ESAB PT-35 Plasmarc Cutting Torch User manual

PT-35

Plasmarc Cutting Torch

0558004721

Instruction, Operation and Maintenance Manual (GB)

80

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of opera-

tion 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 before installing or operating

this equipment.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying la-

bels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 mainte

-

nance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the

manufacturer.

81

SECTION TITLE PAGE

SECTION 1

SAFETY ................................................................................................................................................ 83

1.0 Safety Precautions ..................................................................................................................................................................83

SECTION 2 DESCRIPTION .........................................................................................................................................................................

85

2.0 Description ................................................................................................................................................................................85

2.1 Accessories .................................................................................................................................................................................86

SECTION 3 INSTALLATION ....................................................................................................................................................................... 89

3.0 Installing Front End Parts ......................................................................................................................................................89

SECTION 4 OPERATION .............................................................................................................................................................................

91

Cutting Parameters ............................................................................................................................... 91

SECTION 5 MAINTENANCE ...................................................................................................................................................................... 93

5.0 General ......................................................................................................................................................................................93

SECTION 6 REPLACEMENT PARTS ........................................................................................................................................................ 99

6.0 General ......................................................................................................................................................................................99

6.1 Ordering ......................................................................................................................................................................................99

TABLE OF CONTENTS

82

TABLE OF CONTENTS

83

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.

84

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 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

85

SECTION 2 DESCRIPTION

2.0 DESCRIPTION

This booklet covers accessories, maintenance, and parts information for the PT-

35 plasma torches. For installation and operating instructions for your cutting

package, refer to your power source instruction manual.

The PT-35 is a 50 amp capacity, pilot-arc mechanized torch available in 4 diﬀerent

versions. The torch uses clean, dry air as the cut gas for cutting carbon steel,

aluminum, or stainless steel.

DO NOT use oxygen with

this torch! A hazardous ﬁre

may result.

PT-35

With Rack; 7.6m (25 ft.) ..........................................................................................0558004351

With Rack; 15.2m (50 ft.) .......................................................................................0558004352

Without Rack; 7.6m (25 ft.) ...................................................................................0558004353

Without Rack; 15.2m (50 ft.) ................................................................................0558004354

Dimensional Data

WARNING

86

SECTION 2 DESCRIPTION

2.1 ACCESSORIES

Description P/N Quantity

Shield, Retaining 0558004357 1

50 amp "A" Nozzle 0558004356 4

Electrode 0558005200 6

Fuse 2amp, 600vdc 0558003075 1

Insulator 0558004387 1

PT-35, 50 A, Spare Parts Kit, P/N 0558005210

Contents:

Description P/N Quantity

Electrode 0558005200 10

50 amp "A" Nozzle 0558004356 15

Consumable Value Pack, P/N 0558005203

Contents:

Consumable Value Pack .................................................................................................0558005203

Description P/N Quantity

Electrode 0558005200 1

50 amp "A" Nozzle 0558004356 1

Consumable Set, P/N 0558005201

Contents:

Consumable Set ..............................................................................................................0558005201

50 A Spare Parts Kit ........................................................................................................

0558005210

Description P/N Quantity

Electrode 0558005200 1

50 amp "B" Nozzle 0558004358 1

Consumable Set, P/N 0558005202

Contents:

Consumable Set ..............................................................................................................0558005202

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

87

SECTION 2 DESCRIPTION

NOTE:

Part numbers in parenthesis ap-

ply to "CE" / European units only.

Plasma Flow Measuring Kit:

This valuable troubleshooting tool allows measurement of the actual plasma gas ﬂow

through the torch .................................................................................................

19765 (0558000739)

CNC Cable 50' ........................................................................................................................0558004366

Adaptor Cable - Adaptor to directly connect HT or

TD control cable to ESP-50 .............................................................................................

0558004363

Torch Holder Assembly ...................................................................................................

16V83 (0558004250)

Plate Rider - height control for PT-35 ...........................................................................

0560936972

Standoﬀ Tool - Designed for use with Plate Rider for setting nozzle standoﬀ height.

Can also be used separately. ..........................................................................................

0558004364

88

SECTION 2 DESCRIPTION

89

SECTION 3 INSTALLATION

3.0 INSTALLING FRONT END PARTS

Make sure power switch on

console is in OFF position

and primary input power

is de-energized.

1. The seat comes assembled to the front end of the torch. If the seat becomes

damaged, the torch body must be replaced. DO NOT attempt to remove the seat

from torch body.

SEAT

WARNING

NOZZLE

ELECTRODE

INSULATOR

SHIELD

TORCH BODY

2. Thread electrode into the seat and then install the electrode insulator onto the

torch body. Tighten the electrode ﬁrmly by hand. Do not use wrenches or pliers.

3. If front end of the torch is facing down as normal in a setup, the nozzle can be

seated in the heat shield and then assembled to the torch.

IMPORTANT:

See Maintenance section.

Follow all instructions in

the booklet packed with

your unit. DO NOT install

or attempt to operate this

torch without following

these instructions.

CAUTION

ELECTRODE HOLDER ASSEMBLY

4. Tighten heat shield fully to hold the parts in ﬁrm contact with each other and to

the torch head.

To connect the PT-35 torch to the console, connect the power cable of the torch to

the ‘‘NEG’’ terminal and pilot arc cable to the ‘‘POS’’ terminal of the unit.

90

SECTION 3 INSTALLATION

91

SECTION 4 OPERATION

Cutting Parameters for the PT-35 Torch

CARBON STEEL

50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200

Metal

Thickness

15.875

12.700

9.525

6.350

3.175

2.515

1.499

1.067

0.610

mm

in.

Travel Speed

Optimum

Maximum

18

30

48

86

200

250

450

600

750+

457

762

1219

2184

5080

6350

11430

15240

19050+

12

25

42

82

150

225

375

450

750+

304

635

101

2082

3810

5715

9525

11430

19050+

ipm (mm/min)

.625

.500

.375

.250

.125

.099

(12/13 ga.)

.059

( 16 ga.)

.042

(19 ga.)

.024

(24 ga.)

Amps

50

Air

Pressure

psig

bar

60

4.1

Cutting

Height

in.

mm

3.175

.125

Pierce

Height

in.

mm

NR

4.750

3.962

3.175

NR

.187*

.156*

.125

NR = Not Recommended

* = If using a ﬁxed height torch or plate rider, set cutting height equal to pierce height; cutting speed may

have to be reduced due to increased cut height.

50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200

STAINLESS STEEL

Metal

Thickness

12.700

9.525

6.350

4.763

3.175

2.515

1.499

1.067

0.610

mm

in.

Travel Speed

Optimum

Maximum

18

30

60

93

162

195

390

750+

457

762

1524

2362

4114

4953

9906

19050+

13

22

50

70

125

172

345

750+

330

558

1270

1778

3175

4368

8763

19050+

ipm (mm/min)

.500

.375

.250

.188

.125

.105

(12/13 ga.)

.060

(16 ga.)

.043

(19 ga.)

.025

(24 ga.)

Amps

50

Air

Pressure

psig

bar

60

4.1

in.

mm

3.175

.125

Cutting

Height

Pierce

Height

in.

mm

NR

4.750

3.962

3.175

NR

.187*

.156*

.125

92

SECTION 4 OPERATION

GALVANIZED STEEL

50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200

NR = Not Recommended

* = If using a ﬁxed height torch or plate rider, set cutting height equal to pierce height; cutting speed may

have to be reduced due to increased cut height.

Metal

Thickness

1.803

1.575

0.635

mm

in.

Travel Speed

Optimum

Maximum

210

352

750

5334

8940

19050

170

315

450

4318

8001

11430

ipm (mm/min)

.071

(15 ga.)

.062

(16 ga.)

.025

(25 ga.)

Amps

50

Air

Pressure

psig

bar

60

4.1

in.

mm

3.175

.125

Cutting

Height

Pierce

Height

in.

mm

3.175

.125

50 AMP Data, Nozzle P/N 0558004356, Heat Shield P/N 0558004357, Electrode P/N 0558005200

ALUMINUM

Cutting Parameters for the PT-35 Torch

Metal

Thickness

12.700

9.525

7.950

6.350

4.763

3.175

2.413

1.245

1.092

0.762

mm

in.

Travel Speed

Optimum

Maximum

30

45

57

87

150

230

300

465

502

750+

762

1143

1447

2209

3810

5842

7620

11811

12750

19050+

21

36

50

72

110

200

275

420

450

750+

533

914

1270

1828

2794

5080

6985

10668

11430

19050+

ipm (mm/min)

.500

.375

.313

.250

.188

.125

.095

(10/11 ga.)

.049

(16 ga.)

.043

(17 ga.)

.031

(20 ga.)

Amps

50

Air

Pressure

psig

bar

60

4.1

in.

mm

3.175

.125

Cutting

Height

Pierce

Height

in.

mm

NR

6.350

4.775

3.962

3.175

NR

.250*

.188*

.156*

.125

93

SECTION 5 MAINTENANCE

Before any maintenance

is attempted on this torch,

make sure the POWER

SWITCH on the console is

in the OFF position and the

PRIMARY INPUT POWER is

DEENERGIZED.

5.0 GENERAL

A. Periodically check shield, electrode holder and electrode insulator. Replace if

worn or damaged.

B. Power and pilot arc cables should be inspected periodically. If there are any

cuts through the protective sheath or if gas leaks are noted, replace the damaged

component.

1. Dirt or Contamination

Dirt or other contamination in the torch and loose consumable parts can cause

premature failure of the PT-35 Torch through internal arcing. To avoid this, users are

instructed to do the following:

Ensure that clean, dry, and oil-free air is being used.

Wipe the torch body insulator clean with a cloth before installing each fresh set

of consumables. The ability of the insulator to resist arc tracking over its surface is

reduced when dirt or other contamination is allowed to collect there.

2. Loose Consumables

Tests have shown that with proper use of the torch within rated operating conditions

(especially arc current and gas ﬂow rate), the torch consumable parts do not become

loose if they are ﬁrmly installed.

A. Tighten shield fully at each consumable change or inspection.

B. Check consumable tightness at beginning of each work shift, even if everything

was working normally at the end of the previous shift.

Ensure that the electrode seat and electrode holder are clean and free of dust or dirt.

Debris may prevent mating surfaces from having solid contact.

WARNING

94

SECTION 5 MAINTENANCE

The torch requires good

electrical contact between

the electrode seat and elec-

trode holder. If good contact

is not maintained, then the

resulting potential differ-

ence causes internal arcing

and possible torch dam-

age.

3. Damage Caused by Loose Parts and Torch Overheating.

4. Consumables- Remove and Replace

Arc tracking indicates loose parts. Make sure heat shield is tightened fully, at least

5mm (0.20") of rotation after electrode seat contacts electrode holder. Check tight-

ness again after a few minutes of use. Parts damaged by arcing will cause destruc-

tion of torch and must be replaced.

a. Bring torch to a position where it is easily accessed by machine operator, in its

normal vertical position and at least 152.4mm (6.00") above the workpiece or the

edge of the water table.

Make sure that the power

source has been turned oﬀ

and that the power cable

has been unplugged at the

wall receptacle before pro-

ceeding.

b. Unscrew the heat shield and lower it away from the torch, allowing nozzle to

remain with shield.

c. Remove the nozzle and inspect for wear. The nozzle oriﬁce should be round at

both the entrance and the exit. If the nozzle oriﬁce is worn in an oval shape or shows

other signs of damage at either end, it should be replaced. The inside of the nozzle

may have light gray deposits from the electrode. These may be removed with steel

wool but care must be taken to remove all traces of the steel wool afterward.

CAUTION

NOZZLE

SHIELD

WARNING

ELECTRODE

INSULATOR

TORCH BODY

95

SECTION 5 MAINTENANCE

If the electrode has a pit which is more than 1.5mm (0.06") deep at its center, it must

be replaced. This is done by unscrewing the electrode from the electrode holder.

Inspect the electrode insulator and electrode holder assembly for signs of damage

such as arc tracking or cracking and replace them if neccessary. After installing the

electrode insulator onto the electrode holder assembly, install electrode by screwing

into place. Note that ﬁrm tightening of the electrode by hand is suﬃcient, the use of

tools such as wrenches or pliers is not required or recommended.

REPLACE ELECTRODE BE-

FORE LENGTH BECOMES

SHORTER THAN 19/32 INCH

(15.1 MM)

CAUTION

Replace when eroded beyond

.06"(1.5mm) depth.

NEW

WORN

5. Measuring Torch Gas Flows

If low gas ﬂow is suspected of causing poor cutting performance or short consumable

life, the ﬂow can be checked by using the Plasma Torch Flow Measuring Kit 19765

(0558000739). The kit includes a hand held rotameter (ﬂowmeter) which will indicate

the gas ﬂow rate exiting the torch. The kit also includes a set of instructions which

should be followed exactly to insure safe and accurate use of the rotameter.

Total air ﬂow rate in the PT-35 should be 153.5 l/m (325 cfh) minimum with any

nozzle at 5.2 bar (75 psig).

Flow Measuring Kit

SEAT

INSULATOR

ELECTRODE

96

SECTION 5 MAINTENANCE

6. Removal and Replacement of the Torch Body

Make sure that the power

source has been turned oﬀ

and that primary power

has been disconnected

before proceeding.

PT-35 Torch

1. Unscrew the right hand threaded handle (clockwise) from the torch body and slide

it back onto the torch cable assembly in order to expose the torch connections.

WARNING

2. Unscrew the main power cable ﬁtting from the torch’s power lead by using a

7/16" (11.11 mm) and an adjustable wrench. Apply pressure to the 7/16" wrench in

direction shown by the arrow.

7/16"

Adjustable wrench

Torch Body

Handle

Main Power Cable

97

SECTION 5 MAINTENANCE

Heatshrink Tubing

Knife-splice connection

3. Remove the electrical tape which secures the pilot arc (red) cable to the main

power cable. This exposes the wire splice. Remove the heatshrink tubing from

pilot arc cable to expose the pilot arc knife-splice connection. Disconnect the

connection.

Electrical Tape

Pilot Arc Cable (red)

Wire splice

Main Power Cable

98

SECTION 5 MAINTENANCE

5. Tape pilot arc cable connection back to main power cable.

6. Slide the handle forward and thread it ﬁrmly onto the torch body.

Electrical Tape

4. To install the new torch head assembly - Insert the new piece of heatshrink

tubing onto the pilot arc cable attached to the new torch head assembly. Connect

the pilot arc cable and the main power cable by reversing the steps taken to

disconnect them. Be sure to slide the heatshrink tubing completely over the knife-

splice connection. Apply heat to form the tubing to the connection, ensuring that

the connection is completely insulated. (Several layers of electrical tape can also

be used in place of heatshrink tubing if desired).

New Heatshrink Tubing

New Torch Head Assembly

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ESAB PT-35 Plasmarc Cutting Torch User manual

ESAB PT-35 Plasmarc Cutting Torch User manual

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