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  5. PT-15XL Plasmarc Water Injection Cutting Torch

ESAB PT-15XL Plasmarc Water Injection Cutting Torch Installation guide

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F-15-031
July 2002
Installation, Operation, and Maintenance for the
PT-15XL PLASMARC
Water Injection Cutting Torch
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.
Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.
ESAB Cutting Systems first priority
ESAB Cutting Systems first priorityESAB Cutting Systems first priority
ESAB Cutting Systems first priority is total customer
is total customer is total customer
is total customer
satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to
satisfaction. We constantly look for ways to
improve our products, service and documentation.
improve our products, service and documentation. improve our products, service and documentation.
improve our products, service and documentation.
As a result, we make e
As a result, we make eAs a result, we make e
As a result, we make en
nn
nhancements and/or design
hancements and/or design hancements and/or design
hancements and/or design
changes as r
changes as rchanges as r
changes as re
ee
equired. ESAB makes every possible
quired. ESAB makes every possible quired. ESAB makes every possible
quired. ESAB makes every possible
effort to ensure our documentation is current
effort to ensure our documentation is currenteffort to ensure our documentation is current
effort to ensure our documentation is current. We
. We . We
. We
cannot guarantee that each piece of docume
cannot guarantee that each piece of documecannot guarantee that each piece of docume
cannot guarantee that each piece of documen
nn
ntation
tation tation
tation
received by our customers reflects the latest design
received by our customers reflects the latest design received by our customers reflects the latest design
received by our customers reflects the latest design
enhancements. Therefore, the information
enhancements. Therefore, the information enhancements. Therefore, the information
enhancements. Therefore, the information
contained in this document is subject to change
contained in this document is subject to change contained in this document is subject to change
contained in this document is subject to change
without n
without nwithout n
without no
oo
otice.
tice.tice.
tice.
This manual is ESAB Part Number F15031
This manual is ESAB Part Number F15031This manual is ESAB Part Number F15031
This manual is ESAB Part Number F15031
Rev. D - Re-written and expanded Sept., 2001
July 02 corrected P/N in Sec. 7
This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.
©
©©
© ESAB Cutting Systems, 2000
Printed in U.S.A.
PT-15XL Plasma Cutting Torch Table of Contents
i
Page
Section 1 Safety
1.1 Introduction......................................................................................... 1
1.2 Safety Notations And Symbols............................................................. 1
1.3 General Safety Information................................................................... 2
1.4 Electrical Grounding ............................................................................ 3
1.5 Operating A Plasma Cutting Machine................................................... 4
1.6 Service Precautions............................................................................. 9
1.7 Safety References ............................................................................... 10
Section 2 Description
2.1 General............................................................................................... 1
2.2 Scope................................................................................................. 1
2.3 Package Options Available .................................................................. 1
2.4 Technical Specifications
2.4.1 Plasma Gas.................................................................................. 2
2.4.2 Start Gas...................................................................................... 2
2.4.3 Cutwater ...................................................................................... 2
2.4.4 PT-15 Torch................................................................................. 2
2.5 Physical Dimensions............................................................................ 3
Section 3 Installation
3.1 General............................................................................................... 1
3.2 Connection of Hose and Cable Bundle to Torch Body.......................... 1
3.3 Disassembly of Torch Bundle from Torch Body.................................... 4
3.4 Torch Mounting “Precaution”............................................................... 5
PT-15XL Plasma Cutting Torch Table of Contents
ii
Page
Section 4 Operation
Safety Precautions..................................................................................
1,2,3
4.1 Set Up................................................................................................ 3
4.1.1 Mirror Cutting Requirements......................................................... 4
4.1.1.1 Cut Water Swirl Rings.......................................................... 4
4.1.1.2 Gas Swirl Baffles ................................................................. 5
4.1.1.3 Nozzles............................................................................... 6
4.1.2 PT-15XL Front-end Consumables ............................................... 7
4.1.3 Nozzle Retaining Cups ................................................................ 8,9
4.1.4 Underwater Cutting..................................................................... 10
4.1.5 Bevel Cutting .............................................................................. 11
4.1.5.1 Bevel Front-end Oxygen Consumables 260A to 300A......... 12
4.2 Fume and Noise Reduction................................................................. 13
4.2.1 Fume and Noise Reduction Aids.................................................. 13
4.3 Cut Quality
4.3.1 Introduction ................................................................................ 14
4.3.2 Cut Angle.................................................................................... 15
4.3.3 Cut Flatness................................................................................ 16
4.3.4 Surface Finish ............................................................................. 17
4.3.5 Dross.......................................................................................... 18,19
4.3.6 Dimensional Accuracy................................................................. 20
4.4 Torch Flow Passages.......................................................................... 21
4.5 Influence of Gas Options on Cut Quality
4.5.1 Introduction ................................................................................ 22
4.5.2 Aluminum.................................................................................... 23
Aluminum and H-35 ............................................................ 24
4.5.3 Carbon Steel............................................................................... 25
4.5.4 Stainless Steel............................................................................. 26
Stainless Steel and H-35 ..................................................... 27
4.6 Process Data
4.6.1 Introduction ................................................................................ 28,29
4.6.2 Process Data Settings
Aluminum............................................................................ 30
Carbon Steel....................................................................... 42
Stainless Steel..................................................................... 58
600 Ampere Bevel Cutting, Aluminum and Stainless Steel 68,69,70,71
PT-15XL Plasma Cutting Torch Table of Contents
iii
Section 5 Maintenance
5.1 Introduction......................................................................................... 1
5.2 Torch Body Maintenance..................................................................... 1
5.2.1 O-Ring Part Numbers and Inspection Schedule............................ 1
5.2.2 Contact Ring............................................................................... 2
5.3 Torch Front End Disassembly .............................................................. 2
5.3.1 Nozzle Retaining Cup and Nozzle................................................. 2,3,4
5.3.2 Replacing Electrode..................................................................... 4,5,6
5.3.3 Replacing Electrode Holder.......................................................... 7
5.3.4 Replacing Gas Swirl Baffle ........................................................... 7
5.3.5 Replacing Insulator Body ............................................................. 8
5.4 Reassembly of Torch Front End........................................................... 9
5.5 Two Piece Nozzle Maintenance
5.5.1 Nitrogen and Argon/Hydrogen Nozzles ........................................ 10
5.5.2 Oxygen Nozzle Repair ................................................................. 11
5.6 Replacing Cables and Hoses............................................................... 12,13,14
5.7 Reassembly Torch to Hoses/Cable Bundle .......................................... 15 through 20
Section 6 Troubleshooting
6.1 Reduced Consumable Life................................................................... 1
6.2 No Pilot Arc......................................................................................... 2
6.3 No Arc Transfer................................................................................... 2
6.4 No Preflow Plasma.............................................................................. 2
6.5 No Cutwater........................................................................................ 2
6.6 Torch Fails To Fire................................................................................ 3
6.7 No High Frequency in Torch ................................................................ 3
Section 7 Replacement Parts
7.1 General............................................................................................... 1
7.2 Ordering.............................................................................................. 1
7.3 PT-15XL Torch Body Parts.................................................................. 2,3
7.4 PT-15XL Front-end Consumables – Beveling ........................................ 4,5
7.5 PT-15XL Front-end Consumables – Standard....................................... 6,7
7.6 Nozzle Repair Parts............................................................................. 8,9
7.7 HighFlo Front-end parts....................................................................... 10,11
7.8 Hoses and Cables, Part 1.................................................................... 12,13
Hoses and Cables, Part 2.................................................................... 14,15
7.9 Complete Assemblies and Tools.......................................................... 16,17
7.10 Torch Spare Part Kits ......................................................................... 18,19
Customer/Technical Information Back Manual Cover
PT-15XL Plasma Cutting Torch Table of Contents
iv
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SECTION 1 SAFETY
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1-1
DANGER
!
WARNING
!
CAUTION
!
CAUTION
NOTICE
1.1 Introduction
The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool. ESAB
cutting machines are designed to provide both operation
safety and efficiency. However, as with any machine tool,
sensible attention to operating procedures, precautions, and
safe practices is necessary to achieve a full measure of
usefulness. Whether an individual is involved with operation,
servicing, or as an observer, compliance with established
precautions and safe practices must be accomplished.
Failure to observe certain precautions could result in serious
personnel injury or severe equipment damage. The
following precautions are general guidelines applicable when
working with cutting machines. More explicit precautions
pertaining to the basic machine and accessories are found
in the instruction literature. For a wide scope of safety
information on the field of cutting and welding apparatus,
obtain and read the publications listed in the Recommended
References.
1.2 Safety Notations And Symbols
The following words and symbols are used throughout this
manual. They indicate different levels of required safety
involvement.
!
ALERT or ATTENTION. Your safety is involved
or potential equipment failure exists. Used in
concurrence with other symbols and information.
Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.
Used to call attention to potential hazards that
could result in personal injury or loss of life.
Used to call attention to hazards that could result
in minor personal injury or equipment damage.
Used to call attention to minor hazards to
equipment.
Used to call attention to important installation,
operation or maintenance information not
directly related to safety hazards.
SECTION 1 SAFETY
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1-2
1.3 General Safety Information
WARNING
!
Cutting Machine starts automatically.
This torch may be mounted on a mechanized
This torch may be mounted on a mechanized This torch may be mounted on a mechanized
This torch may be mounted on a mechanized
cutting machine. This equipment moves in various
cutting machine. This equipment moves in various cutting machine. This equipment moves in various
cutting machine. This equipment moves in various
directions and speeds and may start automatically.
directions and speeds and may start automatically.directions and speeds and may start automatically.
directions and speeds and may start automatically.
• Moving machinery can crush.
Moving machinery can crush.Moving machinery can crush.
Moving machinery can crush.
• Only qualified pers
Only qualified persOnly qualified pers
Only qualified personnel should operate or
onnel should operate or onnel should operate or
onnel should operate or
service equipment.
service equipment.service equipment.
service equipment.
• Keep all personnel, materials, and equipment
Keep all personnel, materials, and equipment Keep all personnel, materials, and equipment
Keep all personnel, materials, and equipment
not involved in production process clear of
not involved in production process clear of not involved in production process clear of
not involved in production process clear of
entire system area.
entire system area.entire system area.
entire system area.
• Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or
obstructions, such as tools or clothing.
obstructions, such as tools or clothing.obstructions, such as tools or clothing.
obstructions, such as tools or clothing.
• Fence off entire w
Fence off entire wFence off entire w
Fence off entire work cell to prevent personnel
ork cell to prevent personnel ork cell to prevent personnel
ork cell to prevent personnel
from passing through area or standing in the
from passing through area or standing in the from passing through area or standing in the
from passing through area or standing in the
working envelope of the equipment.
working envelope of the equipment. working envelope of the equipment.
working envelope of the equipment.
• Post appropriate WARNING signs at every work
Post appropriate WARNING signs at every work Post appropriate WARNING signs at every work
Post appropriate WARNING signs at every work
cell entrance.
cell entrance. cell entrance.
cell entrance.
• Follow lockout procedure before servicing.
Follow lockout procedure before servicing.Follow lockout procedure before servicing.
Follow lockout procedure before servicing.
WARNING
!
Failure to follow operating instructions
could result in death or serious injury.
Read and understand this operator’s manual before
Read and understand this operator’s manual before Read and understand this operator’s manual before
Read and understand this operator’s manual before
using machine.
using machine.using machine.
using machine.
• Read entire procedure before operating or
Read entire procedure before operating or Read entire procedure before operating or
Read entire procedure before operating or
performing any system maintenance.
performing any system maintenance. performing any system maintenance.
performing any system maintenance.
• Special attention must b
Special attention must bSpecial attention must b
Special attention must be given to all hazard
e given to all hazard e given to all hazard
e given to all hazard
warnings that provide essential information
warnings that provide essential information warnings that provide essential information
warnings that provide essential information
regarding personnel safety and/or possible
regarding personnel safety and/or possible regarding personnel safety and/or possible
regarding personnel safety and/or possible
equipment damage.
equipment damage.equipment damage.
equipment damage.
• All safety precautions relevant to electrical
All safety precautions relevant to electrical All safety precautions relevant to electrical
All safety precautions relevant to electrical
equipment and process operations must be
equipment and process operations must be equipment and process operations must be
equipment and process operations must be
strictly observed by all having system
strictly observed by all having system strictly observed by all having system
strictly observed by all having system
res
resres
responsibility or access.
ponsibility or access. ponsibility or access.
ponsibility or access.
• Read all safety publications made available by
Read all safety publications made available by Read all safety publications made available by
Read all safety publications made available by
your company.
your company.your company.
your company.
SECTION 1 SAFETY
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1-3
WARNING
!
Failure to follow safety warning label
instructions could result in death or
serious injury.
Read and understand all safety
Read and understand all safetyRead and understand all safety
Read and understand all safety warning labels on
warning labels on warning labels on
warning labels on
machine.
machine.machine.
machine.
Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety
information.
information.information.
information.
1.4 Electrical Grounding
Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to your power source
manual’s Installation section for detailed grounding
instructions.
WARNING
!
Electric shock hazard.
Improper grounding can cause sever
Improper grounding can cause severImproper grounding can cause sever
Improper grounding can cause severe injury or death.
e injury or death.e injury or death.
e injury or death.
Machine must be properly grounded before put into
Machine must be properly grounded before put into Machine must be properly grounded before put into
Machine must be properly grounded before put into
service.
service.service.
service.
WARNING
!
Improper grounding can damage machine
and electrical components.
• Machine must be properly grounded before put
Machine must be properly grounded before put Machine must be properly grounded before put
Machine must be properly grounded before put
into service.
into service. into service.
into service.
• Cutting table must be properly grounded to
Cutting table must be properly grounded toCutting table must be properly grounded to
Cutting table must be properly grounded to a good
a good a good
a good
earth ground rod.
earth ground rod.earth ground rod.
earth ground rod.
SECTION 1 SAFETY
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1-4
1.5 Operating A Plasma Cutting Machine
WARNING
!
Flying debris and loud noise hazards.
• Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying debris
goggles to protect eyes from burns and flying debris goggles to protect eyes from burns and flying debris
goggles to protect eyes from burns and flying debris
ge
gege
generated during operation.
nerated during operation.nerated during operation.
nerated during operation.
• Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.
should also wear goggles and safety glasses.should also wear goggles and safety glasses.
should also wear goggles and safety glasses.
• From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear
correct ear protection when cutting above water.
correct ear protection when cutting above water. correct ear protection when cutting above water.
correct ear protection when cutting above water.
WARNING
!
Burn hazard.
Hot metal can burn.
Hot metal can burn.Hot metal can burn.
Hot metal can burn.
• Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after
cutting. Allow metal time to cool, or douse with water.
cutting. Allow metal time to cool, or douse with water.cutting. Allow metal time to cool, or douse with water.
cutting. Allow metal time to cool, or douse with water.
• D
DD
Do not touch plasma torch immediately after
o not touch plasma torch immediately after o not touch plasma torch immediately after
o not touch plasma torch immediately after
cutting. Allow torch time to cool.
cutting. Allow torch time to cool.cutting. Allow torch time to cool.
cutting. Allow torch time to cool.
WARNING
!
Hazardous voltages. Electric shock
can kill.
• Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.
connections during plasma cutting process.connections during plasma cutting process.
connections during plasma cutting process.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before touching or servicing plasma torch.
before touching or servicing plasma torch. before touching or servicing plasma torch.
before touching or servicing plasma torch.
• Always turn power off to plasma power supplies
Always turn power off to plasma power supplies Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
before opening or servicing plasma plumbing or flow
before opening or servicing plasma plumbing or flow before opening or servicing plasma plumbing or flow
before opening or servicing plasma plumbing or flow
control box.
control box.control box.
control box.
• Do not touch live electrical parts.
Do not touch live electrical parts.Do not touch live electrical parts.
Do not touch live electrical parts.
• Keep all panels and covers in place when machine
Keep all panels and covers in place when machine Keep all panels and covers in place when machine
Keep all panels and covers in place when machine
is connected to power source.
is connected to power source.is connected to power source.
is connected to power source.
• Insulate yourself from workpiece and electrical
Insulate yourself from workpiece and electrical Insulate yourself from workpiece and electrical
Insulate yourself from workpiece and electrical
ground: wear insulating glov
ground: wear insulating glovground: wear insulating glov
ground: wear insulating gloves, shoes and clothing.
es, shoes and clothing.es, shoes and clothing.
es, shoes and clothing.
• Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and
equipment dry.
equipment dry.equipment dry.
equipment dry.
SECTION 1 SAFETY
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1-5
WARNING
!
Pinch hazard.
Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.
WARNING
!
Fume hazard.
Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting
process can be hazardous to your health.
process can be hazardous to your health.process can be hazardous to your health.
process can be hazardous to your health.
• Do NOT breathe fumes.
Do NOT breathe fumes.Do NOT breathe fumes.
Do NOT breathe fumes.
• Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal
system operating properly.
system operating properly. system operating properly.
system operating properly.
• Use additional ventilation to remove fumes if
Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if
Use additional ventilation to remove fumes if
necess
necessnecess
necessary.
ary.ary.
ary.
• Use approved respirator if ventilation is not
Use approved respirator if ventilation is not Use approved respirator if ventilation is not
Use approved respirator if ventilation is not
adequate.
adequate.adequate.
adequate.
WARNING
!
Hot Torch Could Burn Skin
Torch is “wet” with cooling water and water
Torch is “wet” with cooling water and water Torch is “wet” with cooling water and water
Torch is “wet” with cooling water and water
injection but may still get hot during high ampere
injection but may still get hot during high ampere injection but may still get hot during high ampere
injection but may still get hot during high ampere
cutting.
cutting.cutting.
cutting.
Allow torch to cool before servicing.
Allow torch to cool before servicing.Allow torch to cool before servicing.
Allow torch to cool before servicing.
Never touch torch u
Never touch torch uNever touch torch u
Never touch torch unless plasma power supply
nless plasma power supply nless plasma power supply
nless plasma power supply
has been turned off.
has been turned off.has been turned off.
has been turned off.
SECTION 1 SAFETY
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1-6
WARNING
!
WARNING
!
Radiation hazard.
Arc rays can injure eyes and burn
Arc rays can injure eyes and burnArc rays can injure eyes and burn
Arc rays can injure eyes and burn skin.
skin. skin.
skin.
• Wear correct eye and body protection.
Wear correct eye and body protection.Wear correct eye and body protection.
Wear correct eye and body protection.
• Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with side
shields. Refer to following chart for recommended
shields. Refer to following chart for recommended shields. Refer to following chart for recommended
shields. Refer to following chart for recommended
lens shades for plasma cutting:
lens shades for plasma cutting:lens shades for plasma cutting:
lens shades for plasma cutting:
Arc Current
Arc CurrentArc Current
Arc Current
Lens Shade
Lens Shade Lens Shade
Lens Shade
Up to 100 Amps
Up to 100 AmpsUp to 100 Amps
Up to 100 Amps
Shade No. 8
Shade No. 8Shade No. 8
Shade No. 8
100
100100
100-
--
-200 Amps
200 Amps200 Amps
200 Amps
Shade
ShadeShade
Shade No. 10
No. 10 No. 10
No. 10
200
200200
200-
--
-400 Amps
400 Amps400 Amps
400 Amps
Shade No. 12
Shade No. 12Shade No. 12
Shade No. 12
Over 400 Amps
Over 400 AmpsOver 400 Amps
Over 400 Amps
Shade No. 14
Shade No. 14Shade No. 14
Shade No. 14
• Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or
broken
brokenbroken
broken
• Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc
unless wearing appropriate safety glasses.
unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.
unless wearing appropriate safety glasses.
• Prepare cutting area to reduce reflection
Prepare cutting area to reduce reflectionPrepare cutting area to reduce reflection
Prepare cutting area to reduce reflection and
and and
and
transmission of ultraviolet light.
transmission of ultraviolet light.transmission of ultraviolet light.
transmission of ultraviolet light.
• Paint walls and other surfaces with dark colors to
Paint walls and other surfaces with dark colors to Paint walls and other surfaces with dark colors to
Paint walls and other surfaces with dark colors to
reduce reflections.
reduce reflections.reduce reflections.
reduce reflections.
• Install protective screens or curtains to reduce
Install protective screens or curtains to reduce Install protective screens or curtains to reduce
Install protective screens or curtains to reduce
ultraviolet transmission.
ultraviolet transmission.ultraviolet transmission.
ultraviolet transmission.
Ruptured Gas Cylinders Can Kill
Mishandling gas cylinders can r
Mishandling gas cylinders can rMishandling gas cylinders can r
Mishandling gas cylinders can rupture and violently
upture and violently upture and violently
upture and violently
release gas.
release gas. release gas.
release gas.
• Avoid rough handling of cylinders.
Avoid rough handling of cylinders.Avoid rough handling of cylinders.
Avoid rough handling of cylinders.
• Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.
• Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.
• Always secure cylinders in an upright position by
Always secure cylinders in an upright position by Always secure cylinders in an upright position by
Always secure cylinders in an upright position by
chain or strap to a suitable stable object
chain or strap to a suitable stable object chain or strap to a suitable stable object
chain or strap to a suitable stable object not part of an
not part of an not part of an
not part of an
electrical circuit.
electrical circuit.electrical circuit.
electrical circuit.
• Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.
• Refer to CGA Standard P
Refer to CGA Standard PRefer to CGA Standard P
Refer to CGA Standard P-
--
-1, “Precautions for Safe
1, “Precautions for Safe 1, “Precautions for Safe
1, “Precautions for Safe
Handling of Compressed Gases in Cylinders”, available
Handling of Compressed Gases in Cylinders”, available Handling of Compressed Gases in Cylinders”, available
Handling of Compressed Gases in Cylinders”, available
from Compressed Gas Associatio
from Compressed Gas Associatiofrom Compressed Gas Associatio
from Compressed Gas Association.
n.n.
n.
SECTION 1 SAFETY
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1-7
WARNING
!
Spark hazard.
Heat, spatter, and sparks cause fire and burns.
Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns.
Heat, spatter, and sparks cause fire and burns.
• Do not cut near combustible mat
Do not cut near combustible matDo not cut near combustible mat
Do not cut near combustible material.
erial.erial.
erial.
• Do not cut containers that have held
Do not cut containers that have held Do not cut containers that have held
Do not cut containers that have held
combustibles.
combustibles.combustibles.
combustibles.
• Do not have on your person any combustibles
Do not have on your person any combustibles Do not have on your person any combustibles
Do not have on your person any combustibles
(e.g. butane lighter).
(e.g. butane lighter).(e.g. butane lighter).
(e.g. butane lighter).
• Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle
away from yourself and others when activating
away from yourself and others when activating away from yourself and others when activating
away from yourself and others when activating
plasma process.
plasma process.plasma process.
plasma process.
• Wear correct eye and bo
Wear correct eye and boWear correct eye and bo
Wear correct eye and body protection.
dy protection.dy protection.
dy protection.
• Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.
• Wear flame
Wear flameWear flame
Wear flame-
--
-retardant clothing that covers all
retardant clothing that covers all retardant clothing that covers all
retardant clothing that covers all
exposed areas.
exposed areas.exposed areas.
exposed areas.
• Wear cuffless trousers to prevent entry of
Wear cuffless trousers to prevent entry of Wear cuffless trousers to prevent entry of
Wear cuffless trousers to prevent entry of
sparks and slag.
sparks and slag.sparks and slag.
sparks and slag.
WARNING
!
Explosion hazard.
Certain molten aluminum
Certain molten aluminumCertain molten aluminum
Certain molten aluminum-
--
-lithium (Al
lithium (Allithium (Al
lithium (Al-
--
-Li) alloys can
Li) alloys can Li) alloys can
Li) alloys can
cause explosions when plasma cut with water.
cause explosions when plasma cut with water. cause explosions when plasma cut with water.
cause explosions when plasma cut with water.
Do not plasma cut the following Al
Do not plasma cut the following AlDo not plasma cut the following Al
Do not plasma cut the following Al-
--
-Li alloys with
Li alloys with Li alloys with
Li alloys with
water:
water:water:
water:
Alithlite (Alcoa)
Alithlite (Alcoa)Alithlite (Alcoa)
Alithlite (Alcoa)
X8192 (Alcoa)
X8192 (Alcoa)X8192 (Alcoa)
X8192 (Alcoa)
Alithally (Alcoa)
Alithally (Alcoa)Alithally (Alcoa)
Alithally (Alcoa)
Navalite (US Navy)
Navalite (US Navy)Navalite (US Navy)
Navalite (US Navy)
2090 Alloy (Alcoa)
2090 Alloy (Alcoa)2090 Alloy (Alcoa)
2090 Alloy (Alcoa)
Lockalite (Lockheed)
Lockalite (Lockheed)Lockalite (Lockheed)
Lockalite (Lockheed)
X8090A (Alcoa)
X8090A (Alcoa)X8090A (Alcoa)
X8090A (Alcoa)
Kalite (Kaiser)
Kalite (Kaiser)Kalite (Kaiser)
Kalite (Kaiser)
X8092 (Alcoa)
X8092 (Alcoa)X8092 (Alcoa)
X8092 (Alcoa)
8091 (Alcan)
8091 (Alcan)8091 (Alcan)
8091 (Alcan)
• These alloys should only be dry cut on a dry
These alloys should only be dry cut on a dry These alloys should only be dry cut on a dry
These alloys should only be dry cut on a dry
table.
table.table.
table.
• DO NOT dry cut over water.
DO NOT dry cut over water.DO NOT dry cut over water.
DO NOT dry cut over water.
• Contact yo
Contact yoContact yo
Contact your aluminum supplier for additional
ur aluminum supplier for additional ur aluminum supplier for additional
ur aluminum supplier for additional
safety information regarding hazards associated
safety information regarding hazards associated safety information regarding hazards associated
safety information regarding hazards associated
with these alloys
with these alloyswith these alloys
with these alloys
.
SECTION 1 SAFETY
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1-8
DANGER
!
Hydrogen explosion hazard.
• Do not cut under water with Hydrogen gas!
• Hydrogen explosions can cause personal
injury or death.
• Hydrogen can create explosive gas pockets
in the water table. These pockets will explode
when ignited by sparks or the plasma arc.
• Before cutting, be aware of possible
hydrogen sources in the water table – molten
metal reaction, slow chemical reaction and
some plasma gases.
• Explosive gas pockets accumulate
underneath the cutting plate and inside the
water table.
• Clean slag (especially fine particles) from
bottom of table frequently. Refill table with
clean water.
• Do not leave plate on table overnight.
• If water table has not been used for several
hours, vibrate or jolt it to break up hydrogen
pockets before laying plate on the table.
• If possible, change water level between cuts
to break up hydrogen pockets.
• Maintain water pH level near 7 (neutral).
• Programmed part spacing should be a
minimum of twice the kerf width to ensure
material is always under the kerf.
• When cutting above water, use fans to
circulate air between plate and water surface.
SEE F14373 for additional information
SECTION 1 SAFETY
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1-9
1.6 Service Precautions
CAUTION
Establish and
Establish and Establish and
Establish and adhere to preventive maintenance. A
adhere to preventive maintenance. A adhere to preventive maintenance. A
adhere to preventive maintenance. A
composite program can be established from
composite program can be established from composite program can be established from
composite program can be established from
recommended schedules in the instruction literature.
recommended schedules in the instruction literature.recommended schedules in the instruction literature.
recommended schedules in the instruction literature.
Avoid leaving test equipment or hand tools on
Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage
could occur to equipment or m
could occur to equipment or mcould occur to equipment or m
could occur to equipment or machine.
achine.achine.
achine.
CAUTION
!
Extreme caution should be used when probing
Extreme caution should be used when probing Extreme caution should be used when probing
Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter. Integrated
circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated
circuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage. circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
Power off before using test probes to prevent Power off before using test probes to prevent
Power off before using test probes to prevent
accidental shorting of components.
accidental shorting of components.accidental shorting of components.
accidental shorting of components.
All circu
All circuAll circu
All circuit boards securely seated in sockets, all cables
it boards securely seated in sockets, all cables it boards securely seated in sockets, all cables
it boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned
guards and covers replaced before power is turned guards and covers replaced before power is turned
guards and covers replaced before power is turned
on.
on.on.
on.
Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while
machine power is on. Instantaneous surges of
machine power is on. Instantaneous surges of machine power is on. Instantaneous surges of
machine power is on. Instantaneous surges of voltage
voltage voltage
voltage
and current can damage electronic components.
and current can damage electronic components.and current can damage electronic components.
and current can damage electronic components.
WARNING
!
Hot Torch Could Result In Burn Injury
Torch is “wet” with cooling water and water
Torch is “wet” with cooling water and water Torch is “wet” with cooling water and water
Torch is “wet” with cooling water and water
injection but may still be hot immediately after high
injection but may still be hot immediately after high injection but may still be hot immediately after high
injection but may still be hot immediately after high
ampere cutting.
ampere cutting.ampere cutting.
ampere cutting.
Allow torch to cool before servicing.
Allow torch to cool before servicing.Allow torch to cool before servicing.
Allow torch to cool before servicing.
WARNING
!
Electric Shock Could Kill or Injure
Turn OFF plasma power supply before servicing
Turn OFF plasma power supply before servicing Turn OFF plasma power supply before servicing
Turn OFF plasma power supply before servicing
torch.
torch.torch.
torch.
SECTION 1 SAFETY
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1-10
1.7 Safety References -- Regulations, Standards, Guidelines
The following recognized publications on safety in welding and cutting
operations are recommended. These publications have been prepared
to protect persons from injury or illness and to protect property from
damage, which could result from unsafe practices. Although some of
these publications are not related specifically to this type of industrial
cutting apparatus, the principles of safety apply equally.
1.7.1 North America
• “Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
• “Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
• “Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
• “Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
• “Safe Practices” - AWS SP, American Welding Society.
• “Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
• “Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
• "Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
• “Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.
SECTION 1 SAFETY
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1-11
1.7.2 International
Accident Prevention
VBG 1 General Provisions
VBG 4 Electrical Equipment and operating
Equipment
VBG 15 Welding, Cutting and related working
methods
VBG 48 Shot Blasting Works
VBG 61 Gases
VBG 62 Oxygen
VBG 87 Operating liquid jet cutting machines
VBG 93 Laser beams, accident prevention and
Electro-technology
VBG 121 Noise
VDE Regulations
VDE 0100 Erection of power installations with normal
voltages up to 1000 volts
VDE0113 Electrical equipment of industrial machines
VDE 0837 Radiation safety of laser products; users
guide (DIN EN 60825)
VDE 0837-
50
Specification for laser guards
TRAC Technical Rules for Acetylene and Carbide Stores
TRAC-204 Acetylene lines
TRAC-206 Acetylene cylinder battery systems
TRAC-207 Safety devices
TRG Technical Rules for Pressure gases
TRG 100 General regulations for pressure gases
TRG 101 Pressure gases
TRG 102 Technical gas mixtures
TRG 104 Pressure gases; alterative use of
compressed gas tanks
SECTION 1 SAFETY
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1-12
DIN Standards
DIN 2310
Part 1
Thermal cutting; terminology and
nomenclature
DIN 2310
Part 2
Thermal cutting; determination of quality of cut
faces
DIN 2310
Part 4
Thermal cutting; arc plasma cutting; process
principles, quality, dimensional tolerances
DIN 2310
Part 5
Thermal cutting; laser beam cutting of metallic
materials; process principles
DIN 4844
Part 1
Safety markings (DIN EN 7287)
DIN EN ISO Harmonized Standards
DIN EN
292/1 and 2
Safety of machinery
DIN EN 559 Hoses for welding, cutting and allied
processes
DIN EN 560 Hose connections and hose couplings for
equipment for welding, cutting and allied
processes
DIN EN 561 Gas welding equipment hose couplings
DIN EN
626-1
Safety of machines, reduction of risks to
health
DIN EN
848-1
Single spindle vertical milling machines
DIN EN
1829
High pressure water jet machines
DIN EN
9013
Thermal cutting, oxygen cutting, process
principles, dimensional tolerances
DIN EN
12584
Imperfections in oxy/fuel flame cuts, laser
beam cuts and plasma
DIN EN
12626
Laser processing machines
DIN EN
28206
Acceptance testing for oxygen cutting
machines
DIN EN
31252
Laser Equipment
DIN EN
31553
Laser and laser related equipment
DIN EN
60204-1
Electrical equipment of machines
DIN EN
60825
Radiation safety of laser products
DIN EN 999 Arrangement of protection devices
VDI Guidelines
VDI 2906 Quality of cut faces on metallic workpieces;
abrasive water jet cutting and arc plasma
cutting
VDI 2084 Room air; Technical systems for welding
workshops
SECTION 2 DESCRIPTION
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2-1
2.1 General
The PT-15XL Mechanized Plasma Cutting Torch is
designed for plasma water injection cutting using
nitrogen, oxygen or H-35. (H-35 is industry
nomenclature for a mixture of 65% argon and 35%
hydrogen. It can effectively cut mild steel, stainless
steel and aluminum in 1/8" to 3" (3,2mm to
76,2mm) material. A high current nozzle is available
for cutting materials from 3" to 6" (76,2mm
152,4mm) thickness at up to 1000 amperes.
Note: Because of slower cutting speeds, dross
formation is to be expected when cutting thicker
materials (3" to 6").
2.2 Scope
The purpose of this manual is to provide the
operator with all the information required to install
and operate the PT-15XL Mechanized Plasma
Cutting Torch. Technical reference material is also
provided to assist in troubleshooting the cutting
package.
2.3 Package Options Available
PT-15XL package options available through your ESAB dealer
See section 7 for replacement component part numbers
PT-15XL Body Assembly (less front end and leads) 20754
PT-15XL Torch without leads 16365
4.5 ft. (1,3 m) 21307
6 ft. (1,8 m) 21304
12 ft. (3,7 m) 21305
15 ft. (4,6 m) 21301
17 ft. (5,2 m) 21306
20 ft. (6,1 m) 21302
Torch Assemblies
25 ft. (7,6 m) 21303
NOTES:
• Control lead from the power source to customer CNC is supplied based on customer order.
• See Replacement Parts for assembly components.
• See Process Data Sheets for a list of front-end torch consumable parts.
• Assemblies shipped with nut driver (P/N 996568) for electrode removal, nozzle and electrode holder removal
tool (P/N 999630), and 2 hex key wrenches (7/64 inch – P/N 93750010 and 0.062 – P/N 937500006)
SECTION 2 DESCRIPTION
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2-2
2.4 PT-15XL Technical Specifications
2.4.1 Plasma Gas Technical Specifications
Type O
2
, N
2
, H-35
Pressure 100 to 125 psig (6,9 – 8,6 bars)
Flow
O
2
at 180 cfh max
N
2
at 240 cfh max
H-35 at 450 cfh max
Purity Required*
O
2
-99.5%
N
2
-99.995%
H-35 Specialty gas – 99.99%
Recommended Liquid Cylinder Service
Regulators
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
Recommended Cylinder 2-Stage
Regulators
Oxygen: R-77-150-540 (P/N 998337
Hydrogen/Methane: R-77-150-350 (P/N
998342)
Nitrogen: R-77-150-580 (P/N 998344)
Recommended Heavy –Duty Hi-flow
Station or Pipeline Regulators
Oxygen: R-76-150-024 (P/N 19151)
Recommended High-capacity Station
or Pipeline Regulators
R-6703 (P/N 22236)
Gas Filter Required 25 micron w/bowl guard (P/N 56998133)
2.4.2 Start Gas Technical Specifications
Type N
2
, H-35
Pressure 100 to 125 psig (6,9 – 8,6 bars)
Flow
280 to 300 cfh (7929 l/min) max
@ 1000A (varies with application)
Minimum Purity Required 99.995%
/