ESAB Bubble Muffler System: Designed for plasma cutting underwater, this system creates an air bubble to enable cutting with a PT-19XLS Plasmarc Cutting Torch, while also reducing fume, noise, and arc U.V. radiation when used above water. It connects to a water pump and compressed air supply to generate the air bubble. It features simple installation on the PT-19XLS torch and is compatible with optional accessories for further customization.
ESAB Bubble Muffler System: Designed for plasma cutting underwater, this system creates an air bubble to enable cutting with a PT-19XLS Plasmarc Cutting Torch, while also reducing fume, noise, and arc U.V. radiation when used above water. It connects to a water pump and compressed air supply to generate the air bubble. It features simple installation on the PT-19XLS torch and is compatible with optional accessories for further customization.
THE BUBBLE MUFFLER 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 HYDROGEN
DETONATION.
WARNING
BuBBle Muffler SySteM
For use with PT-19XLS / PT-600
ESAB Assembly Number: 37439
F15-474 08/2011
Instruction Manual
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 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
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
The Bubble Muer System creates a bubble of air so that a
PT-19XLS Plasmarc Cutting Torch can be used underwater
with slight sacrice of cut quality. This system also permits
operation above water as the ow of water through the
muer reduces fume, noise, and arc U.V. radiation.
Optional Accessories
Bubble Muer System
Bubble Muer PT-19XLS P/N 37439 1
Strainer P/N 2133340 1
Water Pump P/N 2135445 1
Adaptor, 1.06-12F 3/4" Hose P/N 2135571 3
Adaptor, 3/4" NPTM, 3/4" Hose P/N 2135572 1
PIP, Pipe S.ST 2.357X2.00 CL P/N 43350490 1
Bushing Pipe 2X3/4 P/N 44056390 1
Compressed Air Supply
(Air Curtain)
Source: 80 psi @ 1200cfh
(5.5 bar @ 34 m
3
h)
Clean, dry & oil-free shop air
Control Box Assembly P/N 33383 1
Control Cable, 18 GA, 3-Cond P/N 33253 25 ft.
Control Cable, 18 GA, 3-Cond P/N 33254 50 ft.
Control Cable, 18 GA, 3-Cond P/N 33255 75 ft.
Control Cable, 18 GA, 3-Cond P/N 33256 100 ft.
Control Cable, 18 GA, 3-Cond P/N 33257 125 ft.
Fittings 3/8" Hose Control Box
B-Air/Water Nut
3/8" ID Hose Nipple
P/N 10N40 1
P/N 347995 1
Fittings 3/8" Hose to Bubble Muf-
er
R.H. Air Water Nut
3/8" ID Hose Nipple
P/N 36Z40 1
P/N 03Z74 1
Hose, 3/4" ID for Water P/N 2027202 Specify
Length
Hose, 3/8" ID for Air P/N 23079995 Specify
Length
SECTION 2 INSTALLATION
8
A. Installation of Bubble Muer Assembly on PT-19XLS Torch (Figure 2)
1. Remove the Nozzle Retaining Cup from the torch.
2. Slide the chrome plated Air Curtain Body, P/N 37438 on to the stainless steel body of the torch. (Split Bushing P/N 21380
should be in place.)
NOTE: It will ease assembly if all O-rings in the air curtain body are lightly lubricated with silicone grease.
3. Install Nozzle Retaining Cup P/N 37431, and any front-end parts you may have removed from the torch including the
nozzle, shield, diuser and shield retainer.
4. Install Air Curtain Sleeve, P/N 37436, over the completely assembled torch and snap it into the Air Curtain Body. Secure
the sleeve by installing the Bubble Muer Retainer, P/N 37433. The Retainer turns to engage or disengage with the
locking pins.
5. Adjust the position of the Bubble Muer Assembly on the torch until the nozzle extends 1/16 inch from the end of the
air curtain sleeve as illustrated in Fig. 1. Lock the Bubble Muer in place by tightening the Allen screw on the Bubble
Muer.
NOTE: The Air Curtain Sleeve must remain completely bottomed in the Curtain Body for the adjustment in step 5 to be correct.
B. Installation of the Water Pump (P/N 2135445)
Figure 1. Installation of Water Pump
SECTION 2 INSTALLATION
IF A BUBBLE MUFFLER IS BEING USED, TURN OFF WATER RECIRCU
LATING PUMP.
WARNING
9
C. Installation of the Control Box Assembly (P/N 33383)
1. Mount the control box at a convenient location and use the 3/8" ID hose to connect the box with the Bubble Muer
mounted on the torch.
2. Connect the control box to a source of 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 water pump, in parallel with the 115VAC signal from the ESP or cutting ma-
chine control. The connection of the control is made at the terminals marked F. C.
4. The user supplied 115 V ac may be connected to the terminals so marked. This will allow manual operation of the air
curtain control.
5. Connect a ground wire to the stud provided in the control box.
D. Operation
1. Provide control box with oil free air at 80 psig minimum. Energize solenoid in control box and adjust 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. The pump will recirculate approximately 20
gpm from the water table.
Bubble Muer Pump Input Voltage
50 Hz Operation of ESAB
60 Hz Motors
To On
Use
60 50 Hertz
Hertz Operational Voltage
Motor Ratings +5%
230 V 190 V 200 V 208 V
460 V 380 V 400 V 415 V
Multiply
Nameplate .70 .75 .80
HP By
SECTION 2 INSTALLATION
10
SECTION 2 INSTALLATION
11
E. Servicing
Refer to Figure 2 for Bubble Muer O-ring part numbers and Figure 3
for air curtain box assembly component part numbers. Replacement
parts may be ordered from an ESAB distributor or from:
ESAB Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545
411 S. Ebenezer Road
Florence, SC 29501-0545
SECTION 3 REPLACEMENT PARTS
Figure 2. Bubble Muer PT-19XLS, P/N 37150
1
5
6
9
4
8
3
7
2
Torch Body (Ref.)
10
0.06" Ref.
Item Part Number Description
1 21380 BUSHING SPLIT BEVEL A/C
2 37438 BODY A/C
3 37433 RETAINER BUBBLE MUFFLER
4 37431 CUP NOZZLE RETAINING
5 519369 O-RING, 3" ID X 3-3/16" O.D. X 3/32"
6 443315 O-RING, 2.612 ID X .103W NEOPRENE
7 2221978 O-RING, 1.799 ID X .103W SILICONE RUBBER
8 2114581 O-RING, 2.114 ID X .070W NEOPRENE 70A
9 37436 SLEEVE PT-19XLS A/C
10 0558009395 SHIELD RETAINER, INSULATED
11 996528 O-RING, 1.984 ID X .139W NEOPRENE
NOTE: 4 each of the above o-rings are supplied.
12
ITEM QTY. PART
NO. REQ. NO. DESCRIPTION
1 2 180W38 CONNECTOR, STRAIN RELIEF
2 1 951041 TERMINAL, BLOCK, 4 POSITIONS
3 1 636702 SWITCH, DPDT 3 POSITIONS
4 2 58V75 ADAPT. BULKHD. B SIZE, 1/4 NPT
5 2 182W82 ELBOW, STREET 90° BRASS
6 1 636387 SOLENOID VALVE
7 1 67101075 NIPPLE, CLOSE, 1/4 NPT BR. M TO M
8 1 522368 REGULATOR W/GAUGE
9 2 60101025 PLUG, 1/8" NPT ALLEN HEAD
10 1 67100081 NIPPLE, 2" LG. 1/4NPT BRASS M TO M
11 1 68161103 TEE, 1/4 NPT BRASS
5
6
8*, 9
10
4
3
2
1
7
11
* Air Regulator and pressure gauge are supplied together as item 8. Regulator w/gauge P/N 522368.
Figure 3, Air Curtain Control Box Assembly, P/N 33383
SECTION 3 REPLACEMENT PARTS
13
NOTES
14
NOTES
15
REVISION HISTORY
Revision 08/2011 - Updated BOM's, changed p/n 0558004616 to p/n 0558009395 per CCARES 110608095137.
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
COMMUNICATION GUIDE - CUSTOMER SERVICES
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ESAB Bubble Muffler System: Designed for plasma cutting underwater, this system creates an air bubble to enable cutting with a PT-19XLS Plasmarc Cutting Torch, while also reducing fume, noise, and arc U.V. radiation when used above water. It connects to a water pump and compressed air supply to generate the air bubble. It features simple installation on the PT-19XLS torch and is compatible with optional accessories for further customization.
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