ESAB PT-15XL Plasmarc Cutting Torch User manual

Brand: ESAB

Model: PT-15XL Plasmarc Cutting Torch

Category: Welding System

Type: User manual

PT-15XL PLASMARC CUTTING TORCH

P/N 21307 .............................4 1/2' Leads for ESP System

P/N 21304 .............................6' Leads for ESP System

P/N 21305 .............................12' Leads for ESP System

P/N 21306 .............................17' Leads for ESP System

P/N 21301 .............................15' Leads for ESP System

P/N 21302 .............................20' Leads for ESP System

P/N 21303 .............................25' Leads for ESP System

P/N 16365 .............................PT-15XL w/o Leads

P/N 20762 .............................6' Leads for PCM-8

P/N 602711 ...........................8' Leads for PCM-8

F-15-031B

NOTICE: This torch and its components are protected by

various U.S. and foreign patents with additional patents

pending. It is the policy of ESAB Welding & Cutting

Products to react vigorously to patent infringement of

unauthorized manufacture, sale, or use of its patented

products or spare parts.

High Voltage can kill

Disconnect Power supply from incoming electrical

power before touching or servicing the torch. Metal

parts of the torch can be at high voltage.

Plasma Cutting can produce Deadly Fumes, Fire, or

Explosion.

• Gases from plasma cutting can cause suffoca-

tion, fire, or explosion.

• Loud noise from plasma cutting can cause hear-

ing loss.

Before beginning use of the PT-15XL Torch refer to

the safety precautions in this literature and in Form

15-116 “ESP-1000 system” or Form 12-528 “PCM-8

Plasma Cutting Outfit.” Also read form 52-529 “Pre-

cautions & Safe Practices, etc. and Form 14-373

“Hydrogen Explosion Hazard” both supplied with

this torch.

I. INTRODUCTION

The PT-15XL torch, an improved version of the original

PT-15, is a component of the PCM-8 Plasmarc Mecha-

nized Cutting Package (see Form 12-528) and the ESP-

1000 System (see Form 15-116). It is designed for

plasma water injection cutting using either nitrogen (up

to 750 amps DCSP), or oxygen (up to 360 amps DCSP),

or H-35 mixture (up to 1000 amps DCSP). Each gas

requires proper front end parts (see Table 1). With

nitrogen, 1/8-in. to 3-in. thick mild steel, stainless steel,

and aluminum can be cut. Steels up to 1-1/4 in. thick can

be cut using oxygen. A high-current nozzle is available

for cutting materials from 3-in. to 6-in. thick with the PT-

15XL at up to 1000 amps. The nozzle is water cooled and

requires the use of H-35 mixture (65 Ar-35 H

) for the cut

gas.

PARTS & MAINTENANCE MANUAL for

F-15-031-B

July,1995

ESAB

ESAB Welding &

Cutting Products

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 electric welding 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.

CAUTION

DANGER

20920*

21207B

Argon

H-35

PROCESS

Nitrogen w/

Water

Injection

600236

2075343

DIA.

.125

.156

.200

.230

P/N

2075691

2075611

2075612

2075613

250A

400A

600A

750A

RATING

.125 Rev.

.156 Rev.

.200 Rev.

.230 Rev.

2075692

2075614

2075615

2075690

**4 Hole **4Hole

(Plastic) (Pink Ceramic)

2075341 948142

**4 Hole

Reverse **4 Hole Reverse

(Plastic) (Pink Ceramic)

2075360 948143

**8 Hole

(Pink Ceramic) None

2075586

Plastic baffles are usu-

ally preferred for nitro-

gen cutting.

NOTES

STANDARD

OPTIONAL

SWIRL BAFFLES

250A

400A

600A

750A

NOZZLE ASSEMBLY

ELECTRODE

HOLDER

ELECTRODE

Only ceramic baffles

may be used with over

800A .

875 A

1000 A

2075587

.250

.099

20751*

21206B

**8 Hole

(Pink Ceramic)

2075586

**4 Hole

(Pink Ceramic)

948142

Only ceramic baffles

may be used with oxy-

gen cutting

.099 Rev.

**8 Hole

Reverse Swirl

(Pink Ceramic)

20918

**4 Hole

Reverse Swirl

(Pink Ceramic)

948143

20763

Retaining Cup

Nozzle

Electrode

Electrode Holder

Baffle

Oxygen

Electrode

Gasket

Oxygen

Nozzle

Oxygen

Electrode

Holder

Baffle

.116

.120

35662

35664

300A

340A

35663

35665

300A

340A

.116 Rev.

.120 Rev.

Ceramic on Nozzle is

Replaceable

P/N 21193

35660

Baffle, Std.

**8X.047

Dia Holes

(Pink Ceramic)

35661

Baffle, Rev.

**8X.047

Dia Holes

(Pink Ceramic)

Oxygen w/

Water

Injection

.0995

2075586

**8 Hole

Used With PT-19XL

Air Curtain, P/N 34752

& P/N 35570 Retain-

ing Cup

.0995

Rev.

35666

(Flat)

20398

260A

34084

34086

(PT-19

Long)

Oxygen w/

Water

Injection

(Beveling)

None

35569

Reverse

35568

*Nozzle, 21206B and 21207B have a replaceable insulator, P/N 21193; Nozzles 20751 and 20920 do not.

20918

**8 Hole

Reverse

**8-Hole Baffles are recomended for ESP Units. 4-Hole Baffles are recomended for PCM-8.

4-Hole Optimizes Squareness.

8-Hole Optimizes Consumable Life

Cutting conditions have been developed which use the 340Amp nozzle at 360 Amps.

Table 1 - PT-15 XL Plasma Arc Cutting Torch

Front End Consumables

Table 2 - Repair Parts for N2 and H-35 Nozzles

Orif. Dia

.140

.180

.225

.260

CURRENT

RATING

250A

400A

600A

750A

1000A

Rev. Swirl

2075692

2075614

2075615

2075690

Std. Swirl

2075691

2075611

2075612

2075613

2075587

P/N

2075694

2075608

2075609

2075610

19810

Orif. Dia

.125

.156

.200

.230

.250

Std.

2075693

2075617

2075606

2075607

2075588

•Spacer - 996619

Gasket - 996628

Centering Sleeve - 996618

Std. Water Swirl Ring - 2075584

Rev. Water Swirl Ring - 2075616

NOZZLE ASSY. NOZZLE BASE INSULATORS

2075586 -8 HOLE BAFFLE, GAS SWIRL, CERAMIC - 20918 REVERSE

948142 - 4 HOLE BAFFLE, CERAMIC - 848143 REVERSE

34084 - ELECTRODE HOLDER ASSY

WATER - SET WATER FLOW AT 0.51 GPM, (High 7 on ESP Flow Control)

INLET TO TORCH PRESSURE - 35-42 PSI AT TORCH - CUTTING

25 PSI AT TORCH - STARTING

35568 - NOZZLE PT-15 O

BEVEL - 35569 REVERSE

35570 -CUP, NOZZLE RETAINING

34086 - ELECTRODE, HF

PT-15XL Plasmarc Cutting Torch For Bevel Cut

Centering Sleeve•

Gasket•

Spacer•

Insulator

Gasket

•

Nozzle Base

Water Swirl

•

0.250" DIAM.

Water Swirl•

Nozzle

Base

Centering Sleeve

•

Spacer•

Insulator

High Current Nozzle Assy

Nozzle Assy

CURRENT - 260 Amps

OXYGEN - SET O

FLOW AT 100 SCFH, (Low 5 on ESP Flow Control)

PT-15 XL Plasma Arc Cutting Torch Retaining Cups

XR Nozzles

Electrodes

Electrode Holder

Baffles

Notes on PT-15 "O" & PT-15 XL Replacement Parts

The following PT-15 "O" P/N's have been superseded

PT-15 "O" PT-15 XL Description

996252 20762 Torch Assembly

996240 20754 Body Assembly

The PT-15 XL body assembly is completely interchangeable with the PT-15

"O" body assembly and can be used to repair and maintain the PT-15 "O" as

standard PT-15 "O" assemblies

No other PT-15 "O" parts have been discontinued or superseded.

INTERCHANGEABILITY

The following components have not changed

between PT-15 "O" & PT-15XL:

Boot Hose

Nozzle Removal Tool

Electrode Removal Tool

Power Cables

Gas Hose

Water Hose

Sleeve

O-Rings

Contact Ring

Clamp

FRONT INSULATOR BODIES AND

PILOT ARC COMPONENTS

The PT-15 "O" insulator body (P/N 996232) can be used in a PT-15 XL torch

assembly if:

The PT-15 "O" pilot arc cable (996251) is used and the

PT-15 XL torch is NOT used with oxygen.

The PT-15 XL insulator Body (P/N 20755 can be used in a PT-15 "O" torch

assembly

if:

The PT-15 "O" pilot arc cable is replaced with:

RETAINING CUP NOTES

PT-15 XL cups are longer to engage an O-ring on the torch body protecting the threads when cutting underwater.

PT-15 "O" Original cups may be used with the PT-15 XL torch.

a) Some difficulty might be experienced getting the cup started onto the threads.

b) The threads will not be sealed.

PT-15 XL cups cannot be used with the PT-15 "O" torch assembly.

PT-15 "O" cups can be used with PT-15 XL torch bodies and front insulator body P/N 996232 without difficultly.

P/N Description

20760 Pilot Arc Cable

21082 Pilot Arc Bus Wire

20403 Pilot Arc Insulator

20408 HF Connector

20409 HF Connector Insulator

Oxygen & Beveling Retain-

ing Cup

P/N 20758

Cup has smaller feet and steeper

sloping sides required for beveling

up to 45

. It is also used for oxygen

cutting, straight cutting, beveling with

any gas, and is required with a bubble

muffler or air curtain. Note that long

beveling nozzles require a different

cup.

(see Figure at top of page 5)

& AR-H

Retaining

Cup

P/N 20759

Standard cup with large feet

used for flat plate cutting with or

without standard water muffler

using Nitrogen or H-35.

No Feet Retaining Cup

P/N 20973

Used where feet are an ob-

struction. This cup should not

be used with the Omni Height

Control.

Corrosion Resistant

Retaining Cup P/N

21217

Same as oxygen beveling cup

but designed to resist corrosion

in service with conductive wa-

ter.

The PT-15XL is ruggedly designed to eliminate double

arcing, high frequency leakage, and electrolytic corro-

sion of parts. Marked improvements are made in elec-

trode cooling and nozzle-electrode concentricity. As a

result, arc ignition is more reliable; the nozzle, elec-

trode, and other components will last longer; and cut

angles will be uniform and will not vary when changing

the direction of torch travel. This makes the PT-15XL

ideal for shape cutting.

This booklet covers only the accessories, maintenance,

and replacement parts for the PT-15XL torch. For com-

plete installation and operating instructions for the torch,

refer to the PCM-8 booklet, 12-528 or ESP 1000 Booklet

15-116.

II. ELECTRODES, NOZZLES, BAFFLES, &

CUPS

A. REQUIRED ACCESSORIES.

The PT-15XL torch is supplied with front end parts for

water injection cutting using nitrogen cutting gas with

currents up to 400 amps DCSP. Available nozzles and

electrodes are listed on page 4.

Typical cutting conditions on each nozzle assembly, are

in the operating table in the PCM-8 & ESP 1000 book-

lets.

B. OPTIONAL ACCESSORIES

1. PT-15XL /N

Cut Gas Spare Parts Kit, P/N 999906.

Recommended for maintaining the PT-15XL torch

with minimum downtime.

P/N 999906 Nitrogen Kit contains the following PT-

15XL, parts and tools:

4 - 0.125" Nozzle Assembly, P/N 2075691

8 - 0.156" Nozzle Assembly, P/N 2075611

6 - 0.200" Nozzle Assembly, P/N 2075612

2 - 0.230" Nozzle Assembly, P/N 2075613

10 - Electrode Tip, P/N 600236

1 - Electrode Tip Holder, P/N 2075343

4 - Gas Swirl Baffle, P/N 2075341

1 - Nozzle Retaining Cup, P/N 20759

1 - Insulator Body, P/N 20755

1 - Pilot Arc Cable, P/N 20760

1 - Contact Ring Assembly, P/N 996341

10 - O-ring, P/N 86W85

20 - O-ring, P/N 996526

10 - O-ring, P/N 996527

10 - O-ring, P/N 996528

1 - Nozzle/Elec. Tip Holder Removal Tool, P/N 999630

1 - Electrode Tip Removal Tool, P/N 996568

1 - 1/16" Allen Wrench, P/N 93750006

1 - Silicone Grease (1 oz. tube), P/N 17672

1 - Tool Box, P/N 950561

Figure 1 - PT-15XL Torch Front End Parts

ELECTRODE TIP (O )

20763 (Pkg. OF 4)

O NOZZLE ASS'Y

20751*

Oxygen Cutting Parts

TIP HOLDER (O ) - 20763

Includes O-Ring - 86W99

GAS SWIRL BAFFLE

(Ceramic) - 948142*

* See Table 1

For Options

Note:

All Set Screws Are Stainless Steel & Should Only

Be Replaced With Stainless Steel or Brass Screws.

NOZZLE RETAINING

CUP -20759

ELECTRODE TIP (N )

600236

View "A"

View "B"

TIP HOLDER

(N ) -2075343

Includes: O-Ring - 86W99

FRONT BODY

INSULATOR ASS'Y

20755

(Includes Items Marked•)

O-RING - 2064106•

(1-5/16" I.D.)

NOT SHOWN:

O-RING - 86W85• (1/2" I.D.)

(2) O-RING - 996526• (5/32" I.D.)

BODY ASS'Y - 20754

Pilot Arc Cable

& Connections

(See Fig. 4)

Hose &Cable

Connections

(See Fig. 3)

*GAS SWIRL

BAFFLE -2075341

(Poly)

NOZZLE ASS'Y -2075611

(Supplied) See Table 1

O-RING - 996527•

LOCATING PIN -

996242

O-RING - 996528•

CONTACT RING ASS'Y - 996341

Includes: Setscrew, No. 6-32 X 3/16 lg.(Cup Point)

Screw, No. 6-32 X 1/2" lg.

2. P/N 20813 Oxygen Kit contains the following PT-

15XL parts and tools:

4-0.098" Nozzle Assembly, P/N 21206B

8-Electrode Tip, P/N 20763

1-Electrode Tip Holder, P/N 20398

4-Gas Swirl Baffle, P/N 2075586

1-Nozzle Retaining Cup, P/N 20758

1-Insulator Body, P/N 20755

1-Pilot Arc Cable, P/N 20760

1-Contact Ring Assembly, P/N 996341

10-O-ring, P/N 86W85 .468 I.D.

20-O-ring, P/N 996526 .145 I.D.

10-O-ring, P/N 996527 1.30 I.D.

10-O-ring, P/N 996528 1.614 I.D.

1-Nozzle/Elec. Tip Holder Removal Tool, P/N 999630

1-Electrode Tip Removal Tool, P/N 996568

1-1/16" Allen Wrench, P/N 93750006

1-Silicone Grease (1 oz. tube), P/N 17672

1-Tool Box, P/N 950561

1-Retainer For Front Body Insulator P/N 33768

3.Reverse Swirl Nozzles and Gas Baffle

Standard swirl produces the least bevel on the right

hand side of the cut, as viewed in the direction of

travel. Sometimes, such as when mirror image cut-

ting, it is desirable for the square side to be on the left.

This requires the use of reverse swirl Nozzles and

Baffles. See Table 1 for P/N's. DO NOT mix standard

and reverse swirl parts on the same torch!

4. Oxygen and Beveling Nozzle Retaining Cup, P/N

20758 - Permits beveling up to 45

. Required for use

with Air Curtain or Bubble Muffler.

5. Corrosion Resistant Nozzle Retaining Cup P/N

21217. This cup has the same shape as the cup,P/N

20758 above but is insulated to reduce corrosion in

service with conductive cut water. This insulation

does not make it safe to touch the torch with the

power source on.

6. Two Piece O

Nozzle Assemblies: 21206B (STD) &

21207B (Rev.) These nozzles have a replaceable

ceramic insulator (P/N 21193).

III. FUME & NOISE REDUCTION

explosions can kill. H

explosions can result from

cutting underwater, especially when cutting active

metals such as aluminum or magnesium. See Form

14-373 (supplied with torch) or forms 12-528 or 15-

116 for more information.

A. Underwater cutting (N

ONLY)

1. Simply immersing the top of the workpiece under 2" to

3" of water markedly reduces fume and noise. Mate-

rials up to 1" thick can generally be cut underwater

with slight reductions in speed and quality.

2. Underwater cutting substantially reduces speed and

quality on thicker plates, especially aluminum. Cutting

plates thicker than 3 inches underwater is not recom-

mended.

3. Cutting underwater with Argon-Hydrogen is not rec-

ommended as explosive gas mixtures may collect in

the water table.

4. Underwater cutting with O

requires the use of a

Bubble Muffler or Air Curtain.

B. Air Curtain - The air curtain directs a flow of air around

the arc which permits underwater cutting with O

gas.

See Form 15-128 for details.

Standard Air Curtain Kit P/N 21385

Beveling Air Curtain Kit P/N 21404

C. Bubble Muffler - This device traps a bubble of air

around the arc using water recirculated from the water

table. This allows use of O

under water. The water

flow acts as a shield to block radiation and trap fumes

so that protection is also afforded when cutting above

water. See form 15-127 for details.

Bubble Muffler system P/N 2232615

D. Water Muffler - this device is used for suppression of

fume and noise when cutting with N

above water.

Contact your cutting machine representative for de-

tails.

IV. Maintenance (Refer to Figures 2 thru 5)

Electric Shock can kill.

Disconnect Power Source from incoming electrical

power before touching or servicing the torch. Metal

parts of the torch can be at high voltage.

Never use oil or grease on this torch. Handle parts

only with clean hands on a clean surface. Oil and

grease are easily ignited and burn violently in the

presence of oxygen under pressure. Use silicone

lubricant only where directed.

A. Removal & Replacement of Nozzle Assembly

1. Unscrew the nozzle retaining cup from the torch. If

the fine threads on the nozzle retaining cup and

torch body are dirty, clean and then spray the -

7. Retainer for Front Body Insulators: 33768, can be

used to prevent movement of front body insulator

when servicing torch.

WARNING

DANGER

more tha 0.030-in. Cracks in the insert are normal.

When using oxygen for cutting gas, replace elec-

trode tip (20763) if the hafnium insert is pitted more

than .090-in. or if a crater more than 0.120-in.

diameter has formed.

4. Check O-ring (86W99) inside tip holder periodi-

cally. If nicked, it should be replaced exercising

care to avoid scratching the O-ring groove. Lubri-

cate new O-ring lightly with silicone grease before

installing it into the tip holder.

5. Replace the gas swirl baffle if it is cracked or if the

front edge (nozzle seating surface) is chipped.

6. When reassembling slip the gas swirl baffle over

the electrode tip - tip holder assembly. Apply a light

coating of silicone grease (about 1/4-in. wide band)

just below the water exit holes and chamfer of the

tip holder. Then screw the electrode assembly into

the torch using 7/16" nut driver. Tighten firmly but

do NOT overtighten.

C. REPLACING THE INSULATOR BODY

The plastic insulator body (20755) should be removed

periodically and inspected for cracking and for possible

replacement of O-rings. To remove the insulator body,

do the following:

1. Remove nozzle retaining cup, nozzle assembly,

electrode tip, tip holder, and gas swirl baffle as

described previously.

2. Pull the insulator body straight out.

NOTE: The pilot arc cable will be attached, so allow

plenty of slack.

3. Lubricate the O-rings lightly with silicone grease. If

necessary, replace O-rings.

4. If replacing the insulator body, disconnected the

pilot arc cable by loosening the setscrew with the

1/16: Allen wrench (supplied with torch) at the

contact right assembly (996341). Remove contact

ring assembly from the insulator body by removing

one socket head screw with a 7/64" Allen wrench

(not supplied).

5. Reassemble in reverse order. Align insulator body

with locating pin (996242) and push in.

FRONT END

(See Table 1)

NOTE

For Service Lines Supplied

(See Figure 3)

SLEEVE - 19483

CLAMP INSULATOR BUSHING - 996342

CLAMP - 996565

BOOT HOSE - 996647

B. REPLACING ELECTRODE AND GAS SWIRL BAFFLE

1. Remove retaining cup and nozzle assembly as de-

scribed above in Sect. IV-A. Front insulator retainer

P/N 33768 may be installed to prevent movement of

front insulator body.

2. Remove electrode by using the 7/16" nut driver

(996568) supplied with the torch). If electrode holder

did not come out with the electrode, then remove it by

using removal tool (999630) supplied with the torch.

The lugs will engage with the slots on the top holder.

To avoid damaging the gas baffle when removing or

reassembling the electrode, hold the nut driver or

removal tool straight.

The gas swirl baffle should come out with the elec-

trode holder. If it does not, remove by using one

finger.

3. If using nitrogen or H-35 for cutting gas, replace

electrode (600236) if the tungsten insert is pitted

threads with a commercially available silicone spray

to prevent thread damage or cross-threading during

reassembly.

2. To remove the nozzle assembly, grip the nozzle

assembly with the slotted tubular tool (999630 -

supplied with the torch) and pull straight out.

3. Apply a very light coating of silicone grease (17662,

1 oz. tube) around the outer periphery of the copper

body on the nozzle assembly. (This will lubricate the

O-ring in the torch body when inserting the nozzle

assembly.) Make sure the silicone rubber gasket is

set evenly around the shoulder of the ceramic nozzle

insulator on the nozzle assembly. Handle the nozzle

assembly carefully to avoid breaking the insulator.

4. Place the nozzle assembly inside the retaining cup by

locating the ceramic insulator through the hole of the

retaining cup.

5. Carefully assemble the retaining cup onto the torch

and tighten slowly until HAND TIGHT. The nozzle

assembly will seat against the gas swirl baffle. Do

NOT over-tighten. (Holes in the plastic gas swirl

baffle may squeeze close and restrict the gas flow,

ceramic baffles may break. Improper seating or a

poor gasket will be revealed by an uneven cutting

water spray once the torch is set up.)

Dimensions & Weight

Length 15-1/2-in.

Diameter 2-in.

Diam of Ins. Bushing 2-1/4-in.

Weight (Less Service Lines) 3.5 lbs.

Shipping Weight 16 lbs.

Supplied:

Nozzle & Electrode Tip Removal Tool - 999630

Electrode Tip Removal Tool - (7/16" Nut Driver) - 996568

1/16" Allen Wrench - 93750006

Figure 2 - PT-15XL Plasma Arc Cutting Torch Assembly

Figure 3 - PT-15XL Hose and Cable Assemblies (supplied with torch) and Connections

WATER OUT

CABLE CONNECTION

7/16 X 20 R.H.

"CUT WATER" INJECTION

HOSE CONNECTION

7/16 X 20 R.H.

GAS HOSE

CONNECTION

3/8 X 24 R.H.

POWER CABLE (6')

996248*

7/16 X 20 L.H.

7/16 X 20 R.H.

POWER CABLE (6')

996248*

COOLING WATER INJECTION

HOSE CONNECTION

7/16 X 20 L.H.

WATER INJECTION

HOSE ASS'Y

(6') - 996250

5/18 X 18 R.H.

GAS HOSE ASS'Y

(6') - 996249

5/18 X 18 R.H.

* Note That 996248 Power Cables have 7/16 X 20 R.H. Thread At One End, 7/16 X 20 L.H. At The Other.

NOTE - 6 ft. Cables

and Hoses for 20762

Torch Shown.

Refer to Tables on

Page 11 For Other

Lengths.

PILOT ARC CABLE (8') - 20760

Not Shown:

CONNECTOR - 20408

(2) SETSCREW - #6-32 X 1/4"

INSULATOR - 20409

SOCKET HEAD SCREW

Remove to Release Contact Ring

Use 7/16" Allen Wrench (Not Supplied)

INSULATOR BODY

SEE

VIEW "A"

(2) O-RING - 951000

.176 ID X .050W

CONTACT RING ASS'Y

996341

PILOT ARC CABLE SET SCREW

Remove to Release Pilot Arc Cable

Use 1/16" Allen Wrench (Supplied with torch)

CONNECTOR, HI-FREQ. - 20408

fully remove the deposits using a small brush or drill

bit. If using a drill bit, insert carefully and push it

back and forth. Do NOT twist the drill bit.

5. To reassemble the nozzle assembly, snap the

centering sleeve onto the copper nozzle body

(bevel facing away from body). Insert the nylon

spacer.

6. Oxygen nozzles P/N's 20751 & 20920 are one

piece nozzles and do not come apart. They must

be replaced as complete units.

7. Two piece oxygen nozzles P/N's 21206B & 21207B

have a replaceable ceramic insulator P/N 21193.

Pry along the outside of the white ceramic to

remove it.

To install a new insulator, lubricate the red o-ring

with silicone grease and push the insulator on with

a twisting motion.

HI-FREQ.

CONNECTOR INSULATOR - 20409

P.A. BUS INSULATOR - 20403

PILOT ARC CABLE ASSEMBLY

(4) SCREW - #6/32 X 1/8

Figure 4 - PT-15XL Pilot Arc Cable Assembly

Pilot

Arc Cable

D. INSPECTION & DISASSEMBLY OF NOZZLES

1. Check the copper nozzle for melting from excessive

current, gouges from internal arcing, tungsten par-

ticles in the throat, or nicks and deep scratches on

the outer O-ring sealing surface. If any of these

defects are visible, replace the nozzle assembly.

White Hf-O deposits are normal in O nozzles.

2. To disassemble an XR nozzle assembly, pry off the

centering sleeve (996618) using a small screw-

driver between the sleeve and nozzle body. Re-

place the parts shown in figure 2 if necessary.

3. Replace the ceramic insulator if it is cracked. Check

the orifice diameter of the replacement insulator. It

should be 0.015 to 0.030-in. larger than the nozzle

body orifice. (See Table in Figure 2.)

4. In some locations, deposits left by evaporated hard

water may build up on the nozzle orifice tip Care-

8. Cleaning of oxygen nozzles:

As the electrode wears considerable deposits of

hafnium oxide and silver can build up in the nozzle.

Calcium carbonate can build up at the nozzle exit

if the cut water is not adequately treated. These

deposits sometimes cause substantial reductions

in cut quality, speed, and consumable life.

Nozzle performance can be restored by removing

these deposits from the inside of the nozzle and the

nozzle exit. A twisted piece of sandpaper or crocus

cloth usually cleans the nozzle well enough. Care

must be taken not to damage the thin copper edge

at the nozzle exit. The 340 AMP nozzles P/Ns

35664 & 35665 have a heavier, less easily dam-

aged exit as compared to the 260 AMP and 300

AMP nozzles.

Note that nozzle performance is also degraded by

nicks or elongation of the orifice due to double arcs

or mechanical damage. Cleaning will not restore

performance to a damaged nozzle.

Whenever a nozzle is removed for cleaning the

electrode should be inspected. If wear is greater

than .090 inches or very irregular the electrode

should be replaced.

E. REPLACING CABLES AND HOSES

1. To disconnect the two power cables, water injection

hose, and the gas hose at the back end of the torch,

unscrew the plastic sleeve (19483) from the stain-

less steel body.

2. Pilot arc cable (20760) is attached to a connector

(20408) under insulator tubing (20409). Loosen set

screw with 7/62" Allen wrench to remove cable

from connector. A 12-in. long 14 ga. copper wire is

connected to the contact ring assembly and to this

connector.

3. Straighten out all cables and hoses and make sure

the torch sleeve is straight when screwing it back

onto the torch body. Threads are rather fine and

easy to cross thread. Do not force the sleeve. A little

bit of silicone grease will help.

4. Make sure the boot hose (996647) is secured to

protect the service lines from arc radiation when

the torch is ready to operate, make sure the service

lines are well out of the way.

BACK OF SLEEVE - 19483

5 inches

15 turns of tape to form barrier to slipage of braid.

BRAIDED SHIELD - 72020003

BOOT

Braid is taped in place, then folded back and taped again.

BACK OF SLEEVE - 19483

inches

4 1/4

inches

SLEEVING

BOOT

NOTE: Braid does not go over Gas or Cut Water Hoses

Securely tape around hose bundle 2" wide.

Slide braid down and tape over 4-1/4".

PCM-8 Style Cable Bundle

ESP-1000 Style Cable Bundle

Figure 5 - PT-15XL Cable and Hose Assembly

PT-15XL 8ft. For PCM-8 P/N 602711 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

996248

34360

34354

34357

PT-15XL 6ft. P/N 21304 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

34363

34361

34355

34358

PT-15XL 12ft. P/N 21305 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

34364

34362

34356

34359

PT-15XL 17ft. P/N 21306 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

34775

34776

34777

34778

PT-15XL 4-1/2ft. P/N 21307 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

21267

21261

21258

21264

PT-15XL 20ft. P/N 21302 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

21268

21262

21259

21265

PT-15XL 25ft. P/N 21303 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

21266

21260

21257

21263

PT-15XL 15ft. P/N 21301 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

996248

996249

996250

20760

PT-15XL 6ft. For PCM-8 P/N 20762 Part No.

Power Cable (2) Required

Gas Hose

Water Injection Hose

Pilot Arc Cable

602712

602713

602714

602715

PT-15XL Cables and Hoses, Parts Information

F-15-031-B 7/95 5C

ESAB

ESAB Welding & Cutting Products

PO Box 100545, Florence SC 29501-0545

ESAB PT-15XL Plasmarc Cutting Torch User manual

Brand: ESAB

Model: PT-15XL Plasmarc Cutting Torch

Category: Welding System

Type: User manual

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ESAB PT-15XL Plasmarc Cutting Torch User manual

ESAB PT-15XL Plasmarc Cutting Torch User manual

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