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ESAB Bubble Muffler System User manual

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BUBBLE MUFFLER SYSTEM
For use with m3 Plasma System
and the PT-36 Plasma Torch
ESAB Assembly Number: 37439
Instruction Manual
0558006722 08/2011
THE BUBBLE MUFFLER CAN NOT BE USED WHEN USING H35 OR CH
4
GAS MIXES. THE WATER LEVEL MUST BE LOWERED 4 TO 6 INCHES BE
NEATH THE BOTTOM OF THE PLATE.
FAILURE TO COMPLY TO THIS WARNING CAN RESULT IN A HYDROGEN
DETONATION.
WARNING
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!
TABLE OF CONTENTS
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Section / Title Page
4
TABLE OF CONTENTS
5
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, ame proof
clothing, safety gloves.
- Do not wear loose tting 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 qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not in-
tended to be used outside during precipitation unless sheltered.
Enclosure Class
Maximum
Tilt Allowed
15°
CAUTION
If equipment is placed on a surface that
slopes more than 15°, toppling over may oc-
cur. Personal injury and / or signicant dam-
age to equipment is possible.
6
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 lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus 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
This product is solely intended for plasma cutting. Any other
use may result in personal injury and / or equipment damage.
CAUTION
CAUTION
To avoid personal injury and/or equipment
damage, lift using method and attachment
points shown here.
7
ELECTRIC SHOCK CAN KILL!
DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH-
ING OR SERVICING THE BUBBLE MUFFLER AT THE TORCH.
DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.
WARNING
SECTION 2 INSTALLATION
The Bubble Muer System creates a bubble of air so that a Plasmarc
Cutting Torch can be used underwater with slight sacrice of cut
quality. This system also permits operation above water as the ow of
water through the muer reduces fume, noise, and arc U.V. radiation.
Optional Accessories
Bubble Muer System
Bubble Muer PT-19XLS P/N 37439 1
Strainer P/N 2133340 1
Water Pump P/N 2135445 1
Adaptor, 1.06-12F 3/4" Hose P/N 2135571 3
Adaptor, 3/4" NPTM, 3/4" Hose P/N 2135572 1
PIP, Pipe S.ST 2.357X2.00 CL P/N 43350490 1
Bushing Pipe 2X3/4 P/N 44056390 1
Compressed Air Supply
(Air Curtain)
Source: 80 psi @ 1200cfh
(5.5 bar @ 34 m
3
h)
Clean, dry & oil-free shop air
Control Box Assembly P/N 33383 1
Control Cable, 18 GA, 3-Cond P/N 33253 25 ft.
Control Cable, 18 GA, 3-Cond P/N 33254 50 ft.
Control Cable, 18 GA, 3-Cond
P/N 33255 75 ft.
Control Cable, 18 GA, 3-Cond P/N 33256 100 ft.
Control Cable, 18 GA, 3-Cond P/N 33257 125 ft.
Fittings 3/8" Hose Control Box
B-Air/ Nut
3/8" ID Hose Nipple
P/N 10N40 1
P/N 347995 1
Fittings 3/8" Hose to Bubble
Muer
R.H. Air Nut
3/8" ID Hose Nipple
P/N 36Z40 1
P/N 03Z74 1
Hose, 3/4" ID for Water P/N 2027202 Specify
Length
Hose, 3/8" ID for Air P/N 23079995 Specify
Length
Adapt B-A/W*F B-A/W*M 90 deg
assy
P/N 19X19 1
DATE
RELEASED FOR
ENGLISH DWG
TITLE
REPRO MADE FROM
SIMILAR TO
SUP.
SUP. BY
APPROVED
BY
DATE
CHECKED
BY
DATE
DRAWN
BY
DATE
SCALE
FIRST MADE FOR
ESAB WELDING & CUTTING PRODUCTS
FLORENCE, SC 29501
UNLESS OTHERWISE
SPECIFIED, DIM ARE
IN INCHES.
TOL .XX
.XXX
ANGLES
CHAMFERS & C'SINKS 2
SURFACE ROUGHNESS IS IN
REMOVE ALL BURRS
BREAK SHARP EDGES
MICROINCHES
M
CHANGE
BY
DATE
CH'KD
THIS DRAWING CONTAINS PROPRIETARY CONFIDENTIAL INFORMATION OF ESAB WELDING &
CUTTING PRODUCTS AND IS LOANED WITH THE EXPRESS AGREEMENT THAT THIS DRAWING
(1) WILL NOT BE REPRODUCED OR COPIED, (2) WILL NOT BE USED OTHER THAN IN WORK
FOR ESAB WELDING & CUTTING PRODUCTS, AND (3) WILL NOT BE DISCLOSED EXCEPT
TO EMPLOYEES OF THE PARTY TO WHOM THIS DRAWING IS LOANED ON A CONFIDENTIAL BASIS.
A-
A-
MATERIAL:
.015
.005
PRO/ENGINEER DWG.
NOV.1994
A
A
19X19
ADAPT B-A/W*F B-A/W*M 90ASSY
19X19
BLP
10/23/08
63
2
1:1
FINISH:
BRIGHT DIP PER SPI 45.315.3 METHOD 6
P/N QTY DESCRIPTION
1. 836Z40 1 NUT HOSE B/A-W* .63-18F RH OLD
2. 03Z59 1 NPL B/SIZE .425ODX 0.81LG
3. 19Z48 1 BODY FOR 90 AIR WATER ADAPTOR
4. 6270869 1 RING SSBAG-1 0.438KDX.03D STD
"E" CN-083187 REVISED & RED BLP
WSS10/23/08
WSS
10/23/08
WSS
10/23/08
1
2
3
4
8
A. Installation of Bubble Muer Assembly on Plasma Torch (Figure 2)
1. Remove the Nozzle Retaining Cup from the torch.
2. Slide the chrome plated Bubble Muer Body on to the stainless steel body of the torch. Split Bushing P/N 21380 should
be in place.
NOTE:
It will ease assembly if all o-rings in the bubble muer body are lightly lubricated with silicone grease.
3. Install Nozzle Retaining Cup P/N 37431 and any front-end parts you may have removed from the torch including the
nozzle, shield, diuser and shield retainer.
4. Install Bubble Muer Sleeve over the completely assembled torch and snap it into the Bubble Muer Body. Secure
the sleeve by installing the Bubble Muer Retainer. The Retainer turns to engage or disengage with the locking pins.
5. Adjust the position of the Bubble Muer Assembly on the torch until the nozzle extends 0.06" from the end of the
bubble muer sleeve as illustrated in Figure 1. Lock the Bubble Muer in place by tightening the Allen screw on the
Bubble Muer.
NOTE:
The Bubble Muer Sleeve must remain completely bottomed in the Muer Body for the adjustment in
Step 5 to be correct.
SECTION 2 INSTALLATION
9
m3
Plumbing
Box
Torch
Bubble Muer
Water
Table
Water
StrainerInlet
Pump
Pump
Power
Control Cable
0.75" ID
Hose
Appropriate Amphenol
Connector On Back
Cutting Machine CNC
Figure 1. Installation of Water Pump
Bubble Muer Pump Input Voltage
50 Hz Operation of ESAB
60 Hz Motors
To On
Use
60 50 Hertz
Hertz Operational Voltage
Motor Ratings +5%
230 V 190 V 200 V 208 V
460/575 V 380 V 400 V 415 V
Multiply
Nameplate .70 .75 .80
HP By
SECTION 2 INSTALLATION
B. Installation of the Water Pump (P/N 2135445)
IF A BUBBLE MUFFLER IS BEING USED, TURN OFF WATER RECIRCU
LATING PUMP.
WARNING
10
Plasma Gas Box
Shield Gas Box
Bubble Muer Hose
Bubble Muer Assembly
37439
Bubble Muer Hose
25 Micron
Filter
Earth
Ground
Work Table
Torch
Lead
Workpiece
Plasma Torch
Note:
For a complete listing of all available
lengths and part numbers for bubble
muer hose assemblies refer to m3
plasma system instruction manual.
See Detail "A"
See Detail "D"
See Detail "C"
See Detail "B"
See Detail D for location of air
pressure regulator / gauge
SECTION 2 INSTALLATION
Compressed Air Supply
(Air Curtain)
Source: 80 psi @ 1200cfh
(5.5 bar @ 34 m
3
h)
Use clean, dry, oil free shop air
11
Plasma Gas Box 0560941491
Detail "A"
Detail "B"
Torch Leads
Bubble Muer
Connection
Note:
For Bubble Muer hose assembly con-
nector details refer to m3 plasma sys-
tem instruction manual.
For torch lead connection details re-
fer to m3 plasma system instruction
manual.
Bubble Muer Connection
(to air curtain assembly)
SECTION 2 INSTALLATION
12
Detail "D"
Detail "C"
Shield Gas Box 0560941536
Bubble Muer Connection
Bubble Muer Connection
(air supply)
Note:
For Bubble Muer hose assembly con-
nector details refer to m3 plasma sys-
tem instruction manual.
Air Pressure Regulator
Remove outer enclosure and
adjust between 18-22 psi
(1.2-1.5 bar)
Air Pressure
Gauge
SECTION 2 INSTALLATION
13
Replacement Parts for Bubble Muer - P/N 37439
SECTION 3 REPLACEMENT PARTS
Figure 2 - Bubble Muer
1
5
6
9
4
8
3
7
2
Torch Body (Ref.)
10
0.06" Ref.
Item Part Number Description
1 21380 BUSHING SPLIT BEVEL A/C
2 37438 BODY A/C
3 37433 RETAINER BUBBLE MUFFLER
4 37431 CUP NOZZLE RETAINING
5 519369 O-RING, 3" ID X 3-3/16" O.D. X 3/32"
6 443315 O-RING, 2.612 ID X .103W NEOPRENE
7 2221978 O-RING, 1.799 ID X .103W SILICONE RUBBER
8 2114581 O-RING, 2.114 ID X .070W NEOPRENE 70A
9 37436 SLEEVE PT-19XLS A/C
10 0558009395 SHIELD RETAINER, INSULATED
11 996528 O-RING, 1.984 ID X .139W NEOPRENE
NOTE: 4 each of the above o-rings are supplied.
14
NOTES
15
REVISION HISTORY
Revision 03/2010 - added 19X19 to optional accessories.
Revision 08/2011 - Updated BOM's, changed p/n 0558004616 to p/n 0558009395 per CCARES 110608095137.
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
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ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
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