressure of 32 psi.



P1 (potentiometer)

6. Set screen value for "Cut Water or Shield" to 20. Check voltage on Pins 2 to 3 on Cut Water/Shield proportional valve. The voltage should be approximately 2 volts. Check Shield gas gauge for minimum output pressure equal to 4 psi approximately (this is the first tick mark on the gauge above the needle rest). Adjust P1 on proportional valve board to 4 psi. Use a similar procedure to step 4) to reach a consistent value on the gauge. This will result in a minimum opening of the valve at low settings.

7. Check the gauge pressure for Secondary Shield set at 50 on the screen. This should be approximately 14 psi on the plumbing box gauge (adjust P2 to obtain 14-16 psi ).

8. Lower the inlet gas regulator to 60 psi with the screen value set to 100. This should result in a gauge pressure of approximately 22 psi. This will insure the SDP files generated since January 2000 will be consistent in the field.

SECTION 7 REPLACEMENT PARTS


7.1 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.

7.2 Ordering

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 or from: ESAB Welding and Cutting Products ATTN: Customer Service Department PO Box 100545 Ebenezer Road Florence, SC USA 29501-0545 Phone (843) 664-4405 (800) ESAB-123 (372-3123) ESAB Cutting Systems - Canada 6010 Tomken Road Mississauga, Ontario, Canada L5T 1X9 Phone (905) 670-0220 Fax (905) 670-4879 ESAB Cutting Systems GmbH Robert-Bosch-Strasse 20 Postfach 1128 D-61184 Karben Phone 011-49-6039-400 Fax 011-49-6039-403-02 http://www.esab.de Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the last page of this manual for a list of customer service phone numbers.



7.3 Right Inside without H-35 Option -- Replacement Parts

12

3

45

6

78

9

N2

O2/N2

Pressure Switch

O2

Air Curtain

Primary CutWater

Aux. CutWater

Cut WaterPressure Switch

O2/N2Proportional Valve

Plasma GasPressure Tap

Air CurtainPressure Tap

Cut WaterPressure Tap

10



Item Item Item Item

NumberNumberNumberNumber Part NumberPart NumberPart NumberPart Number QuaQuaQuaQuantityntityntityntity DescriptionDescriptionDescriptionDescription

1 0558001056 1 Manifold Assembly without H-35 proportional valve

2 0558001068 1 Valve Sentronic 0-6 bar Manifold Mount Oxygen

0558001282 2 O-Ring…Proportional valve 5mm ID X 1mm

0558001283 1 O-Ring…Proportional valve 4mm ID X 1mm

3 0558001066 5 Valve solenoid, 2 way series 2, 120vac 150 mopd 1/8 oriface

4 952920 2 Pressure Switch 50 psi non-adj

5 0558001064 1 Hose ¼ npt M X ¼ npt F X Swivel Ball 13.5" long

6 0558001063 1 Hose ¼ npt M X ¼ npt F X 10.75" long

7 0558001062 1 Hose ¼ npt M X ¼ npt F X 6" long

8 56998261 1 Valve Proportional Water Pulse Width Modulator

56997044 1 Valve Proportional Water 24VDC


10 37540 SmartFlow II Plumbing Box Assembly without H-35



7.4 Right Inside with H-35 Option – Replacement Parts

12

3

457

N2

O2/N2Pressure Switch

O2

Air Curtain

Primary CutWater

Aux. CutWater

Cut WaterPressure Switch

O2/N2Proportional Valve

Plasma GasPressure Tap

Air CurtainPressure Tap

Cut WaterPressure Tap

689

H-35

Pressure SwitchH-35

H-35Proportional Valve

P4 P5 P7

11

10



Item Item Item Item

NumberNumberNumberNumber Part NumberPart NumberPart NumberPart Number QuantityQuantityQuantityQuantity DescriptionDescriptionDescriptionDescription

1 0558001061 1 Manifold Assembly H-35 proportional valve

2 0558001068 1 Valve Sentronic 0-6 bar Manifold Mount Oxygen

0558001282 2 O-Ring… Proportional valve 5mm ID X 1mm


3 0558001066 6 Valve solenoid, 2 way series 2, 120vac 150 mopd 1/8 oriface

4 952920 2 Pressure Switch 50 psi non-adj

5 0558001064 1 Hose ¼ npt M X ¼ npt F X Swivel Ball 13.5" long


7 0558001062 1 Hose ¼ npt M X ¼ npt F X 6" long

8 56998261 1 Valve Proportional Water Pulse Width Modulator

56997044 1 Valve Proportional Water 24VDC


10 37538 SmartFlow II Plumbing Box Assembly with H-35

11 0558001065 1 Valve Sentronic 0-6 bar Manifold Mount H-35





7.5 Front Outside Parts – SmartFlow II

60

100

100

AIR CURTAIN

CUT GAS

CUT WATER

AIR CURTAIN

CUT GAS

CUT WATER

1

2

3456

To Pilot ArcStart Box



Item Item Item Item


1 0558001060 1 Pressure Gauge 2½" 60 psi

2 0558001059 2 Pressure Gauge 2½" 100 psi

3 0558001054 1 Label Set

4 33053 1 Strain Relief 2" Torch

5 0558001057 1 Knurled Nut-Fiber Optic Cable Holder

6 0558001058 1 (Internal) Fiber Optic Cable Assembly for spark viewing.



7.6 Left Inside Parts

P3

P1

P2

R2C1

12

34567



Item Item Item Item


1 0558001055 1 High Freq Arc Starter Box

2 0558001050 1 Printed Circuit Board

3 0558001053 1 Buss Bar Block Assembly

4 0558001051 1 Check Valve ¼ NPT M X ¼ NPT M

5 0558001049 1 Hose ¼ NPT F X ¼ NPT F X 7.5" Long

6 0558001052 1 Hose ¼ NPT M X ¼ NPT M X 11" Long

7 63383 1 Flow Switch 1.0 GPM

0558001051 1 Check Valve ¼ NPT M X ¼ NPT M



7.7 Back Outside Parts

COOLING WATEROUT IN

CUT WATER

AIR

OXYGEN

NITROGEN

3

2

1

4



Item Item Item Item


1 0558001047 4 Grommet Cable Clamp “Small” 14-15mm

0558001048 3 Grommet Cable Clamp “Large” 27-28mm

2 0558001054 Ref Label Set (Same set as shown on front parts)

3 56997206 3 Muffler Exhaust Brass 1/8 NPT Male

4 56998133 As required 25 micron gas filter with bowl guard

Not shown 0560988406 1 per filter Replacement filter ELEMENT for 56998133




Customer // Technical Support

(843) 664-4405 (800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road Florence, SC 29501-0545

http://www.esab.com

ESAB Cutting Systems – Canada 6010 Tomken Road

Mississauga, Ontario Canada L5T 1X9 Phone: (905) 670-0220

Fax: (905) 670-4879

ESAB Cutting Systems GMBH Robert-Bosch-Strasse 20

Postfach 1128 D-61184 Karben 1

Germany Phone 011-49-6039-400 Fax 011-49-6039-403-02

http://www.esab.de

Printed in U.S.A

SmartFlow II Plasma System Plumbing Box - ESAB equipment... · 2015-11-17 · SmartFlow II Plasma System Plumbing Box . The equipment described in this manual is ... 3.8 System Component

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