ESAB PT-27 Plasma Arc Cutting Torch User manual

PT-27

Plasma Arc Cutting Torch

Instruction Manual

0558005160 07/2006

This manual provides installation and operation instructions for the following PT-27 torches:

P/N 21620 - 25 ft (7.6 m), PT-27, w/PLUG Pilot Arc Connection

P/N 21621 - 50 ft (15.2 m), PT-27, w/PLUG Pilot Arc Connection

P/N 21661 - 25 ft (7.6 m), PT-27, w/RING Pilot Arc Connection

P/N 21662 - 50 ft (15.2 m), PT-27, w/PLUG Pilot Arc Connection

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

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

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

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

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

2.0 Description

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.3 Speciﬁcations

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.4 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

3.0 Assembly & Operation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

3.3 Steel Heat Shield Guards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

4.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.2 Inspection and Cleaning of Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4.3 Removing/Replacing Torch Head & Switch from Service Line

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

4.4 Pilot Arc Lead and Insulators Assembly Detail

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.5 Switch and Pillot Arc Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Section / Title Page

4

TABLE OF CONTENTS

5

SECTION 1 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

precautions 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 ﬁtted with the correct ﬁlter and

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

ears from sparks and rays of the arc when operat-

ing 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 ﬂameproof gauntlet type gloves, heavy long-

sleeve shirt, cuﬄess 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 ﬂameproof 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 cuﬀs, 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-ﬂammable partition or

curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can ﬂy far.

Bystanders should also wear goggles over safety

glasses.

FIRES AND EXPLOSIONS --

Heat from

ﬂames and arcs can start ﬁres. Hot

slag or sparks can also cause ﬁres and

explosions. Therefore:

1. Remove all combustible materials well away from

the work area or cover the materials with a protec-

tive non-ﬂammable 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 ﬂoors or wall openings and cause a hid-

den smoldering ﬁre or ﬁres on the ﬂoor 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 ﬂammable or toxic vapors. Do not do hot

work on closed containers. They may explode.

4. Have ﬁre extinguishing equipment handy for instant

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

or portable ﬁre 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 ﬁre 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 ﬁre. Use ﬁre 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 conﬁned, or if there is

danger of falling.

6

SECTION 1 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 oﬀ the power before removing your gloves.

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

next page) for speciﬁc grounding recommenda-

tions. Do not mistake the work lead for a ground

cable.

ELECTRIC AND MAGNETIC FIELDS

— May be dangerous. Electric cur-

rent ﬂowing 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 eﬀects 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 conﬁned 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 speciﬁc ventilation recommendations.

7

SECTION 1 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 ﬁttings 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 ﬁxtures 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 ﬂames.

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 Jeﬀerson Davis Highway,

Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualiﬁed personnel perform the instal

-

lation, troubleshooting, and maintenance work.

Do not perform any electrical work unless you are

qualiﬁed 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

SECTION 1 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

SECTION 2 DESCRIPTION

WARNING

2.1 General

The patented PT-27 (Figure 2-2) is a manual torch with a 75° head designed for use with several Plasma Arc Cut-

ting Packages using clean, dry air as the plasma gas. The service line lengths available with the PT-27 torch are

25 feet (7.6 m) and 50 feet (15.2 m). The PT-27 torch is rated to operate at a maximum of 80 amperes at 100%

duty cycle.

2.2 Scope

This manual is intended to provide the operator with all the information required to assemble, operate, and

repair the PT-27 Plasma Arc Cutting Torch. For additional safety precautions, process instructions, and system

troubleshooting; refer to the appropriate instruction manual for your Plasma Arc Cutting Package.

2.3 Speciﬁcations

Refer to Figure 2-1, Figure 2-2, and Figure 2-3 for speciﬁcations.

THE PLASMA ARC CUTTING PROCESS EMPLOYS HIGH VOLTAGES.

CONTACT WITH "LIVE" PARTS OF THE TORCH AND MACHINE MUST

BE AVOIDED. ALSO, THE IMPROPER USE OF ANY OF THE GASES EM

PLOYED CAN PRESENT A SAFETY HAZARD. BEFORE BEGINNING OP

ERATION WITH THE PT27 TORCH, REFER TO THE SAFETY PRECAU

TIONS AND OPERATING INSTRUCTIONS IN THE APPROPRIATE POWER

SOURCE INSTRUCTION MANUAL.

USING THE TORCH ON ANY UNIT NOT EQUIPPED WITH A MATING

SAFETY INTERLOCK CIRCUIT MAY EXPOSE OPERATOR TO UNEXPECT

ED HIGH VOLTAGE.

Figure 2-1. PT-27 Speciﬁcations

Torch Assembly

(P/N)

Service Line

Length

Weight Pilot Arc Connection Type Current Capacity

(100% duty)

21620 25 ft (7.6 m) 6.9 lbs (3.1 kg) PLUG

(for service with older consoles

equipped with pilot arc receptacles) 80 A DCSP21621 50 ft (15.2 m) 9.6 lbs (4.4 kg)

21661 25 ft (7.6 m) 6.9 lbs (3.1 kg) RING

(for service with current consoles

equipped with pilot arc terminal studs) 21662 50 ft (15.2 m) 9.6 lbs (4.4 kg)

18

SECTION 2 DESCRIPTION

7.3" (185 mm)

1" (25.4 mm)

75°

3" (76 mm)

Figure 2-2. PT-27 Dimensions

THICKNESS (IN. STEEL)

SPEED (IN. PER MIN.)

Figure 2-3. PT-27 Cutting Performance

19

SECTION 2 DESCRIPTION

2.4 Optional Equipment (NOT SUPPLIED WITH TORCH)

A. Spare Parts Kits - The spare parts kits listed in ﬁgure 2-4 are recommended for maintaining the PT-27

torch with minimum downtime.

DESCRIPTION PART NUMBER (50/70 A Kit - P/N 21623) PART NUMBER (80 A Kit - P/N 21624)

Heat Shield 21616 (QTY 2) 21616 (QTY 2)

Stand Oﬀ Guide 21420 (QTY 1) 21420 (QTY 1)

Nozzle, 50-70 A 33369 (QTY 4) --

Nozzle, 80 A -- 33418 (QTY 4)

Swirl Baﬄe 33367 (QTY 1) 33367 (QTY 1)

Electrode 33366XL (QTY 3) 33366XL (QTY 3)

Fuse, 600 Vdc, 15 A, Fast Acting 952137 (QTY 1) 952137 (QTY 1)

Figure 2-4. Contents of PT-27 Spare Parts Kits

B. Steel Guards (for extending the life of the heat shield) - Refer to Figure 3-2 for installation and opera-

tion.

PLASMA GUIDE KIT - P/N 604607

consists of:

circle guide adapter/bushing

roller guide radius bar

pivot pin suction pivot

magnetic pivot operator's manual

PLAIN TYPE

P/N 35443

GOUGING NOZZLE

P/N 35442

STAND OFF GUIDE TYPE

P/N 21420

C. Gouging Nozzle

D. Plasma Guide Kit

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21

SECTION 3 ASSEMBLY & OPERATION

3.1 GENERAL

THE TORCH HEAD CONTAINS A GAS FLOW CHECK VALVE THAT ACTS IN

CONJUNCTION WITH CIRCUITRY WITHIN THE POWER SOURCE. THIS

SYSTEM PREVENTS THE TORCH FROM BEING ENERGIZED WITH HIGH

VOLTAGE IF THE TORCH SWITCH IS ACCIDENTALLY CLOSED WHEN THE

SHIELD IS REMOVED. ALWAYS REPLACE TORCH WITH THE PROPER

TORCH MANUFACTURED BY ESAB SINCE IT ALONE CONTAINS ESAB'S

PATENTED SAFETY INTERLOCK.

ELECTRODE

SWIRL BAFFLE

NOZZLE

SHIELD

THREAD THIS ASSEMBLY TO THE

TORCH BODY AND HAND TIGHTEN.

2

3

IMPORTANT!

MAKE SHIELD VERY TIGHT!

PLACE THE NOZZLE, SWIRL BAFFLE,

AND ELECTRODE INTO THE SHIELD

1

Figure 3-1. Assembly of PT-27 Torch Front End Parts

3.2 Assembly

Install PT-27 front end parts as shown in Figure 3-1.

MAKE SURE POWER SWITCH ON CONSOLE IS IN THE "OFF" POSITION

AND PRIMARY INPUT POWER IS DEENERGIZED.

WARNING

22

SECTION 3 ASSEMBLY & OPERATION

3.3 Steel Heat Shield Guards

THIN GAUGE MATERIALS

CAN BE CUT WITH 1/16" (2.6 mm)

TORCH-TO-WORK DISTANCE

ADJUST TO 3/16" (4.8 mm) FOR

MATERIALS OVER 1/4" (6.4 mm) THICK

ADJUST GUIDE BY TURNING

IN A CLOCKWISE DIRECTION

ONLY. THIS WILL PREVENT

ACCIDENTAL LOOSENING

OF SHIELD.

STEEL GUARD

STAND OFF GUIDE

P/N 21420

IF GUIDE IS TOO TIGHT ON

SHIELD, OPEN SLOT WITH

SCREWDRIVER.

IF TOO LOOSE, CLOSE

SLOT WITH VISE OR

LARGE PLIERS.

1/16" (2.6 mm) TO 1/4" (6.4 mm)

TORCH-TO-WORK

GUIDE AGAINST

STRAIGHT EDGE

OR FREE-HAND

CUT

STEEL GUARD (P/N 35443) PRO-

TECTS SHIELD WHEN CUTTING

OR GOUGING.

Figure 3-2. Installation and Operation of Steel Heat Shield Guards

23

4.2 INSPECTION AND CLEANING OF CONSUMABLES

A. Disassemble the front end of the PT-27 as follows:

1. Position torch head in a downward direction (refer to Figure 3-1) and remove the shield. The nozzle, swirl

baﬄe, and electrode will drop from the head and remain in the shield. Remove these components and

inspect for wear. The nozzle and electrode will generally wear at the same rate. For best performance,

replace together.

2. Nozzle: Replace if the oriﬁce is clogged, nicked, or out-of-round.

3. Electrode: See Figure 4-1 for electrode maintenance.

4. Shield: The face of the shield will gradually erode from the heat and molten metal spray. Replace the

shield if more than 1/8 inch (3.2 mm) has eroded from the face. Refer to Figure 4-1.

5. Swirl Baﬄe: This is a ceramic part and may crack or chip if dropped. Always replace if cracks or chips are

present.

6. O-ring: Lubricate as per Figure 4-1. Replace if cut or worn. Air leaking past this seal will reduce cutting

performance.

B. To replace the above front end components, refer to Figure 3-1.

Figure 4-1. O-ring, Electrode, and Shield Maintenance

HEAT SHIELD

LUBRICANT (P/N 17672) CAN BE APPLIED TO

O-RING OR HEAT SHIELD.

THE HEAT SHIELD FACE WILL GRADUAL-

LY ERODE WITH USE. SEE PARAGRAPH

4.2.A.4.

19/32"

(15.1 mm)

REPLACE ELECTRODE BEFORE LENGTH

BECOMES SHORTER THAN 19/32 INCH -

(15.1 mm).

O-RING

ELECTRODE

WARNING

4.1 GENERAL

BEFORE ANY MAINTENANCE IS ATTEMPTED ON THIS TORCH, MAKE

SURE THE POWER SWITCH ON THE CONSOLE IS IN THE "OFF" POSI

TION AND THE PRIMARY INPUT IS DEENERGIZED.

SECTION 4 MAINTENANCE

24

SECTION 4 MAINTENANCE

BE SURE TO TIGHTEN POWER CABLE CONNECTIONS SECURELY US

ING 2 WRENCHES DURING REASSEMBLY. FACTORY RECOMMENDED

TORQUE IS 3.39 NM OR 30 INLBS. FAILURE TO DO SO COULD RE

SULT IN SERIOUS INJURY TO THE OPERATOR.

WARNING

4.3 Removing / Replacing Torch Head and Switch from Service Line

Figure 4-2. Removal of Torch Head and Switch from Service Line

2

3

1

Snap switch band from handle and release

switch, no further disassembly is required

for switch replacement. (see ﬁgure 4-5 for

switch replacement)

Vinyl tape

Cable Bundle Assembly

Push ﬂex support

back from handle

Handle

Power Cable

Tube Insulator

Two wrenches (3/8” & 7/16”)

Strip Insulator

Torch Head-

Unscrew handle, remove tape that secures both strip

and tube insulators. Remove head from power cable.

(use two wrenches, see warning above)

Knife connection

Cable Bundle Assembly

Handle

Tube Insulator

jacket rolled back

Black Pilot Arc lead

Switch leads

Remove tape securing the jacket and control wires.

(note how switch leads are coiled around power

cable and the loop in the pilot arc lead. Reassemble

in like manner). See ﬁgure 4-3 for reassembling pilot

arc lead.

Pull black pilot arc lead out from tube

insulator to expose knife connections.

Open knife connections. Slide handle

and tube insulator from service line to

complete the disassembly. (see ﬁgure

4-3 for reassembling the pilot arc lead

and insulators)

25

SECTION 4 MAINTENANCE

Figure 4-3. Attaching Pilot Arc Lead and Assembling Insulators

4.4 Pilot Arc Lead and Insulators Assembly Detail

2

3

1

PT-27 Head

Slide tube insulator on pilot arc lead

jacket rolled back

Black Pilot Arc lead

Vinyl tape

Strip Insulator

p/n 21510

Connect power cable

(see warning ﬁgure 4-2)

Pull pilot arc lead out

from handle. Keep tube

insulator against head.

Place strip insulator between power cable

connection and tube insulator. Tape in place

as illustrated.

Loop to remove slack

(see ﬁgure 4-2).

26

4.5 SWITCH AND PILOT ARC PLUGS

Figure 4-4. Switch and Pilot Arc Plug Removal/Replacement

STRAIN RELIEF

TUBING - 21622

SWITCH PLUG

P/N 2062336

WHITE SWITCH LEADS (2)

FROM TORCH SWITCH

STRAIN RELIEF

TUBING - P/N 18226

STRIP INSULATION 1/4" (6.4 mm)

BRASS TERMINAL

BLACK PILOT ARC LEAD

BLUE JUMPER

(SEE BELOW)

DO NOT STRIP INSULATION FROM

THESE THREE WIRES

*PILOT ARC PLUG

P/N 21427

A. SWITCH PLUG

CHROME PLATED TERMINAL

BLACK PILOT ARC LEAD

(ATTACH TO CHROME PLATED TERMINAL)

BLUE JUMPER

STRAIN RELIEF TUBING

P/N 21622

PILOT ARC PLUG

P/N 21427

BRASS TERMINAL

CHROME PLATED TERMINAL

B. PILOT ARC LEAD AND PLUG

(ON TORCH ASSEMBLY 21620)

DO NOT INTERCHANGE THE TORCH SWITCH PLUG AND THE PILOT

ARC PLUG. IF IT BECOMES NECESSARY TO REMOVE THESE PLUGS,

MAKE SURE THE SWITCH PLUG P/N 2062336 IS ATTACHED TO THE

TWO WHITE SWITCH LEADS AND THE PILOT ARC PLUG P/N 21427 IS

ATTACHED TO THE BLACK LEAD WITH THE BLUE JUMPER WIRE.

INTERCHANGING THESE PLUGS MAY CREATE AN UNSAFE CONDITION

THAT COULD CAUSE ELECTRIC SHOCK AND BURNS.

*TORCH ASSEMBLY 21661 USES A RING CONNECTOR IN PLACE OF THIS

PLUG (REFER TO FIGURE 5-1)

WARNING

SECTION 4 MAINTENANCE

27

SECTION 4 MAINTENANCE

Figure 4-5. Switch Replacement Detail

CRIMP OR SOLDER

To replace - Remove switch band from torch (see ﬁgure 4-2). Pull the switch and end plug out of the cover. Snip

the white leads from the switch (leads supplied with the torch cable bundle are suﬃciently long to allow cut-

ting). Crimp or solder the replacement switch to the leads.

WHITE LEADS

COVER

SWITCH END PLUG

SWITCH KIT P/N 0558005509

Note:

Switch can be mounted on top or bottom of handle.

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29

SECTION 5 REPLACEMENT PARTS

5.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on

the unit nameplate.

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this

equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone

numbers.

5.2 Ordering

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

Note

5.0 Replacement Parts

30

SECTION 5 REPLACEMENT PARTS

Switch Kit - p/n 0558005509

(see ﬁgure 4-5)

jacket shown rolled back

Flex Support - p/n 21218

Boot - p/n 49N83

Cable Bundle Assembly

25 ft (7.6 m) - p/n 0558005677

50 ft (15.2 m) - p/n 0558006547

Switch Band - p/n 33400

Tube Insulator supplied

with torch assembly

Insulator - p/n 21510

(supplied with head)

Knife connections -

p/n 98W40

(2 supplied with head)

Handle - p/n 33399

Gas & Power 5/8 - 18 L.H.

Switch Plug -

p/n 2062336

Figure 4-4 A

Pilot Arc Ring Terminal

(supplied on torch assembly

21661)

Strain Relief

- p/n 18226

Strain Relief

- p/n 21622

Pilot Arc Plug -

(supplied on torch assembly 21620,

see ﬁgure 4-4 B)

75° Head - p/n 21610

includes:

Insulator - p/n 21510

Knife Connect - p/n 98W40

O-ring - p/n 85W51

Seat - p/n 0558003032

PT-27 Torch

Replaceable Seat -

p/n 0558003032

Seat Installation Tool -

p/n 0558003027

The seat is removed and replaced using the ESAB seat

tool.

All torch assemblies and replacement heads are supplied

with the seat installed.

O-ring - p/n 85W51

(Supplied with head)

Electrode - p/n 33366XL

Swirl Baﬄe - p/n 33367

Nozzle 30 amp - p/n 33368

*50 - 70 amp - p/n 33369

80 amp - p/n 33418

Gouging - p/n 35442

Shield - p/n 21616

*Replacement torches are supplied

with 50 amp nozzles.

Figure 5-1. PT-27 Torch Assembly Replacement Parts

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ESAB PT-27 Plasma Arc Cutting Torch User manual

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