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

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

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

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

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.

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.

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

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.

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.“

or portable re extinguisher. Be sure you are trained

in its use.

ample, overloaded welding cable can overheat and

create a re hazard.

to make certain there are no hot sparks or hot metal

which could cause a later re. Use re watchers when

necessary.

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.

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

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.

Welding"

Cutting"

Arc Gouging and Cutting"

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

PT-26 Torch

Specications

Ordering Information

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.

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.

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.

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

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,

(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

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:

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

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

WARNING

NOTE: