ESAB PLASMARC™ Air Curtain and Air Curtain Kit for PT-19XLS and PT-600 Troubleshooting instruction
- Category
- Welding System
- Type
- Troubleshooting instruction
Instructions for
F15-475
March, 2010
37440 Air Curtain Assembly
PT-19XLS/PT-600
PLASMARC
TM
Air Curtain and Air Curtain Kit
for PT-19XLS and PT-600
P/N 37460
33383 Air Curtain Control Box
PT-19XLS/PT-600
THE AIR CURTAIN CAN NOT BE USED WHEN USING H35 OR CH
4
GAS
MIXES. THE WATER LEVEL MUST BE LOWERED 4 TO 6 INCHES BE
NEATH THE BOTTOM OF THE PLATE.
FAILURE TO COMPLY TO THIS WARNING CAN RESULT IN A HYDRO
GEN DETONATION.
WARNING
2
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions 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 imme-
diately. 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 ser-
vice facility designated by the manufacturer.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
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 be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
TABLE OF CONTENTS
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Section / Title Page
4
TABLE OF CONTENTS
5
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-
tended to be used outside during precipitation unless sheltered.
Enclosure Class
Maximum
Tilt Allowed
15°
CAUTION
If equipment is placed on a surface that
slopes more than 15°, toppling over may oc-
cur. Personal injury and / or signicant dam-
age to equipment is possible.
6
SECTION 1 SAFETY PRECAUTIONS
WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING
This product is solely intended for plasma cutting. Any other
use may result in personal injury and / or equipment damage.
CAUTION
CAUTION
To avoid personal injury and/or equipment
damage, lift using method and attachment
points shown here.
7
SECTION 2 INSTALLATION
The Air Curtain is a device used to improve the performance of the PT-19XLS
and PT-600 Plasmarc Cutting Torch when cutting underwater.
The device mounts onto the torch and produces a curtain of air. This allows
the plasma arc to operate in a relatively dry zone, even though the torch has
been submerged to reduce noise, fume, and arc radiation.
Optional Accessories
Cable, 18 GA 3-Cond. P/N 33253 25 ft.
Cable, 18 GA 3-Cond. P/N 33254 50 ft.
Cable, 18 GA 3-Cond. P/N 33255 75 ft.
Cable, 18 GA 3-Cond. P/N 33256 100 ft.
Cable, 18 GA 3-Cond. P/N 33257 125 ft.
PT-19XLS/PT-600 Air Curtain Kit, P/N 37460
Air Curtain PT-19XLS P/N 37440 1 pc
Control Box Assy. P/N 33383 1 pc
Hose Assy., 50 ft. P/N 34033 1 pc
Compressed Air Supply
(Air Curtain)
Source: 80 psi @ 1200cfh
(5.5 bar @ 34 m
3
h)
Clean, dry & oil-free shop air
Adapt B-A/W*F B-A/W*M
90 deg assy
P/N 19X19 1
DATE
RELEASED FOR
ENGLISH DWG
TITLE
REPRO MADE FROM
SIMILAR TO
SUP.
SUP. BY
APPROVED
BY
DATE
CHECKED
BY
DATE
DRAWN
BY
DATE
SCALE
FIRST MADE FOR
ESAB WELDING & CUTTING PRODUCTS
FLORENCE, SC 29501
UNLESS OTHERWISE
SPECIFIED, DIM ARE
IN INCHES.
TOL .XX
.XXX
ANGLES
CHAMFERS & C'SINKS 2
SURFACE ROUGHNESS IS IN
REMOVE ALL BURRS
BREAK SHARP EDGES
MICROINCHES
M
CHANGE
BY
DATE
CH'KD
THIS DRAWING CONTAINS PROPRIETARY CONFIDENTIAL INFORMATION OF ESAB WELDING &
CUTTING PRODUCTS AND IS LOANED WITH THE EXPRESS AGREEMENT THAT THIS DRAWING
(1) WILL NOT BE REPRODUCED OR COPIED, (2) WILL NOT BE USED OTHER THAN IN WORK
FOR ESAB WELDING & CUTTING PRODUCTS, AND (3) WILL NOT BE DISCLOSED EXCEPT
TO EMPLOYEES OF THE PARTY TO WHOM THIS DRAWING IS LOANED ON A CONFIDENTIAL BASIS.
A-
A-
MATERIAL:
.015
.005
PRO/ENGINEER DWG.
NOV.1994
A
A
19X19
ADAPT B-A/W*F B-A/W*M 90ASSY
19X19
BLP
10/23/08
63
2
1:1
FINISH:
BRIGHT DIP PER SPI 45.315.3 METHOD 6
P/N QTY DESCRIPTION
1. 836Z40 1 NUT HOSE B/A-W* .63-18F RH OLD
2. 03Z59 1 NPL B/SIZE .425ODX 0.81LG
3. 19Z48 1 BODY FOR 90 AIR WATER ADAPTOR
4. 6270869 1 RING SSBAG-1 0.438KDX.03D STD
"E" CN-083187 REVISED & RED BLP
WSS10/23/08
WSS
10/23/08
WSS
10/23/08
1
2
3
4
ELECTRIC SHOCK CAN KILL!
DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH-
ING OR SERVICING THE AIR CURTAIN AT THE TORCH.
DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.
WARNING
8
A. Installation of Air Curtain Assembly on PT-
19XLS and PT-600 (Figure 1).
1. Slide Split Bushing on to stainless steel body of torch
as shown.
2. Slide the chrome plated Air Curtain Body, P/N 37438,
onto the stainless steel body of the torch. Snug locking
collar screw on air curtain body. Final psoitioning of
air curtain will be done as a last step.
NOTE: It will ease assembly if all O-rings in the air cur-
tain body are lightly lubricated with silicone
grease.
3. Install Nozzle Retaining Cup, P/N 37431,
4. Assemble shield in shield retainer separately to assure
proper metal to metal contact.
5. Hand tighten shield and retainer assembly on torch.
Double check shield/retainer for proper seating.
6. Install an Air Curtain Sleeve, P/N 37436, over the com-
pletely assembled torch and push it into the air curtain
body until fully seated.
7. Secure the sleeve by installing the air curtain Retainer,
P/N 37435. The Retainer turns to engage or disengage
with the locking pins.
8. Adjust the position of the Air Curtain Assembly on the
torch until the shield gas cup clearance is 0.06 inch from
the inside surface of the air curtain sleeve as illustrated.
Lock the air curtain in place by tightening the Allen
screw on the air curtain.
NOTE: The Air Curtain Sleeve (37436) must remain
completely bottomed in the Air Curtain Body
for adjustment to be correct.
NOTE: Remove Existing Nozzle Retaining Cup
before Installing air curtain.
0.06 (1/16) in.
5
4
2
6
3
7
8
1
PT-19XLS/PT600 Torch Body
ELECTRIC SHOCK CAN KILL!
DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH-
ING OR SERVICING THE BUBBLE MUFFLER AT THE TORCH.
DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.
WARNING
SECTION 2 INSTALLATION
9
B. Installation of the Control Box Assembly
(P/N 33383)
NOTE: This equipment is not required for a Smart-
Flow II Flow Control application
1. Mount the control box at a convenient location and
use the hose supplied to connect the box with the
unit mounted on the torch. Mounting hole pattern
on the back panel is for 2 each 1/4 (.250) inch bolts
set 7 inches apart.
2. Connect the control box to a source of dry and oil
free shop air capable of delivering at least 20 scfm at
80 psig. The hose used should be at least 3/8" ID.
3. Use SJO wire to connect the control to the cutting
machine control. If the ESP system is used, then the
connection may be made to the appropriate amphe-
nol connector on the back of the ow control. The
connection of the control is made at the terminals
marked F.C. An appropriate cable may be selected
from the table of optional accessories.
4. The user supplied 115 V ac may be connected to the
terminals so marked. This will allow manual opera-
tion of the air curtain control.
5. Connect a ground wire to the stud provided in the
control box.
7 inches
.312 diameter clearance holes (2 ea,)
Inlet
Outlet
Ground Stud
BLACK
WHITE
BLACK
WHITE
F.C.
115 V.A.C.
SECTION 2 INSTALLATION
ELECTRIC SHOCK CAN KILL!
DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH-
ING OR SERVICING THE BUBBLE MUFFLER AT THE TORCH.
DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.
WARNING
10
SECTION 2 INSTALLATION
11
C. Operation
1. Provide control box with dry and oil free air at 80 psig
minimum. Energize solenoid in control box and ad-
just regulator screw on box to 15 psig delivery. Some
adjustment up or down of pressure may be required
to get best cut quality.
2. Place switch to AUTO. The system should turn on
when the preow begins.
3. ON position is for manual operation.
D. Control Box Wiring Diagram
BLACK
WHITE
BLACK
WHITE
F.C.
115
V.A.C.
Switch, 3 POS
ORANGE
ORANGE
Solenoid
Valve
SECTION 3 OPERATION
12
SECTION 3 OPERATION
13
1
4
2
3
5
7
8
9
10
11
6
12
SECTION 4 REPLACEMENT PARTS
Item Part Number Description
1 21380 Split Bevel Bushing
2 37438 Air Curtain Body
3 37435 Air Curtain Retainer
4 37431 Nozzle Retaining Cup Assembly
5 37081 Shield Retainer
6 37436 Air Curtain Sleeve
7 85W87 O-ring, 1.984 id X .139 w Neoprene
8 REF. O-ring used on Water Muer ONLY
9 443315 O-ring, 1.612 id X .093 w Neoprene
10 2221978 O-ring, 1.799 id X .093 w Silicone Rubber
11 92114581 O-ring, 2.114 id X .070 w Neoprene 70A
12 REF. O-ring, Component of nozzle retaining cup
14
*AIR REGULATOR AND PRESSURE GAGE ARE SUPPLIED TOGETHER AS ITEM 8. REGULATOR W/GAGE P/N 522368.
Air Curtain Control Box Assembly, P/N 33383
ITEM QTY PART
NO. REQ. NO. DESCRIPTION
1 1 636702 SWITCH, DPDT 3 POSITIONS
2 1 951041 TERMINAL, BLOCK, 4 POSITIONS
3 1 636387 SOLENOID VALVE
4 1 522368 REGULATOR W/GAGE
SECTION 4 REPLACEMENT PARTS
15
REVISION HISTORY
Revision 03/2010 - added 19X19 to optional accessories.
F15-475 03/2010
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 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
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ESAB PLASMARC™ Air Curtain and Air Curtain Kit for PT-19XLS and PT-600 Troubleshooting instruction
- Category
- Welding System
- Type
- Troubleshooting instruction
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