ESAB PT-600 Mechanized Plasma Cutting Torch User manual

F-15-646

October, 2011

Installation, Operation, and Maintenance for the

PT-600 Mechanized

Plasma 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 is total customer

satisfaction. We constantly look for ways to

improve our products, service and documentation.

As a result, we make enhancements and/or design

changes as required. ESAB makes every possible

effort to ensure our documentation is current. We

cannot guarantee that each piece of documentation

received by our customers reflects the latest design

enhancements. Therefore, the information

contained in this document is subject to change

without notice.

This manual is ESAB Part Number F15646

November 2001 updated spare parts

June 2002 boot part number changed

Dec 2002 Added no underwater cut with H-35 tp process data

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.

DECLARATION OF CONFORMITY

according to the EC Low Voltage Directive 73/23/EEC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

enligt lågspänningsdirektivet 73/23/EEG

Fill in and put a cross in appropriate boxes Fyll i och kryssa tillämpliga rutor

Type of equipment

Materialslag

Plasma Cutting Torch

Brand name or trade mark

Fabrikatnamn eller varumärke

ESAB

Type designation etc.

Typbeteckning etc.

PT-600 AY, (8)0558001827, (8)0558001828, (8)0558001829, (8)0558001830, (8)0558001831,

(8)0558001832, (8)0558001833,

Manufacturer’s name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB Welding & Cutting Products

411 South Ebenezer Road, Florence, South Carolina 29501, USA

Phone: +1 843 669 4411, Fax: +1 843 664 4258

Manufacturer’s authorised representative established within the EEA; Name, address, telephone No, telefax No:

Tillverkarens representant inom EES; Namn, adress, telefon, telefax:

ESAB AB

Box 8004, 402 77 Göteborg, Sweden

Phone: +46 31 50 90 00, Fax: +46 31 50 92 61

The following harmonised standards or technical specifications (designations) which comply with good engineering

practice in safety matters in force within the EEA have been used in the design:

Följande harmoniserande standarder eller tekniska specifikationer (beteckningar) som uppfyller god säkerhetsteknisk

praxis inom EES har använts i konstruktionen:

EN 60 974-7 Arc welding equipment - Part 7: Torches

1. The equipment conforms completely, with the above stated harmonised standards or technical

specifications.

Materielen överensstämmer helt med ovan angivna harmoniserade standarder eller tekniska specifikationer.

OR ELLER

2. The equipment conforms only partially with the above stated harmonised standards or technical

specifications but complies with good engineering practice in safety matters in force within the EEA.

Materielen överensstämmer endast delvis med ovan angivna harmoniserade standarder eller tekniska

specifikationer men uppfyller god säkerhetsteknisk praxis inom EES.

Additional information

Övriga uppgifter

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised

representative established within the EEA, that the equipment in question complies with the safety requirements

stated above.

Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom

EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Manufacturer

Tillverkare

Or Manufacturer’s authorised representative

eller Tillverkarens representant

Date

Datum

Göteborg 2003-01-10

Signature

Underskrift

Position

Befattning

Managing Director

Clarification

namnförtydligande

Henry Selenius

PT-600 Plasma Cutting Torch Table of Contents

i

Page

Section 1 Safety

1.1 Introduction 1

1.2 Safety Notations And Symbols 1

1.3 General Safety Information 2

1.4 Electrical Grounding 3

1.5 Operating A Plasma Cutting Machine 4

1.6 Service Precautions 8

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 Secondary Gas 2

2.4.4 PT-600 Torch 2

2.5 Parts Kits

2.5.1 Starter Kit 3

2.5.2 Spare Parts Kit 4

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 3

3.4 Torch Mounting “Precaution” 4

PT-600 Plasma Cutting Torch Table of Contents

ii

Page

Section 4 Operation

Safety Precautions 1

4.1 Set Up 2

4.1.1 Mirror Cutting Requirements 2

4.2 Cut Quality 3

4.2.1 Introduction 3

4.2.2 Cut Angle 3

4.2.3 Cut Flatness 4

4.2.4 Surface Finish 5

4.2.5 Dross 6

4.2.6 Dimensional Accuracy 7

4.3 Torch Flow Passages 8

4.4 Influence of Gas Options on Cut Quality

4.4.1 Introduction 9

4.4.2 Aluminum 10

4.4.3 Carbon Steel 11

4.4.4 Stainless Steel 12

4.5 Process Data

4.5.1 Introduction 13

4.5.2 Process Data Settings

Carbon Steel 14

Aluminum 34

Stainless Steel 66

Section 5 Maintenance

5.1 Introduction 1

5.2 Torch Body 1

5.3 Torch Front End Disassembly 2

5.4 Front End Assembly 5

PT-600 Plasma Cutting Torch Table of Contents

iii

Page

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 Preflow Shield 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-600 Torch Front End 2

7.4 Hoses and Cables 4

7.5 Complete Assemblies and Tools 6

7.6 Parts Kits 8

Customer/Technical Information Back Manual Cover

PT-600 Plasma Cutting Torch Table of Contents

iv

This page intentionally left blank

SECTION 1 SAFETY

1-1

DANGER

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

1.1 Introduction

The process of cutting metals with plasma equipment

provides industry with a valuable and versatile tool.

ESAB cutting machines are designed to provide both

operation safety and efficiency. However, as with any

machine tool, sensible attention to operating

procedures, precautions, and safe practices is

necessary to achieve a full measure of usefulness.

Whether an individual is involved with operation,

servicing, or as an observer, compliance with

established precautions and safe practices must be

accomplished. Failure to observe certain precautions

could result in serious personnel injury or severe

equipment damage. The following precautions are

general guidelines applicable when working with

cutting machines. More explicit precautions pertaining

to the basic machine and accessories are found in the

instruction literature. For a wide scope of safety

information on the field of cutting and welding

apparatus, obtain and read the publications listed in

the Recommended References.

1.2 Safety Notations And Symbols

The following words and symbols are used throughout

this manual. They indicate different levels of required

safety involvement.

!

ALERT or ATTENTION. Your safety is involved

or potential equipment failure exists. Used in

concurrence with other symbols and information.

Used to call attention to immediate hazards

which, if not avoided, will result in serious

personal injury or loss of life.

Used to call attention to potential hazards

that could result in personal injury or loss of

life.

Used to call attention to hazards that could

result in minor personal injury or equipment

damage.

Used to call attention to minor hazards to

equipment.

Used to call attention to important

installation, operation or maintenance

information not directly related to safety

hazards.

SECTION 1 SAFETY

1-2

1.3 General Safety Information

WARNING

!

Cutting Machine starts automatically.

This torch may be mounted on a mechanized cutting

This torch may be mounted on a mechanized cutting This torch may be mounted on a mechanized cutting

This torch may be mounted on a mechanized cutting

machine. This equipment moves in various directions

machine. This equipment moves in various directions machine. This equipment moves in various directions

machine. This equipment moves in various directions

and speeds and may start automatically.

and speeds and may start automatically.and speeds and may start automatically.

and speeds and may start automatically.

• Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

Moving machinery can crush.

• Only qualified personnel should o

Only qualified personnel should oOnly qualified personnel should o

Only qualified personnel should operate or service

perate or service perate or service

perate or service

equipment.

equipment.equipment.

equipment.

• Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not

involved in production process clear of entire

involved in production process clear of entire involved in production process clear of entire

involved in production process clear of entire

system area.

system area.system area.

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 work cell to pr

Fence off entire work cell to prFence off entire work cell to pr

Fence off entire work cell to prevent personnel

event personnel event personnel

event 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 be given to all

Special attention must be given to allSpecial attention must be given to all

Special attention must be given to all hazard

hazard hazard

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

responsibility or

responsibility orresponsibility or

responsibility or access.

access. access.

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

1-3

WARNING

!

Failure to follow safety warning label

instructions could result in death or

serious injury.

Read and understand all safety warning label

Read and understand all safety warning labelRead and understand all safety warning label

Read and understand all safety warning labels on

s on s on

s 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 severe injury or de

Improper grounding can cause severe injury or deImproper grounding can cause severe injury or de

Improper grounding can cause severe injury or death.

ath.ath.

ath.

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

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

goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying

debris generated dur

debris generated durdebris generated dur

debris generated during operation.

ing operation.ing operation.

ing 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

cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with

cutting. Allow metal time to cool, or douse with

water.

water.water.

water.

• Do not touch

Do not touchDo not touch

Do not touch plasma torch immediately after

plasma torch immediately after plasma torch immediately after

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 open

before openbefore open

before opening or servicing plasma plumbing or

ing or servicing plasma plumbing or ing or servicing plasma plumbing or

ing or servicing plasma plumbing or

flow control box.

flow control box.flow control box.

flow 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 gloves, shoes a

ground: wear insulating gloves, shoes aground: wear insulating gloves, shoes a

ground: wear insulating gloves, shoes and

nd nd

nd

clothing.

clothing.clothing.

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

1-5

WARNING

!

Pinch hazard.

Moving ver

Moving verMoving ver

Moving vertical slides can crush or pinch.

tical slides can crush or pinch.tical slides can crush or pinch.

tical 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

necessary.

necessary.necessary.

necessary.

• Use appr

Use apprUse appr

Use approved respirator if ventilation is not

oved respirator if ventilation is not oved respirator if ventilation is not

oved respirator if ventilation is not

adequate.

adequate.adequate.

adequate.

SECTION 1 SAFETY

1-6

WARNING

!

WARNING

!

Radiation hazard.

Arc rays can injure eyes and bur

Arc rays can injure eyes and burArc rays can injure eyes and bur

Arc rays can injure eyes and burn skin.

n skin.n skin.

n 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

Shad

ShadShad

Shade No. 10

e No. 10e No. 10

e 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 reflectio

Prepare cutting area to reduce reflectioPrepare cutting area to reduce reflectio

Prepare cutting area to reduce reflection and

n and n and

n 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

Mishandling gas cylinders can Mishandling gas cylinders can

Mishandling gas cylinders can rupture and violently

rupture and violently rupture and violently

rupture 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 objectchain or strap to a suitable stable object

chain or strap to a suitable stable object not part of

not part of not part of

not part of

an electrical circuit.

an electrical circuit.an electrical circuit.

an 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”,

Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”,

Handling of Compressed Gases in Cylinders”,

available from Compressed Gas Associati

available from Compressed Gas Associatiavailable from Compressed Gas Associati

available from Compressed Gas Association.

on.on.

on.

SECTION 1 SAFETY

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 combustibles.

Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.

Do not cut containers that have held combustibles.

• Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g. Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g.

butane lighter).

butane lighter).butane lighter).

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 sparks

Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks

Wear cuffless trousers to prevent entry of sparks

and slag.

and slag.and slag.

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 table.

These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.

These alloys should only be dry cut on a dry 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

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.

1.6 Service Precautions

CAUTION

Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. A

c

cc

composite program can be established from

omposite program can be established from omposite program can be established from

omposite 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 machine.

could occur to equipment or machine.could occur to equipment or machine.

could occur to equipment or machine.

SECTION 1 SAFETY

1-9

CAUTION

!

Extreme caution should

Extreme caution should Extreme caution should

Extreme caution should be used when probing

be used when probing be used when probing

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 circuit boards securely seated in sockets,

All circuit boards securely seated in sockets, All circuit boards securely seated in sockets,

All circuit boards securely seated in sockets, all cables

all cables all cables

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 voltage

machine power is on. Instantaneous surges of voltage machine power is on. Instantaneous surges of voltage

machine power is on. Instantaneous surges of voltage

and current can damage electro

and current can damage electroand current can damage electro

and current can damage electronic components.

nic components.nic components.

nic components.

SECTION 1 SAFETY

1-10

1.7 Safety References

The following nationally 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.

• “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.

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.

• See end of section or replacement parts for information on torch part kits.

Torch For Mini-Bevel Head 12 ft (3.7 m) lead 12 ft. (3.7 m) 0560935685

Torch For Mini-Bevel Head 14 ft (4.3 m) lead 14 ft. (4.3 m) 0558005850

Torch Assemblies 4.5 ft. (1,3 m) 0558001827

6 ft. (1,8 m) 0558001828

7.2 ft. (2,2 m) 0558004123

12 ft. (3,7 m) 0558001829

15 ft. (4,6 m) 0558001830

17 ft. (5,2 m) 0558001831

20 ft. (6,1 m) 0558001832

25 ft. (7,6 m) 0558001833

2.3 Package Options Available

PT-600 package options available through your ESAB dealer, see section 7 for replacement component part numbers.

2.2 Scope

The purpose of this manual is to provide the operator with all the information required to install and operate the PT-600 Mecha-

nized Plasma Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package.

2.1 General

The PT-600 Mechanized Plasma Cutting Torch is a plasma arc torch factory assembled to provide torch component concentric-

ity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the Only the torch front-end has

replaceable parts.

SECTION 2 DESCRIPTION

2-1

Torch For Mini-Bevel Head 14 ft (4.3 m) lead 14 ft. (4.3 m) 0558007580

( Karben - Replacement Parts 7.8 )

Technical Specications

SECTION 2 DESCRIPTION

2-2

2.4 PT-600 Technical Specifications

2.4.1 Plasma Gas Technical Specifications

Type O

2

, N

2

, Air, H-35

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

Flow

250 cfh (118 l/min) max. at 600A

(varies with application)

Purity Required*

O

2

-99.5%

N

2

-99.995%

H-35 Specialty gas

Air-clean, dry and oil free

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)

Industrial Air: R-77150-590 (P/N

998348)

Recommended Heavy –Duty Hi-flow

Station or Pipeline Regulators

Oxygen: R-76-150-024 (P/N 19151)

Recommended High-capacity Station

or Pipeline Regulators

R-6703 (P/N 22236)

Gas Filter Required 25 micron w/bowl guard (P/N 56998133)

2.4.2 Start Gas Technical Specifications

Type N

2

, Air, H-35

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

Flow

250 cfh (118 l/min) max @ 600A

(varies with application)

Minimum Purity Required 99.995% clean, dry, oil free

2.4.3 Secondary Gas Technical Specifications

Type N

2

, Air

Pressure 100 to 125 psig (6.9 – 8,6 bars)

Flow

485 cfh (228,9 l/min) max (varies with

application)

Minimum Purity Required

99.995% clean, dry, oil free (

Same source as

start gas)

Gas Filter Required 25 micron w/bowl guard (P/N 56998133)

2.4.4 PT-600 Torch Technical Specifications

Type Water-Cooled, Dual Gas

Rating 600 amps @ 100 % duty cycle

Dimensions See Package Options (2.3). This section.

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ESAB PT-600 Mechanized Plasma Cutting Torch User manual

ESAB PT-600 Mechanized Plasma Cutting Torch User manual

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