ESAB PT-26 Plasma Arc Cutting Torch User manual

PT26

Plasma Arc Cutting Torch

Instruction Manual

F15-345-H 03/2010

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

TABLE OF CONTENTS

1.0 Safety Precautions ..........................................................................................................................................................................5

1.1 Safety - English .....................................................................................................................................................................5

1.2 Safety - Spanish ....................................................................................................................................................................9

1.3 Safety - French ................................................................................................................................................................... 13

2.0 Description ..................................................................................................................................................................................... 17

2.1 Description ......................................................................................................................................................................... 19

3.0 Installation ...................................................................................................................................................................................... 21

3.1 Torch to Power Source Connections .......................................................................................................................... 21

3.2 Retrots to Older Power Sources ................................................................................................................................21

3.3 Gas Selection .....................................................................................................................................................................22

3.4 Gas Connections ...............................................................................................................................................................22

3.5 Assembling Front End Parts .........................................................................................................................................23

3.6 Stand-o Guide .................................................................................................................................................................24

3.7 Loose Comsumables .......................................................................................................................................................24

3.8 installation of Swirl Bae ..............................................................................................................................................24

4.0 Operation ........................................................................................................................................................................................25

4.1 Operation ............................................................................................................................................................................25

4.2 Operating Parameters ....................................................................................................................................................27

4.3 Cut Data ...............................................................................................................................................................................27

5.0 Maintenance .................................................................................................................................................................................. 33

5.1 Disassembly of Front End ..............................................................................................................................................33

5.2 General .................................................................................................................................................................................33

5.3 Dirt or Contamination ....................................................................................................................................................34

5.4 Removal and Replacement of the Torch Head ......................................................................................................34

5.5 Removal and Replacement of Torch Cables ...........................................................................................................35

5.6 Replacement of Flex Support, Switch Board, or Handle ....................................................................................35

5.7 Replacement of Torch Switch ......................................................................................................................................35

5.8 Measuring Torch Gas Flows ..........................................................................................................................................36

6.0 Replacement Parts ....................................................................................................................................................................... 37

6.1 General ................................................................................................................................................................................. 37

6.2 Ordering .............................................................................................................................................................................. 37

Section / Title Page

TABLE OF CONTENTS

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation 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 operat-

ing 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 protec-

tion 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 protec-

tive 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 hid-

den 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

workpiece has been completely cleaned so that there

are no substances on the workpiece 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 ex-

ample, 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 Standard

51B, "Fire Prevention in Use of Cutting and Welding

Processes", available from the National Fire Protec-

tion Association, Batterymarch 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.

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 workpiece to a good electrical

ground.

3. Connect the work cable to the workpiece. 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 workpiece 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.

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"

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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SECTION 2 DESCRIPTION

PT-26 Torch

This versatile, easy-to-use 300 amp torch provides superior performance for a full range of manual and mechanized cutting

applications.

• Excellent cutting capability - cuts up to 3-1/2 in. and severs 4 in.

using air, nitrogen or argon-hydrogen at 300 amps

• Produces clean, high quality cuts

• Operates with shop or cylinder air, nitrogen or argon-hydrogen

at 300 amps

• Compact, lightweight design for ease of handling

• Long life electrodes lower operating costs

• Pilot arc starting - even starts on paint

• Gouging nozzle available

• Intermittent cutting capacity for grate or expanded metal

applications

• Gouging guard and stand-o guide available for operator

convenience

• One-year warranty

Specications

Voltage Class "M" (EN 50078)

Current Capacity (All Service Gases and Pressures)

100% duty cycle ..................................................................................200 A DCSP

60% duty cycle, Manual torches, 100% In-line ........................300 A DCSP

Maximum Rated Current .................................................................300 A DCSP

Approved Service Gases

Plasma ..............................................................0

, Air, N

, H-35, N

Mixtures

Shield .................................................................................................Air, N

, CO

, Ar

Min. Gas Supply Flow Requirements

Shield ................................................ 200 cfh @ 85 psig (94 l/min. @ 6.0 BAR)

Plasma ............................................240 cfh @ 80 psig (112 l/min. @ 5.6 BAR)

Length of Service Lines .................................. 25 ft.or 50 ft. (7.6 m or 15.2 m)

Weight .....................................................................................25 ft. - 16 lbs. (7.3 kg)

50 ft. - 28 lbs. (12.7 kg)

Max. Allowable Inlet Gas Pressure ....................................... 100 psig (6.9 BAR)

Start Gas Pressure .........................................................................30 psig (2.1 BAR)

Minimum Coolant Supply Flow Requirements ..............0.9 gpm @ 95 psig

(3.4 l/min @ 6.6 BAR)

Maximum Coolant Inlet Pressure ........................................ 120 psig (8.3 BAR)

Maximum Coolant Temperature ....................................................105° F (40° C)

Ordering Information

PT-26, 90°, 25 ft. line .........................................................................................36558

PT-26, 90°, 50 ft. line .........................................................................................36559

PT-26, 70°, 25 ft. line ............................................................................ 0558002208

PT-26, 70°, 50 ft. line ............................................................................ 0558002209

PT-26, IN-LINE, 6 ft. ............................................................................... 0558002132

PT-26, IN-LINE, 17 ft.............................................................................. 0558002133

PT-26, IN-LINE, 25 ft.............................................................................. 0558002320

PT-26, IN-LINE, 50 ft.............................................................................. 0558002321

NOTE: IN-LINE torches have 2" barrel diameter and come without

rack or torch holder.

PT-26SL, IN-LINE, 17 ft. ........................................................................ 0558005620

PT-26SL, IN-LINE, 25 ft. ........................................................................ 0558005621

PT-26SL, IN-LINE, 50 ft. ........................................................................ 0558005622

NOTE: IN-LINE “SL” torches have 1 3/8" barrel diameter and come

with a 32 pitch rack.

Optional Accessories

Plasmit Torch Head Protector

For gouging ....................................................................................................... 20806

25 ft. Leather Sheath*

Protects torch leads from abrasion and molten metal; particularly

recommended for plasma gouging .............................................0558002921

50 ft. Leather Sheath* ...................................................................0558002922

Spare Parts Kit 150A .......................................................................0558002864

Torch Holder, 2" ..............................................................................0558002985

Torch Rigging Kit ............................................................................0558003186

*Standard on manual torch.

Spare Parts Kit ............................................................................................... 36821

Compatible Consoles

ESP-150, ESP-200 and DEUCE PACK 150

PT-26

PT-26 IN-LINE

Electrode

36565 - Air, Nitrogen, Nitrogen/Hydrogen

36566 - Argon/Hydrogen (H-35)

Bae Tube - 34585

O-Ring Location - 2029450

Heat Shield

Manual Torch - 34592

*Close Proximity - 37146

Insulator - 34593

Includes O-Ring - 84W87

Electrode Holder - 34583

Includes O-Rings

85W49 (Upper)

948317 (Lower)

Stand-O Guide - 36648

Torch Head -

90° ............................... 34599

70° ....................0558002204

Includes O-Rings:

2110706 (1)

2029450 (3)

O-Ring Location - 2110706

* Close proximity Heat Shield. Optional for Manual

Torch when cutting or gouging in close proxim-

ity of workpiece.

AMPS P/N ORIFICE SIZE

Cutting Nozzle

50 36567 .052

150 36568 .078

200 36569 .089

300 36570 .104

Gouging Nozzle

200 36571 .125

300 36572 .144

All include O-Rings 2110578 (Upper)

994092 (Lower)

SECTION 2 DESCRIPTION

Figure 2.1 Assembly of PT-26 Front End Parts

PT-26 Manual Models

PT-26 In-Line Models

Electrode

36565 - Air, Nitrogen, Nitrogen/Hydrogen

36566 - Argon/Hydrogen (H-35)

Bae Tube - 34585

**Swirl Bae, In-line - 0558003583

Includes O-Ring - 2110578 & 14K07

Electrode Holder - 34583

Includes O-Rings

85W49 (Upper)

948317 (Lower)

Torch Head -

IN-LINE.......0558002110

Includes O-Rings:

2110706 (1)

2029450 (3)

O-Ring Location - 2029450

O-Ring Location - 2110706

**These items along with a bae installa-

tion tool (0558003584) are shipped with

all mechanized versions of this torch.

Heat Shield -

Manual Torch - 34592

Shield Cup, Mechanized - 0558003582

AMPS P/N ORIFICE SIZE

Cutting Nozzle

50 36567 .052

150 36568 .078

200 36569 .089

300 36570 .104

Gouging Nozzle

200 36571 .125

300 36572 .144

All include O-Rings 2110578 (Upper)

994092 (Lower)

SECTION 2 DESCRIPTION

2.1 Description

The PT-26 is a dual gas, water cooled, torch with a 70° or 90° head for manual cutting and gouging and an in-line head for

mechanized cutting and gouging. Each of which is designed for use with certain plasma arc cutting packages. These pack-

ages include the ESP-150, ESP-200 and properly equipped Deuce Pack 150 Systems.

Figure 2.2 PT-26 Dimensions

WARNING

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 OF THE PT26 TORCH, REFER TO THE SAFETY PRECAUTIONS

AND OPERATING INSTRUCTIONS PACKED WITH YOUR POWER SOURCE

PACKAGE.

USING THE TORCH ON ANY UNIT NOT EQUIPPED WITH A MATING

SAFETY INTERLOCK CIRCUIT WILL EXPOSE OPERATOR TO UNEXPECT

ED HIGH VOLTAGE.

4.01”

(102 mm)

13.11”

(333 mm)

1.60”

(41 mm)

1.66”

(42 mm)

1.50”

(38 mm)

SECTION 2 DESCRIPTION

Figure 2.3 PT-26 In-line Torch Dimensions

2.00”

(50.8mm)

16.50”

(419.1mm)

Figure 2.4 PT-26 “SL” In-line Torch Dimensions

1.38”

(35.1 mm)

8”

(203.2 mm)

11.25”

(285.8 mm)

2.00”

(50.8 mm)

3.1 Torch to Power Source Connections

Consult your power source instruction literature to learn how to access the torch connections.

The order in which the torch connections can be made will vary with the power source used. Study your power

source to determine the order which will best allow you to make the connections correctly with a wrench.

The PT-26 torch uses a “C” sized left hand thread tting for the negative terminal and coolant connection. Con-

nect this tting to the corresponding female tting on the power source and tighten it rmly with a wrench.

After tightening the tting, slide the rubber boot (49N83) on the power cable over the connection. The “B” sized

right hand tting is used to make the positive terminal and coolant connection. Tighten it rmly as well.

The plasma gas and shield gas connections are made with two “B” sized ttings, each with a dierent thread.

Tighten them rmly with a wrench at the corresponding power source panel tting.

The torch switch connection is made with the 5-pin plug on the torch switch lead. Insert the plug into the socket

on the power source and twist the locking ring to secure it in place.

3.2 Retrots to Older Power Sources

The PT-26 torch may be retrotted to older Deuce Pack 150 power sources. This requires installation of a new

plumbing box. The kit for this is P/N 000759.

SECTION 3 INSTALLATION

WARNING

MAKE SURE POWER SWITCH ON CONSOLE IS IN THE OFF POSITION

AND PRIMARY INPUT POWER IS DEENERGIZED.

THE PT26 IS DESIGNED TO FORM A SAFE SYSTEM WITH CERTAIN

POWER SOURCES WHICH HAVE MEANS FOR DETECTING A LOSS OF

COOLANT FLOW RETURNING FROM THE TORCH AND WHICH WILL

NOT ENERGIZE THE TORCH WHEN SUCH A LOSS OF COOLANT IS DE

TECTED. THE REMOVAL OR LOOSENING OF THE TORCH HEAT SHIELD

WILL CAUSE SUCH A COOLANT LOSS. DO NOT USE THE PT26 ON

POWER SOURCES WHICH ARE NOT EQUIPPED WITH SUCH A SYS

TEM.

WARNING

3.3 Gas Selection

The PT-26 is a dual gas torch, allowing for one gas to be used for plasma gas and another to be used for shielding

the cut zone. Recommended combinations of gases are listed below.

Air Plasma/Air Shield

Best overall combination for cut quality, cut speed and economy on mild steel, stainless steel and aluminum.

This combination causes some surface nitrating at cut face and some surface oxidation of alloying elements on

stainless steels. Always use clean, dry air. Moisture or oil in the air supply will reduce torch parts life.

Nitrogen Plasma/Air Shield

This combination provides improved parts life, especially for the electrode. Cut speeds will usually be slightly

slower than with air plasma. It creates surface nitriding but provides cleaner cut face on stainless steels. Nitrogen

or CO

may be substituted for cooling.

H-35 Plasma/Nitrogen Shield

This combination gives excellent parts life with minimum amount of cut surface contamination, providing ex-

cellent weldability. It is most often used for gouging on mild steel, aluminum, and stainless steel. It gives poor

cut quality on mild steel, good cut quality on aluminum and stainless, particularly on thicker sizes.

40% Hydrogen - 60% Nitrogen Plasma/Air Shield

On aluminum only, gives increased speed and thickness capability. Poor performance on stainless and mild

steel.

Oxygen Plasma/Air Shield

Best quality for mechanized cutting of mild steel 1” thick or thinner with 150 to 300 amps. Highest metal removal

rate for gouging on mild steel.

3.4 Gas Connections

Refer to Section 1.2 for the list of approved service gases. Do not use gases which are not expressly approved for

the PT-26 torch.

After the gases for the job have been selected, connect the gas supply hoses to the ttings at the back of the

power source. Note that there may be two ttings for each gas. Use the tting which matches your hose. Make

sure that the ttings not used are plugged with the plug attached to the power source.

Note that the ESP-150 & ESP-200 power source has a gas connection labeled “Start Gas”. This allows a dier-

ent plasma gas type and pressure setting to be used for the plasma gas at the start of the cut. This is done to

increase electrode life during some types of mechanized plasma cutting. The start gas most typically used in

manual cutting is either the same gas as that used for the cutting/gouging plasma or nitrogen.

IMPORTANT! A gas supply MUST be supplied to the “Start Gas” connection at all times. If this is not

done, the torch will be damaged. The start gas may be any of the approved Plasma gases listed in section

above.

SECTION 3 INSTALLATION

USE ONLY THOSE GASES LISTED AS APPROVED IN THIS DOCUMENT.

WARNING

SECTION 3 INSTALLATION

3.5 Assembling Front End Parts

Be sure:

• All O-Rings are in place (torch head, nozzle, electrode holder)

• Electrode holder is tight

• Bae tube is installed and tight

• Electrode is installed and tight

• Nozzle is installed

Refer to gure 2.1 for the assembly of the front end parts into the torch head.

First, inspect the torch body to ensure that no debris or o-rings are left inside. Remove any found.

Inspect the electrode holder (34583) to make sure that both O-rings are in place. Thread the electrode holder

into the torch head and tighten it rmly using a 3/16" (.187) hex allen wrench. The holder must be tight, but avoid

overtightening to the point of rounding-o the hex inside the holder.

Insert the bae tube (34585) into the electrode holder and thread it into the torch head using the plastic hex

allen wrench tool ( 19129 ). Take care not to overtighten the tube but make sure that it is secured.

Insert the insulator (34593) into the torch head. Make sure the O-ring is in place on the insulator so that the insu-

lator will hold its place in the head. Do not push the insulator too far back. When installed, the nozzle will push

it to the correct position.

Thread the electrode (36565 or 36566) onto the thread of the electrode holder and tighten it in place with the

hex socket end of the plastic tool (19129).

Press the nozzle (36568 - 72) into the front of the torch head. This will probably push the insulator further into

the head. This is normal. Make sure that both O-rings are in place and that the nozzle seats against the torch

head.

WARNING

MAKE SURE POWER SWITCH ON POWER SOURCE IS IN THE OFF PO

SITION AND PRIMARY INPUT POWER IS DEENERGIZED. FAILURE TO

INSTALL FRONT END PARTS PROPERLY CAN EXPOSE YOU TO HIGH

VOLTAGE OR FIRE.

FOLLOW ALL INSTRUCTIONS IN THE APPROPRIATE BOOKLET

PACKED WITH YOUR POWER SOURCE PACKAGE. DO NOT INSTALL

OR ATTEMPT TO OPERATE THIS TORCH WITHOUT FOLLOWING

THESE INSTRUCTIONS. THE TORCH FRONT END DESIGN CONTAINS

COMPONENTS WHICH, WORKING TOGETHER WITH POWER SOURCE

CIRCUITRY, PREVENT THE TORCH FROM BEING ACCIDENTLY EN

ERGIZED WHEN THE HEAT SHIELD IS REMOVED AND THE TORCH

SWITCH IS CLOSED.

WARNING

SECTION 3 INSTALLATION

3.6 Stand-o Guide

The stand-o guide (36648) provides the operator with the ability to hold a consistent stand-o by keeping the

guide’s feed in contact with the work.

Install the guide by sliding it onto the heat shield (heat shield should be in place on torch) with a clockwise

twisting motion. Always install or adjust the guide on the shield with a clockwise twisting motion to prevent

loosening of the shield.

If the t of the stand-o guide is too tight on the shield, open the slot in the shield by twisting with a large at

blade screw driver. If the t is too loose, close the slot by squeezing the guide in a bench wise.

3.7 Loose Consumables

Proper performance of the torch will rely on proper and secure installation of the front end consumable parts,

particularly the electrode holder, bae tube, electrode, and heat shield as well as the associated o-rings.

1. Make sure that the electrode holder is fully threaded into the torch head and securely tightened using a 3/16"

hex allen wrench. Use a metal allen wrench. The plastic wrench is not strong enough for this. Also make sure

that the bae tube is fully installed into the torch and seated against the electrode holder, use the plastic

allen wrench (19129) for this.

2. Fully tighten the electrode onto the electrode holder using the hex socket end of the plastic wrench

(19129).

3. Make sure that the nozzle is secured and its o-rings sealed by fully tightening the heat shield. “Fully” means

as tightly as possible using the hands alone, do not use wrenches.

Improperly installed front end parts will cause coolant leaks which may cause poor cutting or gouging perfor-

mance and may cause damage to the torch itself from internal arcing.

3.8 Installation of Swirl Bae

To install the swirl bae use the swirl bae installation tool, p/n 0558003584. This tool allows the o-ring on the

inside of the swirl bae to easily go onto the O.D. of the electrode holder. Installing swirl bae hand-tight will

be sucient.

Thread the heat shield (34592) onto the torch head to retain the nozzle. The heat shield should be tightened as

tight as possible by hand to prevent coolant leaks from the nozzle O-ring seal.

If the optional stand-o guide (36648) is to be used, install it onto the heat shield by pushing or twisting in a

CLOCKWISE direction until it is fully seated on the shield.

IMPORTANT - Do not twist the stand-o guide in the counter-clockwise direction as this will loosen the heat

shield.

4.1 Operation

The torch is now ready for cutting or gouging operation. Refer to the instructions for your power source for mak-

ing any control adjustments.

1. Turn the gas test or gas mode switch to the test or set-up position.

NOTE:

The “CUT” position is to set the cutting plasma gas. The “START/SHIELD” position is to set the starting plasma gas and the

shield gas. If the starting plasma gas and the cutting plasma gas are to be the same and supplied by the same regulator,

use the START/SHIELD position only, the CUT position is not needed.

2. Turn the power switch to the ON position. Gas should now ow at the torch.

3. Adjust the gas pressure settings at the gas supply regulators to the values given in the operating parameters

section. Turn the gas test or gas mode switch to the operating position. Gas Flow should now stop. Adjust

the current control to the correct setting for the nozzle.

4. Bring the torch into the proper position for cutting or gouging. For cutting, the torch stand-o (nozzle-to-

work distance) should be approximately 1/4". If possible, start the cut from an edge on the workpiece. If

piercing must be done, tilt the torch at an angle to deect the molten metal away from the torch and op-

erator until the pierce is complete, then bring the torch back to the vertical and begin the cut. For gouging,

place the torch over the work at an angle of 35° to 45° from the horizontal.

5. Lower your protective helmet.

6. Push down and hold the torch switch button. The gas should start owing. Two seconds later, the main

contactor should close and the arc should transfer to the workpiece.

CAUTION

WARNING

Wear the usual protective gloves, clothing, ear protection and hel-

met. Read Safety Precautions covered in the instruction manual

packed with your power source.

NEVER TOUCH ANY PARTS FORWARD OF THE TORCH HANDLE NOZ

ZLE, HEAT SHIELD, ELECTRODE, ETC. UNLESS THE POWER SWITCH

ON THE POWER SOURCE IS IN THE OFF POSITION.

SECTION 4 OPERATION

NOTE:

Your power source may allow the preow time to be extended longer than two seconds, usually up to four or ve seconds.

If, at the end of the preow time, the pilot arc does not ignite, release the torch switch and check the gas pressure settings.

If the pilot arc does ignite but does not transfer to the work, release the torch switch and check to see that the torch is in

the proper distance from the work and that the work clamp is rmly connected to the work piece.

7. When cutting, maintain the torch stand-o at a distance of between 3/16" and 1/2". When cutting thinner

plates, the stand-o should be closer to the lower end of the range and it should be closer to the upper end

of the range for thicker plates. Maintain a cutting speed which gives a cut of the desired quality and pro-

duces a stream of molten metal emitting from the bottom of the workpiece.

8. When gouging, maintain an angle and speed which causes the desired amount of metal to be removed on

each pass. Maintain the torch angle so that all the molten metal is blown directly away from the torch, along

the top surface of the plate or down the groove of the previous pass. Gouging at too steep an angle will

cause molten metal to y directly back at the torch.

9. If the main arc is lost during the cut (or gouge), the pilot arc will immediately reignite as long as the torch

switch is depressed. At this time the torch should quickly be repositioned at the workpiece to re-establish

the main arc or else the torch switch should be released.

10. The main arc will automatically extinguish at the end of the cut as the torch is moved away from the work-

piece. The torch switch should be released immediately to keep the pilot arc from reigniting.

11. When cutting (or gouging) operations are completed, wait a few minutes before placing the power switch

on the power source in the OFF position to allow the fan to remove heat from the unit. After this time, shut

o the primary power at the main disconnect switch.

SECTION 4 OPERATION

To ensure optimum cutting performance and aid in troubleshooting any cut quality problems, please refer to

the following cutting parameters charts.

4.3 Cut Data

PT-26 in-line torch cutting conditions:

Data taken with Swirl Bae (0558003583) and Shield Cup (0558003582).

65 Amp data uses standard Heat Shield (34592) or Close Proximity Heat Shield (37146) in place of Shield Cup

(0558003582) and uses a 50 Amp Nozzle (36567).

Material

Thickness

inch (mm)

Stando

inch (mm)

Speed

ipm (mm/m)

Start Gas and

Pressure

psig (bar)

Cut Gas and

Pressure

psig (bar)

Shield

Gas and Pressure

for ESP-150 and 200

psig (bar)

Carbon

Steel

0.12 (3.2)

0.19 (4.8)

190 (4826)

Air

30 (2.1)

Air

60 (4.1)

Air

50 (3.4)

0.25 (6.4) 100 (2540)

0.50 (12.7) 0.25 (6.4) 30 (762)

Aluminum

0.12 (3.2)

0.19 (4.8)

50* (1270)

0.25 (6.4) 70 (1778)

0.50 (12.7) 0.25 (6.4) 20 (508)

Stainless

Steel

0.12 (3.2)

0.19 (4.8)

75 (1905)

0.25 (6.4) 50 (1270)

0.50 (12.7) 0.25 (6.4) 20 (508)

SECTION 4 OPERATION

Table 4.1 65 Amp Cut Data

4.2 Operating Parameters

Recommended Gas Pressures -

Start ............................................ 30 psig

Plasma (Cutting) .................... 50 - 70 psig

Plasma (Gouging) .................. 40 - 45 psig

Shield .......................................... 40 - 50 psig

Recommended Stand-o -

5/16" - 1/2"

Travel Speeds -

Travel speeds for the PT-26 are given in Tables 4-1 through 4-4.

Material

Thickness

inch (mm)

Stando

inch (mm)

Speed

ipm

(mm/m)

Start Gas and

Pressure

psig (bar)

Cut Gas and

Pressure

psig (bar)

Shield

Gas and Pressure for

ESP-150 and 200

psig (bar)

Carbon

Steel

0.19 (4.8)

150 (3810)

Air / N

30 (2.1)

60 (4.1)

Air

60 (4.1)

0.25 (6.4) 130 (3302)

0.38 (9.7) 80 (2032)

0.50 (12.7) 70 (1778)

0.62 (15.7)

0.25 (6.4)

50 (1270)

0.75 (19.1) 35 (889)

1.00 (25.4) 20 (508)

0.19 (4.8) 0.19 (4.8) 150 (3810)

Air

30 (2.1)

Air

60 (4.1)

0.25 (6.4)

130 (3302)

0.38 (9.7) 80 (2032)

0.50 (12.7) 70 (1778)

0.62 (15.7) 50 (1270)

0.75 (19.1) 35 (889)

1.00 (25.4) 20 (508)

Aluminum

0.19 (4.8) 0.19 (4.8) 175 (4445)

0.25 (6.4)

130 (3302)

0.38 (9.7) 90 (2286)

0.50 (12.7)

0.31 (7.9)

70 (1778)

0.62 (15.7) 50 (1270)

0.75 (19.1) 35 (889)

1.00 (25.4) 25 (635)

Stainless

Steel

0.19 (4.8) 0.19 (4.8) 165 (4191)

0.25 (6.4)

125 (3175)

0.38 (9.7) 80 (2032)

0.50 (12.7) 0.31 (7.9) 50 (1270)

0.62 (15.7)

0.38 (9.7)

35 (889)

0.75 (19.1) 20 (508)

1.00 (25.4) 10 (254)

SECTION 4 OPERATION

Table 4.2 150 Amp Cut Data

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ESAB PT-26 Plasma Arc Cutting Torch User manual

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