ESAB PT-19XLS Plasmarc™ Cutting Torch User manual

PT-19XLS

Plasmarc™ Cutting Torch

F15-430-H 08 / 2008

Instruction Manual

2

This equipment will perform in conformity with the description thereof contained in this manual and accompa-

nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-

tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment

should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-

diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone

or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.

The user of this equipment shall have the sole responsibility for any malfunction which results from improper

use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-

vice facility designated by the manufacturer.

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the

principles of operation and safe practices for arc welding and cutting equipment, we urge

you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and

Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain

this equipment. Do NOT attempt to install or operate this equipment until you have read

and fully understand these instructions. If you do not fully understand these instructions,

contact your supplier for further information. Be sure to read the Safety Precautions be-

fore installing or operating this equipment.

CAUTION

USER RESPONSIBILITY

3

TABLE OF CONTENTS

SAFETY PRECAUTIONS

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

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

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

SECTION 1 INTRODUCTION

1.1 Introduction .......................................................................................................................................17

1.2 Available Models ..............................................................................................................................17

SECTION 2 REQUIRED EQUIPMENT

2.1 Accessories .........................................................................................................................................19

SECTION 3 INSTALLATION and OPERATION

3.1 Installation ..........................................................................................................................................21

3.2 Operation ............................................................................................................................................22

3.3 Gas Settings ........................................................................................................................................23

Cut Data for the PT-19XLS .............................................................................................................24

Cutting Parameters for the ESP-150 & ESP-200 .....................................................................38

SECTION 4 MAINTENANCE

4.1 Introduction .......................................................................................................................................45

4.2 Replacing the PT-19XLS Nozzle ...................................................................................................46

4.3 Replacing the Electrode and Gas Swirl Bae ........................................................................46

4.4 Replacing the Insulator Assembly ..............................................................................................46

4.5 Replacing the Cable and Hoses ...................................................................................................47

SECTION 5 REPLACEMENT PARTS

5.1 General .................................................................................................................................................49

5.2 Ordering ..............................................................................................................................................49

SUPPLEMENT for the PROCESS DATA using SMARTFLOW II and SDP FILES .........................................56

SECTION TITLE PAGE

4

TABLE OF CONTENTS

5

SAFETY PRECAUTIONS

1.0 Safety Precautions

1.1 Safety - English

WARNING: These Safety Precautions are

for your protection. They summarize pre-

cautionary information from the references

listed in Additional Safety Information sec-

tion. Before performing any installation or operating

procedures, be sure to read and follow the safety precau-

tions listed below as well as all other manuals, material

safety data sheets, labels, etc. Failure to observe Safety

Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation

and can injure skin and eyes. Hot metal can cause

burns. Training in the proper use of the processes

and equipment is essential to prevent accidents.

Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and

ears from sparks and rays of the arc when operating

or observing operations. Warn bystanders not to

watch the arc and not to expose themselves to the

rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes,

and a welding helmet or cap for hair protection, to

protect against arc rays and hot sparks or hot metal.

A ameproof apron may also be desirable as protec-

tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from

the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS -- Heat from

ames and arcs can start res. Hot

slag or sparks can also cause res and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ammable covering. Combustible materials

include wood, cloth, sawdust, liquid and gas fuels,

solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in oors or wall openings and cause a hid-

den smoldering re or res on the oor below. Make

certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might

produce ammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant

use, such as a garden hose, water pail, sand bucket,

or portable re extinguisher. Be sure you are trained

in its use.

5. Do not use equipment beyond its ratings. For ex-

ample, overloaded welding cable can overheat and

create a re hazard.

6. After completing operations, inspect the work area

to make certain there are no hot sparks or hot metal

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

necessary.

7. For additional information, refer to NFPA Standard

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

Processes", available from the National Fire Protec-

tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with

live electrical parts and ground can

cause severe injury or death. DO NOT

use AC welding current in damp areas,

if movement is conned, or if there is

danger of falling.

6

SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con-

nected to the ground system of the input power.

2. Connect the workpiece to a good electrical

ground.

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

or missing connection can expose you or others

to a fatal shock.

4. Use well-maintained equipment. Replace worn or

damaged cables.

5. Keep everything dry, including clothing, work

area, cables, torch/electrode holder, and power

source.

6. Make sure that all parts of your body are insulated

from work and from ground.

7. Do not stand directly on metal or the earth while

working in tight quarters or a damp area; stand

on dry boards or an insulating platform and wear

rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the

power.

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on

next page) for specic grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent owing through any conduc-

tor causes localized Electric and

Magnetic Fields (EMF). Welding and

cutting current creates EMF around welding cables

and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with

some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

3. Welders should use the following procedures to

minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of

your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in conned spaces. Do

not breathe fumes and gases. Shield-

ing gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area

by natural or mechanical means. Do not weld, cut, or

gouge on materials such as galvanized steel, stain-

less steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided.

Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly

toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir-

ritation while operating, this is an indication that

ventilation is not adequate. Stop work and take

necessary steps to improve ventilation in the work

area. Do not continue to operate if physical discom-

fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specic ventilation recommendations.

7

SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding

or cutting, produces fumes or gases

which contain chemicals known to

the State of California to cause birth

defects and, in some cases, cancer.

(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,

if mishandled, can rupture and vio-

lently release gas. Sudden rupture

of cylinder, valve, or relief device can

injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to

operate from the compressed gas cylinder. Do not

use adaptors. Maintain hoses and ttings in good

condition. Follow manufacturer's operating instruc-

tions for mounting regulator to a compressed gas

cylinder.

2. Always secure cylinders in an upright position by

chain or strap to suitable hand trucks, undercar-

riages, benches, walls, post, or racks. Never secure

cylinders to work tables or xtures where they may

become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases

in Cylinders", which is available from Compressed

Gas Association, 1235 Jeerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualied personnel perform the instal-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualied to perform such work.

2. Before performing any maintenance work inside a

power source, disconnect the power source from

the incoming electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do

not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do

not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for

electric arc welding and cutting equip-

ment, ask your supplier for a copy of

"Precautions and Safe Practices for Arc

Welding, Cutting and Gouging", Form

52-529.

The following publications, which are available from

the American Welding Society, 550 N.W. LeJuene Road,

Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

8

SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal

Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

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

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used

throughout this manual: Means Atten-

tion! Be Alert! Your safety is involved.

Means immediate hazards which,

if not avoided, will result in im-

mediate, serious personal injury

or loss of life.

Means potential hazards which

could result in personal injury or

loss of life.

Means hazards which could result

in minor personal injury.

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17

1.1 INTRODUCTION

The PT-19XLS is a water-cooled plasma arc torch designed for mechanized cutting at currents up to 360 amps with oxygen

and up to 600 amps with nitrogen or H-35.

The PT-19XLS incorporates arrangements for secondary gas shielding and various minor improvements over the PT-19XL.

The PT-19XLS remains fully repairable.

1.2 AVAILABLE MODELS

Table 1-1. PT-19XLS Specications

Current Rating 400A O

2

or Air Plasma Gas

600A N

2

or H-35 Plasma Gas

Duty Cycle 100%

Torch Mounting Diameter 2 in. (50.8mm)

Length of Torch without 16.6 inches (422mm)

Leads

Cooling Requirements 0.75 gpm min. @ 90 psig (150 A)

1.00 gpm min. @ 120 psig (250 A)

Plasma 35 cfh (50 A)

Gas Consumption 65 cfh (150 A)

(Arc On) 110 cfh (250A)

Shield Gas 90 to 450 scfh

Consumption Air or N

2

SECTION 1 INTRODUCTION

*Used on the Smart Flow ESP-1000 Plasma Cutting Outts with ESP ULTRA-LIFE 300, ESP-400C or ESP-600C Power Sources.

Also used on PCM-1500 console units modied for use with PCC-12 control and on the ESP-200 with Plumbing Box.

**Used on ESP-150 & ESP-200 without Plumbing Box.

NOTICE:

This torch and its components are protected by various U.S. and foreign patents with additional patents pending. It is the policy of

ESAB Welding & Cutting Products to react vigorously to patent infringement of unauthorized manufacture, sale, or use of its patented products

or spare parts.

PLASMA Cutting can produce deadly fumes, re, or explosion.

• Gasesusedforplasmacuttingcancausesuocation,re,orexplosion.

• Loudnoisefromplasmacuttingcancausehearingloss.

High Voltage can kill. Disconnect Power supply from incoming electrical power before

touching or servicing the torch. Metal parts of the torch can be at high voltage.

Torch Assembly PT-19XLS, 4-1/2 ft.* P/N 37086

Torch Assembly PT-19XLS, 6 ft.* P/N 37087

Torch Assembly PT-19XLS, 12 ft.* P/N 37088

Torch Assembly PT-19XLS, 15 ft.* P/N 37089

Torch Assembly PT-19XLS, 17 ft.* P/N 37090

Torch Assembly PT-19XLS, 20 ft.* P/N 37091

Torch Assembly PT-19XLS, 25 ft.* P/N 37092

Torch Assembly PT-19XLS, 50 ft** P/N 37093

Torch Assembly PT-19XLS, Less Leads P/N 37543

Torch Assembly PT-19XLS, 25 ft** P/N 0558004636

18

PT-36 Technical Specications

SECTION 1 INTRODUCTION

19

SECTION 2 REQUIRED EQUIPMENT

2.1 ACCESSORIES

A. PT-19XL Torch Spare Parts Kit, P/N 37307

Recom mended for maintaining the PT-19XLS torch with minimum downtime. The kit contains the following PT-19XLS

parts and tools:

4 - Electrode, Long .................................................P/N 34086XL

4 - Electrode, Long N

2

/ArH

2

.....................................P/N 22403

2 - Nozzle Base, 100 - 200A ......................................P/N 22028

5 - Nozzle Tip, 150A .....................................................P/N 22030

2 - Nozzle Base, 50A ....................................................P/N 22027

5 - O-Ring (1.301 ID X .070 W) ............................P/N 2064106

2 - Shield, 50A ...............................................................P/N 21795

1 - Electrode Holder ....................................................P/N 37068

2 - Diuser, 50A ............................................................P/N 21796

5 - Nozzle Tip, 50A .......................................................P/N 22026

6 - #6-32 X 1/8 Setscrews .................................. P/N 61330980

6 - #6-32 X 3/16 Setscrews ............................... P/N 61630631

5 - Nozzle, 250A ............................................................P/N 21822

4 - Gas Swirl Bae ....................................................P/N 948142

1 - Nozzle Retaining Cup ...........................................P/N 37082

1 - Insulator Assembly ...............................................P/N 37083

1 - Contact Ring Assembly .......................... P/N 0558003858

2. For cutting machine operation, the torch will mount on a standard PT-15 torch mounting setup.

3. Adaptor Assembly, P/N 22463 is required for mounting the PT-19XLS to the PCC-90.

B. Torch Mounting

1. Torch Clamp Assembly, P/N 598707 is required for mounting the PT-19XLS.

For stationary or boom mounting, the following parts may also be needed:

P/N 39V35 - Rack & Tube Assembly P/N 40V26 - Torch Adjustment Assembly

P/N 25V39 - Adjustable Slide P/N 29N04 - Angle Bracket

P/N 996342 - Clamp Insulator Bushing

C. Air Curtain Kit, PT-19XLS - P/N 37460, consisting of :

P/N 37440 - Air Curtain Assembly

P/N 33383 - Control Panel

P/N 34033 - Hose, 50 ft.

For installation refer to F-15-475.

The air curtain directs a ow of air around the arc which permits underwater cutting with O

2

gas.

Note: Underwater cutting cannot be done below 150A.

D. Water Muer, PT-19XLS - P/N 37439

The water muer uses a ow of water recirculated from the water tank to shield the arc thus reducing noise and fumes. The

water muer may be used above or under water.

10 - O-Ring (.468 ID X .07 W) .................................P/N 86W85

5 - O-Ring (.145 ID X .070 W) ...............................P/N 996526

30 - O-Ring (.176 ID X .050 W) ..............................P/N 951000

20 - O-Ring (1.614 ID X .070 W) ........................... P/N 996528

20 - O-Ring (.363 ID X .070 W) ...............................P/N 86W99

1- Nozzle & Electrode Stem Tool ............................P/N 37110

1- Electrode Tip Removal Tool .............................. P/N 996568

1- Hex Wrench, 1/16" .......................................... P/N 93750006

1- Silicone Grease ........................................................P/N 17672

2 - Heat Shield 50A ......................................................P/N 34885

2 - Heat Shield 150/250A .......................................P/N 948186

1 - Allen Wrench .................................................. P/N 93750010

4 - Shield, 100 - 250A ..................................................P/N 21802

4 - Diuser, 100 - 360A ...............................................P/N 21944

2 - Shield Retainer .......................................................P/N 37081

2 - Contact Ring Screw ..............................................P/N 37073

2 - Gasket ........................................................................P/N 37308

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21

SECTION 3 INSTALLATION / OPERATION

Wear the usual protective gloves, clothing, and helmet. Helmet

with lter lens shade No. 6 or 7 should provide adequate protec-

tion for your eyes.

Never touch any torch front end parts (nozzle, retaining cup, etc.) unless

the power switch is in the OFF position, and primary power is shut OFF

at the disconnect.

3.1 INSTALLATION

Refer to machine manual.

Mount Torch

On Insulated

Sleeve (Torch

Handle) here

Clamping on Torch Body May Cause Dangerous Cur-

rent To Flow Through Machine Chassis.

• Do not mount on stainless steel torch body.

• Torch body is electrically insulated, however high

frequency start current may arc through to nd a

ground.

• Clamping near torch body may result in arcing be

tween body and machine.

• When this arcing occurs, torch body may require

non-warranty replacement.

• Damage to machine components may result.

• Clamp only on insulated torch sleeve not less

than 1.25” (31.75mm) from the torch end of the

sleeve.

DO NOT mount on

steel torch body

AUTION: CLAMP TORCH ABOVE THIS LA

PT-19XLS

PLASMARC TORCH

B

E

L

C

ELECTRIC SHOCK CAN KILL. Precautionary measures should be taken to

provide maximum protection against electric shock. Therefore, before

making any adjustments or performing any maintenance on the torch,

makesurethepowertothetorchisshuto.

Never use oil or grease on this torch. Handle parts only with clean hands

on a clean surface. Oil and grease are easily ignited and burn violently

in the presence of oxygen under pressure. Use silicone lubricant only

where directed.

22

SECTION 3 INSTALLATION / OPERATION

Figure3-1.EectofCuttingSpeed

NOTE

If piercing thick plate, increase stando to 1/2" for up to 1/2" thick plate, 3/4" for thicker plate. Then return to 3/8" stando

after completing the pierce and you are ready to cut.

NOTE

If cutting arc does not start within seven seconds, the pilot arc will shut o. Deactivate start switch. Make sure gas pressures

are adequate, work cable is rmly connected to workpiece, cooling water is on, stando is correct, etc. Then restart.

A. Select an appropriate condition from the cutting tables or install recommended nozzle, electrode, bae,

diuser or shield. Set recommended ows, pressures, currents, etc.

B. Position the torch over the edge of the workpiece with the tip of the nozzle set at the recommended stando.

(See tables in the cutting parameter section).

3.2 OPERATION

23

Fig 3-3. PT-19XL Regulator Assembly

(For Use With ESP-1000 System) Kit - P/N 36283

ADAPTOR - 999304

HEX NIPPLE -639501

AIR REGULATOR

ASSY. - 522368

CONNECTOR - 3389

B-Oxy -F*

1/4 NPTM*

1/4 NPTF*

(2) 1/8" NPT Pipe Plugs - 643792*

B-Oxy-M*

CHECK VALVE ASSY. - 21124

1/4 NPTM*

1/4 NPTF*

SECTION 3 INSTALLATION / OPERATION

3.3 GAS SETTINGS

A. PCC-1500 / PCC-12 Systems

150 AMP Nozzle

Starting gas set to 20 psig.

Cutting gas set to 45 psig.

NOTE: Do not use 0

2

, use only air for cutting carbon steel over

3/4" thick at 150 AMPS.

50 AMP Nozzle

Use Air/Air or N

2

/N

2

only.

Starting gas set to 40 psig.

Cutting gas set to 60 psig.

Use 4-hole bae for all 50A & 150A cutting.

B. PCM-8

150A Nozzle - set owmeter to 3.0

250A Nozzle - set owmeter to 5.0

C. ESP-1000 - Refer to data in cutting tables.

D. Operation of 50 AMP Nozzle For ESP-1000

Systems With Regulator & Gauge Kits.

1. Build up a regulator assembly as shown below:

2. Install this regulator at the "Cut Gas" connection

on the ESP Plumbing Box.

3. Set control on the ESP Flow Control as follows:

a. O

2

/N

2

Switch to "N

2

".

b. Cut Water Switch to "OFF".

c. Cut Gas Flowrate to "HIGH 7".

d. Test/Run Switch to "Run 1".

4. Set Start Gas Pressure as follows:

a. Test/Run Switch to "START GAS TEST".

b. Adjust Start Gas Regulator to 30 psig.

c. Return TEST/RUN Switch to "Run 1".

5. Set Cut Gas Pressure as follows:

a. TEST/RUN Switch to "CUT GAS TEST".

b. Adjust Cut Gas Regulator to 60 psig.

c. Return TEST/RUN Switch to "RUN 1".

6. Set Range Switch on ESP-300 to "LOW". Adjust

current setting to 50 amps (about 3 on dial).

YOU ARE NOW READY TO CUT WITH N

2

To cut with air, disconnect N

2

from the Flow Control

and connect a supply of clean ltered air at 100 psig. to

the N

2

inlet on the Flow Control.

To return the system to use with higher currents:

a. Reconnect N

2

to the N

2

Inlet.

b. Turn the pressure adjusting screw on the

cut gas regulator all the way in and set the gas

owrate setting back to that recom- mended.

c. Readjust the Start Gas Regulator to the recom-

mended setting.

d. Set the O

2

/N

2

switch to "O

2

" if desired.

e. Set the ESP-300 range switch to "HIGH".

For PCC-12 Systems

a. Set Start Gas Pressure to 30 psig.

b. Set Cut Gas Pressure to 60 psig.

c. Set PCC-1500 to 50 amps (About 3 on dial).

24

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

50

ALUMINUM

AIR

PT-19XLS

50-65 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22027

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21795

DIFFUSER: 21796

PILOT ARC: LOW

REQUIREMENTS:

NOZZLE TIP 22026

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

SHIELD

@ 60 PSI / 4 BAR

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.063

.125

.250

1.6

3

6

30/2.1

60/4

2.2

3.5

.250

6

.125

.156

3

4

115

128

50

65

180

110

65

4572

2294

1651

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

50

ALUMINUM

N

2

N

2

N

2

PT-19XLS

50-65 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22027

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21795

DIFFUSER: 21796

PILOT ARC: LOW

REQUIREMENTS:

NOZZLE TIP 22026

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.063

.125

.250

1.6

3

6

30/2.1

60/4

2.2

3.5

.250

6

.125

3

118

117

125

50

65

180

120

70

4572

3048

1778

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

50

STAINLESS STEEL

AIR

PT-19XLS

50-65 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22027

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21795

DIFFUSER: 21796

PILOT ARC: LOW

REQUIREMENTS:

NOZZLE TIP 22026

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.063

.125

.250

1.6

3

6

30/2.1

60/4

2.2

3.5

.250

6

.156

4

111

119

118

50

65

180

80

60

4572

2032

1524

SHIELD

@ 60 PSI / 4 BAR

SHIELD

@ 60 PSI / 4 BAR

CUTTING TABLES FOR PT-19XLS

A. To use the 50A or 100A nozzles with the ESP-1000 System, you must install a regulator at the Cut Gas connection on the

Plumbing Box. See Figure 3-3.

B. Cut Gas and Start Gas input pressures to the Flow Control should be 100 psig (6.9 bar) for all nozzles and gases.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

SECTION 3 INSTALLATION / OPERATION

25

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

50

STAINLESS STEEL

N

2

N

2

N

2

PT-19XLS

50-65 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22027

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21795

DIFFUSER: 21796

PILOT ARC: LOW

REQUIREMENTS:

NOZZLE TIP 22026

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.063

.125

.250

1.6

3

6

30/2.1

60/4

2.2

3.5

.250

6

.156

4

119

125

127

50

65

180

80

55

4572

2032

1397

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

50

CARBON STEEL

AIR

PT-19XLS

50-65 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22027

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21795

DIFFUSER: 21796

PILOT ARC: LOW

REQUIREMENTS:

NOZZLE TIP 22026

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.063

.125

.187

.250

1.6

3

5

6

30/2.1

60/4

2.2

3.5

.250

6

.156

.125

.156

4

3

4

115

112

110

118

120

50

65

220

120

95

80

5588

3048

2413

2032

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

100

ALUMINUM

AIR

PT-19XLS

100 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22029

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.250

.375

.500

.750

6

10

13

19

25/1.7

45/3.1

3.5

4.4

3.5

.375

.500

10

13

.187

.250

.312

5

6

8

154

174

183

189

100

70

50

30

2540

1778

1270

762

SHIELD

@ 60 PSI / 4 BAR

SHIELD

@ 60 PSI / 4 BAR

SHIELD

@ 60 PSI / 4 BAR

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

SECTION 3 INSTALLATION / OPERATION

26

N

2

N

2

N

2

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

100

STAINLESS STEEL

AIR

PT-19XLS

100 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22029

MATERIAL

THICKNESS

GAS SET UP

STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.250

.375

.500

.750

6

10

13

19

25/1.7

45/3.1

4.4

3.5

.375

.500

10

13

.125

.187

.312

3

5

8

154

165

180

189

100

55

35

25

10

1397

889

635

254

SHIELD

@ 60 PSI / 4 BAR

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

100

STAINLESS STEEL

PT-19XLS

100 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22029

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.250

.375

.500

.750

6

10

13

19

25/1.7

35/2.4

4.4

3.5

.375

.500

10

13

153

157

162

185

100

55

45

35

13

1397

1143

889

330

SHIELD

@ 60 PSI / 4 BAR

.125

.187

.312

3

5

8

N

2

N

2

AIR

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

100

STAINLESS STEEL

PT-19XLS

100 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22029

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.250

.375

.500

.750

6

10

13

19

25/1.7

35/2.4

4.4

3.5

.375

.500

10

13

153

157

162

185

100

55

45

35

13

1397

1143

889

330

SHIELD

@ 60 PSI / 4 BAR

.125

.187

.312

3

5

8

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

SECTION 3 INSTALLATION / OPERATION

27

AIR

N

2

O

2

AIR

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

100

CARBON STEEL

PT-19XLS

100 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22029

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN

MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.625

.750

4

6

10

13

16

19

25/1.7

45/3.1

5.2

4.4

3.5

.375

.500

10

13

148

154

159

162

175

184

100

150

120

65

50

35

20

3810

3048

1651

1270

889

508

SHIELD

@ 60 PSI / 4 BAR

.125

.156

.187

.281

.312

3

4

5

7

8

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

100

CARBON STEEL

PT-19XLS

100 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22029

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.625

.750

4

6

10

13

16

19

25/1.7

45/3.1

4.4

3.5

.375

.500

10

13

135

133

149

141

159

162

100

150

120

80

60

37

20

3810

3048

2032

1524

940

508

SHIELD

@ 60 PSI / 4 BAR

.156

.250

.187

.312

4

6

5

8

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

150

ALUMINUM

PT-19XLS

150 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22030

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.750

1

4

6

10

13

19

25

20/1.4

LOW 3

4.4

3.5

4.4

3.5

.375

.500

10

13

148

149

159

174

180

184

150

200

140

105

80

45

30

5080

3556

2667

2032

1143

762

SHIELD

@ 60 PSI / 4 BAR

.187

.250

.312

5

6

8

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

SECTION 3 INSTALLATION / OPERATION

28

* 34086XL Electrode can also be used for this application.

N

2

OR H-35

H-35

N

2

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

150

ALUMINUM

PT-19XLS

150 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 22403

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22030

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.750

1

4

6

10

13

19

25

20/1.4

LOW 4

LOW4

LOW 4

3.5

.375

.500

10

13

136

141

145

155

166

171

150

200

150

110

90

50

30

5080

3810

2794

2286

1270

762

SHIELD

@ 60 PSI / 4 BAR

.187

.250

.312

.375

5

6

8

10

AIR

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

150

STAINLESS STEEL

PT-19XLS

150 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22030

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN

MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.750

1

4

6

10

13

19

25

20/1.4

LOW 3

4.4

3.5

.375

.500

10

13

138

146

155

163

175

185

150

200

165

95

60

25

15

5080

4191

2413

1524

635

381

SHIELD

@ 60 PSI / 4 BAR

.187

.250

.312

.375

5

6

8

10

N

2

N

2

AIR

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

150

STAINLESS STEEL

PT-19XLS

150 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 22403*

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22030

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.750

1

4

6

10

13

19

25

20/1.4

LOW 3

4.4

3.5

.375

.500

10

13

132

140

143

154

164

179

150

200

130

85

60

18

10

5080

3302

2159

1524

457

254

SHIELD

@ 60 PSI / 4 BAR

.125

.187

.250

.312

3

5

6

8

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

SECTION 3 INSTALLATION / OPERATION

29

AIR

N

2

O

2

AIR

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

150

CARBON STEEL

PT-19XLS

150 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22030

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.625

.750

1

4

6

10

13

16

19

25

20/1.4

LOW 3

4.4

2.6

3.5

4.4

3.5

.375

.500

10

13

127

130

134

142

151

157

160

150

160

150

90

75

55

45

25

4064

3810

2286

1905

1397

1143

635

SHIELD

@ 60 PSI / 4 BAR

.125

.187

.250

.312

.375

.312

3

5

6

8

10

8

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

150

CARBON STEEL

PT-19XLS

150 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 34086XL

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22030

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.188

.250

.375

.500

.625

.750

1

4

6

10

13

16

19

25

20/1.4

LOW 3

4.4

3.1

3.5

.375

.500

10

13

143

145

156

160

164

179

184

150

160

140

90

75

50

45

25

4064

3556

2286

1905

1270

1143

635

SHIELD

@ 60 PSI / 4 BAR

.125

.187

.250

.375

3

5

6

10

N

2

OR H-35

H-35

N

2

Cutting Data:

NOZZLE

MATERIAL

START GAS

CUT GAS

SHIELD GAS

200

ALUMINUM

PT-19XLS

200 AMP

PROCESS PARAMETERS

NOZZLE BASE: 22028

ELECTRODE: 22403

GAS BAFFLE: 948142

SHIELD: 21802

DIFFUSER: 21944

PILOT ARC: HIGH

REQUIREMENTS:

NOZZLE TIP 22031

MATERIAL

THICKNESS

GAS SET UP STANDOFF

PIERCE

IN MM

CUT

IN MM

CUT

PSI/BAR

START

PSI/BAR

IN MM

ARC

VOLTAGE

ARC

CURRENT

TRAVEL

SPEED

IPM

MM/MIN

.250

.375

.500

.750

1

1.25

6

10

13

19

25

32

25/1.7

LOW 4

LOW4

LOW 4

3.5

2.6

4.4

.375

.500

NR

10

13

NR

146

148

155

166

169

175

200

155

120

110

60

40

26

3937

3048

2794

1524

1016

660

SHIELD

@ 60 PSI / 4 BAR

.312

.250

.312

.375

8

6

8

10

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

See Supplement for

process data using SmartFlow II

and SDP les.

SECTION 3 INSTALLATION / OPERATION

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ESAB PT-19XLS Plasmarc™ Cutting Torch User manual

ESAB PT-19XLS Plasmarc™ Cutting Torch User manual

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