ESAB PT-20AMX Plasmarc Cutting Torch and PT-21AMX Plasmarc Cutting Torch Installation guide

F15-778

December 2006

Installation, Operation and Maintenance

PT-20AMX Plasmarc Cutting Torch

and

PT-21AMX Plasmarc 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

F15-778

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.

Table of Contents

i

Page

Safety

Introduction ........................................................................................... 1

Safety Notations And Symbols ................................................................ 2

General Safety Information ...................................................................... 3

Installation Precautions............................................................................ 3

Electrical Grounding................................................................................ 5

Operating A Plasma Cutting Machine ...................................................... 5

Service Precautions ................................................................................ 9

Safety References................................................................................... 10, 11, 12

I. Description Introduction .....................................................................

13

II. Accessories.......................................................................................... 14

III. Installing Front End Parts.................................................................. 16

IV. Operation – Cutting Parameters....................................................... 20

V. Maintenance........................................................................................ 21

A. General.............................................................................................

21

B. Dirt or Contamination........................................................................

22

C. Loose Consumables.........................................................................

22

D. Damage Caused By Loose Parts and Torch Over Heating...............

23

E. Consumables – Removal and Replacement.....................................

23

F. Measuring Torch Gas Flows.............................................................

25

G. Removal and Replacement of Torch Body .......................................

26

PT-20AMX Torch ...............................................................................

26

PT-21AMX Torch ...............................................................................

27

H. Removal and Replacement of Torch Cables.....................................

28

VI. Replacement Parts ............................................................................ 30

PT-20AMX 4ft, 17ft, and 25 ft.................................................................

30,31

PT-20AMX 50 ft. Wire Mesh Shielded....................................................

32,32

PT-21AMX Torches................................................................................

34,35

Table of Contents

ii

PT-20/21 AMX Plasmarc Torches

1

Safety 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.

PT-20/21 AMX Plasmarc Torches

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 with other symbols and information.

DANGER

!

Used to call attention to immediate hazards

which, if not avoided, will result in serious

personal injury or loss of life.

WARNING

!

Used to call attention to potential hazards that

could result in personal injury or loss of life.

CAUTION

!

Used to call attention to hazards that could

result in minor personal injury or equipment

damage.

CAUTION

Used to call attention to minor hazards to

equipment.

NOTICE

Used to call attention to important

installation, operation or maintenance

information not directly related to safety

hazards.

PT-20/21 AMX Plasmarc Torches

3

General Safety Information

WARNING

!

Machinery often starts automatically.

This equipment moves in various directions and

speeds.

· Moving machinery can crush.

· Only qualified personnel should operate or

service this power source.

· Keep all personnel, materials, and equipment

not involved in production process clear of

entire system area.

· Fence off entire work cell to prevent personnel

from passing through area or standing in the

working envelope of the equipment.

· Post appropriate WARNING signs at every

work cell entrance.

· Follow lockout procedure before servicing any

equipment.

WARNING

!

Failure to follow operating instructions

could result in death or serious injury.

Read and understand this operator’s manual

before using machine.

· Read entire procedure before operating or

performing any system maintenance.

· Special attention must be given to all hazard

warnings that provide essential information

regarding personnel safety and/or possible

equipment damage.

· All safety precautions relevant to electrical

equipment and process operations must be

strictly observed by all having system

responsibility or access.

· Read all safety publications made available by

your company.

PT-20/21 AMX Plasmarc Torches

4

WARNING

!

Failure to follow safety warning label

instructions could result in death or

serious injury.

Read and understand all safety warning labels on

machine.

Refer to operator’s manual for additional safety

information.

Installation Precautions

DANGER

!

Improperly Installed Equipment Can

Cause Injury Or Death.

Follow these guidelines while installing machine:

· Contact your ESAB representative before

installation. He can suggest certain

precautions regarding piping installation and

machine lifting, etc. to ensure maximum

security.

· Never attempt any machine modifications or

apparatus additions without first consulting a

qualified ESAB representative.

· Observe machine clearance requirements for

proper operation and personnel safety.

· Always have qualified personnel perform

installation, troubleshooting and maintenance

of this equipment.

· Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

PT-20/21 AMX Plasmarc Torches

5

Electrical Grounding

Electrical grounding is imperative for proper

machine operation and SAFETY. Refer to this

manual’s Installation section for detailed grounding

instructions.

WARNING

!

Electric shock hazard.

Improper grounding can cause severe injury or

death.

Machine must be properly grounded before put

into service.

Operating A Plasma Cutting Machine

WARNING

!

Flying debris and loud noise

hazards.

· Hot spatter can burn and injure eyes. Wear

goggles to protect eyes from burns and flying

debris generated during operation.

· Chipped slag may be hot and fly far.

Bystanders should also wear goggles and

safety glasses.

· Noise from plasma arc can damage hearing.

Wear correct ear protection when cutting

above water.

WARNING

!

Burn hazard.

Hot metal can burn.

· Do not touch metal plate or parts immediately

after cutting. Allow metal time to cool, or douse

with water.

· Do not touch plasma torch immediately after

cutting. Allow torch time to cool.

PT-20/21 AMX Plasmarc Torches

6

DANGER

!

Hazardous voltages. Electric shock

can kill.

· Do NOT touch plasma torch, cutting table or

cable connections during plasma cutting process.

· Always turn power off to plasma power

supplies before touching or servicing plasma torch.

· Always turn power off to plasma power

supplies before servicing any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when

machine is connected to power source.

· Wear insulating gloves, shoes and clothing to

insulate yourself from workpiece and electrical

ground.

· Keep gloves, shoes, clothing, work area, and

equipment dry.

· Replace worn or damaged cables.

WARNING

!

Fume hazard.

Fumes and gases generated by the plasma cutting

process can be hazardous to your health.

· Do NOT breathe fumes.

· Do not operate plasma torch without fume

removal system operating properly.

· Use additional ventilation to remove fumes if

necessary.

· Use approved respirator if ventilation is not

adequate.

· Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper,

zinc, beryllium, or cadmium. Do not breathe these

fumes.

·

Do not operate near degreasing and spraying

operations. Heat or arc rays can react with

chlorinated hydrocarbon vapors to form phosgene,

a highly toxic gas and other irritant gases.

PT-20/21 AMX Plasmarc Torches

7

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn skin.

· Wear correct eye and body protection.

· Wear dark safety glasses or goggles with side

shields. Refer to following chart for recommended

lens shades for plasma cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

· Replace glasses/goggles when lenses are

pitted or broken

· Warn others in area not to look directly at the

arc unless wearing appropriate safety glasses.

· Prepare cutting area to reduce reflection and

transmission of ultraviolet light.

§ Use special paint on walls to absorb UV

light.

§ Install protective screens or curtains to

reduce ultraviolet transmission.

PT-20/21 AMX Plasmarc Torches

8

WARNING

!

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

· Do not cut near combustible material.

· Do not have on your person any combustibles

(e.g. butane lighter).

· Pilot arc can cause burns. Keep torch nozzle

away from yourself and others when activating

plasma process.

· Wear correct eye and body protection.

· Wear gauntlet gloves, safety shoes and hat.

· Wear flame-retardant clothing covering all

exposed areas.

· Wear cuffless trousers to prevent entry of

sparks and slag.

· Have fire extinguishing equipment available for

use.

WARNING

!

Explosion hazard.

· Certain molten aluminum-lithium (Al-Li) alloys

can cause explosions when plasma cut OVER

water.

§ These alloys should only be dry cut on a

dry table.

§ DO NOT dry cut over water.

§ Contact your aluminum supplier for

additional safety information regarding

hazards associated with these alloys

.

·

Do not cut in atmospheres containing

explosive dust or vapors.

·

Do not carry any combustibles on your person

(e.g. butane lighter)

· Do not cut containers that have held

combustibles.

PT-20/21 AMX Plasmarc Torches

9

Service Precautions

DANGER

!

Hazardous voltages. Electric shock

can kill.

· Do NOT touch plasma torch, cutting table or

cable connections during plasma cutting process.

· Always turn power off to plasma power

supplies before touching or servicing plasma torch.

· Always turn power off to plasma power

supplies before removing covers or panels to

service any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when

machine is connected to power source.

· Keep gloves, shoes, clothing, work area, and

equipment dry.

· Inspect power and ground leads cables for

wear or cracking. Replace worn or damaged

cables. Do not use if damaged.

· Never bypass safety interlocks.

· Follow lock-out procedures.

CAUTION

Establish and adhere to preventive maintenance.

A composite program can be established from

recommended schedules.

Avoid leaving test equipment or hand tools on

machine. Severe electrical or mechanical damage

could occur to equipment or machine.

CAUTION

!

Extreme caution should be used when probing

circuitry with an oscilloscope or voltmeter.

Integrated circuits are susceptible to over voltage

damage. Power off before using test probes to

prevent accidental shorting of components.

All circuit boards securely seated in sockets, all

cables properly connected, all cabinets closed and

locked, all guards and covers replaced before

power is turned on.

PT-20/21 AMX Plasmarc Torches

10

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.

USA

· “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.

PT-20/21 AMX Plasmarc Torches

11

International

Accident Prevention

VBG 1 General Provisions

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working

methods

VBG 48 Shot Blasting Works

VBG 61 Gases

VBG 62 Oxygen

VBG 87 Operating liquid jet cutting machines

VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE Regulations

VDE 0100 Erection of power installations with normal

voltages up to 1000 volts

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users

guide (DIN EN 60825)

VDE 0837-

50

Specification for laser guards

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-204 Acetylene lines

TRAC-206 Acetylene cylinder battery systems

TRAC-207 Safety devices

TRG Technical Rules for Pressure gases

TRG 100 General regulations for pressure gases

TRG 101 Pressure gases

TRG 102 Technical gas mixtures

TRG 104 Pressure gases; alterative use of

compressed gas tanks

PT-20/21 AMX Plasmarc Torches

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

PT-20/21 AMX Plasmarc Torches

13

WARNING

!

· The plasma arc cutting process employs

extremely high voltages. Avoid contact with

"live" parts of the torch and machine.

· The improper use of any of the gases

employed can present a safety hazard.

· Before beginning operation with the PT-

20AM torch, read and understand all safety

precautions covered in this instruction

manual.

I. Description Introduction

PT-20 AMX

This booklet covers mainly accessories,

maintenance, and parts information for the PT-

20AMX and PT-21AMX plasma torches. For

installation and operating instructions for your

cutting package, refer to your power source

instruction manual.

The patented PT-20AMX is a 100 amp capacity,

pilot-arc mechanized torch available in 6 different

versions. The torch uses clean, dry air as the cut

gas for cutting carbon steel, aluminum, or stainless

steel.

PT-21 AMX Torch is identical to the PT-20 AMX torch

except it is specifically designed to connect to the

PowerCut 1250 and 1500 plasma power sources.

Without Rack; 25 ft. 0558003426

With Rack; 25 ft. 0558003427

Without Rack; 50 ft. 0558003422

With Rack; 50 ft. 0558003421

RAS; With Rack, 4 ft. 0558003424

RAS, With Rack, 17 ft. 0558003425

PT-21 AMX (for use with PowerCut 1250 and PowerCut 1500)

Without Rack; 50 ft. 0558003615

With Rack; 50 ft. 0558003614

Without Rack; 25 ft. 0558003617

With Rack; 25 ft. 0558003616

WARNING

!

DO NOT use oxygen with this torch!

A hazardous fire may result.

PT-20AMX

PT-20/21 AMX Plasmarc Torches

14

Dimensional Data – PT-20AMX

Without Rack

With Rack

II. Accessories

PT-20AMX Torch Spare Parts Kits - The following

three spare parts kits are available for maintaining

the PT-20AMX torch with minimum downtime.

50 Amps - 21370

70 Amps - 21369

100 Amps – 21376

PT-21 AMX torch uses the same spare parts as

the PT-20AMX.

50 AMP 21370 70 AMP 21369 100 AMP 21376

Description

Quantity

Heat Shield (70/100 A), 21326 - 2 2

Heat Shield (50 A), 21447 2 1 1

Cutting Nozzle (50 A), 21330 5 5 5

Cutting Nozzle (70 A), 21329 - 5 5

Cutting Nozzle (100 A), 21328 - - 5

Electrode, 21150 5 5 5

Electrode 50Hz, 0558001617 5** 5** 5**

Electrode Seat, 21372

1 1 1

Electrode Insulator, 21373 1 1 1

Electrode Holder Assy, 21332 1 1 1

Baffle Tube, 21374 1 1 1

Pilot Arc Adaptor, 19497 1 1 1

O-ring, 488157 5 5 5

Lubricant (1 oz.), 17672 1 1 1

Seat/Baffle Wrench, 21375 1 1 1

1/16: Hex-Key Wrench, 93750006 1 1 1

17.125 inches

1.375 inches

14.5 inches

7.63 inches

PT-20/21 AMX Plasmarc Torches

15

Torch Holder Assembly – 0558005926

Plasma Flow Measuring Kit -- 19765

Remote Hand Control Switch with 7,6m lead

For PT-20 AMX -- 680982

For PT-21 AMX -- 0558003612

Adaptor for PCM-875 and PCM-1125 -- 19500

PT-20/21 AMX Plasmarc Torches

16

III. Installing Front End Parts

WARNING

!

Make sure power switch on console is in

OFF position and primary input power is

de-energized.

Seat

Wrench

21375

1. The seat comes assembled to the front end

of the torch. IF the seat becomes damaged, the

torch body must be replaced. DO NOT attempt

to remove the seat from torch body.

Electrode Holder Assembly

Baffle Tube

2. Electrode holder assembly (21332) includes

the baffle tube (21374). If baffle tube becomes

damaged, it can be replaced by un-threading the

damaged tube out of the holder. Use small hex

end of the wrench (21375) in hex broach on the

tube. Tighten tube securely but do not over-

tighten.

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ESAB PT-20AMX Plasmarc Cutting Torch and PT-21AMX Plasmarc Cutting Torch Installation guide

ESAB PT-20AMX Plasmarc Cutting Torch and PT-21AMX Plasmarc Cutting Torch Installation guide

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