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

Brand: ESAB

Model: PT-15XL Plasmarc Water Injection Cutting Torch

Category: Welding System

Type: Installation guide

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

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

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

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

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.

©©

Printed in U.S.A.

PT-15XL Plasma Cutting Torch Table of Contents

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

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

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SECTION 1 SAFETY

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

1-1

DANGER

WARNING

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

PTPT

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-15XL Plasmarc Cutting Torch

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15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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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-15XL Plasmarc Cutting Torch

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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

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

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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-15XL Plasmarc Cutting Torch

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15XL Plasmarc Cutting Torch

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

PTPT

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-15XL Plasmarc Cutting Torch

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15XL Plasmarc Cutting Torch

1-6

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.

SECTION 1 SAFETY

PTPT

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-15XL Plasmarc Cutting Torch

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15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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-

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

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

PTPT

PT-

-15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch15XL Plasmarc Cutting Torch

15XL Plasmarc Cutting Torch

2-2

2.4 PT-15XL Technical Specifications

2.4.1 Plasma Gas Technical Specifications

Type O

, N

, H-35

Pressure 100 to 125 psig (6,9 – 8,6 bars)

Flow

at 180 cfh max

at 240 cfh max

H-35 at 450 cfh max

Purity Required*

-99.5%

-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

, 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%

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

Brand: ESAB

Model: PT-15XL Plasmarc Water Injection Cutting Torch

Category: Welding System

Type: Installation guide

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

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

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