ESAB PT-17A & PT-17AM Plasma Arc Cutting Torches Troubleshooting instruction

Brand: ESAB

Model: PT-17A & PT-17AM Plasma Arc Cutting Torches

Type: Troubleshooting instruction

INSTRUCTIONS for

F14-441-D

December, 2006

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe

practices for arc welding 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.

Plasma arc cutting process employs high voltages.

High voltage can kill. Therefore, contact with live

parts of the torch and machine must be avoided.

Also, the improper use of any of the gases employed

can present a safety hazard. Before beginning op-

eration with the PT-17A or 17AM torch, refer to the

safety precautions in the appropriate booklet of the

following Plasma Arc Cutting Packages:

Form 14-471 - PCM-100

14-474 - PCM-150

I. INTRODUCTION

The PT-17A and PT-17AM torches offer performance,

economy and safety for all plasma cutting needs up to

1-in. on most common metals. The PT-17A, within its

current rating, is usable on all of ESAB’s consoles listed

above. (Adaptor may be necessary. See Section III-A).

PT-17A & PT-17AM

PLASMA ARC CUTTING TORCHES

F14-441-D

WARNING

CAUTION

Be sure this information reaches the operator.

You can get extra copies through your supplier.

ESAB

ESAB Welding &

Cutting Products

Fig. 1- Dimensional Data - PT-17A & PT-17AM Torches

PT-17A

1-1/4"

2-7/8"

1-1/4"

10"

Shipping Weight. 9lbs. (25-ft.) / 15lbs. (50-ft.)

PT-17AM

17-1/4"

Shipping Weight. 10lbs. (25-ft.) / 16lbs. (50-ft.)

13"

5/8"

STUD

1-3/8"

8-3/16" MIN.

14-3/4" MAX.

II. ACCESSORIES

1. PT-17A/17AM Spare Parts Kits,

P/N 20062 - 50 amps

P/N 20063 - 70 amps

P/N 20064 -100 amps (PCM-100/150)

Recommended for maintaining PT-17A or PT-17AM

torch with minimum downtime. The kits contain spare

parts listed in Table 1 in a convenient tool box. P/N

20064 kit is supplied with each PCM-100 manual air

package.

2. Drag Type Shield Guard, P/N 19989 - Protects the

heat shield and permits the operator to drag a manual

torch on the plate while cutting. Thus maintaining a

fixed stand-off (tip-to-work distance) throughout the

cut resulting in a uniform appearance of the cut edge.

Two drag type guards are supplied with each spare

parts kit.

3. Standard Shield Guard, P/N 19990 (non drag type)

- protects the shield against accidental breakage on

both manual and mechanized torches. One standard

guard is supplied with each spare parts kit.

4. Mechanized Torch (PT-17AM) Mounting and Travel

Carriage - Refer to the appropriate booklet supplied

with your PCM package.

Table 1 - Contents of PT-17A/17AM Spare Parts Kit

Quantity

50amp 70amp 100amp

Kit Kit Kit

Description P/N P/N 20062 P/N 20063 20064

Heat Shield, H-D 20747 3 3 3

Shield Guard, Drag 19989 2 2 2

Type

Shield Guard, Std. Type 19990 1 1 1

CuttingTip, .046 19915 5 5 —

Cutting Tip, .052 19916 — 5 5

Cutting Tip, .057 19917 — 5 5

Cutting Tip, .067 20056 — — 5

Electrode 19918 5 5 5

Electrode Adaptor 20053 1 1 1

BaffleTube 19114 1 1 1

Shroud Cap 19498 1 1 1

Shroud 19499 1 1 1

Wrench 19129 1 1 1

Pilot Arc Adaptor 19497 1 1 1

70 Amp Gouging Tip 20426 — 1 1

100 Amp Gouging Tip 20427 — — 1

5. Plasma Gas Flow Measuring Kit, P/N 19765 - Used

for checking gas flows through torch. Improper flows

can cause short life of consumables, poor starting,

bad cuts, or overheated torches.

6. Spatter Shield, P/N 20748 - Protects torch from spat-

ter produced by initial cut starts and piercing opera-

tions. Also, it reflects radiant heat away from the neck

of the torch during cutting operations which will pro-

long the life of the torch.

7. “Plasmit” Torch Head Protector, P/N 20803 (75°

Hd.); P/N 20804 (Mech.) - Protects torch head from

radiant heat during cutting operations.

III. INSTALLATION

Make sure power switch on console is in OFF posi-

tion and primary input power is deenergized.

A. CONNECTING TORCH TO PCM CONSOLE

The torch service lines should be connected to the out-

put connections of the appropriate PCM console as fol-

lows (refer to interconnecting diagram in the PCM book-

let):

1. Power cable (male nut) to “NEG” fitting. (If using old

PCM-31, “C” to “B” size adaptor, P/N 19500, is re-

quired).

1. Push guard over heat shield and

onto the shroud.

The step inside the guard

should stop against bottom of

shroud. When using the drag-

type guard, a 1/8" tip-to-work

standoff it provided.

The guard can be rotated to

any desired position and need

not be removed from the

shroud when changing

consumables.

2. Periodically remove spatter

and splashed metal from tip

and edge of heat shield that

could cause arcing between

the guard and work.

2. Pilot arc cable to “POS” connection. (Pilot arc adap-

tor, P/N 19497 - supplied with each spare parts kit, is

required for connecting cable to PCM-150).

3. Torch switch plug is connected to the 2-prong recep-

tacle.

B. INSTALLING TORCH FRONT END PARTS

1. Referring to Fig. 2 assemble desired electrode to the

torch head, and then tighten it with the wrench (P/N

19129) supplied with torch or spare parts kit.

2. Assemble cutting tip to torch head finger tight.

NOTE: Always check the threads on the electrodes and

tips for dirt or other damage before assembling

to torch.

3. Assemble heat shield and shroud and then secure

them in place by assembling and hand tightening the

shroud cap.

4. If shield guard is to be used, attach to torch as illus-

trated in Fig. 3.

CAUTION: Make sure all front end parts are properly

assembled before operating the torch. If one

or more parts are missing, the torch will be

damaged beyond repair.

IV. OPERATION

The torch is now ready for cutting operations. Refer to

the appropriate booklet for control adjustments of your

PCM console.

The front end of the torch contains a gas flow valve

that acts in conjunction with the circuitry provided

in the console. This patented system provides a

safety interlock preventing the torch from being ac-

cidentally energized with high voltage when the heat

shield is removed and the torch switch is acciden-

tally closed. Occasionally check this system by re-

moving the heat shield. Turn on console. Do NOT

WARNING

Fig. 2 - Front End Assembly

HEAT SHIELD

20747

SHROUD

19499

SHROUD CAP - 19498

ELECTRODE

19918

TIP, CUTTING

19915 - .046

19916 - .052

19917 - .057

20056 - .067

WARNING: Do not touch or remove parts unless

switch on console is in OFF position and primary

input power is deenergized.

Tighten with wrench

19129 (Supplied).

GUARD

(Drag Type illustrated)

HEAT

SHIELD

PT-17

SHROUD

WARNING

Fig. 3 - Attaching Shield Guard

touch the metallic parts on the torch front end. Close

the torch switch. If torch energizes and gas flows,

DO NOT USE. Do NOT tamper with the gas flow

valve. Return torch to your ESAB distributor for re-

pair.

Wear the usual protective gloves, clothing, ear pro-

tection, and helmet. Helmet with filter lens shade

No. 8 should provide adequate protection for your

eyes.

Never touch any parts forward of the torch handle (cut-

ting tip, heat shield, electrode, etc.) unless the Ready-

Off switch is in the OFF position.

1. Position the torch on the workpiece by resting the tip

or drag type shield guard on the edge of the workpiece

where you intend to start the cut.

2. Lower your protective helmet and then lift the torch

about 1/8-in. above the workpiece. (Not necessary to

lift when using guard).

3. Push down on the torch switch button mounted on

the torch handle. Pilot arc contactor and high fre-

quency will energize, and gas will start flowing. Two

seconds later, the main contactor will come on. The

cutting arc should then transfer to the workpiece.

NOTE: If cutting arc does not start within 6 seconds,

the pilot arc will shut off. Release torch switch.

Check to be sure gas pressures are adequate,

work cable is firmly connected to workpiece,

torch was about 1/8 to 1/4-in. above workpiece,

etc. Then start from step 1 again.

4. For ease of operation, use the drag shield guard. If

using the standard shield guard, maintain a standoff

(torch-to-work distance) of about 1/16-in. to 3/16-in.

Keep the torch head vertical, and move it at a rate

that produces the desired cut quality. The cutting

should produce a straight fine spray of molten metal

emitting from beneath the workpiece.

5. If cutting arc is lost during cut, the pilot arc will imme-

diately reignite as long as the torch switch is de-

pressed. You then have about 6 seconds to move the

torch close enough to work to reestablish the cutting

arc.

6. The cutting arc will extinguish at the end of the cut;

however, the torch switch should be released to keep

the pilot arc from reigniting.

7. When cutting operation is completed, wait a few min-

utes before placing the READY-OFF to the OFF po-

sition so that the cooling fan has time to remove the

heat from the unit. Then shut off the primary power at

the main disconnect switch.

V. MAINTENANCE

Make sure power switch on console is in OFF posi-

tion and primary input power is deenergized.

1. The torch electrode, cutting tip, heat shield and the

tip and electrode threads in the torch body should be

checked whenever tips and electrodes are replaced.

2. Torch body threads: The threads for attaching the tip

in the body can be reconditioned and the threaded

electrode adaptor can be replaced if these threads

become worn or damaged.

Procedure: Use plastic wrench P/N 19129 supplied with

the torch and parts kits for removing the electrode and

the baffle tube. Use a 3/16 hex allen key to remove the

electrode adaptor. At this point, the tip threads in the

body can be reconditioned, if necessary, using a 5/8-18

NF BOTTOMING END TAP. (A standard tap cannot be

used because of the long taper on the starting end).

Measure back from the end 5/16 inches or use a tip as a

guide and wrap a piece of tape around the tap at this

point to act as a depth gauge. See illustration below.

With the tape in place, carefully start the tap into the

torch body. Be sure not to cross thread the tap or the

thread will be ruined beyond repair. Turn the tap in up to

the tape. Do not turn the tap deeper or the plastic insula-

tor at the bottom of the thread will be damaged. Turn the

tap in and out until the tap turns smoothly. Blow out all

chips and dirt from within the torch body. Assemble a

new electrode adaptor P/N 20053 using a 3/16 hex allen

key. Reassemble the baffle tube using the plastic wrench.

NOTE: DO NOT use the plastic wrench for tightening

the electrode adaptor. The adaptor cannot be

tightened sufficiently to prevent the possibility

of the adaptor and baffle tube from coming free

and remaining attached to the electrode. Should

this occur the parts can be separated by grip-

ping the two small flats on the adaptor with an

adjustable wrench and then removing the elec-

trode.

3. The power cable and switch leads in the service line

should be inspected periodically. If cuts through the

protective sheath or gas leaks are noted, replace the

damaged component.

By following steps 1, 2, and 3 in Fig. 4 the service line

can be removed from the torch. To disassemble the ser-

vice line, lay the line out straight, remove the tape from

around the switch lead splices, and free the switch by

cutting the leads close to the splices. (Replacement

switches have extra long leads to make up for any loss

WARNING

TIP

TAPE

5/16"

BOTTOMING END TAP

5/8 - 18NF

F14-441-D 12 / 2006 Printed in U.S.A.

ESAB

ESAB Welding & Cutting Products

PO Box 100545, Florence SC 29501-0545

due to cutting.) Remove the rubber boot from the inlet

end of the cable and remove the tape that secures the

sheath at each end. Pull the sheath off the cable (over

small fitting at torch end). Note that the switch leads

wrapped around the power cable are secured with tape

several places along the cable. The leads, switch cord

plug, and strain relief can now be removed. DO NOT

remove the white tape that forms a band around the

power cable at each end. The sheath is taped to the

cable in front of the band which acts as a shoulder to

prevent the sheath from sliding back on the cable. (Re-

placement cables have this tape in place.) If the switch

leads are to be replaced, replace with 16 AWG STAN-

DARD COPPER, 600-VOLT, 90° C INSULATED WIRE.

Reassemble in reverse order. Make sure the end of the

Nomex insulator and insulator tubing of the high freq.

are butted against the end of the torch body before tap-

ing them in position.

To reposition the switch on the torch, slide the flex sup-

port 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.

Fig. 4 - PT-17A Torch Assy. (75° hd.) w/25-ft. Iines - P/N 19999

PT-17A Torch Assy. (75° hd) w/50-ft. Iines - P/N 20000

PT-17AM Mech. Torch Assy. w/25-ft. Iines - P/N 20001

PT-17AM Mech. Torch Assy. w/50-ft. Iines - P/N 20002

NOTE: A thin film of silicone lubricant P/N 17672 (1 oz.

tube) applied inside of the flex support will ease

the assembly of this part.

IV. REPLACEMENT PARTS

Replacement parts are keyed in Fig. 4 and 5. Order re-

placement parts by part number and part name as shown

on the illustrations. DO NOT order by part number alone.

Parts may be ordered from your ESAB welding equip-

ment distributor or from ESAB Welding & Cutting Prod-

ucts, Customer Service Department, Florence, SC.

Fig. 5 - Torch Holder Assy. (PT-17AM) - P/N 0558005926

GASKET - 19575

Gouging Tip

70A - 20426

100A - 20427

CUTTING TIP,

30A, 0.038 - 19914

50A, 0.046 - 19915**

70A, 0.052 - 19916**

80A, 0.057 - 19917**

100A, 0.067 - 20056**

SWITCH - 18224

SWITCH BAND - 19127

SHROUD CAP - 19498

ELECTRODE

ADAPTOR - 20053

BAFFLE

TUBE - 19114

NUT, No. 6-32

LOCKWASHER - No. 6

SCREW,No. 6-32 X 1/4"

BODY (75½) - 20008

(MECH.) -20010

ELECTRODE - 19918**

HEAT SHIELD - 20747**

SHROUD - 19499

FLEX SUPPORT - 19156

HANDLE (PT-17) - 18635

(PT-17AM) - 999482*

INSULATOR - 18619 (PT-17)

18613 (PT-

17AM)

BOOT - 49N83

PILOT ARC CABLE ASS'Y.

25-ft. - 17277

50-ft. - 19322

SHEATH

25-ft. - 20534

50-ft. 20533

POWER CABLE ASS'Y.

25-ft. - 19993

50-ft. - 19994

PLUG - 2062336

* Includes RACK ASS'Y. - 49V29 &

LOCK RING - 57N70

** Accessory (Supplied with Spare

Parts Kit - See Table 1).

Slide switch and band

from handle. (Snip leads

at splice to replace switch.)

Pull flex support back.

Remove tape holding

switch lead splices and sheath.

Unscrew handle. Remove tape

& Nomex insulator. Slide tub-

ing on H.F. cable back and

disconnect torch head.

Supplied: TORCH HOLDER ASS'Y. (PT-17AM)

P/N16V83 (See Fig. 5)

ESAB PT-17A & PT-17AM Plasma Arc Cutting Torches Troubleshooting instruction

ESAB PT-17A & PT-17AM Plasma Arc Cutting Torches Troubleshooting instruction

ESAB PT-17A & PT-17AM Plasma Arc Cutting Torches Troubleshooting instruction

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