m3 Plasma-Shield Gas Boxes 0558005487

Precision Plasmarc
Plasma Gas Box & Shield Gas Box

Shield Gas Box
Plasma Gas Box
Instruction Manual
0558005487
10 / 2008
Be sure this information reaches the operator.

You can get extra copies through your supplier.
caution
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging, Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!
table of contents
Section / Title
1.0

Page
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Safety - English . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety - Spanish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 Safety - French . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.1 System Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 System Gas Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Plasma Gas Box Water Supply Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5 Plasma Gas Box Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.6 Shield Gas Box Electrical Input Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.7 System Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.8 Plasma Gas Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.9 Shield Gas Box Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.1 Plasma Gas Box Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.2 Plasma Gas Box Mounting (Bottom View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.3 Plasma Gas Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4 Plasma Gas Box Nomex Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.5 Plasma Gas Box Gas Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.6 Shield Gas Box Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.7 Shield Gas Box Mounting (Bottom View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.8 Shield Gas Box Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.9 Component Relationship Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.1 Plasma Gas Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.2 Plasma Gas Box Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4.3 Plasma Gas Box Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.4 Shield Gas Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.5 Shield Gas Box Air Regulator for Air Curtain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4.6 Shield Gas Box Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
table of contents
5.0

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Plasma Gas Box Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.2 Plasma Gas Box Schematic (Plumbing Schematic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.3 Plasma Gas Box Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.4 Spark Gap Of the Arc Starter Box (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.5 Spark Adjustment Procedure (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.6 Cooling Water Circuit (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.7 Plasma Gas Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.8 Voltage Divider Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.9 Voltage Divider Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.10 Shield Gas Box Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.11 Shield Gas Box Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.12 Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.13 Mass Flow Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.14 Gas Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.15 Fluid Schematic m3 Plasma System Plasma Gas Box and Shield Gas Box . . . . . . . . . . . . . . . . . . . . . . . . 60
6.0

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
6.3 Plasma Gas Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.4 Start Gas Manifold (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5 Buss Bar Manifold (Plasma Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.6 Shield Gas Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.7 Shield Gas Manifold (Shield Gas Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
section 1
safety precautions
1.0 Safety Precautions
1.1 Safety - English
WARNING: These Safety Precautions are

for your protection. They summarize precautionary information from the references
listed in Additional Safety Information section. Before performing any installation or operating
procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.
FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot
slag or sparks can also cause fires and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protective non-flammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make
certain that such openings are protected from hot
sparks and metal.
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and
create a fire hazard.
6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269.
PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging

processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy longsleeve shirt, cuffless trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.
5. Protect other personnel from arc rays and hot
sparks with a suitable non-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.
ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is confined, or if there is
danger of falling.
section 1
safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
3. Welders should use the following procedures to

minimize exposure to EMF:
2. Connect the workpiece to a good electrical

ground.
A. Route the electrode and work cables together.

Secure them with tape when possible.
3. Connect the work cable to the workpiece. A poor

or missing connection can expose you or others
to a fatal shock.
B. Never coil the torch or work cable around your

body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
D. Connect the work cable to the workpiece as close

as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
6. Make sure that all parts of your body are insulated

from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
Therefore:
9. Turn off the power before removing your gloves.
FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specific grounding recommendations. Do not mistake the work lead for a ground
cable.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
ELECTRIC AND MAGNETIC FIELDS

May be dangerous. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discomfort persists.
1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specific ventilation recommendations.
2. Exposure to EMF may have other health effects which

are unknown.
6
section 1
safety precautions
5. WARNING: This product, when used for welding

or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
25249.5 et seq.)
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and fittings in good
condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas
cylinder.
5. Keep all safety devices and cabinet covers in position

and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
Cutting"
EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can
cause injury or death. Therefore:
4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"
7
section 1
safety precautions
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding

6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
Meaning of symbols - As used

throughout this manual: Means Attention! Be Alert! Your safety is involved.
Means immediate hazards which,

if not avoided, will result in immediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
section 1
sEGURIDAD
1.2 Safety - Spanish
La escoria puede estar caliente y dEPPrenderse con

velocidad. Personas cercanas debern usar gafas
de seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de Seguridad son para su proteccin. Ellas hacen

resumen de informacin proveniente de las
referencias listadas en la seccin "Informacin Adicional Sobre La Seguridad". Antes de hacer cualquier
instalacin o procedimiento de operacin , asegrese
de leer y seguir las precauciones de seguridad listadas
a continuacin as como tambin todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en dao a la persona o muerte.
FUEGO Y EXPLOSIONES -- El calor de

las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del rea
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, lquidos y gases flamables, solventes,
pinturas, papel, etc.
2. Chispas y partculas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o EPPacios.
Asegrese de que toda grieta y agujero est cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo est totalmente limpia y libre de substancias que puedan
producir gases inflamables o vapores txicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor porttil. Asegrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operacin. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.
6. DEPPus de termirar la operacin del equipo, inspeccione el rea de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego ms
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para informacin adicional , haga referencia a la
publicacin NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a travs de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte

y ranurado son ruidosos y requiren
proteccin para los odos. El arco,
como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden daar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:
1. Utilice gafas de seguridad con proteccin a los lados
siempre que est en el rea de trabajo, an cuando
est usando careta de soldar, protector para su cara
u otro tipo de proteccin.
2. Use una careta que tenga el filtro correcto y lente
para proteger sus ojos, cara, cuello, y odos de las
chispas y rayos del arco cuando se est operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse
a los rayos del arco elctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantaln de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.
4. Chispas y partculas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantaln o los bolsillos. Mangas y cuellos debern
mantenerse abotonados, bolsillos al frente de la
camisa debern ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable
como divisin.
6. Use careta protectora adems de sus gafas de seguridad cuando est removiendo escoria o puliendo.
CHOQUE ELECTRICO -- El contacto

con las partes elctricas energizadas
y tierra puede causar dao severo o
muerte. NO use soldadura de corriente alterna (AC) en reas hmedas,
de movimiento confinado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
section 1
sEGURIDAD
1. Asegrese de que el chasis de la fuente de poder

est conectado a tierra atravs del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra fsica.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque elctrico fatal.
4. Use el equipo solamente si est en buenas condiciones. Reemplaze cables rotos, daados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el rea de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegrese que todas las partes de su cuerpo estn
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o reas hmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicacin ANSI/ASC
Standard Z49.1 (listado en la prxima pgina) para
recomendaciones EPPecficas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
3. Los soldadores debern usar los siguientes procedimientos para minimizar exponerse al EMF:
A. Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C. Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un slo lado de su cuerpo.
D. Conecte el cable de trabajo a la pieza de trabajo
lo ms cercano posible al rea de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo ms lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
dao, particularmente en EPPacios
sin ventilacin. No inhale el humo
o gases. El gas de proteccin puede
causar falta de oxgeno.
Por lo tanto:
1. Siempre provea ventilacin adecuada en el rea
de trabajo por medio natural o mecnico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berlio, o cadmio a menos que provea ventilacin mecnica
positiva . No rEPPire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias qumicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfgeno,
o gas txico, y otros irritant es.
3. Si momentneamente desarrolla inrritacin de
ojos, nariz o garganta mientras est operando, es
indicacin de que la ventilacin no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilacin en el rea de trabajo.
No contine operando si el malestar fsico persiste.
4. Haga referencia a la publicacin ANSI/ASC Standard
Z49.1 (Vea la lista a continuacin) para recomendaciones EPPecficas en la ventilacin.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente

elctrica fluye atravs de cualquier
conductor causando a nivel local
Campos Elctricos y Magnticos
(EMF). Las corrientes en el rea de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazn debern consultar a su mdico antes de
soldar. El Campo Electromagntico (EMF) puede
interferir con algunos marca-pasos.
2. Exponerse a campos electromagnticos (EMF) puede
causar otros efectos de salud an desconocidos.
10
section 1
sEGURIDAD
5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,

produce humos o gases, los
cuales contienen qumicos
conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code 25249.5 et seq.)

1. Siempre tenga personal cualificado para efectuar l a instalacin, diagnstico, y mantenimiento

del equipo. No ejecute ningn trabajo elctrico a
menos que usted est cualificado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningn
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, tambin lugares hmedos como charcos
de agua , aceite o grasa, atmsferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artculos de seguridad y
coverturas del equipo en su posicin y en buenas
condiciones.
6. Use el equipo slo para el propsito que fue
diseado. No modifique el equipo en ninguna
manera.
MANEJO DE CILINDROS-- Los

cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, vlvula, o vlvula de
escape puede causar dao o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize

un regulador diseado para operar y reducir la
presin del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operacin del manufacturero para montar el
regulador en el cilindro de gas comprimido.
INFORMACION ADICIONAL DE SEGURIDAD -- Para ms informacin sobre las

prcticas de seguridad de los equipos de
arco elctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
2. Asegure siempre los cilindros en posicin vertical

y amrrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazn. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito ellectrico.
Las siguientes publicaciones, disponibles atravs de

la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
3. Cuando el cilindro no est en uso, mantenga la

vlvula del cilindro cerrada. Ponga el capote de
proteccin sobre la vlvula si el regulador no
est conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los

Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo

defectuoso o mal mantenido puede
causar dao o muerte. Por lo tanto:

Cutting"
11
section 1
sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Segn usted avanza en la lectura
de este folleto: Los Smbolos Significan Atencin! Est Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio dao
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio dao personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daos
a la persona.
12
section 1
sCURIT
1.3 Safety - French
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les tincelles
peuvent galement provoquer un
incendie ou une explosion. Par consquent :
AVERTISSEMENT : Ces rgles de scurit

ont pour but d'assurer votre protection. Ils
rcapitulent les informations de prcaution
provenant des rfrences dans la section
des Informations de scurit supplmentaires. Avant
de procder l'installation ou d'utiliser l'unit, assurezvous de lire et de suivre les prcautions de scurit cidessous, dans les manuels, les fiches d'information sur la
scurit du matriel et sur les tiquettes, etc. Tout dfaut
d'observer ces prcautions de scurit peut entraner
des blessures graves ou mortelles.
1. loignez suffisamment tous les matriaux combustibles de l'aire de travail et recouvrez les matriaux
avec un revtement protecteur ininflammable. Les
matriaux combustibles incluent le bois, les vtements, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revtements, le
papier, etc.
2. Les tincelles et les projections de mtal incandescent peuvent tomber dans les fissures dans
les planchers ou dans les ouvertures des murs et
dclencher un incendie couvant l'tage infrieur
Assurez-vous que ces ouvertures sont bien protges
des tincelles et du mtal incandescent.
3. N'excutez pas de soudure, de coupe ou autre travail chaud avant d'avoir compltement nettoy la
surface de la pice traiter de faon ce qu'il n'ait
aucune substance prsente qui pourrait produire
des vapeurs inflammables ou toxiques. N'excutez
pas de travail chaud sur des contenants ferms
car ces derniers pourraient exploser.
4. Assurez-vous qu'un quipement d'extinction
d'incendie est disponible et prt servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'tre bien
instruit par rapport l'usage de cet quipement.
5. Assurez-vous de ne pas excder la capacit de
l'quipement. Par exemple, un cble de soudage
surcharg peut surchauffer et provoquer un incendie.
6. Une fois les oprations termines, inspectez l'aire de
travail pour assurer qu'aucune tincelle ou projection de mtal incandescent ne risque de provoquer
un incendie ultrieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplmentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
PROTGEZ-VOUS -- Les processus de

soudage, de coupage et de gougeage
produisent un niveau de bruit lev et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, met des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures la
peau et les yeux. Le mtal incandescent peut causer
des brlures. Une formation relie l'usage des
processus et de l'quipement est essentielle pour
prvenir les accidents. Par consquent:

1. Portez des lunettes protectrices munies d'crans latraux lorsque vous tes dans l'aire de travail, mme
si vous devez porter un casque de soudeur, un cran
facial ou des lunettes tanches.
2. Portez un cran facial muni de verres filtrants et de
plaques protectrices appropries afin de protger
vos yeux, votre visage, votre cou et vos oreilles des
tincelles et des rayons de l'arc lors d'une opration
ou lorsque vous observez une opration. Avertissez
les personnes se trouvant proximit de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
lectrique ou le mtal incandescent.
3. Portez des gants ignifugis crispin, une chemise
paisse manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protger des
rayons de l'arc, des tincelles et du mtal incandescent,
en plus d'un casque de soudeur ou casquette pour
protger vos cheveux. Il est galement recommand
de porter un tablier ininflammable afin de vous protger des tincelles et de la chaleur par rayonnement.
4. Les tincelles et les projections de mtal incandescent
risquent de se loger dans les manches retrousses,
les rebords de pantalons ou les poches. Il est recommand de garder boutonns le col et les manches et
de porter des vtements sans poches en avant.
5. Protgez toute personne se trouvant proximit des
tincelles et des rayons de l'arc l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes tanches par dessus vos lunettes
de scurit lors des oprations d'caillage ou de
meulage du laitier. Les cailles de laitier incandescent
peuvent tre projetes des distances considrables.
Les personnes se trouvant proximit doivent galement porter des lunettes tanches par dessus leur
lunettes de scurit.
CHOC LECTRIQUE -- Le contact avec

des pices lectriques ou les pices
de mise la terre sous tension peut
causer des blessures graves ou mortelles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en EPPace
restreint ou si un danger de chute se pose.
13
section 1
sCURIT
1. Assurez-vous que le chssis de la source

d'alimentation est branch au systme de mise
la terre de l'alimentation d'entre.
2. Branchez la pice traiter une bonne mise de
terre lectrique.
3. Branchez le cble de masse la pice traiter et
assurez une bonne connexion afin d'viter le risque
de choc lectrique mortel.
4. Utilisez toujours un quipement correctement
entretenu. Remplacez les cbles uss ou endommags.
5. Veillez garder votre environnement sec, incluant
les vtements, l'aire de travail, les cbles, le portelectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isol
de la pice traiter et des pices de la mise la
terre.
7. Si vous devez effectuer votre travail dans un EPPace
restreint ou humide, ne tenez vous pas directement sur le mtal ou sur la terre; tenez-vous sur
des planches sches ou une plate-forme isole et
portez des chaussures semelles de caoutchouc.
8. Avant de mettre l'quipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'quipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (list
la page suivante) pour des recommandations
spcifiques concernant les procdures de mise
la terre. Ne pas confondre le cble de masse avec
le cble de mise la terre.
3. Les soudeurs doivent suivre les procdures suivantes

pour minimiser l'exposition aux champs lectriques
et magntiques :
A. Acheminez l'lectrode et les cbles de masse
ensemble. Fixez-les l'aide d'une bande adhsive
lorsque possible.
B. Ne jamais enrouler la torche ou le cble de masse
autour de votre corps.
C. Ne jamais vous placer entre la torche et les cbles
de masse. Acheminez tous les cbles sur le mme
ct de votre corps.
D. Branchez le cble de masse la pice traiter le
plus prs possible de la section souder.
E. Veillez garder la source d'alimentation pour le
soudage et les cbles une distance approprie
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulirement
dans les EPPaces restreints. Ne rEPPirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par consquent :
1. Assurez en permanence une ventilation adquate
dans l'aire de travail en maintenant une ventilation naturelle ou l'aide de moyens mcanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matriaux tels que
l'acier galvanis, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mcaniques de ventilation efficaces. Ne
rEPPirez pas les vapeurs de ces matriaux.
2. N'effectuez jamais de travaux proximit d'une
opration de dgraissage ou de pulvrisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chlor, ceci peut dclencher
la formation de phosgne ou d'autres gaz irritants,
tous extrmement toxiques.
3. Une irritation momentane des yeux, du nez ou de la
gorge au cours d'une opration indique que la ventilation n'est pas adquate. Cessez votre travail afin
de prendre les mesures ncessaires pour amliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opration si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 ( la page
suivante) pour des recommandations spcifiques
concernant la ventilation.
CHAMPS LECTRIQUES ET MAGNTIQUES comportent un risque de

danger. Le courant lectrique qui
passe dans n'importe quel conducteur produit des champs lectriques
et magntiques localiss. Le soudage et le courant de coupage crent des champs lectriques
et magntiques autour des cbles de soudage et
l'quipement. Par consquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son mdecin avant d'entreprendre une
opration de soudage. Les champs lectriques et
magntiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition des champs lectriques et magntiques peut avoir des effets nfastes inconnus pour
la sant.
14
section 1
sCURIT
5. AVERTISSEMENT : Ce produit, lorsqu'il est utilis

dans une opration de soudage ou de
coupage, dgage des vapeurs ou des
gaz contenant des chimiques considres par l'tat de la Californie comme
tant une cause des malformations
congnitales et dans certains cas, du
cancer. (California Health & Safety
Code 25249.5 et seq.)
ENTRETIEN DE L'QUIPEMENT -- Un quipement entretenu de faon dfectueuse ou

inadquate peut causer des blessures
graves ou mortelles. Par consquent :
1. Efforcez-vous de toujours confier les tches
d'installation, de dpannage et d'entretien un
personnel qualifi. N'effectuez aucune rparation
lectrique moins d'tre qualifi cet effet.
2. Avant de procder une tche d'entretien
l'intrieur de la source d'alimentation, dbranchez
l'alimentation lectrique.
3. Maintenez les cbles, les fils de mise la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon tat. N'utilisez jamais un quipement s'il prsente une dfectuosit
quelconque.
4. N'utilisez pas l'quipement de faon abusive. Gardez
l'quipement l'cart de toute source de chaleur,
notamment des fours, de l'humidit, des flaques
d'eau, de l'huile ou de la graisse, des atmosphres
corrosives et des intempries.
5. Laissez en place tous les dispositifs de scurit et
tous les panneaux de la console et maintenez-les
en bon tat.
6. Utilisez l'quipement conformment son usage
prvu et n'effectuez aucune modification.
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans

observer les prcautions ncessaires,
peut produire des fissures et un
chappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par consquent :
1. Utilisez toujours le gaz prvu pour une opration
et le dtendeur appropri conu pour utilisation
sur les cylindres de gaz comprim. N'utilisez jamais
d'adaptateur. Maintenez en bon tat les tuyaux et
les raccords. Observez les instructions d'opration
du fabricant pour assembler le dtendeur sur un
cylindre de gaz comprim.
2. Fixez les cylindres dans une position verticale,
l'aide d'une chane ou une sangle, sur un chariot
manuel, un chssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre un poste de travail ou toute autre
dispositif faisant partie d'un circuit lectrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermes. Si le dtendeur n'est pas branch, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et dplacez les
cylindres l'aide d'un chariot manuel appropri.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres une distance approprie
de toute source de chaleur, des tincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplmentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis votre disposition par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
INFORMATIONS SUPPLMENTAIRES RELATIVES LA SCURIT -- Pour obtenir de

l'information supplmentaire sur les rgles
de scurit observer pour l'quipement
de soudage l'arc lectrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont galement recommandes et mises votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
Welding"
Cutting"
15
section 1
sCURIT
SIGNIFICATION DES SYMBOLES

Ce symbole, utilis partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
scurit est en jeu.
DANGER
Signifie un danger immdiat. La situation peut
entraner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraner des blessures
corporelles mineures.
16
section 2 description
2.0 Description
2.1 System Introduction
The m3 Plasma System is a streamlined, high performance-cutting package designed for use exclusively with the
ESAB CNC. This advanced technology integrates gas and water control into the machine CNC.
Using a system of electronic valves driven by CNC outputs, this system:
dramatically reduces the amount of Plasma Gas hardware necessary to control the plasma torch.
reduced purge time/increased part throughput .
simplified operation with gas and water flow rates are controlled by the ESAB CNC process parameter
screen.
allows for programmed/automated control of fluid and water flow rates using SDP Files (SchneidDatenPaket = Cutting Data Package, see Vision control and programming manuals for details on SDP Files.
Data used to generate SDP files can be found in your model specific torch manual.) SDP files can also
be referred to as TDF files (Technology Data Files).
to be used with the PT-36 cutting torch.
Shield Gas Box
Plasma Gas Box
2.2 m3 Plasma System Plasma Gas Box, Shield Gas Box and PT-36
The complete m3 cutting system requires a variety of components. See section 3.9, Component Relationship
Block Diagram for components and hook-up.
17
2.3 System Gas Requirements
Argon
125 PSI (8,6 bar) with 0.25 NPT, 99.995% purity, Filtered to 25 microns
Nitrogen
Oxygen
H-35 (Argon/Hydrogen)
75 PSI (5,2 bar), Speciality Gas, 99.995% purity, Filtered to 25 microns
Methane
75 PSI (5,2 bar) with 0.25 NPT, 93% purity, Filtered to 25 microns
Compressed Air
(Process)
80 PSI (5,5 bar) with 0.25 NPT, clean, dry, oil-free and filtered to 25 microns
Compressed Air
(Air Curtain )
80 PSI @ 1200cfh (5,5 bar @ 35 m3h) filtered to 25 microns

DIN Quality ISO 8573-1
Oil quality mg/m3 = 0.1 class 2
Particle Size 0.1um class 1
Temparature +3 C class 4
2.4 Plasma Gas Box Water Supply Requirements

Cooling Water....................................................................................... 175 PSI (12,1 bar), 1.5 gallons per minute (5.68 liters/minute)
2.5 Plasma Gas Box Electrical Input Requirements

Voltage Supply
+24 VDC for proportional valves, mfc

+15 VDC for pressure switch
Voltage Signals
24 VAC input to start gas solenoid valve

120 VAC input to arc starter
0-10 VDC input to proportional valves
0-10 VDC for mass flow valve
2.6 Shield Gas Box Electrical Input Requirements

Voltage Supply
+24 VDC for 120/230 transformer and I/O board

+24 VDC for proportional valves and mfcs
2.7 System Accessories

Coolant Hose Adapter Kit.............................................................................................. 0558006698
Adapter Coolant EPP-200...............................................................................................0558006162
Speedloader assembly, handheld...............................................................................0558006164
Speedloader assembly, 5 fixtures................................................................................0558006165
18
2.8 Plasma Gas Box Dimensions
11.28
286.5 mm
17.13
435.1 mm
7.25
184.2 mm
19
2.9 Shield Gas Box Dimensions
20.00
508.0 mm
12.00
304.8 mm
8.00
203.2 mm
20
section 3 installation
3.0 Installation
WARNING
Electricity Can Kill!

Before performing any maintenance or assembly of this
equipment, ensure the power source (EPP) is turned off and
disconnected.
3.1 Plasma Gas Box Introduction

The m3 Plasma System Plasma Gas Box interfaces with the ESAB Vision machine controls and the EPP product
line of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control
electronic valves. The result is CNC management of gas or shield gas delivery to the plasma torch. Analog signal
feedback is sent back to the CNC, creating a control loop.
3.2 Plasma Gas Box Mounting (Bottom View)

If mounting the box is required:
The box has four (1.10) 28 mm threaded mounting holes in a pattern offset from longitudinal center. Note relationship of hole pattern to gauges and cable clamp.
back
front
.75
19.1 mm
4.50
114.3 mm
2.00
50.8 mm
4.13
104.9 mm
11.00
279.4 mm
2.00
50.8 mm
21
3.3 Plasma Gas Box Connections
1. To access the inside of the box: remove or unlock screws

and lift the box cover off to expose internal components.
2. Disassemble the strain relief/clamp block. (When apart,

this strain relief will allow placement of cables and hoses
without removing plugs and fittings.)
A. Remove two screws holding block together.
B. Insert cables for making connections inside box.
C. Reattach block.
Strain Relief / Clamp Block
Note:
Wires can be inserted in any of the three holes in

the Strain Relief / Clamp Block, only one power
source cable is used in picture below.
Pilot Arc Cable

Power Source Cable
22
3.3.1 Plasma Gas Box Starter Box Connections
Arc Starter Box
TB1 Pilot arc cable from the plasma power source.
TB4 Connected to buss bar (lower back right hand
corner).
TB2 Pilot Arc Torch cable from the torch leads.
Black Lead - 120 vdc input
TB1
TB4
Pilot Arc Cable
TB2
Black Lead
Buss Bar
View from underneath the Arc Starter Box
23
3.3.2 Plasma Gas Box Torch Connections
To connect the torch see the following illustrations. Hook-up requires connection of the cut and start gas hoses,
shield gas hose, coolant hoses, air curtain hose, the pilot arc cable (TB2) and the Torch Tip / Electrical soft touch
wire on the PC board X4 terminal.
Torch Bundle Hose Connections
1 - Female old-style air water nut for Shield Gas connection

2 - B-IG fittings for Plasma Start gas and Plasma Cut gas. Either hose can be attached in either location.
3 - Cooling Water Connections.
4 - Pilot Arc Cable - connects to TB2 underneath Arc Starter
Box.
5 - Torch Tip / Electrical soft touch wire - connects to PC
board at X4 terminal.
6 - Air Curtain Hose - to air curtain at torch tip
7 - Torch Grounding Stud (for CE units only).
2
5
4
3
1
1
6
3
24
3.3.3 Plasma Gas Box Torch Cooling Water Connections
Coolant Connections To and From Power Source
H2O OUT
When packaged with a torch and power supply at the factory,

connections are labeled. Additional labels are available if relabeling becomes necessary. Tracing the Plasma Gas boxes interior lines can identify the proper connections. Flow switch is
located on the IN line.
H2O IN
Coolant Connections To And From Torch
Plasma Gas Box Rear View
Note arrows on fittings indicating coolant flow direction.

Coolant Out has right-hand threads.
Coolant In has left-hand threads.
Note:
Coolant hoses connect as shown from the

water cooler to the Plasma Gas box.
Plasma Gas Box

Rear View
25
3.3.4 Power Source To Plasma Gas Box Buss Connection
1. Strip 4/0 (95 mm2) insulation, approximately 38 mm.
2. Insert 4/0 (95 mm2) cable in buss bar hole until copper
extends to the edge of the buss block.
3. Tighten locking screw(s) on cable.
Note:
The buss will accommodate these cables.

(1) 4/0 (95 mm2) - 400 amps
(2) 4/0 (95 mm2) - 800 amps
(3) 4/0 (95 mm2) - 1000 amps
Pilot Arc Cable

Buss Block
Power Source Cable
notice
Careful attention while stripping insulation will make installation of

the 4/0 (95 mm2) cable in the buss easier. Do not spread or flare the
copper conductors.
3.3.5 Plasma Gas Box PC Board Connections

X1-10 - +24 vdc Input
X1-9 - Sensor Input
X1-2 - Common / Chassis Ground
X4 -
Torch Tip / Electrical soft touch wire
PE -
Chassis Ground
Note:
For more detailed information, refer to PC

board schematic next page.
26
27
PC Board Schematic
25.07.2005 12:51:42 C:\Programme\EAGLE_V4-11\projects\2256510\2256510.sch (Sheet: 1/1)
3.4 Plasma Gas Box Nomex Insulation
Nomex Insulation
1. To access the inside of the box: remove or

unlock screws and lift the box cover off to
expose internal components.
2. Position Nomex insulation to prevent any
possible arcing between the buss and arc
start box terminals.
3. Replace enclosure of m3 Plasma System Plasma Gas Box.
28
3.5 Plasma Gas Box Gas Connections
Gas Connections are made on the exterior of the box. Gas lines are connected to the back of the plasma gas box
from supply sources. Gas lines are connected to the front of the plasma gas box from the torch.
caution
Unfiltered 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. ESAB Filter P/N 56998133 (replacement filter
element P/N 0560988406). Proportional valves contain no serviceable parts. Replace valve assembly with factory parts.
Plasma Gas Box Rear Gas Connections
Plasma Gas Box Front Gas Connections
29
Gas Line Contamination Will Damage Proportional Valves.
Purge Gas Lines.
Before connecting gas delivery lines to the m3 Plasma System Plasma Gas Box, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the proportional valves in your
m3 Plasma System Plasma Gas Box.
caution
1
1. Purge gas and air lines completely before connecting

to 25 micron gas filters.
2. Connect oxygen, H-35, nitrogen and air lines to gas
filters.
3. Purge gas/air lines between shield gas box and m3
Plasma System Plasma Gas Box.
4. Connect gas/air lines to back of Plasma Gas box.
2
5
6
4
3
8
10
20
12
11
13
19
15
17
18
16
14
30
PG1
PG2
Air Curtain
PG2 Out
PG1 Out
Shield
Torch
14 Pin To B3 Lifter
8 Pin to Shield Box
10
10 Pin To B3 Lifter
11
H-35
12
Start Gas Selection (O2 N2 AIR)
13
Argon
14
H2O IN
15
Shield
16
Air Curtain
17
Cut Gas Selection (O2 N2 AIR)
18
H2O OUT
19
LED Volt Meter
20
Torch Cable Grounding Stud

(for CE units only)
WARNING
Electricity Can Kill!

Before performing any maintenance or assembly of this
equipment, ensure the power source (EPP) is turned off and
disconnected.
3.6 Shield Gas Box Introduction

The m3 Plasma System Shield Gas Box interfaces with the ESAB Vision machine controls and the EPP product line
of plasma power sources. An interface pc board receives voltage signals from the machine CNC that control proportional and solenoid valves. The result is CNC management of gas or shield gas delivery to the plasma torch.
Analog signal feedback is sent back to the CNC, creating a control loop.
3.7 Shield Gas Box Mounting (Bottom View)

If mounting the box is required:
The box has four (1.10) 28 mm threaded mounting holes in a pattern offset from longitudinal center. Note relationship of hole pattern to gauges and cable clamp.
back
front
.75
19.1 mm
6.50
165.1 mm
.75
19.1 mm
1.50
38.1 mm
16.00
406.4 mm
2.50
63.5 mm
31
3.8 Shield Gas Box Connections
All connections are made on the exterior of the box. See diagrams and chart below.
Gas Line Contamination Will Damage Internal Components.

Purge Gas Lines.
Before connecting gas delivery lines to the m3 Plasma System Shield
Gas Box, purge all lines thoroughly. Residue from the hose manufacturing process may clog/damage the valves in your m3 Plasma System Shield Gas Box.
caution
3.8.1 Shield Gas Box front connections
4
10
1
11
6
3
Power Cable
Ground Connection
Buss Connection Communication
CNC Out to Power Source
To Plasma Gas Box
Spare
To Air Curtain
To Plasma Gas 2
To Plasma gas 1
10
Spare
11
Power Cable Connector
7
8
9
4
5
6
View from inside showing connections
of Items 4, 5 & 6
32
3.8.2 Shield Gas Box rear connections
1
7
2
Shield Gas Out
Air Curtain Inlet
Oxygen Inlet
N2 Inlet
Air Inlet
Check Valves (typical)
CH4 Inlet
3
4
5
6
m3 Gas Fittings Kit (0558005229, included w/ m3 system) Consists of the following:

P/N
Description
Quantity
36Z40
NUT HOSE B-A/W* .63-18F RH
136Z08
NUT HOSE B-I/G* .63-18M RH
3380
NUT HOSE B-OXY* .56-18F RH
3381
NUT HOSE B/ACET .56-18F LH
136Z07
NUT HOSE A-I/G* .38-24M RH
2064114
NPL PUSH A/A-W* 3/16 ID HOSE
03Z74
NPL PUSH B/SIZE 3/8* HOSE
347995
NPL PUSH B/A-W* 3/8 ID HOSE
0558006336
m3 PLASMA FILTER ASSEMBLY
20373
Flash Arrestor Assembly
33
3.9 Component Relationship Block Diagram
3-phase w/
ground
O2
Argon H-35
Pilot Arc
Cable
Power Cable
Pilot Arc Cable
CH4
13
Cable 4 Twisted
Pair
Air
(plasma
shield
supply
DIN
Quality ISO
8573-1)
11
25 Micron filters
N2
CNC
Cable 4c
Air
(clean,
dry, oilfree shop
air for Air
Curtain
supply)
PS & WC Control Cables
Power Cable
3a
9
8
16
12
Note:
Air Curtain or Bubble Muffler can
be used here. See torch manual for
conditions.
14
Torch Lead
10
LED Volt Meter
15a = 10 Pin
15b = 14 Pin
Encoder / Voltage
Height Control
17
Workpiece
Work Table
Earth Ground
34
ITEM NUMBER
PART NUMBER
DESCRIPTION
0558004315
EPP-200, 200,230,380,415,460,575V
0558006470
EPP-400 400V, 50/60Hz CE
0558006471
EPP-400 460V, 60Hz
0558006472
EPP-400 575V, 60Hz
0558006473
EPP-600 400V, 50/60Hz CE
0558006474
EPP-600 460V, 60Hz
0558006475
EPP-600 575V, 60Hz
0558007800
EPP-201, 380/400V, 50/60Hz, CCC/CE
0558007801
EPP-201, 460V, 60Hz
0558007802
EPP-201, 575V, 60Hz
0558007831
EPP-360, 380/400V, 50/60Hz, CCC/CE
0558006832
EPP-360, 460V, 60Hz
2
3
3a
0558006833
EPP-360, 575V, 60Hz
0558007730
EPP-401/450, 380/400V, 50/60Hz CE
0558007731
EPP-450, 460V, 60Hz
0558007732
EPP-450, 575V, 60Hz
0558007733
EPP-601, 380/400V, 50/60Hz, CCC/CE
0558007734
EPP-601, 460V, 60Hz
0558007735
EPP-601, 575V, 60Hz
0558006086
Junction Box, PS & WC
0558004837
Cable Control, WC, 5m (16)
0558004838
0558004839
0558004849
Cable Control, PS & WC, 5m (16)
0558004850
0558004851
0558004852
0558004853
0558004854
0558005237
0558005238
0558005246
Coolant Hose, 5m (16)
0558005563
0558005564
0558005565
0558005247
0558005248
0558005567
0558005249
0558004400
Coolant Circulator PCC-10
0558007515
Coolant Circulator PCC-11
35
ITEM NUMBER
PART NUMBER
DESCRIPTION
0558006089
Hose, Plasma Gas #1, 1.5m (5)
0558006090
Hose, Plasma Gas #1, 5m (16)
0558006091
0558006092
0558006093
0558006094
0558006095
0558006096
0558006097
0558006098
0558006099
0558006100
0558006101
0558006102
0558006103
0558006104
0558006105
0558006106
Hose, Plasma Gas #2, 1.5m (5)
0558006107
0558006108
0558006109
0558006110
0558006111
0558006112
0558006113
0558006114
0558006115
0558006116
0558006117
0558006118
0558006119
0558006120
0558006121
0558006122
36
ITEM NUMBER
PART NUMBER
DESCRIPTION
0558006200
Hose, Shield Gas, 1.5m (5)
0558006201
Hose, Shield Gas, 5m (16)
0558006202
0558006203
0558006204
0558006205
0558006206
0558006207
0558006208
0558006209
0558006210
0558006211
0558006212
0558006213
0558006214
0558006215
0558006216
0558006217
Hose, Air Curtain, 1.5m (5)
0558006218
Hose, Air Curtain, 5m (16)
0558006219
0558006865
Hose, Air Curtain, 6.1m (20)
0558006220
0558006221
0558006222
0558006223
0558006224
0558006225
0558006226
0558006227
0558006228
0558006229
0558006230
0558006231
0558006232
0558006233
37
ITEM NUMBER
PART NUMBER
DESCRIPTION
10
0558004841
Air Curtain Hose 1.4m (4.5)
0558004842
Air Curtain Hose 1.8m (6)
0558004843
0558004844
0558004845
0558004846
0558005915
Fixture Assy SpeedLoader
0558005916
Nozzle Retainer SpeedLoader
0558005917
Tool Preassembly
11
0560941536
Shield Gas Box
12
0560941491
Plasma Gas Box
13
2239606
Power Junction Box
14
37440
Air Curtain Assembly
37439
Bubble Muffler
0560940129
Cable, PGC-B3, 10p, 1.4m (4.5) - 2 Plug
0560941700
Cable, PGC-B3, 10p, 1.8m (6) - 2 Plug
0560940135
0560941701
0560940138
0560940141
0560940142
0560941482
0560941483
0560941484
0560941485
15a
38
ITEM NUMBER
PART NUMBER
DESCRIPTION
15b
0560940144
Cable, PGC-B3, 14p, 1.4m (4.5) - 2 Plug
0560941702
0560940147
0560941703
0560940148
0560940149
0560940152
0560941487
0560941488
0560941489
0560941490
0560939938
Cable, GS-PGC, 8p, 1.8m (6)
0560939939
0560939940
0560939941
0560939942
0558003849
Plasma Torch PT-36, 1.4m (4.5)
0558003850
Plasma Torch PT-36,
0558003852
Plasma Torch PT-36, 3.6m (12)
0558005741
0558003853
0558003854
0558003856
16
17
39
1.8m (6)
40
section 4
operation
4.0 Operation
4.1 Plasma Gas Box Operation
A major advantage of the m3 Plasma System Plasma Gas Box is that operating parameters are managed by the
machine CNC. There are no operating procedures necessary with the m3 Plasma System Plasma Gas Box. 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 (known by the acronyms SDP or TDF) are files stored in the machine control
memory containing all necessary information for cutting a thickness and a material type. It is specific to
material, thickness, torch model, gas and material type. The information used to create the files can be
found in your torch manual. Refer to ESAB CNC Part Programming manual for more detail on the creation
and use of parameter files.
notice
See CUT DATA MANUAL, P/N 0558006163 for cutting parameter settings for using the m3 Plasma System Plasma Gas Box.
4.2 Plasma Gas Box Pressure Gauges

Pressure gauges display actual pressure to the torch. They provide visual feedback to the operator, and can be
helpful in spotting torch problems.
Note:
PG1 & PG2 are referred to as Start & Cut gas

most of the time. Certain cutting conditions
require PG1 conditions only.
Start Gas
(PG1)
Cut Gas
(PG2)
41
section 4
operation
4.3 Plasma Gas Box Pressure Switches

Pressure switches monitor line pressure and provide inputs to the CNC. If the pressure drops below 50 psi, the
CNC can shut the process down. Switches are in-line between the solenoid and the proportional valve for shield
gas 1 & 2, start gas and cut gas.
Plasma Gas Box
Gas Pressure Switch
42
section 4
operation
4.4 Shield Gas Box Operation

A major advantage of the m3 Plasma System Shield Gas Box is that operating parameters are managed by the
machine CNC. There are no operating procedures necessary with the m3 Plasma System Shield Gas Box. 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 (known by the acronyms SDP or TDF) are files stored in the machine control
memory containing all necessary information for cutting a thickness and a material type. It is specific to
material, thickness, torch model, gas and material type. The information used to create the files can be
found in your torch manual. Refer to ESAB CNC Part Programming manual for more detail on the creation
and use of parameter files.
notice
See CUT DATA MANUAL, P/N 0558006163 for cutting parameter settings for using the m3 Plasma System Shield Gas Box.
43
section 4
operation
4.5 Shield Gas Box Air Regulator for Air Curtain
The Air Regulator displays actual air pressure to the torch.

It provides visual feedback to the operator, and can be
helpful in spotting torch problems.
To access the Air Regulator:
1. Remove the cover. No adjustment should be necessary
to the regulator. Regulator is factory set to 40 psi (2.8
bar) while flowing.
44
section 4
operation
4.6 Shield Gas Box Check Valves

Check Valves stop backflow between gas selections. Periodic purging of check valves is necessary to clear gas
lines. To purge lines simply unscrew caps on check valves to bleed the gas pressure.
Check Valves
(9 typical)
45
section 4
operation
46
section 5 maintenance
5.0 Maintenance
5.1 Plasma Gas Box Maintenance
The m3 Plasma System Plasma Gas Box 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.
WARNING
Electric Shock Can Kill!

Always disconnect power from the EPP power source and
the cutting machine before opening or servicing the m3
Plasma System Plasma Gas Box.
caution
Only Qualified Maintenance Personnel Should Repair And Maintain

This Equipment.
5.2 Plasma Gas Box Schematic (Plumbing Schematic)

Shield IN
Shield to Torch
PS 1
Argon
H35-1
N2/O2/Air
PS 2
Spark Arrestor
N2/O2/Air
Air Curtain
To AIr Curtain
47
5.3 Plasma Gas Box Pressure Switches
Gas Pressure Switch monitors the pressure of plasma gas supply to the Plasma Gas box. One switch monitors
both O2. The other switch is used for monitoring alternate gas, either H-35, Air or N2.
Note:
H-35 is an industry name for a mixture of 65 % argon and 35% hydrogen.
Secondary Shield Switch monitors the pressure of the secondary shield gas in the shield box. These switches
are wired as an input to the CNC. Logic codes in the control look for a change of state (low/high) of the input
signals, therefore these switches cannot be jumpered out of the circuit. Both pressure switches are factory set
and non-adjustable to close at 50 PSI (3.45 Bar). They contain no serviceable parts. Replacement P/N 952920.
Plasma Gas Box
Gas Pressure Switch
48
5.4 Spark Gap Of the Arc Starter Box (Plasma Gas Box)
Arc Starter Box
The m3 Plasma System Plasma Gas Box 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 Plasma Gas box. The arc starter box
contains an adjustable spark gap.
The recommended spark gap setting is 0.040 (1,0 mm).
Risk of High Frequency

Interference Damage
HIGH
LOW
Starting Reliability
Spark Gap
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):
Negative Effect increased damage risk from high frequency
interference
Positive Effect - starting reliability increased (to a point where it
doesnt work at all).
.040"
(1 mm)
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).
49
WARNING

Always turn power off before opening and servicing the
m3 Plasma System Plasma Gas Box.
5.5 Spark Adjustment Procedure (Plasma Gas Box)
1. Disconnect input power to plasma power source (EPP) and cutting machine.
2. Remove access cover from the arc starter box.
3. Use a 0.040 (1 mm) feeler gauge or shim to measure the spark gap setting.
4. Adjust as required. When correctly adjusted, there should be slight pressure felt when a back and forth motion is applied to the shim.
5. Replace cover.
50
5.6 Cooling Water Circuit (Plasma Gas Box)
Torch
To torch check valve
Flow Switch (In water cooler and/or

power supply
Return coolant check valve
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-36 torch. The PT-36 torch has an 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.
Buss Block
Coolant line to torch (from cooler)
Coolant line from torch (to cooler)
Flow Switch (In water cooler and/or power supply
Check Valve from torch
Check Valve to torch
3
6
51
5.7 Plasma Gas Schematic
Plasma gases are controlled with proportional valves mounted on the manifold.
Plasma Gas Box
Shield
To Torch
Shield
To Torch
Torch PG 1
Argon
PS 1
0-9 bar
PV - PG1
H35-1
N2/O2/Air
N2/O2/Air
PG
to Torch
0-10 m3/h
MFC - PG1
Spark Arrestor
N2/O2/Air
Torch PG 2
PS 2
To
AIr Curtain
Air Curtain - optional for under water cutting only
52
Air Curtain
5.8 Voltage Divider Adjustment Procedure
The Voltage Dividers or VDRs can be adjusted to provide optimum cut and marking capability. Follow the procedure below to start tuning the cut and mark VDR. Once this range has been obtained more precise cuts can be
tuned in by adjusting the pot and making test cuts to gauge accuracy.
TB1-11 will be located here
VDR (cutting)
VDR Adjustment Pot
VDR (marking)
Procedure:
To adjust the VDR for cutting, place ohm meter leads between TB1-11 and chassis ground. With VDR hooked up
and in place as shown, the reading should be approximately 690 ohms.
To adjust the VDR for marking, place ohm meter leads between TB1-11 and chassis ground. With VDR hooked up
and in place as shown, the reading should be approximately 900 ohms.
To obtain a more accurate cut or mark, turn the pot adjustment screw and make a test cut. Adjust and test until
desired cut or mark is achieved. Ohm meter readings can vary according to cable lengths. Test cuts will have to
be made to fine tune the quality.
53
5.9 Voltage Divider Schematic
2K
Cutting Board - 56997963
Marking Board - 0560940947
54
5.10 Shield Gas Box Maintenance
The m3 Plasma System Shield Gas Box has proven to be a very reliable product. Regular maintenance is important for many years of trouble free use. Only trained personnel should perform maintenance on this equipment.
This section contains a brief description of the most common problems and schematics.
WARNING

Plasma System Shield Gas Box.
caution
Only Qualified Maintenance Personnel Should Repair And Maintain

This Equipment.
5.11 Shield Gas Box Schematic

Shield Gas Box
PS 3
Air-1
Air
N2-1
N2
O2-1
O2
CH4
0-10 m3/h
MFC - SG1
Shield
To Torch
PS 4
CH4
Fuel
Check
Valve
0-10 m3/h
MFC - SG2
O2-2
N2/O2/Air
N2-2
Air-2
O2-3
N2-3
O2/N2/Air
Air-3
Air
Air Curtain
To
AIr Curtain
55
5.12 Solenoid Replacement
WARNING

Plasma System Shield Gas Box.
Common Problems:

Coil has malfunctioned, no flow to the

MFC.
Shorted output.
Procedure:
To replace a solenoid on the shield gas assembly,
unscrew solenoid nut on the faulty solenoid.
Remove solenoid assembly and unplug the attached
wires on the output board (make note of the red and
white wire connections).
Shield Gas Assembly
Replace solenoid assembly, plug in the wires and replace nut on assembly.
Solenoid Valve
Solenoid Nut
Solenoid Coil
Output Boards
56
5.13 Mass Flow Controller Replacement
Common Problems:

No flow through Mass Flow Controller

(MFC).
Procedure:
1. Check LED indicator on top of MFC for power.
2. Ensure gas is flowing to the MFC. Refer to schematic for input flow setting. If no flow is present,
check gas and gas lines.
Mass Flow Controllers
3. Check for gas passage through the MFC. When

gas is on and power is on MFC, gas should flow
through.
4. If no gas flows through, replace MFC. Replace
by unscrewing (4) four screws in bottom of MFC.
Remove cable and hose connections. Take note
of placement for reassembly.
5. Replace MFC and reconnect hoses and cables.
LED Power Indicator
Mass Flow Controller
57
5.14 Gas Filters
Unfiltered Gas Will Clog Proportional Valves
caution
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.
All gases supplied to the m3 Plasma System Plasma Gas Box 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.
58
59
5.15 Fluid Schematic m3 Plasma System Plasma Gas Box and Shield Gas Box
Water Cooler PCC-10
Shield Gas Box

PS 3
Air-1
Air
N2
O2-1
O2
CH4
0-10 m3/h
MFC - SG1
N2-1
Shield
To Torch
PS 4
CH4
Fuel
Check
Valve
0-10 m3/h
MFC - SG2
O2-2
N2/O2/Air
N2-2
Air-2
O2-3
N2-3
O2/N2/Air
Air-3
Air
Air Curtain
To
AIr Curtain
60
Plasma Gas Box
Shield
To Torch
Shield
To Torch
Torch PG 1
Argon
PS 1
0-9 bar
PV - PG1
H35-1
N2/O2/Air
N2/O2/Air
PG
to Torch
0-10 m3/h
MFC - PG1
Spark Arrestor
N2/O2/Air
Torch PG 2
PS 2
To
AIr Curtain
Air Curtain - optional for under water cutting only
61
Air Curtain
62
section 6
replacement parts
6.0 Replacement Parts

6.1 General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
6.2 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.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
63
EW
section 6
replacement parts
6.3 Plasma Gas Box

1 1 .2 8
0 .3 8 R E F .
0 .7 5
1 1 .2 8
1 1 .0 0
1 .7 5
7 .5 0
1 7 .1 3
(N O T E 8 )
85
0 .3 8 R E F .
4 .5 0
0 .7 5
7 .5 0
31
(N O T E 8 )
48
85
36
35
64
A -A
ALE 1 / 2
11
10
(N O T E 5 )
4 .5 0
(N O T E 1 )
48
7 .5 0
section 6
replacement parts
31
48
36
35
82
1 1 .0 0
1 .7 5
1 7 .1 3
25
26
31
83
44
D E T A IL
SCALE 1 : 1
42
43
41
V IE W
40
61
54
53
52
A -A
SC ALE 1 / 2
65
11
10
(N O T E 5 )
section 6
replacement parts
69
70
68
55
1
56
17
61
88
62
60
39
17
86
88
17
(N O T E 2 )
11
39
21
18
2
13
88
63
10
(2 X )
38
77
6
29
24
67
66
50
37
51
26
48
80
24
67
66
72
65
58
24
67
66
39
81
71
89
50
29
51
(N O T E 7 )
14
19
20
90
16
66
25
59
section 6
(N O T E 3 )
5
66
68
91
69
70
68
1
56
17
61
62
60
17
17
86
88
(N O T E 2 )
11
21
99
10
16
63
88
Item #99 attached to inside of enclosure cover

18
17
38
6
27
26
25
58
65
88
38
88
87
74
73
14
88
88
19
14
(N O T E 7 )
59
80
64
39
39
92
92
(2 X )
replacement parts
81
30
11
87
14
(N O T E 7 )
14
19
20
90
39
(2 X )
1
13
15
11
10
16
D E T A IL
SC ALE 1 : 1
39
67
10
section 6
replacement parts
Plasma Gas Box Parts List
ITEM
QTY
PART NUMBER
DESCRIPTION
0558001055
ENCLOSURE HIGH FREQ BOX
0560940776
ASSY BUSS BAR m3 FLOW CONTRO L
0560940808
MASS FLOW PROPORTIONAL VALVE
4a
56997963
ASSY VOLTAGE DIVIDER BOARD - CUTTING
4b
0560940947
ASSY VOLTAGE DIVIDER BOARD - MARKING
0002256510
BOARD TOOL TOUCH
0560940875
CLAMP, PANEL GAGE MOUNT
Helical Spring Lock Washer

ASME B 18.21 . 1 - 1/4 Regular. Carbon Steel
Washer A ANSI B 18.22. 1 - 1/4 - narrow - Type A
Hex Nut ANSI B 18.2.2 - 1/4 - 20
10
13
Spring Washer DIN 127 - A4
11
12
Hexagon Socket Button Head Screw ISO 7380 - M4 x 8
12
13
33053
STRAIN RELIEF 2 TORCH
14
2236750
15
3390
ADAPTER 1/4 NPT - B FG
16
3389
ADAPTER 1/4 NPT - B OXY
17
10Z30
FITTING 1/4 NPT TO B A/W
18
0560940876
19
2233664
FITTING 90 X 1/4 NPTM X 1/4 TU
20
44151500
COUPLING 1/4 NPT F-F
21
22
23
TEE, STREET 1/4 NPTF x 1/4 NPTM
FITTING 1/4 NPTF TO 1/4 TUBE
Plain Washer ANSI B 18.22 M - 4N

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

24
18
25
26

STD-000037
27
Cylinder Head Cap Screw DIN 912 - M6 x 16
28
29
Hex Nut DIN 934 - M6 STD-000024
30
952920
SWITCH PRESSURE NON-ADJUSTING
68
section 6
replacement parts
ITEM
QTY
PART NUMBER
31
2234485
DESCRIPTION
END CLAMP
32
33
34
Washer DIN 125 - A 6.4
35
15
2237993
TERMINAL BLOCK MINI DBL LEVEL
36
2237994
END COVER MINI DBL LEVEL
37
636692
CONNECTOR AMPHEN MS3102A-18-19S
38
11N16
ADAPTER 1/4 NPTTO B FEMALE
39
74S76
ADAPTER 1/4 NPT TO B FEMALE
40
5700062900
41
Slotted Cheese Head Screw DIN 84 - M5 x 8
43
44
0560940865
DIN RAIL MOUNTING
45
0560940862
FASTNER 1/4 TURN RECEPTACLE
46
0560940863
STUD 1/4 TURN SLOTTED HEAD
47
0560940864
RING RETAINER FOR 1/4 TURN FSTR
48
0560940779
ENCLOSURE WLDMT m3 FLOW CTRL
49
Slotted Cheese Head Screw DIN 84 - M5 x 10
50
Toothed Lock Washer DIN 6797 - A 6.4
51
0560940873
52
634220
53
WIRE TIE CRADLE
42
STUD, M6 - 1.0 X 1 PLATED

CLIP GROUND
Recessed Pan Head Screw ISO 7045 - M4 x 8 - 4.8 - H
54
55
0560940874
GAGE, 2-1/2 PANEL MTG. 0-100
56
0560940879
CHECK VALVE 1/4 M IN 1/4 F OUT
58
2135688
59
0560940761
57
NIPPLE 1/4 NPT M-M
ASSY START GAS MANIFOLD
69
section 6
replacement parts
ITEM
QTY
PART NUMBER
60
0560938404
61
Toothed Lock Washer DIN 6797 - A 4.3 STD-000452
62
Recessed Pan Head Screw ISO 7045 - M4 x 5 - 4.8 - H STD-000453
63
0560940916
64
33501007
ELBOW STREET 45 DEG 1/4 N P T
65
44251100
ELBOW 90 1/4 NPT BRONZE
66
12
Cylinder Head Cap Screw DIN 912 - M3 x 12 STD-000457
67
12
Hex Nut DIN 934 - M3
68
Spring Washer DIN 127 - A 3.5
69
70
71
72
636665
73
0560940777
CABLE CLAMP, m3 FLOW CONTROL
74
0560940778
CABLE CRADLE
75
0560940919
m3 HOSE ASSY SHIELD GAS
76
0560940920
m3 HOSE ASSY AIR CURTAIN
77
0560940918
m3 HOSE ASSY PLASMA GAS 1
78
0560940917
m3 HOSE ASSY COOLING WATER
0560940922
DESCRIPTION
FILTER RFI POWER 2VB3 CORCOM
SHIELD, ELECTRICAL, BUSS BAR
STANDOFF, M3.5 - 0.6 X 22mm

Recessed Pan Head Screw JIS B 1111 - AM 3.5 x 6 - H
2062307
CONNECTOR AMPHEN DMS 3102A-22-23S

CONNECTOR AMPHEN MS 3102A-20-27S
79
80
57001682
HOSE MANIFOLD TO GAGE
81
57001682
HOSE MFC TO GAGE
82
0560941602
ASSY, RELAY
83
0560941603
MODULE, SIGNAL RELAY
84
0560940921
m3 HOSE ASSY MFC IN
85
954075
NAMEPLATE 2.30 X 3.38
86
951188
Lock Nut
87
44052550
88
0560941905
89
527376
90
67101075
91
674969
FILTER BOARD
92
20373
FLASHBACK ARRESTOR
94
0560943621
22mm Nylon Standoff
99
0560945880
Shield, Electrical, Enclosure Cover
Bushing 1/8 to 1/4 Brass

Adpt. Blkhd 1/4 NPT w/ Flats
Strain Relief 1/2
Nipple 1/4 NPT Close
70
section 6
replacement parts
6.4 Start Gas Manifold (Plasma Gas Box)
23
24
3
8
9
1
6
3
19
10
12
13
14
15
View B-B
See View B-B
71
20
21
section 6
replacement parts
Start Gas Manifold (Plasma Gas Box) Parts List
ITEM
QTY
PART NUMBER
DESCRIPTION
0560940760
952920
952921
VALVE SOLENOID 2-WAY MAN.MT.
0560939508
VALVE, PROPORTIONAL 833-354N03010
4440167500
PLUG PIPE 1/8 NPT
567596
MUFFLER 1/8 NPT BRASS
3390
ADAPTER 1/4 NPT -B FG

FITTING 1/4 NPT TO B A/W
MANIFOLD, START GAS
10Z30
10
0560940763
11
12
950654
BALL 1/2 DIA RUBBER
13
639678
TUBE
14
639669
SPRING 0.47 x 0.43 1 L
15
36358
PLUG MANIFOLD
16
68100126
18
0560940762
19
44401900
20
0558001282
O RING PROPORTIONAL VALVE 5mm X 1mm
21
0558001283
O RING PROPORTIONAL VALVE 4mm X 1mm
23
44052550
24
631475
O RING 11/16 X 13/16 X .07 VITON

Cylinder Head Cap Screw DIN 912 - M4 x 40
REDUCER HEX 3/8 NPT X 1/4 NPT

STANDOFF MANIFOLD MOUNTING
PLUG 1/4 NPT SQR HD BRS

FITTING, A TO I-G TO 1/8 NPT
72
section 6
replacement parts
6.5 Buss Bar Manifold (Plasma Gas Box)

2, 3
4
6, 7
73
section 6
replacement parts
Buss Bar Manifold (Plasma Gas Box) Parts List
ITEM
QTY
PART NUMBER
0560940772
BUSS BAR SOLDERED ASSY.
672225
STANDOFF, FIBERGLASS 1. 25 LG.
0560940774
STUD (BUSS BAR INSUL)
10Z30
FIT TING 1/4 NPT TO B A / W
0560940775
SET SCR 5/8 -18 X 1/2 OVAL PNT
E x ternal Tooth Lock Washer Type A

ASME B18. 21.1 - No. 10. Carbon Steel
Cross Recessed Fillister Head Machine Screw - Type IA

ANSI B18.6. 3 - No. 10. - 32 - 3/8
0560940879
DESCRIPTION
CHECK VALVE 1/4 F IN 1/4 M OUT
74
D E
0 .3 8
section 6
replacement parts
0 .7 5
6 .5 0
8 .0 0
6.6 Shield Gas Box
85
43
59
57
58
59
137
D E T A IL
SC ALE 1 : 1
L U G T O O U T S ID E
O F EN CLO SUR E.
47
65
D E T A IL
D E T A IL
SC ALE 3 / 4
43
40
21
63
59
57
58
D E T A IL
1
3
79
63
63
66
20
11
40
29
40
20
20
84
84
63
SC ALE 1 : 1
(N O T E 6 )
SC ALE 1 : 1
21
1 2 .0 0
O F EN CLO SUR E.
D E T A IL
SC ALE 1 : 1
O F EN CLO SU RE.
0 .3 8
A
1 6 .0 0
0 .7 5
6 .5 0
8 .0 0
2 0 .0 0
75
SC A
section 6
replacement parts
B
63
63
66
20
40
11
29
20
84
1 2 .0 0
0 .3 8
1 6 .0 0
1 .5 0
0 .7 5
2 0 .0 0
2
26
25
18
19
(N O T E 6 )
46
73
78
15
16
14
74
44
45
45
2
2
16
85
15
14
23
40
21
63
(N O T E 6 )
79
47
65
D E T A IL
SC ALE 3 / 4
63
15
14
16
(N O T E 5 )
V IE W
A -A
SCALE 1 / 2
76
(N O T E 2 )
40
21
section 6
replacement parts
56
54
55
42
41
37
38
21
64
34
39
20
21
139
31
50
69
49
68
2
53
77
75
76
13
12
2
2
80
48
24
67
58
57
3
36
24
82
70
72
71
30
21
84
84
77
27
84
37
section 6
replacement parts
56
54
55
42
41
21
138
63
64
17
21
34
39
64
D E T A IL
SCALE 1 : 1
20
51
21
31
50
69
49
68
2
53
77
75
76
13
12
2
2
80
24
67
58
57
3
146
24
82
70
52
72
71
30
25
27
21
84
19
21
27
24
78
84
84
48
section 6
replacement parts
0 .3 8
1 .5 0
1 6 .0 0
0 .7 5
2 0 .0 0
2
26
25
18
19
15
16
14
(N O T E 6 )
40
21
63
(N O T E 6 )
79
63
15
14
16
(N O T E 5 )
V IE W
A -A
SCALE 1 / 2
79
(N O T E 2 )
40
21
section 6
replacement parts
Shield Gas Box Parts List
ITEM
QTY
PART NUMBER
DESCRIPTION
0560940923
2237924
MB03 MAIN BOARD ASSEMBLY
0560940808
MASS FLOW CONTROL VALVE
0560941466
TRANSFORMER ASSY
522368
0560940926
Enclosure, SF3 Flow Control
REGULATOR AIR WITH GAGE
6
7
ASSY, SHIELD GAS MANIFOLD SF3
2236432
CLIP, STIRRUP .32 - .47 DIA .
0560938111
CONN ASIOB FEMALE 5 PIN
11
950249
VALVE, 2-WAY 1/4 NPT 24V 60/50HZ
12
2237927
ANALOG CARD ASSEMBLY
13
0002256475
RELAY OUTPUT CARD ASSY
14
Washer DIN 125 - A 4.3
15
Spring Washer DIN 127 - A 4
16
17
0560995891
18
3390
19
2236750
20
10Z30
FITTING 1/4 NPT TO B-A/W
21
3389
ADAPTER 1/4 NPT -BOXY
23
0560941465
10
Hexagon Socket Button Head Screw IS0 7380-M4 x 8

ELBOW STREET 90 1/4 NPTF x 1/4 NPTM
TEE, STREET 1/4 NPTF x 1/4 NPTM
22
DIN RAIL
24
527376
STRAIN RELIEF 1/2 (1/4-3/8 Insert)
25
952920
26
44052550
27
74S76
29
44352230
30
11N16
28
NIPPLE, PIPE 1/4 X 2 BRASS
80
section 6
replacement parts
ITEM
QTY
PART NUMBER
31
950167
DESCRIPTION
GROMMET,RUBBER 1-1/2 X 1-1/8
32
33
34
36

STD-000037
37
38
39
40
4425110000
ELBOW 1/4 NPT BRONZE
41
0560940925
RAIL, GROUND CLAMP
42
0560940912
Switch , VoItage Select Slide
43
0560938112
CONN FLANGE ASIOB
44
10
2237993
TERMINAL BLOCK MINI DBL LEVEL
45
2234485
END CLAMP
46
2234477
FUSE HOLDER
47
15
2237987
TERM BLOCK DBL LEVEL W/COMB
48
0560941463
ASSY, HOSE, PLASMA GAS 1
49
0560941461
ASSY, HOSE, AIR CURTAIN
50
0560941462
ASSY, HOSE, PLASMA GAS 2
51
0560941459
ASSY, HOSE, SHIELD GAS 1
52
0560941460
53
Hexagon Socket Button Head Screw IS0 7380 - M3 x 6
54
55
Hexagon SocketButton Head Screw ISO 7380 - M3 x 10
56
Hex Nut DIN 934 - M 3
57
Hex Nut DIN 934 - M 2.5
58
Spring Washer DIN 127 - A 2.5
59
Cylinder Head Cap Screw DIN 912 - M 2.5 x 8
35
81
section 6
replacement parts
ITEM
QTY
PART NUMBER
DESCRIPTION
63
639501
NIPPLE 1/4 HEX BRASS
64
639110
VALVE CHECK OXYGEN
65
2237994
END COVER MINIDBL LEVEL
66
950906
TERM INLINE FML .25 X 18-22 AWG
60
61
62
67
0560942023
ASSY MALE CONN PWR
68
0560941600
69
0560941601
70
0560940873
STUD, GND. 1/4 - 20 X 1 PLATED
71
Toothed Lock Washer DIN 6797 -J 6.4 STD-000483
72
Hex Nut DIN 934 - M6 STD-000024
73
0560941602
74
20
2213249
3 PIN CONNECTOR
75
56997679
BL 3.5/2/S N 2 PIN PLUG
76
56995340
BL 3.5/3/180 3 PIN PLUG
77
56995341
BL 3.5/4/180 4 PIN PLUG
78
0560941604
MODULE, POWER RELAY
79
954075
NAMEPLATE 2.30 X 3.38
80
2010560
Strain Relief 3/4
0560942026
ASSY FEMALE CONN PWR
84
0560941905
adpt blkhd 1/4 npt w/ flats
85
2770891
137
0560942021
138
2059603
139
0560985522
CHECK VALVE FUEL GAS
140
ref
0560988032
5 A Slow Blow
141
ref
0560939203
1.0 Amp Slow Blow
142
ref
0560943657
0.5 A Slow Blow
146
526651
ASSY, RELAY
81
82
83
Phoenix end cover
COVER PLT SHIELD GAS BOX M3 PLASMA
TEE 1/4 NPT FFF
STRAIN RELIEF, 1/2 (3/8-1/2 Insert)
82
section 6
replacement parts
6.7 Shield Gas Manifold (Shield Gas Box)

10, Methane
12
10
9, Oxygen
4, typ. 13 plcs
See View A-A
7, Nitrogen
12
8, Air
5
11
View A-A
83
section 6
replacement parts
Shield Gas Manifold (Shield Gas Box) Parts List
ITEM
QTY
PART NUMBER
DESCRIPTION
10
0560940763
O RING 11/16 X 13/16 X .07 VITON
0560940899
SHIELD MANIFOLD
10
36358
PLUG MANIFOLD
13
4 4 4016750 0
PLUG PIPE 1/8 NPT
10
639669
SPRING 0.47x0.43 1 L
10
639678
TUBE
74S76
10Z30
FIT TING 1/4 NPT TO B A / W
3389
ADAPTER 1/4 NPT - B OX Y
10
3390
11
10
950654
BALL 1/2 DIA RUBBER
12
10
952921
VALVE SOLENOID 2-WAY MAN. MT.
84
notes
85
notes
86
revision history
1. Original release - 05/2006
2. 06/2006 - Changes made through out the manual: updated flip-top covers, gas filters, added hose fittings kit, various
editorial changes, updated boms, added previously uncompleted information.
3. 12/2006 - Changes per cutting systems CN #064113. Changes made to various pictures of the shield gas and plasma
gas boxes. New pictures show new handle, strain relief & power cable connector for shield gas box. Plasma gas box
has new strain relief connector. Added P/N 20373, Flash Arrestor to the m3 Gas Fittings Kit, P/N 0558005229. Added
LED Volt Meter to the component block diagram. Updated schematics to show check valve & spark arrestor placement.
Updated 2.3 System Gas Requirements to show new information and match torch manual.
4. 06/2007 - Removed ground wires from illustration page 24, chgd item 1 p/ns page 35, chgd item 17 p/ns page 39,
revised note to call for correct cut data manual page 41 & 43, del note from page 52.
5. 02/2008 - Added second Voltage Divider Board (0560940947) to Pages 54 and 68 per e-mail request.
6. 10/2008 - Added chassis grounding stud and updated replacement parts / schematics.
87
ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES
A.

CUSTOMER SERVICE QUESTIONS:

Telephone: (800)362-7080 / Fax: (800) 634-7548
Hours: 8:00 AM to 7:00 PM EST
Order Entry
Product Availability
Pricing Order Information Returns
B.

ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C.

TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications

Equipment Recommendations
D.

LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
E.

WELDING EQUIPMENT REPAIRS:

Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status
F.

WELDING EQUIPMENT TRAINING

Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
G.

WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123
H.

TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070
IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123
Fax: (843) 664-4462
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
0558005487
10 / 2008

m3 Plasma-Shield Gas Boxes 0558005487

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Precision Plasmarc

Plasma Gas Box & Shield Gas Box

Be sure this information reaches the operator.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

FIRES AND EXPLOSIONS -- Heat from

PROTECT YOURSELF AND OTHERS -Some welding, cutting, and gouging

ELECTRICAL SHOCK -- Contact with

3. Welders should use the following procedures to

2. Connect the workpiece to a good electrical

A. Route the electrode and work cables together.

3. Connect the work cable to the workpiece. A poor

B. Never coil the torch or work cable around your

4. Use well-maintained equipment. Replace worn or

D. Connect the work cable to the workpiece as close

6. Make sure that all parts of your body are insulated

9. Turn off the power before removing your gloves.

FUMES AND GASES -- Fumes and

1. Always provide adequate ventilation in the work area

10. Refer to ANSI/ASC Standard Z49.1 (listed on

ELECTRIC AND MAGNETIC FIELDS

1. Welders having pacemakers should consult their

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

2. Exposure to EMF may have other health effects which

5. WARNING: This product, when used for welding

CYLINDER HANDLING -- Cylinders,

4. Do not abuse any equipment or accessories. Keep

5. Keep all safety devices and cabinet covers in position

2. Always secure cylinders in an upright position by

ADDITIONAL SAFETY INFORMATION -- For

3. When not in use, keep cylinder valves closed. Have

The following publications, which are available from

5. For additional information, refer to CGA Standard P-1,

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

EQUIPMENT MAINTENANCE -- Faulty or

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

5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding

Meaning of symbols - As used

Means immediate hazards which,

1.2 Safety - Spanish

La escoria puede estar caliente y dEPPrenderse con

ADVERTENCIA: Estas Precauciones de Seguridad son para su proteccin. Ellas hacen

FUEGO Y EXPLOSIONES -- El calor de

PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte

CHOQUE ELECTRICO -- El contacto

1. Asegrese de que el chasis de la fuente de poder

CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente

5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,

1. Siempre tenga personal cualificado para efectuar l a instalacin, diagnstico, y mantenimiento

MANEJO DE CILINDROS-- Los

1. Utilize el gas apropiado para el proceso y utilize

INFORMACION ADICIONAL DE SEGURIDAD -- Para ms informacin sobre las

2. Asegure siempre los cilindros en posicin vertical

Las siguientes publicaciones, disponibles atravs de

3. Cuando el cilindro no est en uso, mantenga la

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

MANTENIMIENTO DEL EQUIPO -- Equipo

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

1.3 Safety - French

AVERTISSEMENT : Ces rgles de scurit

PROTGEZ-VOUS -- Les processus de

CHOC LECTRIQUE -- Le contact avec