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.
© ESAB Cutting Systems, 2002
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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