Installation checklist

This checklist summarizes major installation steps. You can use it to record their completion. For full information, refer to Installation steps.

  • Put the system components in position.
    • Plasma power supply
    • Cooler
    • Gas connect console
    • TorchConnect™ console
    • Torch

    Refer to Configuration with the gas connect console, Configuration with the gas connect console, or Configuration with or gas consoles.

  • Ground the system components.
    • Plasma power supply
    • Cooler
    • Gas connect console
    • TorchConnect console
    • Torch lead collar
    • Cutting table
    • Computer Numerical Control (CNC)

    Before you connect hoses, cables, and leads, make sure that all system components are correctly and fully grounded. Refer to Recommended grounding and shielding.

  • Connect all of the hoses, cables, and leads to the plasma power supply.

    Refer to Connect the plasma power supply.

    • Coolant-supply hose and coolant-return hose to the cooler
    • Power cable, 220 VAC, to the cooler
    • Power cable, 120 VAC, to the gas connect console
    • Controller Area Network (CAN) cable to the cooler
    • Pilot-arc cable to the gas connect console
    • Both negative cables ( - ) to the gas connect console
    • Both work cables to the cutting table
  • Connect all of the hoses, cables, and leads to the cooler.

    Refer to Connect the cooler.

    • Coolant-supply hose and coolant-return hose from the plasma power supply
    • Coolant-supply hose and coolant-return hose to the gas connect console
    • Power cable, 220 VAC, from the plasma power supply
    • CAN cable from the plasma power supply
    • CAN cable to the gas connect console
  • Connect all of the hoses, cables, and leads to the gas connect console.

    Refer to Connect the gas connect console.

    • Coolant-supply hose and coolant-return hose from the cooler
    • Power cable, 120 VAC, from the plasma power supply
    • CAN cable from the cooler
    • Both negative cables ( - ) from the plasma power supply
    • Pilot-arc cable from the plasma power supply
  • Connect both work cables to the cutting table.
  • Connect the cable and lead assemblies between the Core™ or CorePlus™ gas connect console and TorchConnect console.

    Refer to Connect the gas connect console (, ) to the console.

    The number and type of gas hose connections is based on the type of gas connect console you have.

    • Pilot-arc and coolant-hose assembly
    • Power, CAN, and 3-gas assembly
    • Power, CAN, and 4-gas assembly
  • Connect the cable and lead assemblies between the VWI™ or OptiMix™ gas connect console and TorchConnect console.

    Refer to Connect the gas connect console (, ) to the console.

    The number and type of gas hose connections is based on the type of gas connect console you have.

    • Pilot-arc, coolant-hose, and shield-water assembly
    • Power, CAN, and 5-gas assembly
  • Connect the torch-lead assembly to the torch receptacle.

    Refer to Install the torch-lead assembly to the torch receptacle.

  • Connect the torch-lead assembly to the TorchConnect.

    Refer to Connect the torch lead to the console.

  • Make sure that the hoses, cables, and leads are correctly installed.
    • Correct type and correct installation
    • No damage or kinks
    • No coils in cables that can create EMI problems
    • Distances between high-frequency leads and control cables obey requirements
    • Distances for communications obey requirements
  • Remove the torch and consumable parts.

    Refer to Remove the torch and consumable parts.

  • Install the torch into the torch receptacle.

    Refer to Install the torch into the torch receptacle.

  • Install the torch mounting bracket.
  • Install the consumables.

    Refer to Install the consumables.

    • Make sure the consumables are the correct type and correctly installed.

      The torch head that comes with the XPR torch assembly kit (10083906) has 460 A mild steel consumables pre-installed.

  • Install the torch into the torch receptacle.

    Refer to Install the torch into the torch receptacle.

  • Connect electric power to the cutting system.
  • Make sure that the communication method for the CNC interface is installed correctly.
    • EtherCAT® and remote on-off with discrete

      Refer to Connect to the plasma power supply with.

    • Wireless (XPR web interface) and discrete
    • Serial RS-422 and discrete
    • Remote on-off must be wired discretely by the cutting system manufacturer.

      A feature of the control Printed Circuit Board (PCB) is that it offers redundancy to the standard remote on-off switch. If redundant remote-on off is enabled, the switches for both the standard and redundant remote on-off must be set to ON to supply electric power to the cutting system. Refer to Install a redundant remote on-off switch.

  • Install the coolant.