Automated Power Sources for High Precision Plasma Cutting of Thick Plate

ESAB Welding & Cutting Products (Florence, SC) has launched their I-Series™ of high precision automated plasma cutting power sources that deliver higher productivity and the industry’s lowest cost of operation through longer consumables life. The I-Series is available in 100 amp, 200 amp, 300 amp and 400 amp configurations for cutting plate up to 50 mm thick. All models feature a common cabinet and components, as well as StepUp™ modular technology that allows users to increase the output from 100 amps all the way up to 400 amps by adding inverter blocks. “The ability to add inverter blocks means that fabricators never have to worry about purchasing a system that does not have enough capacity to meet future needs,” said Steve Zlotnicki, the product line manager for cutting at ESAB.

I-Series power sources can be used with the heavy duty Combirex DX precision gantry cutting machine that offers smoother motion and longer life and contains an easily installed H-beam mounted rail that provides a sturdy foundation and excellent rail protection. Its Vision T5 touch-screen controller is powerful and easy to use, with a built-in process database and optional automatic nesting as part of a suite of integrated cutting technologies that provides superior cut quality and higher productivity. Providing ISO Class 3 or better cuts on any material from gauge to 50 mm thick, the I-Series reduces bevel and improves edge quality, reducing the need for post-cut finishing.

Choices for plasma gas include air, nitrogen, oxygen and argon-helium, with argon for marking. Shield gas choices include air, nitrogen, oxygen and water as part of the Water Mist Secondary (WMS™) process that incorporates nitrogen as the plasma gas and ordinary tap water for shielding. On stainless steel, the WMS process cuts up to 300 percent faster and lowers cost per cut by 20 percent or more compared to systems that use argon-hydrogen for the plasma gas. WMS also delivers superior results on aluminum. “The I-Series torch dual gas technology provides one of the highest arc density plasma streams in the industry for precision cuts, as well as the highest kW output for maximized duty cycle and cut speed,” noted Zlotnicki. “On mild steel, the I-Series provides a combination of cut quality and performance that meets or exceeds all competitors. For cutting non-ferrous materials, our WMS process delivers unmatched speed and quality.”

The I-Series torch features the SpeedLok™ cartridge that removes in seconds with a simple twist and no tools required. Users can minimize downtime by keeping extra cartridges on hand to change consumables for cutting at different amperages, replacing worn consumables or switching to the WMS or marking process. The I-Series lowers the cost per cut by using XTremeLife™ Wear Parts for cutting at 200 amps, 300 amps and 400 amps. These consumables use a multiple hafnium insert as opposed to a single insert and feature a two-piece tip that runs cooler. Better cooling extends parts life and cut accuracy across the life of the tip, especially when piercing at higher amperages. These combined features can lower operating cost up to 30 percent on mild steel, which in turn reduces cut cost per meter.

To further extend consumables life in higher amperage applications, HeavyCut® Technology, an enhanced arc start/stop routine, can increase arc starts from an average of 900 starts to 1,300 starts per set of consumables. “Consumables wear is the single largest factor affecting cut cost, and consumables wear most during arc starts and stops,” added Zlotnicki. “The combination of HeavyCut Technology and XTremeLife electrodes enables the I-Series to reduce cut cost per foot by up to 16 percent compared to standard consumables. Users can save up to $900 per system per year, with the greatest savings possible at higher outputs.”

ESAB Welding & Cutting Products, PO Box 100545, 411 South Ebenezer Road, Florence, SC 29501, 843-669-4411, Fax: 843-664-4258, www.esabna.com.