ESAB Bubble Muffler System User manual

Brand: ESAB

Model: Bubble Muffler System

Type: User manual

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 H35 OR CH

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

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!

TABLE OF CONTENTS

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

2.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Section / Title Page

TABLE OF CONTENTS

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 qualied 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 signicant dam-

age to equipment is possible.

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 inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus 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

To avoid personal injury and/or equipment

damage, lift using method and attachment

points shown here.

The Bubble Muer System creates a bubble of air so that a

PT-19XLS Plasmarc Cutting Torch can be used underwater

with slight sacrice of cut quality. This system also permits

operation above water as the ow of water through the

muer reduces fume, noise, and arc U.V. radiation.

Optional Accessories

Bubble Muer System

Bubble Muer 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

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

A. Installation of Bubble Muer 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, diuser 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 Muer Retainer, P/N 37433. The Retainer turns to engage or disengage with the

locking pins.

5. Adjust the position of the Bubble Muer 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 Muer in place by tightening the Allen screw on the Bubble

Muer.

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

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 Muer

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 preow begins. The pump will recirculate approximately 20

gpm from the water table.

Bubble Muer 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

E. Servicing

Refer to Figure 2 for Bubble Muer 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 Muer PT-19XLS, P/N 37150

Torch Body (Ref.)

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.

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

8*, 9

* 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

NOTES

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 Specications 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

visit us on the web at http://www.esabna.com

The ESAB web site oers

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ESAB Welding & Cutting Products, Florence, SC

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ESAB Bubble Muffler System User manual

ESAB Bubble Muffler System User manual

ESAB Bubble Muffler System User manual

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