ESAB PT-35 Plasmarc Cutting Torch User manual
- Category
- Welding System
- Type
- 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)
ipm (mm/min)
.625
.500
.375
.250
.125
.099
(12/13 ga.)
.059
( 16 ga.)
.042
(19 ga.)
.024
(24 ga.)
Amps
50
50
50
50
50
50
50
50
50
Air
Pressure
psig
bar
60
60
60
60
60
60
60
60
60
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
Cutting
Height
in.
mm
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
.125
.125
.125
.125
.125
.125
.125
.125
.125
Pierce
Height
in.
mm
NR
NR
4.750
3.962
3.962
3.175
3.175
3.175
3.175
NR
NR
.187*
.156*
.156*
.125
.125
.125
.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+
750+
457
762
1524
2362
4114
4953
9906
19050+
19050+
13
22
50
70
125
172
345
750+
750+
330
558
1270
1778
3175
4368
8763
19050+
19050+
ipm (mm/min)
ipm (mm/min)
.500
.375
.250
.188
.125
.105
(12/13 ga.)
.060
(16 ga.)
.043
(19 ga.)
.025
(24 ga.)
Amps
50
50
50
50
50
50
50
50
50
Air
Pressure
psig
bar
60
60
60
60
60
60
60
60
60
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
in.
mm
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
.125
.125
.125
.125
.125
.125
.125
.125
.125
Cutting
Height
Pierce
Height
in.
mm
NR
NR
4.750
4.750
3.962
3.175
3.175
3.175
3.175
NR
NR
.187*
.187*
.156*
.125
.125
.125
.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)
ipm (mm/min)
.071
(15 ga.)
.062
(16 ga.)
.025
(25 ga.)
Amps
50
50
50
Air
Pressure
psig
bar
60
60
60
4.1
4.1
4.1
in.
mm
3.175
3.175
3.175
.125
.125
.125
Cutting
Height
Pierce
Height
in.
mm
3.175
3.175
3.175
.125
.125
.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)
ipm (mm/min)
.500
.375
.313
.250
.188
.125
.095
(10/11 ga.)
.049
(16 ga.)
.043
(17 ga.)
.031
(20 ga.)
Amps
50
50
50
50
50
50
50
50
50
50
Air
Pressure
psig
bar
60
60
60
60
60
60
60
60
60
60
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
4.1
in.
mm
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
3.175
.125
.125
.125
.125
.125
.125
.125
.125
.125
.125
Cutting
Height
Pierce
Height
in.
mm
NR
NR
6.350
4.775
3.962
3.962
3.175
3.175
3.175
3.175
NR
NR
.250*
.188*
.156*
.156*
.125
.125
.125
.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
- Category
- Welding System
- Type
- User manual
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