ESAB PT-31XL and PT-31XLPC Plasma Arc Cutting Torches User manual

Category
Welding System
Type
User manual
PT-31XL and PT-31XLPC
Plasma Arc Cutting Torches
 

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.




           







3
TABLE OF CONTENTS
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
2.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.2 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
2.3 Technical Data (required by CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
3.0 Installation / Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.1 Torch / Consumables Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2 Disassembly of Torch - Removing Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.3 Installing Consumables - Assembly of Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1.1 Disassembly of Service Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Repositioning Torch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.3 PT-31XL and PT-31XLPC Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section / Title Page
4

5
 
 
 
 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
precautions 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.









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 fitted with the correct filter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat
-
ing 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 flameproof gauntlet type gloves, heavy long-
sleeve shirt, cuffless 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 flameproof 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 cuffs, 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-flammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety
glasses.


      


1. Remove all combustible materials well away from
the work area or cover the materials with a protec
-
tive non-flammable 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 floors or wall openings and cause a hid-
den smoldering fire or fires on the floor 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 flammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable fire 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 fire 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 fire. Use fire 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.
    





6
 
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 off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommenda
-
tions. Do not mistake the work lead for a ground
cable.
   

    
   



1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health effects 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.
     

   

    

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 specific ventilation recommendations.
7
 
 

    

   
  

   

    


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 fittings 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 fixtures 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 flames.
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 Jefferson Davis Highway,
Arlington, VA 22202.



1. Always have qualified personnel perform the instal
-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualified 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.

  

       

     

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
 
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."




      


   




17
 
The patented PT-31XL and PT-31XLPC are manual torches with a 75
°
head designed for use with several plasma arc cutting
packages using clean, dry air as the plasma gas. The service lines are 4.5, 7.6 or 15.2 meters (15, 25 or 50 feet) long and the
torch is rated to operate up to 50 amperes at 100% duty cycle for cutting most metals.









2 1/4"
(57mm)

5 1/4"
(133mm)


5 1/4"
(133mm)
2 7/8"
(73mm)
18
Table 2-1 Contents of Spare Parts Kits:
* PT-31XL and PT-31XLPC Spare Parts Kits P/Ns
P/N 21980 P/N 0558003301 P/N 0558003464 P/N 0558003462
Description P/N (optional P/N) 35/40A 30/40A 50A / HP-50 35A / Caddycut
(Europe only) (Europe only)
Heat Shield 20282 1 1
Heat Shield, Long "CE" 0558000509 (36284) 1 1
30/40 amp High
Performance Nozzle 0558000512 (20860) 3
35/40 amp Extended
Life Nozzle 0558000508 (21008) 3 3
Nozzle, 50 amp 0558000513 (20861) 3
Swirl Baffle 0558000506 (20463) 1 1 1 1
Electrode 0558000507 (20862) 2 2 3 2
O-ring 0558000514 (950790) 1
Lubricant (0.25 ounce) 0558000443 (17672) 1 1
Torch Guide Kit .................................................................................................................................................
0558003258
Permits cutting accurate circles from 45mm (1.7") to 1050mm (41.3") in diameter with the PT-31XL or PT-31XLPC. The at-
tachment includes a head and radius bar assembly, center-point / adaptor, and dual swivel castor assembly. Cuts can be
made inside or outside the circle. The torch head is always held vertical during the cutting operation. The attachment is
also handy for maintaining a constant standoff in other types of cutting.
2.2 ACCESSORIES
A spare parts kit is recommended for maintaining the torch with minimum downtime. A spare parts kit is supplied with each
plasma cutting package.
PCM-500i ONLY and as an option on HandyPlasma 550
35/40A XT Spare Parts Kit (Extended Life) .................................................................................................................................................
21980
PCM-500i, PowerCut-650, HandyPlasma 550 and HandyPlasma 380
30/40A Standard Spare Parts Kit (High Performance) .............................................................................................................0558003301
Note
The high performance kit (0558003301) is the preferred kit and is included with all of the above
referenced plasma cutting systems.
SECTION 2 DESCRIPTION
* Also see Tables 5-2 and 5-3.
19
a. Process:
Manual torch used for plasma arc cutting
b. Method of guidance:
Manual
c. Voltage class:
M (113v peak to 400v peak)
Striking voltage: 8000 VAC
Stabilizing voltage: 200 VDC
d. Maximum rated current: 50 amps
Maximum current at 100% duty cycle: 50 amps
Type gas: 120 I/min. at 5.5 bar (254 cfh at 80 psi)
e. Max. and min. gas pressure at inlet: 4.8 to 5.9 bar (70 to 86 psi)
f. Type of cooling:
Air
g. Rating of auxiliary electrical control in torch:
N/A
h. Requirements for connection of torch:
Wrenches and screwdriver
i. Essential information about safe operation of torch:
Refer to all safety precautions in manual
j. Essential information about safe operation of the plasma cutting torch and the functioning of interlocking and safety
devices:
Meets requirements by means of pneumatic interlock safety system. The interlocking device deenergizes the torch
when parts, particularly protective cone, are removed to expose electrode connection. For the interlocking device
to function properly, the torch electrode must remain in the protective cone. Do not attempt to install the electrode
into the torch without first placing it in proper position (with the other parts) within the protective cone.

k. Type of plasma cutting power source that can form a safe system with the plasma cutting torch:
PCM-500i, PowerCut 650, HandyPlasma 550, HandyPlasma 380, HandyPlasma 50 and Caddycut.
I. Plasma cutting ability:
See Graphs 2-1a and 2-1b on following page:
 
20

80
60
40
20
10
0
0

.750
160
140
120
100

2032
1524
1016
508
254
0
0
3 6 10
13 16

19
4064
3556
3048
2540



100
80
60
40
20
0
0
.125 .250 .375
.500
.625



.125 .250 .375 .500 .625


 
21
1. Periodically check the heat shield, electrode, nozzle, and swirl baffle. Replace if worn or damaged.
2. The power cable assembly should be inspected periodically. If there are any cuts through the protective sheath or if gas
leaks are noted, replace the damaged assembly.
3. Do not continue to use torch if the electrode erodes to a length shorter than 16mm (0.63 inch) as shown in Figure 3-1.
4. The gas flow 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. The light spring force used to close the ball check can be felt by pushing on the
electrode when assembling the front end components.

The electrode seat comes assembled in the front end of the torch. When using the XT consumables, make
sure the plunger, P/N 0558000511 (20324), is installed under the seat. If missing, remove seat and install
plunger. Make sure seat is tightened firmly with a wrench but do NOT overtighten.
 
1. To disassemble the front end, hold the torch with the shield in an upright position as shown in Figure 3-2. This will prevent
the nozzle, electrode, and swirl baffle from falling free when the shield is removed.
2. If the torch is fixed and cannot be rotated upward, the alternate method of disassembly is to disassemble the electrode,
swirl baffle and nozzle as above being careful not to damage them by letting them fall.
 


For detailed installation and operation follow all torch instructions in the plasma system manual packed with your cutting
package. DO NOT install or attempt to operate this torch without following those instructions first.











 




          



22


16mm (0.63")
Heat Shield
Nozzle
Swirl Baffle
Electrode
*Plunger
Torch
Seat
Minimum
"XT" Electrode
Replace electrode when end
wears to 16mm (0.63") long.
Lubricant can be applied to O-ring or Heat Shield
 
*Note: Plunger, P/N 0558000511 (20324), used only with "XT" consumables.
 

Apply a small amount of lubricant - 0558000443 (17672), supplied in spare parts kit, to the heat shield or to
the o-ring as shown in Figure 3-1. Check o-ring for damage whenever the shield is removed. Replace if
necessary. O-ring part number is 0558000514 (950790).
1. To assemble with the torch front end facing up, assemble electrode, swirl baffle, tip and heat shield in that order as shown
in Figure 3-2. The swirl baffle is symmetrical and it can be positioned either way. Tighten heat shield snugly to hold the
parts in firm contact with each other and the torch head. Do not overtighten the heat shield.
2. If the torch is fixed and cannot be rotated upward, the alternate method of assembly is to assemble the electrode, swirl
baffle and nozzle as above and drop them into the heat shield. Then thread the heat shield upward into the torch body.
23
 
Lay the line out straight.
Pull flex support back and remove the tape from around the switch lead splices.
Free the switch by cutting the leads close to the splices.
Replacement switches have extra long leads to make up for any loss due to cutting.
Remove the rubber boot from the inlet end of the cable.
Remove the tape that secures the sheath at each end.
Pull the sheath off the cable (over small fitting at torch end).

The switch leads wrapped around the power cable are secured with tape several places along the cable.
8. The leads, switch cord plug, and strain relief can now be removed. See Figure 4-1, Step 3.








9. Reassemble in reverse order.
 
In some applications it is more convenient for the troch switch to be positioned 180 degrees from current configuration.
To reposition the switch on the torch, slide the flex support back, remove the tape securing the spliced leads to the power
cable, reposition switch, retape the leads, and pull the flex support back in place. See Figure 4-1.

A thin film of silicone lubricant P/N 0558000443 (17672), supplied with the spare parts kit, applied inside of
the flex support will ease the assembly of this part.
1.
2.
3.
4.
5.
6.
7.
 

       




The power cable and switch leads in the service line should be inspected periodically. If there are any cuts through the pro-
tective sheath or if gas leaks are noted, replace the damaged component.



24




Pull flex support back. Remove
tape holding splices.
Slide switch and band from handle.
Snip leads at splice to replace
switch.
Unscrew handle and
power cable from head

 
25
 
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
The use of non-ESAB parts may void your warranty.
Have the plasma power source model number and serial number handy if there are any questions concerning required
parts.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers.
 
 
The PT-31 torch is used on several different cutting packages which require different torch trigger connection configura-
tions as shown in Figure 5-1 and Table 5-1.
The PT-31 torch is adaptable to standard, heavy duty or XT consumables to meet specific cutting applications. See
Subsections 5.3.1, 5.3.2 and 5.3.3.
Individual consumable parts can be ordered as needed if spare parts kits do not fit current needs.
In most cases, it is recommended that you order the same consumable parts that were shipped with your plasma cutting
system.
1.
2.
3.
 - Used with currently produced product (HandyPlasma 380, HandyPlasma 550, PCM-500i, PowerCut
650, Caddycut and HandyPlasma-50), and older products dating back to 1990.
 - Available for support of pre-1990 year machines (PCM-32i,
PCM-50 and PCM-31) and consumables configurations. These are the original consumables designed for the torch.
 - Gives maximum cutting thickness and speed capability.
 - Gives extended nozzle life at the expense of top end cutting thickness and speed capability.
 
26
 
PLUNGER- 0558000511 (20324)
(used only with "XT" consumables)
SEAT - 0558000510 (19679)
(Included with Head)
75
0
HEAD - 0558000790 (20072)
(Includes O-ring and Seat)
POWER CABLE
HANDLE - 0558000796 (18208)
SWITCH BAND
0558000699 (18207)
SWITCH - 0558000818 (18224)
(2) SPLICES (Supplied with Switch)
FLEX SUPPORT - 0558000710 (18225)
SHEATH
5/8 X 18 L.H.
BOOT - 0558000793 (49N83)
PLUG - 2062336
0558000583 (19675) - 4.6m (15')
0558000791 (18320) - 7.6m (25')
0558000792 (19026) - 15.2m (50')
0558005148 (19672) - 4.6m (15')
0558000795 (18221) - 7.6m (25')
0558005146 (19028) - 15.2m (50')
O-ring - 0558000514 (950790)
(included with head)


STRAIN RELIEF
0558000794 (18226)

27
 

2
NOZZLE 30-40 AMP - 20860
PLUNGER - 0558000511 (20324)
O-RING - 0558000514 (950790)
BAFFLE SWIRL - 0558000506 (20463)
ELECTRODE - 0558000507 (20862)
HEAT SHIELD - 20282
BODY ASSEMBLY 75° - 0558000790 (20072)
BAND SWITCH - 0558000699 (18207)
SWITCH - 0558000818 (18224)
FLEX SUPPORT - 0558000710 (18225)
HANDLE - 0558000796 (18208)
SPLICE - 0558004020 (674520)
POWER CABLE
0558003323
3/8-24UNF-2A

28
 






1
20084 - 4.6m (15') lines
20080 - 7.6m (25') lines
20082 - 15.2m (50') lines
Seat and o-ring. Consumables and plunger not
included.
21985 - 7.6m (25') lines
30A / 40A high performance "XT" consumables,
standard heat shield P/N 20282, seat, o-ring and
plunger.
PCM 500i, Handy
Plasma-550 (Asia)
2
0558003183
7.6m (25') lines
30A / 40A high performance "XT" consumables,
standard heat shield P/N 20282, seat, o-ring and
plunger.
Powercut-650
3
0558004482
4.6m (15') lines
30A / 40A high performance "XT" consumables,
standard heat shield P/N 20282, seat, o-ring and
plunger.
 When ordering the PT-31XL torch
assembly for use on the HandyPlasma-380,
Female Torch Connector P/N 0558004947 shown
below
 also be ordered.
HandyPlasma-380
0558001466
4.6m (15') lines
30A / 40A high performance "XT" consumables,
long heat shield P/N 0558000509 (36284), seat,
o-ring and plunger.
CaddyCut
(Europe)
0558004498
7.6m (25') lines
30A / 40A high performance "XT"
consumables,standard heat shield P/N 20282,
seat, o-ring and plunger.
HandyPlasma-550
(North America)
0558003467
7.6m (25') lines
30A / 40A high performance "XT" consumables,
long heat shield P/N 0558000509 (36284), seat,
o-ring and plunger.
HandyPlasma-50
(Europe)

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ESAB PT-31XL and PT-31XLPC Plasma Arc Cutting Torches User manual

Category
Welding System
Type
User manual

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