ESAB PT-38 Plasmarc Cutting Torches 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 Specications ................................................................................................................................................................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, cuess 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 cus, 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 con ned, 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 specic 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 eects 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 con ned 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 specic 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 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied 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 PT38 TORCH, REFER TO THE SAFETY PRECAU

TIONS AND OPERATING INSTRUCTIONS IN THE APPROPRIATE POWER

SOURCE INSTRUCTION MANUAL.

USING THE PT38 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 bae, 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 Speci cations:

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 Bae ....................................................... 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 Bae (0558004870)

*Note: When Gouging use 90 amp Bae (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 DEENERGIZED.

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 bae, 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 Bae (30-70 Amp)

28

SECTION 4 OPERATION

4.3 Gouging with the PT-38

PC-1300/1600: Insert high current gas bae, 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 prole.

PC-900: Insert standard gas bae, 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 prole.

Electrode

Gouge Nozzle 90 Amp - PC-1300/1600

60 Amp - PC-900

Gas Bae 60 Amp - PC-900

Electrode

Torch Body

Assembly

Piston

Electrode/Torch

Body Seat

Retaining/Shield Cup

Gas Bae

(30-70A)

Gas Bae (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

sucient, 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 Bae 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

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