ESAB PLASMARC™ Air Curtain Kits Troubleshooting instruction

Brand: ESAB

Model: PLASMARC™ Air Curtain Kits

Type: Troubleshooting instruction

Instructions for

F-15-189-B

March, 2010

21549 Air Curtain Assembly

PT-19XL

21856 Air Curtain Assembly

PT-15XL H.D.

PLASMARC

Air Curtain Kits

P/N 22018 for PT-15XL Heavy Duty (H. D.)

P/N 34752 for PT-19XL and PT-15XL Beveling

THE AIR CURTAIN 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 HYDRO

GEN DETONATION.

WARNING

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 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

4.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

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.

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-19XL Air Curtain Kit, P/N 34752

Air Curtain Assy. P/N 21549 1 pc

Control Box Assy. P/N 33383 1 pc

Hose Assy., 50 ft. P/N 34033 1 pc

PT-15XL H.D. Air Curtain Kit, P/N 22018

Air Curtain Assy. P/N 21856 1 pc

Control Box Assy. P/N 33383 1 pc

Hose Assy., 50 ft. P/N 34033 1 pc

The Air Curtain is a device used to improve the performance of the PT-19XL and the PT-15XL Plasmarc Cutting Torches when

cutting underwater. Cut quality and speed are enhanced when using the Air Curtain with all the PT-19 cutting and with PT-15

oxygen/water injection cutting. Very minor improvements may be seen with nitrogen/water injection cutting.

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 are radiation.

SECTION 2 INSTALLATION

Compressed Air Supply

(Air Curtain)

Source: 80 psi @ 1200cfh

(5.5 bar @ 34 m

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

DATE

CHECKED

DATE

DRAWN

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

CHANGE

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-

MATERIAL:

.015

.005

PRO/ENGINEER DWG.

NOV.1994

19X19

ADAPT B-A/W*F B-A/W*M 90ASSY

19X19

BLP

10/23/08

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

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

A. Installation of PT-15XL H. D. Air curtain As-

sembly on PT-15XL

1. Remove the brass Nozzle Retaining cup from the

torch.

2. Slide the chrome plated Air Curtain Body, P/N 21550

onto the stainless steel body of the torch.

NOTE: It will ease assembly if all o-rings in the air curtain

body are lightly lubricated with silicone grease

77500101 (5.3 oz.) or 17672 (1 oz.).

3. Replace Nozzle Retaining Cup, P/N 20758, and any

front-end parts you may have removed from the

torch.

4. Tighten the Nozzle Retaining Cup securely on the torch,

then mark the cup with a felt tip marker or pen. Loosen

the cup 3/4 to 1 full turn.

5. Install the PT-15XL H. D. Air Curtain Sleeve (P/N 21859)

over the completely assembled torch and snap it into

the air curtain body. Secure the sleeve by installing the

Air Curtain Retainer, P/N 21553.

ALLEN

SCREW

TORCH

RETAINING

CUP

The Retainer turns to engage or disengage with the

locking pins.

6. Push the Air Curtain Assembly up on the torch until the

inside of the Air Curtain Sleeve, P/N 21859, bottoms

against the Nozzle Retaining Cup, P/N 29758. Lock the

Air Curtain Assembly in place by tightening the Allen

screw on the Air Curtain body.

7. Remove the Retaining Ring and Air Curtain Sleeve.

Tighten the Nozzle Retaining Cup, P/N 20758, securely.

Reinstall the Air Curtain Sleeve and the Nozzle Retain-

ing Cup.

There should now be a gap of .040 to .062 inches be-

tween the Nozzle Retaining Cup, P/N 20758, and the

inside of the Air Curtain Sleeve, P/N 21859.

Figure 1. Air Curtain Installation on PT-15XL

.O40 - .062

SECTION 2 INSTALLATION

B. Installation of Air Curtain Assembly on PT-15XL

with P/N 21378 Sleeve for Beveling with stan-

dard length nozzles.

1. Remove the brass nozzle Retaining Cup from the

torch.

2. Slide the chrome plated Air Curtain Body, P/N 21550,

onto the stainless steel body of the torch.

NOTE: It will ease assembly of all O-rings in the air

curtain body are lightly lubricated with silicone

grease; P/N 77500101 (5.3 oz.) or 176772 (1

oz.).

3. Replace Nozzle Retaining Cup, P/N 20758, and any

front-end parts you may have removed from the torch,

tightening securely, then mark the cup with a felt tip

marker or pen. Loosen the cup 3/4 to 1 full turn.

4. Install an Air Curtain Sleeve, P/N 21378, over the

complete assembled torch and snap it into the Air

Curtain Body. DO NOT use the Air Curtain Retainer, P/N

21553.

5. Push the Air Curtain Assembly up onto the torch until

the inside of the Air Curtain Sleeve, P/N 21378, bottoms

against the Nozzle Retaining cup, P/N 20758. Lock the

Air Curtain Assy. in place by tightening the Allen screw

on the Air Curtain Body.

NOTE: The Air Curtain Sleeve must remain completely

bottomed in the Air Curtain Body for the adjust-

ment in step 5 to be correct.

6. Remove the Air Curtain Sleeve. Tighten the Nozzle

Retaining Cup 20758 securely. Reinstall the Air Curtain

Sleeve. There should be a gap of .040 to .062 inch be-

tween the inside of the Air Curtain Sleeve P/N 21378

and the Nozzle Retaining Cup, P/N 20758.

ALLEN

SCREW

Figure 2. Air Curtain Installation on PT-15XL

(For Beveling with standard length nozzles)

.O40 - .062

SLEEVE

P/N 21378

SECTION 2 INSTALLATION

D. Installation of the Control Box Assembly (P/N 3383)

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.

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 the SJO wire supplied to connect the control to the cutting machine control. If the ESP system is used, then the

connection may be made to the appropriate amphenol 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 operation of the air

curtain control.

5. Connect a ground wire to the stud provided in the control box.

REMOVE HEAT SHIELD,

SET DIMENSION @

.10, SET PRESSURE @

20 PSIG

.10 INCH

RETAINING

NUT

AIR

INLET

BODY

BUSHING

PT-19XL or PT-15XL

Torch Body

C. Installation of Air Curtain Assembly on PT-19XL

or PT-15XL using Long Beveling Nozzles (Figure

3).

1. Remove the plastic nozzle Retaining Cup from the

torch.

2. Slide the chrome plated Air Curtain Body, P/N 29550,

onto the stainless steel body of the torch.

NOTE: It will ease assembly if all O-rings in the air

curtain body are lightly lubricated with silicone

grease.

3. Replace Nozzle Retaining Cup, P/N 34085, and any

front-end parts you may have removed from the torch.

Do not replace the heat shield, P/N 948186.

4. Install an Air Curtain Sleeve, P/N 12551, over the com-

pletely assembled torch and snap it into the Air Curtain

Body. Secure the sleeve by installing the air curtain

Retainer, P/N 21553. The Retainer turns to engage or

disengage with the locking pins.

5. Adjust the position of the Air Curtain Assembly on the

torch until the nozzle is recessed 0.10 inch from the end

of the air curtain sleeve as illustrated in Fig. 1. Lock the

Air Curtain in place by tightening the Allen screw on

the Air Curtain.

NOTE: The Air Curtain Sleeve must remain completely

bottomed in the Air Curtain Body for the adjust-

ment in step 5 to be correct.

Figure 3. Air Curtain Installation

On PT-19XL or PT-15XL Bevel

SECTION 2 INSTALLATION

E. Operation

1. Provide control box will oil free air at 80 psig minimum. Energize solenoid in control box and adjust regulator screw

on box to 20 psig delivery.

2. Place switch to AUTO. The system should turn on when the preow begins.

F. PT-19 Operation Notes

Cutting stando (Torch to Work Distance) must now be measured from the bottom of the Air Curtain Sleeve. This distance

is approximately 1/4".

NOTE: If piercing thick plate, increase stando to 0.400" for 1/2" thick plate, 0.650" for 3/4" thick plate. Then return to 1/4" stando

after completing the pierce and you are ready to cut.

Electric shock can kill. Disconnect power to power source before touching or servicing the air curtain at the torch.

Disconnect power to the control box before servicing.

SECTION 3 OPERATION

ITEM QTY PART

NO. REQ. NO. DESCRIPTION

1 1 21550 BODY, AIR CURTAIN

2 1 21551 SLEEVE, AIR CURTAIN

3 1 21553 RETAINER, AIR CURTAIN

4 1 21380 BUSHING, SPLIT

5 1 2221978 'O' RING, 1.799ID X .103 SILICON, 60A

6 2 21214 ‘O’ RING, 2.484ID X .139 NEOPR, 70A

7 1 85W87 ‘O’ RING, 1.984ID X .070 NEOPR, 70A

Figure 4. Air Curtain Assembly, P/N 21549 for use W/ PT-19XL

and PT-15XL With Long Beveling Nozzle

Note: Some spare o-rings are supplied with the Air Curtain assembly 21549

SECTION 4 REPLACEMENT PARTS

ITEM QTY PART

NO. REQ. NO. DESCRIPTION

1 1 21550 BODY, AIR CURTAIN

2 1 21859 SLEEVE ASSY, AIR CURTAIN

3 1 21553 RETAINER, AIR CURTAIN

4 1 21380 BUSHING, SPLIT

5 1 2221978 "O" RING, 1.799 ID X .103 SILC 60A

6 2 21214 "O" RING, 2.484 ID X .139 NEOPR, 70A

7 1 85W87 "O" RING, 1.984 ID X .139 NEOPR, 70A

8 1 952062 "O" RING. 1.989 ID X .070 NEOPR, 70A

NOT SHOWN, 1PC P/N 21378 SLEEVE BEVELING AIR CURTAIN

Figure 5. H.D. Air Curtain Assembly, P/N 21856 for use W/ PT-15XL

Note: Some spare o-rings are supplied with the Air Curtain assembly 21856

SECTION 4 REPLACEMENT PARTS

*AIR REGULATOR AND PRESSURE GAGE ARE SUPPLIED TOGETHER AS ITEM 8. REGULATOR W/GAGE P/N 522368.

Figure 6. Air Curtain Control Box Assembly

ITEM QTY PART

NO. REQ. NO. DESCRIPTION

1 2 8180W38 CONNECTOR, STRAIN RELIEF

2 1 951041 TERMINAL, BLOCK, 4 POSITIONS

3 1 636702 SWITCH, DPDT 3 POSITIONS

4 2 858775 ADAPT. BULKHD. B SIZE, 1/4 NPT

5 2 182W82 ELBOW, STREET 90 BRASS

6 1 636387 SOLENOID VALVE

7 1 67101075 NIPPLE, CLOSED, 1/4 NPT BR. M TO M

8 1 522368 REGULATOR W/GAGE

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

SECTION 4 REPLACEMENT PARTS

ITEM QTY PART DESCRIPTION

NO. REQ. NO.

2 1 35570 CUP, NOZZLE RETAINING

3 1 21962 NOZZLE PT-15 O

BEVEL - 21963 REVERSE

4 1 35886 ELECTRODE, HF

5 1 34084 ELECTRODE HOLDER ASSY

6 1 35660

8 X.047 HOLE BAFFLE, GAS SWIRL, CERAMIC - 35661 REVERSE

8 1 996341 CONTACT RING ASSY

9 1 20755 INSULATOR ASSY, FRONT BODY

10 2 996528 O-RING

11 1 996242 LOCATING PIN

12 1 20754 REAR MAIN BODY ASSY

13 1 19483 SLEEVE

O-RING - 2064106

(1-5/16" I.D.)

CONTACT RING ASS'Y,

Includes: Setscrew, No. 6-32 X 3/16 lg. (Cup Point)

Screw, No. 6-32 X 1/2" lg.

NOT SHOWN:

O-RING - 86W85 (1/2" I.D.)

(2) O-RING - 996526 (5/32" I.D.)

O-RING - 996527

Note:

All Set Screws Are Stainless Steel & Should Only Be

Replaced With Stainless Steel or Brass Screws.

Figure 7. PT-15XL Plasmarc Cutting Torch For Bevel Cut

OXYGEN - SET O

FLOW AT 100 SCFH 100PSI SUPPLY

WATER - SET WATER FLOW AT 0.51 GPM

INLET TO TORCH PRESSURE - 35-42 PSI AT TORCH - CUTTING

15-20 PSI AT TORCH - STARTING

SECTION 4 REPLACEMENT PARTS

NOTES

REVISION HISTORY

Revision 03/2010 - added 19X19 to optional accessories.

F15-189-B 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 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

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

ESAB PLASMARC™ Air Curtain Kits Troubleshooting instruction

ESAB PLASMARC™ Air Curtain Kits Troubleshooting instruction

ESAB PLASMARC™ Air Curtain Kits Troubleshooting instruction

Related papers

Other documents