ESAB PT-38 Plasmarc Cutting Torches User manual
- Category
- Welding System
- Type
- User manual
PT-38
Plasmarc Cutting Torches
0558007165 03/2011
Instruction Manual
P/N 0558006786 - PT-38 Torch, 25' (7.6 m)
P/N 0558006787 - PT-38 Torch, 50' (15.2 m)
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.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
SECTION TITLE PAGE
SECTION 1 SAFETY ...................................................................................................................................................5
1.0 Safety Precautions..................................................................................................................................................................... 5
1.1 Safety - English ........................................................................................................................................................................... 5
1.2 Safety - Spanish .......................................................................................................................................................................... 9
1.3 Safety - French ..........................................................................................................................................................................13
SECTION 2 DESCRIPTION........................................................................................................................................17
2.0 Description ................................................................................................................................................................................17
2.1 Torch Specications ................................................................................................................................................................18
2.2 Optional Accessories ..............................................................................................................................................................19
2.3 Spare Parts Kits .........................................................................................................................................................................19
2.4 Consumables Breakdown PC-1300/1600 .......................................................................................................................20
2.5 Consumables Breakdown PC-900 .....................................................................................................................................21
SECTION 3 INSTALLATION ......................................................................................................................................23
3.0 Installation .................................................................................................................................................................................23
3.1 Torch Installation .....................................................................................................................................................................23
SECTION 4 OPERATION ...........................................................................................................................................25
4.0 Cutting with the PT-38 ...........................................................................................................................................................25
4.1 Stand-o Guide ........................................................................................................................................................................27
4.2 Drag Cutting 40 Amp .............................................................................................................................................................27
4.3 Gouging with the PT-38 ........................................................................................................................................................28
4.4 Installing Consumables .........................................................................................................................................................28
4.5 Cut Data ......................................................................................................................................................................................29
4.6 Operation of Power Source ..................................................................................................................................................29
SECTION 5 MAINTENANCE .....................................................................................................................................35
5.0 General ......................................................................................................................................................................................35
5.1 Dirt or Contamination ............................................................................................................................................................35
5.2 Inspection, Cleaning and Replacement of Consumables .........................................................................................36
5.3 Disassembly / Assembly of Torch .......................................................................................................................................38
5.4 Measuring Torch Gas Flows ..................................................................................................................................................41
SECTION 6 REPLACEMENT PARTS ..........................................................................................................................43
6.0 Replacement Parts ..................................................................................................................................................................43
6.1 General ......................................................................................................................................................................................43
6.2 Ordering ......................................................................................................................................................................................43
Diagrams and Parts List .........................................................................................................................................................44
TABLE OF CONTENTS
4
TABLE OF CONTENTS
5
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
1.1 Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize
precautionary information from the
references listed in Additional Safety
Information section. Before performing any instal-
lation 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.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and can injure
skin and eyes. Hot metal can cause burns. Training
in the proper use of the processes and equipment
is essential to prevent accidents. Therefore:
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 tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when oper-
ating 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 ameproof gauntlet type gloves, heavy
long-sleeve shirt, cuess 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 ameproof apron may
also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, 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-ammable partition
or curtains.
6. Use goggles over safety glasses when chipping
slag or grinding. Chipped slag may be hot and
can y far. Bystanders should also wear goggles
over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a pro-
tective non-ammable 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 oors or wall openings and cause a
hidden smoldering re or res on the oor 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 work piece has been completely cleaned so
that there are no substances on the work piece
which might produce ammable or toxic vapors.
Do not do hot work on closed containers. They
may explode.
4. Have re extinguishing equipment handy for
instant use, such as a garden hose, water pail,
sand bucket, or portable re extinguisher. Be
sure you are trained in its use.
5. Do not use equipment beyond its ratings. For
example, overloaded welding cable can overheat
and create a re 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 re. Use re
watchers when necessary.
7. For additional information, refer to NFPA Stan-
dard 51B, "Fire Prevention in Use of Cutting and
Welding Processes", available from the National
Fire Protection Association, Battery march Park,
Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO
NOT use AC welding current in damp
areas, if movement is conned, or if there is danger
of falling.
6
SECTION 1 SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the work piece to a good electrical
ground.
3. Connect the work cable to the work piece. 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 o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent owing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects 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 work piece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
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 specic ventilation recommendations.
7
SECTION 1 SAFETY PRECAUTIONS
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
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 ttings 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 xtures 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 ames.
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 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualied personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
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
SECTION 1 SAFETY PRECAUTIONS
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."
MEANING OF SYMBOLS - As used
throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in im-
mediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
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17
SECTION 2 DESCRIPTION
2.0 Description
THE PLASMA ARC CUTTING PROCESS EMPLOYS HIGH VOLTAGES.
CONTACT WITH "LIVE" PARTS OF THE TORCH AND MACHINE MUST
BE AVOIDED. ALSO, THE IMPROPER USE OF ANY OF THE GASES EM
PLOYED CAN PRESENT A SAFETY HAZARD. BEFORE BEGINNING OP
ERATION WITH THE PT38 TORCH, REFER TO THE SAFETY PRECAU
TIONS AND OPERATING INSTRUCTIONS IN THE APPROPRIATE POWER
SOURCE INSTRUCTION MANUAL.
USING THE PT38 TORCH ON ANY UNIT NOT EQUIPPED WITH A MAT
ING SAFETY INTERLOCK CIRCUIT MAY EXPOSE OPERATOR TO UNEX
PECTED HIGH VOLTAGE.
WARNING
The PT-38 is a manual torch with a 90° head designed for use with several ESAB plasma arc cutting packages using clean,
dry air as the plasma gas. The service line lengths available with the PT-38 torch are 25 feet (7.6 m) and 50 feet (15.2 m). The
PT-38 torch is rated to operate at a maximum of 90 amperes at 100% duty cycle.
This manual is intended to provide the operator with all the information required to assemble, operate, and repair the PT-38
Plasma Arc Cutting Torch. For additional safety precautions, process instructions, and system troubleshooting; refer to the
appropriate instruction manual for your Plasma Arc Cutting Package.
Designed for superior cutting performance and ease of handling, the PT-38 produces clean, exceptionally high quality
cuts.
• Most compact 90 amp torch on the market
• Excellent cutting capacity - Cuts 1-1/2 in. (38 mm); severs 1-3/4 in. (45 mm)
• Uses shop air, cylinder air for superior versatility
• Pilot arc starting - even starts through paint
• Choice of 25 ft (7.6 m). or 50 ft (15.2 m) line length
• Excellent consumable life
• Parts in place design
• One-year warranty
18
Cuts ..................................................................................................................................................1-1/2 in. (38 mm); severs 1-3/4 in. (45 mm)
Current Capacity .................................................................................................................................................... 90 amps @ 100% duty cycle
Nominal Flow Rate ........................................................................................................................... 400 cfh @ 80 psig (189 l/min @ 5.5 bar)
Length of Service Lines ....................................................................................................................................... 25 ft (7.6 m) or 50 ft (15.2 m)
Dimensions
Overall Length ................................................................................................................................................................................8.2 in. (208 mm)
Length of Head .................................................................................................................................................................................3.0 in. (76 mm)
PT-38 Torch, 25' (7.6 m) ....................................................................................................................................................................... 0558006786
PT-38 Torch, 50' (15.2 m) ..................................................................................................................................................................... 0558006787
Torches and torch body assemblies are supplied without gas bae, electrode, nozzle, and retaining/shield cup. Order com-
plete spare parts kits or individual components shown in PT-38 Spare Parts Kits or Consumables Breakdown section.
SECTION 2 DESCRIPTION
2.1 Torch Specications:
Compatible ESAB Consoles:
Powercut-1300:
208-230/460 V Console.............................................0558007220
208-230/460 V Console BL ................................... 0558007220F
400 V CE Console ........................................................0558007224
400 V Console...............................................................0558007634
460 V Console...............................................................0558008320
575 V Console BL ........................................................0558007227
Powercut-1600:
208-230/460 V Console.............................................0558007230
208-230/460 V Console BL ................................... 0558007230F
400 V CE Console ........................................................0558007234
400 V Console...............................................................0558007636
460 V Console...............................................................0558008323
575 V Console BL ........................................................0558007237
Powercut-900:
208/230 V Console ......................................................0558008120
208/230 V Console BL.............................................. 0558008120F
230 V CE Console .........................................................0558008123
400 V CE Console .........................................................0558008135
400 V Console................................................................0558008133
460 V Console................................................................0558008127
575 V Console BL ..........................................................0558008131
19
Torch Guide Kit:
This complete kit, in a rugged plastic carrying case, includes attachments for circle and straight line cutting on
ferrous and non-ferrous metals.
Deluxe, 1-3/4" - 42" (44.5 mm - 106 cm) Radius ........................................................p/n 0558003258
Basic, 1-3/4” - 28” (44.5 mm - 71 cm) Radius .............................................................p/n 0558002675
SECTION 2 DESCRIPTION
2.3 Spare Parts Kits:
2.2 Optional Accessories:
PT-38 Spare Parts Kits
0558007640
90 AMP
PC-1600 CE
0558007639
90 AMP
PC-1600
0558007642
70 AMP
PC-1300 CE
0558007641
70 AMP
PC-1300
0558008419
60 AMP
PC-900 CE
0558008418
60 AMP
PC-900
Part
Number
Description
3 3 3 3 3 3 0558005220 ELECTRODE
1 1 1 1 1 1 0558005217 GAS BAFFLE 30-70A
1 1 - - - - 0558004870 GAS BAFFLE 90/100A
- - - - 3 3 0558008417 NOZZLE 60 AMP
- - 4 4 - - 0558005219 NOZZLE 70 AMP
4 4 - - - - 0558007680 NOZZLE 90 AMP
1 1 1 1 - - 0558007682 NOZZLE DRAG 40 AMP
- 1 - 1 - 1 0558007549 RETAINING / SHIELD CUP
1 - 1 - 1 - 0558008094 RETAINING / SHIELD CUP LONG
3 3 3 3 3 3 0558101101 O-RING .301ID .070W Nitrile
1 1 1 1 1 1 0558000443 GREASE SILICON DOW DC-111 (1/4 oz)
1 1 1 1 1 1 0558001379 FUSE MIDGET SLO-BLO 2A 600V
Gas Flow Measuring Kit ...........................................................................p/n 0558000739
Valuable troubleshooting tool allows measurement of the actual air ow through
the torch.
Powercut-1300/1600
Powercut-900
Stand-o Guide Assembly 90 Amp ...................................................................................p/n 0558006614
Use to maintain constant stand-o distance.
Gouging 90 Amp:
• Gouging Nozzle 90 Amp........................................................................................p/n 0558007681
• Gouging Heat Shield Assembly 90 Amp ..........................................................p/n 0558008186
• *Note: Must use 90/100 Amp Gas Bae ....................................................... p/n 0558004870
Stand-o Guide Assembly 60 Amp ...................................................................................p/n 0558008592
Use to maintain constant stand-o distance.
Gouging 60 Amp:
• Gouging Nozzle 60 Amp....................................................................................... p/n 0558008588
• Gouging Heat Shield Assembly 60 Amp ..........................................................p/n 0558008591
20
SECTION 2 DESCRIPTION
2.4 Consumables Breakdown PC-1300/1600:
*
Note: When Gouging use 90 amp Bae (0558004870)
*Note: When Gouging use 90 amp Bae (0558004870)
STAND-OFF GUIDE
0558006611
0558006613
0558006614
0558005217 05580052200558005219
0558008094
70A
0558005217 05580052200558007682
0558008094
40A
0558004870 05580052200558007680
0558008094
90A
CUTTING
0558003694
O-RING
P / N 0 5 5 8 9 5 4 1 3 7 - D 2 / 11
O-RING
0558101101
FUSE 2A 600V
0558001379
GREASE
0558000443
0558007681
0558006611
0558006601
0558004870
0558008186
GOUGING
80 PS I
5. 5 BAR
STAND-OFF GUIDE
0558006611
0558006613
0558006614
0558005217 05580052200558005219
0558008094
70A
0558005217 05580052200558007682
0558008094
40A
0558004870 05580052200558007680
0558008094
90A
CUTTING
0558003694
O-RING
P / N 0 5 5 8 9 5 4 1 3 7 - D 2 / 11
O-RING
0558101101
FUSE 2A 600V
0558001379
GREASE
0558000443
0558007681
0558006611
0558006601
0558004870
0558008186
GOUGING
80 PS I
5. 5 BAR
STAND-OFF GUIDE
GUIDE DE HA U TEUR
0558006611
0558006613
0558006614
0558005217 05580052200558005219
0558007549
70A
0558005217 05580052200558007682
0558007549
40A
0558004870 05580052200558007680
0558007549
90A
CUTTING /
COUPA GE
0558003694
O-RING
PT-38
JOINT TORIQ U E
P / N 0 5 5 8 9 5 4 0 9 0 - D 2 / 11
O-RING
JOINT TORIQ U E
0558101101
FUSE 2A 600V
0558001379
FUSIB L E 2A 600V
GREASE
GRAIS SE
0558000443
GOUGING
0558007681
0558006611
0558006601
0558004870
0558008186
GOUGEAGE
GOUGING
80 PS I
5. 5 BAR
STAND-OFF GUIDE
GUIDE DE HA U TEUR
0558006611
0558006613
0558006614
0558005217 05580052200558005219
0558007549
70A
0558005217 05580052200558007682
0558007549
40A
0558004870 05580052200558007680
0558007549
90A
CUTTING /
COUPA GE
0558003694
O-RING
PT-38
JOINT TORIQ U E
P / N 0 5 5 8 9 5 4 0 9 0 - D 2 / 11
O-RING
JOINT TORIQ U E
0558101101
FUSE 2A 600V
0558001379
FUSIB L E 2A 600V
GREASE
GRAIS SE
0558000443
GOUGING
0558007681
0558006611
0558006601
0558004870
0558008186
GOUGEAGE
GOUGING
80 PS I
5. 5 BAR
21
SECTION 2 DESCRIPTION
2.5 Consumables Breakdown PC-900:
STAND-OFF GUIDE
0558006611
0558008590
0558008592
0558005217 05580052200558007682
0558008094
40A
0558005217 05580052200558008417
0558008094
60A
CUTTING
0558003694
O-RING
P / N 0 5 5 8 9 5 4 1 6 6 - B 2 / 11
O-RING
0558101101
FUSE 2A 600V
0558000443
GREASE
0558000443
0558008588
0558006611
0558006602
0558005217
0558008591
GOUGING
80 PS I
5. 5 BAR
STAND-OFF GUIDE
0558006611
0558008590
0558008592
0558005217 05580052200558007682
0558008094
40A
0558005217 05580052200558008417
0558008094
60A
CUTTING
0558003694
O-RING
P / N 0 5 5 8 9 5 4 1 6 6 - B 2 / 11
O-RING
0558101101
FUSE 2A 600V
0558001379
GREASE
0558000443
0558008588
0558006611
0558006602
0558005217
0558008591
GOUGING
80 PS I
5. 5 BAR
STAND-OFF GUIDE
GUIDE DE HA UTEUR
0558006611
0558008590
0558008592
0558005217 05580052200558007682
0558007549
40A
0558005217 05580052200558008417
0558007549
60A
CUTTING /
COUPA GE
0558003694
O-RING
PT-38
JOINT TORIQ UE
P / N 0 5 5 8 9 5 4 1 6 5 - A 2 / 11
O-RING
JOINT TORIQ UE
0558101101
FUSE 2A 600V
0558001379
FUSIB L E 2A 600V
GREASE
GRAIS SE
0558000443
GOUGING
0558008588
0558006611
0558006602
0558005217
0558008591
GOUGEAGE
GOUGING
80 PS I
5. 5 BA R
STAND-OFF GUIDE
GUIDE DE HA UTEUR
0558006611
0558008590
0558008592
0558005217 05580052200558007682
0558007549
40A
0558005217 05580052200558008417
0558007549
60A
CUTTING /
COUPA GE
0558003694
O-RING
PT-38
JOINT TORIQ UE
P / N 0 5 5 8 9 5 4 1 6 5 - A 2 / 11
O-RING
JOINT TORIQ UE
0558101101
FUSE 2A 600V
0558001379
FUSIB L E 2A 600V
GREASE
GRAIS SE
0558000443
GOUGING
0558008588
0558006611
0558006602
0558005217
0558008591
GOUGEAGE
GOUGING
80 PS I
5. 5 BA R
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23
SECTION 3 INSTALLATION
3.1 Torch Installation
Panel Receptacle
Air Hose quick-connect tting
1. Open torch lead access door on the front panel of the Powercut-900/1300/1600.
2. Connect the torch cable male receptacle to the panel receptacle.
Check orientation of the sockets to ensure a correct t.
3. Connect the air hose to the quick-connect tting. Place the strain relief in the square cutout in the front of
the console. Line up the groove of the strain relief with the half square cutout area.
Torch Cable Male
Receptacle
MAKE SURE POWER SWITCH ON CONSOLE IS IN OFF POSITION AND
PRIMARY INPUT POWER IS DEENERGIZED.
WARNING
strain relief
square cutout
Torch Lead
Access
Door
3.0 Installation
24
Torch Lead Access Door
Work Cable
SECTION 3 INSTALLATION
4. Insert work cable into receptacle on the front of the console and
turn clockwise until secure.
5. Replace torch lead access door.
25
DO NOT USE OXYGEN WITH THIS TORCH! A HAZARDOUS FIRE MAY
RESULT.
DANGER
SECTION 4 OPERATION
Use the following procedures to cut with the PT-38 torch.
1. Make sure that the wall disconnect switch is on. Turn on the Power Switch to the cutting power source console.
2. Set Pressure Regulator to 80 psig (5.5 bar).
3. PC-1300/1600: Hold the torch nozzle approximately 1/8 in. to 1/4 in. (3.2 mm - 6.4 mm) above the work
and tilted at about 5 - 15°. This reduces the chance of spatter entering the nozzle. If the PT-38's 90A stand-
o guide is being used, the distance between nozzle and work piece will be approximately 1/4 in. (6.4 mm).
PC-900: Hold the torch nozzle approximately 1/8 in. to 3/16 in. (3.2 mm - 4.8 mm) above the work and tilted at
about 5 - 15°. This reduces the chance of spatter entering the nozzle. If the PT-38's 60A stando guide is being
used, the distance between nozzle and work piece will be approximately 1/8 in. (3.2 mm).
4. Depress the torch switch. Air should ow from the torch nozzle.
5. Two seconds after depressing the torch switch, the pilot arc should start. The main arc should immediately fol-
low, allowing the cut to begin. If using the trigger LOCK mode, torch switch may be released after establishing
the cutting arc.
6. After starting the cut, the torch should be maintained at a 5 - 15° forward angle (Figure 4-1). This angle is es-
pecially useful in helping to create a "drop" cut. When not using the stando guide, the nozzle should be held
approximately, PC-1300/1600: 1/8 - 1/4 in. (3.2 mm - 6.4 mm), PC-900: 1/8 - 3/16 in. (3.2 mm - 4.8 mm) from the
work.
ELECTRIC SHOCK CAN KILL.
• DO NOT OPERATE THE UNIT WITH THE COVER REMOVED.
• DO NOT APPLY POWER TO THE UNIT WHILE HOLDING OR CARRY
ING THE UNIT.
• DO NOT TOUCH ANY TORCH PARTS FORWARD OF THE TORCH
HANDLE NOZZLE, HEAT SHIELD, ELECTRODE, ETC. WITH POWER
SWITCH ON.
Figure 4-1. Proper Torch Angle
Figure 4-2. Stand-o vs. Power Output
IMPORTANT!!!
Maintain Proper
Stand-O Distance
Power Output increases
with Stand-o Distance!
1/8 in. to 1/4 in.
(3.2 mm - 6.4 mm)
CUT DIRECTION
5˚ to 15˚
WARNING
4.0 Cutting with the PT-38
IMPORTANT!!!
Maintain Proper
Stand-O Distance
Power Output increases
with Stand-o Distance!
1/8 in. to 3/16 in.
(3.2 mm - 4.8 mm)
PC-900/1300/1600 PC-1300/1600 PC-900
26
SECTION 4 OPERATION
Figure 4-3. Piercing & Cutting Techniques using the PT-38
WARNING
ARC RAYS CAN BURN EYES AND SKIN;
NOISE CAN DAMAGE HEARING.
• WEAR WELDING HELMET WITH NO. 6 OR 7 LENS SHADE.
• WEAR EYE, EAR, AND BODY PROTECTION.
2. WHEN THE ARC BREAKS THROUGH THE WORK, BRING
THE TORCH TO AN UPRIGHT POSITION AND PROCEED
TO CUT.
1. TO START A PIERCE, TILT THE TORCH TO PREVENT MOLTEN
MATERIAL FROM COMING BACK AGAINST AND DAMAGING
THE TORCH.
27
SECTION 4 OPERATION
For cutting thin material, under 3/8" (9 mm), insert low current gas bae, electrode, 40 amp drag nozzle, and standard
retaining/shield cup. Set current level to 40 amps and begin cutting.
Figure 4-4. Installation and Operation of Stand-o Guide
4.1 Stand-o Guide
Use to maintain a constant stand-o distance. Attach optional stand-o guide assembly by removing the retaining/shield
cup and installing the stand-o guide assembly.
Guide against
straight edge or
free-hand cut.
Stand-o guide
assembly
DRAG CUTTING, EVEN WITH LOWER CURRENT LEVELS MAY SIGNIFI
CANTLY REDUCE THE LIFE OF TORCH CONSUMABLES. ATTEMPTING
TO DRAG CUT WITH HIGHER CURRENTS GREATER THAN 40 AMPS
MAY CAUSE IMMEDIATE CATASTROPHIC CONSUMABLE DAMAGE.
WARNING
4.2 Drag Cutting 40 Amp
Electrode
40 Amp Drag Nozzle
Retaining/Shield Cup
Gas Bae (30-70 Amp)
28
SECTION 4 OPERATION
4.3 Gouging with the PT-38
PC-1300/1600: Insert high current gas bae, electrode, 90 amp gouge nozzle, and 90 amp gouging heatshield assembly.
Operating parameters are 60 - 80 psi (4.1 - 5.5 bar) and 70 - 90 amps. Air pressure and current can be varied within these
ranges to produce desired metal removal rate and groove prole.
PC-900: Insert standard gas bae, electrode, 60 amp gouge nozzle, and 60 amp gouging heatshield assembly. Operating
parameters are 60 - 80 psi (4.1 - 5.5 bar) and 40 - 60 amps. Air pressure and current can be varied within these ranges to
produce desired metal removal rate and groove prole.
Electrode
Gouge Nozzle 90 Amp - PC-1300/1600
60 Amp - PC-900
Gas Bae 60 Amp - PC-900
Electrode
Torch Body
Assembly
Piston
Electrode/Torch
Body Seat
Retaining/Shield Cup
Gas Bae
(30-70A)
Gas Bae (90A)
Note:
Torch damage and overheating can be
caused by loose parts. Arc tracking indi-
cates loose parts. Make sure retaining
cup is tightened fully. Parts damaged by
arcing will cause destruction of torch and
must be replaced.
Note:
Firm tightening of the electrode by hand is
sucient, the use of tools such as wrench-
es or pliers is not required or
recommended.
Note:
Ensure that the electrode/torch body seat
and piston are clean and free of dust or
dirt. Debris may prevent mating surfaces
from having solid contact.
4.4 Installing Consumables
Tests have shown that with proper use of the torch within rated operating conditions (especially arc current and
gas ow rate), the torch consumable parts do not become loose if they are rmly installed. Torch damage and
overheating can be caused by loose parts.
A. Tighten electrode and retaining/shield cup fully at each consumable change or inspection.
B. Check consumable tightness at beginning of each work period, even if everything was working normally at
the end of the previous period.
Nozzle
Gouging Heatshield Assembly
90 Amp - PC-1300/1600
60 Amp - PC-900
Gas Bae 90 Amp - PC-1300/1600
29
4.5 Cut Data
Use the following pages to adjust your torch settings to obtain optimum cutting performance.
4.6 Operation of Power Source
For operation of the power source, refer to Powercut-900/1300/1600 power source instruction manual.
DO NOT USE OXYGEN WITH THIS TORCH! A HAZARDOUS FIRE MAY
RESULT.
DANGER
SECTION 4 OPERATION
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ESAB PT-38 Plasmarc Cutting Torches User manual
- Category
- Welding System
- Type
- User manual
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