ESAB PT-20AMX and PT-21AMX Plasmarc Cutting Torches User manual

PT-20AMX and PT-21AMX

Plasmarc Cutting Torches

0558004233 01 / 2005

Instruction, Operation and Maintenance Manual

2

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-

tion 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.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying la-

bels 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 mainte-

nance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the

manufacturer.

3

SECTION TITLE ................................................................................................................................. PAGE

SECTION 1 SAFETY .................................................................................................................................... 5

1.0 Safety Precautions .................................................................................................................................................. 5

1.1 Safety - English ........................................................................................................................................................ 5

1.2 Safety - Spanish ....................................................................................................................................................... 9

1.3 Safety - French .......................................................................................................................................................13

SECTION 2 DESCRIPTION ........................................................................................................................................................17

2.0 Description ..............................................................................................................................................................17

2.1 Accessories ..............................................................................................................................................................18

SECTION 3 INSTALLATION ......................................................................................................................................................21

3.0 Installing Front End Parts ...................................................................................................................................21

SECTION 4 OPERATION ............................................................................................................................................................25

Cutting Parameter Charts ..................................................................................................................................25

SECTION 5 MAINTENANCE ....................................................................................................................................................29

5.0 General .....................................................................................................................................................................29

5.1 Dirt or Contamination .........................................................................................................................................29

5.2 Loose Consumables .............................................................................................................................................29

5.3 Damage Caused by Loose Parts and Torch Overheating .......................................................................30

5.4 Consumables - Remove and Replace ............................................................................................................30

5.5 Measuring Torch Gas Flows ...............................................................................................................................32

5.6 Removal and Replacement of the Torch Body ...........................................................................................33

5.7 Removal and Replacement of the Torch Cables ........................................................................................35

SECTION 6 REPLACEMENT PARTS ......................................................................................................................................37

6.0 General .....................................................................................................................................................................37

6.1 Ordering ...................................................................................................................................................................37

TABLE OF CONTENTS

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5

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety precau-

tions 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.

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 tted with the correct lter 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 ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess 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 ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable 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 oors or wall openings and cause a hid-

den smoldering re or res on the oor 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 ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re 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 re. Use re 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 Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

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 conned, or if there is

danger of falling.

6

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

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

or missing connection can expose you or others

to a fatal shock.

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.

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.

9. Turn o the power before removing your gloves.

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

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

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.

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.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

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, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation 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 discom-

fort persists.

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

for specic ventilation recommendations.

7

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.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

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 ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

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

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

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 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied 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.

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.

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.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

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

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

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

Cutting"

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

Arc Gouging and Cutting"

8

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

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 Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, 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.

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17

2.0 Description

This booklet covers mainly accessories, maintenance, and parts information for the

PT-20AMX and PT-21AMX plasma torches. For installation and operating instructions

for your cutting package, refer to your power source instruction manual.

The patented PT-20AMX is a 100 amp capacity, pilot-arc mechanized torch available

in 6 dierent versions. The torch uses clean, dry air as the cut gas for cutting carbon

steel, aluminum, or stainless steel.

PT-21 AMX Torch is identical to the PT-20 AMX torch except it is specically designed

to connect to the PowerCut 1250 and 1500 plasma power sources.

DO NOT use oxygen with this

torch! A hazardous fire may

result.

PT-20 AMX

Without Rack; 7.6m (25 ft.) ....................................................................................0558003426

With Rack; 7.6m (25 ft.) ...........................................................................................0558003427

Without Rack; 15.2m (50 ft.) .................................................................................0558003422

With Rack; 15.2m (50 ft.) ........................................................................................0558003421

RAS; Without Rack, 1.2m (4 ft.) .............................................................................0558003424

RAS, Without Rack, 5.2m (17 ft.) ..........................................................................0558003425

PT-21 AMX (for use with PowerCut 1250 and PowerCut 1500)

Without Rack; 15.2m (50 ft.) .................................................................................0558003615

With Rack; 15.2m (50 ft.) ........................................................................................0558003614

Without Rack; 7.6m (25 ft.) ....................................................................................0558003617

With Rack; 7.6m (25 ft.) ...........................................................................................0558003616

Dimensional Data

435 mm

34,9 mm

368 mm

194 mm

34.9mm (1.38")

435.0mm (17.13")

193.8mm (7.63")

368.3mm (14.50")

WARNING

SECTION 2 DESCRIPTION

18

SECTION 2 DESCRIPTION

2.1 Accessories

PT-20AMX Torch Spare Parts Kits - The following spare parts kits are available for

maintaining the PT-20AMX torch with minimum downtime.

50 Amps - 21370 (2461001)

70 Amps - 21369 (0558000848)

90 Amp - 0558004271 (0558004277)

100 Amps – 21376 (0558004259)

PT-21 AMX torch uses the same spare parts as the PT-20 AMX.

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

Description

Part Number Quantity

Standard "CE" European 50 AMP 70 AMP 90 AMP 100 AMP

Heat Shield (70/100 A) 21326 4485831 - 2 2 2

Heat Shield (50 A) 21447 4485832 2 1 1 1

Cutting Nozzle (50 A) 21330 4485833 5 5 5 5

Cutting Nozzle (70 A) 21329 4485834 - 5 5 5

Cutting Nozzle (90 A) 0558004269 0558004269 - - 5 -

Cutting Nozzle (100 A) 21328 4485835 - - - 5

Electrode 21150 0558004249 5 5 - 5

Electrode 50Hz 0558001617 0558001617 5 5 5 5

Electrode Seat 21372 4485839 1 1 - 1

Electrode Insulator 21373 21373 1 1 1 1

Electrode Holder Assy 21332 4485840 1 1 1 1

Bae Tube 21374 4485838 1 1 1 1

Pilot Arc Adaptor 21803 21803 1 1 1 1

O-ring 488157 4485841 5 5 5 5

Lubricant (1 oz.) 17672 0558000443 1 1 1 1

Seat/Bae Wrench 21375 4485842 1 1 1 1

1/16: Hex-Key Wrench 93750006 4485651 1 1 1 1

19

Torch Holder Assembly – 16V83 (0558004250)

Plasma Flow Measuring Kit — 19765 (0558000739)

Remote Hand Control Switch with 7.6m (25 ft.) lead

For PT-20 AMX — 680982 (0558004251)

For PT-21 AMX — 0558003612

Adaptor for PCM-875 and PCM-1125 — 19500 (0558004252)

SECTION 2 DESCRIPTION

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

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21

SECTION 3 INSTALLATION

3.0 Installing Front End Parts

Make sure power switch on

console is in OFF position and

primary input power is de-

energized.

1. The seat comes assembled to the front end of the torch. IF the seat becomes

damaged, the torch body must be replaced. DO NOT attempt to remove the seat

from torch body.

2. Electrode holder assembly 21332 (4485840) includes the bae tube 21374

(4485834). If bae tube becomes damaged, it can be replaced by un-threading the

damaged tube out of the holder. Use small hex end of the wrench 21375 (4485842)

in hex broach on the tube. Tighten tube securely but do not over-tighten.

Electrode Holder Assembly

Bae Tube

Seat

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

WARNING

Wrench

22

3. Install the electrode insulator 21373 (4485837) onto electrode holder assembly

21332 (4485840) and then thread electrode 21150 (0558004249) onto the electrode

holder assembly. Assemble electrode rmly by hand. Do not use wrenches or pliers.

These three parts combined are the electrode assembly.

4. Install nozzle onto the electrode assembly by inserting small shoulder on elec-

trode insulator into nozzle’s rear opening. Place nozzle and electrode assembly

into the heat shield as shown in Page 6. If front end of the torch is facing down as

normal in a setup, the nozzle and electrode assembly can be stacked in the heat

shield and then assembled to the torch. Be sure to use proper heat shield and

nozzle combination as noted in Page 18.

5. Apply a thin lm of lubricant 17672 (0558000443) to o-ring 488157

(4485841).

O-ring

SECTION 3 INSTALLATION

21332

21373

21150

21332 (4485840)

21373 (4485837)

21150 (0558004249)

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

23

SECTION 3 INSTALLATION

6. Tighten heat shield fully to hold the parts in rm contact with each other and

to the torch head. “Fully” means at least 4.8mm (0.19") rotation after electrode seat

contacts electrode holder.

To connect PT-20AMX torch to the console, connect the power cable of the torch to

the ‘‘NEG’’ terminal and pilot arc cable to the ‘‘POS’’ terminal of the unit using pilot

arc adaptor (21803 - supplied with spare parts kit). A separate remote control switch

cable is required for connecting to the switch receptacle on the console.

The front end of the torch contains a gas ow check valve that acts in conjunction

with the circuitry provided in the power supply. This patented system provides a safety

interlock preventing the torch from being accidentally energized with high voltage

when the heat shield is removed and the torch switch is accidentally closed.

IMPORTANT:

See Maintenance section.

Follow all instructions in the

booklet packed with your unit.

DO NOT install or attempt to

operate this torch without

following these instructions.

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

CAUTION

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25

SECTION 4 OPERATION

Heat Shield

70/100 amp (blue) - 21326 (4485831)

50 amp (white) - 21447 (4485832)

Bae Tube - 21374 (4485838)

Electrode Adaptor

Assembly - 21332

(4485840)

Insulator - 21373

(4485837)

Electrode - 21150 (0558004249)

Electrode - 0558001617

Torch Body Assembly - 21359 (4485850)

O-ring - 488157 (4485841)

Cutting Nozzle (see appropriate

spare parts kit for p/n)

PT-20AMX Torch

NOTE: Part numbers in parenthesis apply to "CE" / European units only.

Metal Thick-

ness

Air Pressure Stand-O Arc Voltage Pierce

Time

Mild Steel Aluminum Stainless

(in.) (mm) psig bar (in.) (mm) DC volts (sec.) ipm mm/m ipm mm/m ipm mm/m

0.25 6 85 6 0.25 6 110 0,1 100 2540 105 2667 80 2032

0.50 13 85 6 0.25 6 120 0,3 45 1143 50 1270 30 762

0.75 19 85 6 0.25 6 125 1,0 27 686 35 889 15 381

1.00 25 85 6 0.25 6 130 2,75 15 381 20 508 10 254

1.25 32 85 6 0.32 8 140 NR 10 254 13 330 7 178

1.50 38 85 6 0.32 8 145 NR 7 178 10 254 5 127

Cutting Parameters for the PT-20AMX Torch

NOTE: Part numbers in parenthesis apply to "CE" / European units only.

100AMP Data, Nozzle P/N 21328 (4485835), Heat Shield P/N 21326 (4485831)

26

SECTION 4 OPERATION

Cutting Parameters for the PT-20AMX Torch

NOTE: Part numbers in parenthesis apply to "CE" / European units only.

“NR” indicates piercing is not recommended

50AMP Data, Nozzle P/N 21330 (4485833), Heat Shield P/N 21447 (4485832)

70AMP Data, Nozzle P/N 21329 (4485834), Heat Shield P/N 21326 (4485831)

Metal Thick-

ness

Air Pressure Stand-O Arc Voltage Pierce

Time

Mild Steel Aluminum Stainless

(in.) (mm) psig bar (in.) (mm) DC volts (sec.) ipm mm/m ipm mm/m ipm mm/m

0.13 3 75 5 0.19 5 105 0,1 190 4826 180 4572 80 2032

0.25 6 75 5 0.19 5 110 0,2 80 2032 85 2159 55 1397

0.50 13 85 6 0.25 6 115 0,6 30 762 30 762 20 508

0.75 19 85 6 0.25 6 130 2,3 15 381 25 635 8 203

1.00 25 85 6 0.32 8 140 NR 7 178 12 305 6 152

1.25 32 85 6 0.32 8 155 NR 5 127 10 254 3 76

Metal Thick-

ness

Air Pressure Stand-O Arc Voltage Pierce

Time

Mild Steel Aluminum Stainless

(in.) (mm) psig bar (in.) (mm) DC volts (sec.) ipm mm/m ipm mm/m ipm mm/m

0.06 2 75 5 0.13 3 110 40 150 3810 150 3810 130 3302

0.13 3 75 5 0.13 3 110 40 100 2540 105 2667 75 1905

0.19 5 85 6 0.13 3 110 50 100 2540 90 2286 50 1270

0.25 6 85 6 0.19 5 120 50 65 1651 75 1905 30 762

0.38 10 85 6 0.25 6 130 50 40 1016 30 762 8 203

0.50 13 85 6 0.32 8 150 50 18 457 8 203 6 152

27

Heat Shield

70/90 amp - 21326 (4485831)

30/50 amp - 21447 (4485832)

Bae Tube - 21374 (4485838)

Electrode Adaptor

Assembly - 21332

(4485840)

Insulator - 21373

(4485837)

Electrode - 21150 (0558004249)

Torch Body Assembly - 21359 (4485850)

O-ring - 488157 (4485841)

Cutting Nozzle (see appropriate

spare parts kit for p/n)

PT-21AMX Torch

Cutting Parameters for the PT-21AMX Torch

90AMP Data, Nozzle P/N 21328 (4485835), Heat Shield P/N 21326 (4485831)

“NR” indicates piercing is not recommended

Pierce

Time

Metal

Thickness

6

13

19

25

32

38

Air

Pressure

psig

Stand-O

in.

mm

Arc

Voltage

DC Volts

seconds

0.25

0.50

0.75

1.00

1.25

1.50

bar

mm

in.

85

5

6

.188

.250

6

Optimum

Mild Steel

Aluminum

Stainless

Maximum

Travel Speed

ipm (mm/min)

Optimum

Maximum

ipm (mm/min)

Optimum

Maximum

ipm (mm/min)

110

120

125

130

140

145

0.1

0.3

1.0

2.75

NR

Metal

Thickness

6

13

19

25

32

38

0.25

0.50

0.75

1.00

1.25

1.50

mm

in.

150

55

25

13

9

5

3810

1397

635

330.2

228.6

127

120

49

22

12

7

3

3175

1549.4

889

508

330.2

254

3048

1244.6

558.8

304.8

177.8

76.2

105

51

31

15

10

7

125

61

35

20

13

10

2667

1295.4

787.4

381

254

177.8

88

37

15

10

7

3

2235.2

939.8

381

254

177.8

76.2

80

31

13

8

5

3

2032

787.4

330.2

203.2

127

76.2

SECTION 4 OPERATION

NOTE: Part numbers in parenthesis apply to "CE" / European units only.

28

SECTION 4 OPERATION

Cutting Parameters for the PT-21AMX Torch

Pierce

Time

Metal

Thickness

3

6

13

19

25

32

Air

Pressure

psig

Stand-O

in.

mm

Arc

Voltage

DC Volts

seconds

.125

.250

.500

.750

1.000

1.250

bar

mm

in.

75

85

5

6

.188

.250

5

6

Optimum

Mild Steel

Aluminum

Stainless

Maximum

Travel Speed

ipm (mm/min)

Optimum

Maximum

ipm (mm/min)

Optimum

Maximum

ipm (mm/min)

105

110

115

125

135

150

0.1

0.2

0.6

2.3

NR

Metal

Thickness

mm

in.

210

101

39

15

7

5

5334

2565.4

990.6

381

177.8

127

190

85

30

13

5

3

5207

2540

990.6

635

304.8

228.6

4826

2159

762

330.2

127

76.2

185

90

31

20

9

5

205

100

39

25

12

9

4699

2286

787.4

508

228.6

127

91

61

23

12

7

3

2311.4

1549.4

584.2

304.8

177.8

76.2

80

55

20

9

6

3

2032

1397

508

228.6

152.4

76.2

“NR” indicates piercing is not recommended

Pierce

Time

Metal

Thickness

2

3

5

6

10

13

Air

Pressure

psig

Stand-O

in.

mm

Arc

Voltage

DC Volts

seconds

0.063

0.125

0.188

0.250

0.375

0.500

bar

mm

in.

75

85

3

5

.125

.188

5

6

Optimum

Mild Steel

Aluminum

Stainless

Maximum

Travel Speed

ipm (mm/min)

Optimum

Maximum

ipm (mm/min)

Optimum

Maximum

ipm (mm/min)

110

120

125

135

0

0.1

0.2

0.4

0.6 / NR

0.8 / NR

Metal

Thickness

mm

in.

170

112

111

71

43

21

4318

2844.8

2819.4

1803.4

1092.2

533.4

155

100

102

66

40

18

4089.4

3581.4

2667

2108.2

939.8

330.2

3937

2540

2590.8

1676.4

1016

457.2

150

110

93

77

31

9

161

141

105

83

37

13

3810

2794

2362.2

1955.8

787.4

228.6

141

79

57

37

15

11

3581.4

2006.6

1447.8

939.8

381

279.4

130

75

50

30

10

8

330.2

1905

1270

762

254

203.2

70AMP Data, Nozzle P/N 21329 (4485834), Heat Shield P/N 21326 (4485831)

40/50AMP Data, Nozzle P/N 21330 (4485833), Heat Shield P/N 21447 (4485832)

.125

.250

.500

.750

1.000

1.250

3

6

13

19

25

32

Arc

Current

amps

40

50

2

3

5

6

10

13

0.063

0.125

0.188

0.250

0.375

0.500

“NR” indicates piercing is not recommended

NOTE: Part numbers in parenthesis apply to "CE" / European units only.

29

SECTION 5 MAINTENANCE

Before any maintenance is at-

tempted on this torch, make

sure the POWER SWITCH on the

console is in the OFF position

and the PRIMARY INPUT POWER

is DEENERGIZED.

WARNING

!

5.0 General

1. The gas ow check valve is part of the safety interlock and is permanently assembled

in the torch head. The head must be replaced if this valve malfunctions.

2. Periodically check heat shield, electrode holder assembly and electrode insulator.

Replace if worn or damaged.

3. Apply a thin lm of lubricant 17672 (0558000443), supplied in spare parts kit, to

o-ring. Check o-ring for damage whenever shield is removed. Replace if necessary.

4. Power and pilot arc cables should be inspected periodically. If cuts through

protective sheath or if gas leaks are noted, replace damaged component.

5.1 Dirt or Contamination

Dirt or other contamination in the torch and loose consumable parts can cause

premature failure of the PT-20AMX / PT-21AMX Torch through internal arcing. To

avoid this, users are instructed to do the following:

1. Ensure that clean, dry, or oil-free air is being used.

2. Avoid excessive use of the silicone o-ring grease used to lubricate the torch o-ring.

A thin lm is sucient.

Wipe the torch body insulator clean with a cloth before installing each fresh set

of consumables. The ability of the insulator to resist arc tracking over its surface is

reduced when dirt or other contamination is allowed to collect there.

5.2 Loose Consumables

Tests have shown that with proper use of the torch within rated operating conditions

(especially arc current and gas ow rate), the torch consumable parts do not become

loose if they are rmly installed in the rst place.

1. Tighten heat shield fully at each consumable change or inspection. “Fully” means

at least 5mm (0.20") of rotation after electrode seat contacts electrode holder.

2. Check consumable tightness at beginning of each work shift, even if everything

was working normally at the end of the previous shift.

Ensure that the torch electrode seat and electrode holder are clean and free of dust

or dirt. Debris may prevent mating surfaces from having solid contact.

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

30

SECTION 5 MAINTENANCE

The torch requires good electrical

contact between the electrode

seat and electrode holder. If good

contact is not maintained, then

the resulting potential dierence

causes internal arcing and pos-

sible torch damage.

CAUTION

5.3 Damage Caused by Loose Parts and Torch Overheating.

Electrode Insulator 21373 (4485837)

Deformation at this edge indicates torch overheating. Check gas pressure, gas

owrate and current setting. Deformation leads to loose parts and internal

arcing. Do not operate torch with a deformed insulator.

5.4 Consumables - Remove and Replace

Arc tracking indicates loose parts. Make sure heat shield is tightened fully, at least

5mm (0.20") of rotation after electrode seat contacts electrode holder. Check tight-

ness again after a few minutes of use. Parts damaged by arcing will cause destruction

of torch. Parts damaged by arcing must be replaced.

1. Bring torch to a position where it is easily accessed by machine operator, in its

normal vertical position and at least 152.4mm (6.00") above the workpiece or the

edge of the water table.

Make sure that the power source

has been turned o and that the

power cable has been unplugged

at the wall receptacle before pro-

ceeding.

WARNING

!

2. Unscrew the heat shield and lower it away from the torch, allowing nozzle and

electrode assembly to remain with shield.

Edge

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

31

SECTION 5 MAINTENANCE

3. Remove the nozzle and electrode assembly and inspect for wear. The nozzle orice

should be round at both the entrance and the exit. If the nozzle orice is worn in an

oval shape or shows other signs of damage at either end, it should be replaced. The

inside of the nozzle may have light gray deposits from the electrode. These may be

removed with steel wool but care must be taken to remove all traces of the steel

wool afterward.

1,5 mm

If the electrode has a pit which is more than 1.5mm (0.06") deep at its center, replace

it. This is done by unscrewing the electrode from the electrode holder. Grasp the

electrode holder with the ngers using the two ats and grasp the electrode between

the thumb and nger of the other hand and twist.Inspect electrode insulator and

electrode holder assembly for signs of damage such as arc tracking or cracking and

replace them if any are found. Insure that the bae tube is securely threaded into

the electrode holder, but do not overtighten. Use the small hex end of the plastic

wrench in the spare parts kit.After installing the electrode insulator onto the electrode

holder assembly, install electrode by reversing the procedure used to remove it. Note

that rm tightening of the electrode by hand is sucient, the use of tools such as

wrenches or pliers is not required or recommended.

4. Inspect heat shield for signs of damage or wear. The gas holes inside shield should

not be blocked by debris, and there should be no signs of arcing anywhere inside

the shield. The outer insulating jacket of the shield should not be severely charred

or eroded. Replace the heat shield if any of the above damage is found.

1.5mm

(0.06")

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ESAB PT-20AMX and PT-21AMX Plasmarc Cutting Torches User manual

ESAB PT-20AMX and PT-21AMX Plasmarc Cutting Torches User manual

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