ESAB Bubble Muffler System Troubleshooting instruction

Brand: ESAB

Model: Bubble Muffler System

Category: Welding System

Type: Troubleshooting instruction

ESAB Bubble Muffler System enables underwater plasma arc cutting without compromising cut quality. It also reduces fumes, noise, and arc UV radiation during above-water cutting. Compressed air forms a protective bubble around the plasma arc, while water circulation cools the torch and shields the operator from harmful emissions. The system includes a control box, hoses, adaptors, and fittings for easy installation and operation.

INSTRUCTIONS for

F-15-127

October, 2006

Bubble Muﬄer System

for PT-15XL

P/N 2232615

The Bubble Muﬄer System creates a bubble of air sur-

rounded by water so that a PT-15XL Plasma Arc Torch can

be used underwater with oxygen/water-injection cutting

without signiﬁcant sacriﬁce of cut quality. This system also

permits operation above water as the ﬂow of water through

the muﬄer reduces fume, noise, and arc U.V. radiation.

Optional Accessories

Bubble Muﬄer System

Muﬄer, Insulated, Underwater P/N 21131 1

Cup, Nozzle Retaining, Beveling P/N 20758 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

NOTE: P/N 2232615 may be ordered as part of P/N 2233409

Bubble Muﬄer Addition which includes hoses, adap-

tors, solenoid valves, ﬁttings and a regulator.

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.

Hose, 3/4" ID for Water P/N 2027202 Specify

Length

Hose, 3/4" ID for Water P/N 23079995 Specify

Length

Fittings, 3/8" Hose to Bubble

Muﬄer

P/N 2233298 AR

Fittings, Nipple 10N40 Nut

for 3/8" Hose to Control Box

P/N 347995 AR

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

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

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, ﬂame proof

clothing, safety gloves.

- Do not wear loose ﬁtting 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 qualiﬁed electrician.

- Appropriate ﬁre extinquishing equipment must be clearly marked and close at hand.

- Lubrication and maintenance must not be carried out on the equipment during operation.

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 ﬁlter lens and wear

protective clothing.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause ﬁre. Make sure therefore that there are no inﬂammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmuﬀs 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

SECTION 1 SAFETY PRECAUTIONS

A. Installation and Adjustment of the Bubble Muﬄer

(see Figure 1)

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.

NOTE: Lubrication of all O-rings with silicone grease is recommend-

ed.

1. Remove the brass nozzle Retaining Cup from the torch.

2. Slide the chrome plated Bubble Muﬄer clamp onto the torch

and about 1/2 inch up the torch sleeve (handle).

3. Replace the Nozzle Retaining Cup and any front-end parts you

may have removed from the torch.

4. Install the Bubble Muﬄer Sleeve in the Bubble Muﬄer Main

Body. Make sure it bottoms completely.

5. Install the Bubble Muﬄer Body (including the Bubble Muﬄer

Sleeve) over the completely assembled Torch and snap it onto

the Bubble Muﬄer Clamp.

6. Adjust the position of the Bubble Muﬄer on the torch until a

gap of between .040 and .060 inch is obtained between the

bubble muﬄer sleeve and the nozzle retaining cup. Lock the

Bubble Muﬄer in position by tightening with an Allen screw on

the Bubble Muﬄer Clamp.

NOTE: The Bubble Muﬄer Sleeve must remain completely bottomed

in the Bubble Muﬄer Main Body for the adjustment in step 6

to be correct.

After tightening the Allen screw in the Bubble Muﬄer Clamp,

the gap between the sleeve and torch cup should be nearly

uniform all the way around.

ALLEN

SCREW

TORCH

RETAINING

CUP

.040-.060

Figure 1. Bubble Muﬄer Installation

SECTION 2 INSTALLATION

WARNING

B. Installation of the Water Pump (P/N 2135445)

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

PUMP

TORCH

WATER

TABLE

AIR CURTAIN

CONTROL

BOX

WATER

STRAINER

INLET

BUBBLE MUFFLER

3/4" ID

HOSE

3/8" ID HOSE

AIR

APPROPRIATE AMPHENOL

CONNECTOR ON BACK

FLOW CONTROL

(or Cutting Machine Control)

AIR CURTAIN

CONTROL BOX

CONTROL CABLE

POWER

115 VAC

OPTIONAL

Figure 2. Installation of H

O Pump

Water/Bubble Muﬄer Pump Input Voltage

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 muﬄer to connect the box with the Bubble

Muﬄer 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 appropriate amphenol connector on the back of the ﬂow 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 acces-

sories.

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.

ITEM QTY. PART

NO. REQ. NO. DESCRIPTION

1 2 21431 O-RING, 2.364 ID X .070 NEOP 70A

2 2 21430 O-RING, 2.175 ID X .103 NEOP 70 A

3 1 21432 O-RING, 2.100 ID X .210 NEOP 70A

4 1 85W87 O-RING, 1.98 ID X .139 NEOP 70A

5 1 21128 SLEEVE

6 1 21130 MAIN BODY

7 1 21127 INSULATOR, CLAMP

8 1 21129 CLAMP

9 1 61640912 SCREW, #10-32X3/4" STAIN. STEEL SOCKET HEAD CAP

NOTE: 4 each of the above o-rings are supplied.

Figure 3. Bubble Muﬄer Assembly, P/N 21131

SECTION 2 INSTALLATION

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 30 psig delivery.

2. Place switch to AUTO. The system should turn on when the preﬂow begins. The pump will recirculate approximately 20

gpm from the water table.

SECTION 3 OPERATION

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.

WARNING

SECTION 3 OPERATION

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 858775 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 4, Air Curtain Control Box Assembly

SECTION 4 REPLACEMENT PARTS

NOTES

F15-127 10/2006

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 Speciﬁcations 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 oﬀers

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ESAB Bubble Muffler System Troubleshooting instruction

Brand: ESAB

Model: Bubble Muffler System

Category: Welding System

Type: Troubleshooting instruction

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ESAB Bubble Muffler System Troubleshooting instruction

ESAB Bubble Muffler System Troubleshooting instruction

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