ESP - 1000 PLASMARC SYSTEM - ESAB Welding & Cutting Products

ESP - 1000 PLASMARC SYSTEM - ESAB Welding & Cutting Products
INSTRUCTION MANUAL
ESP - 1000 PLASMARC SYSTEM
MECHANIZED CUTTING WITH PT-15XL OR PT-19XLS
F15-116-D
07/2007
Be sure this information reaches the operator.
You can get extra copies through your supplier.
caution
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 before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENTS
SECTION
PARAGRAPH
TITLE
PAGE
SAFETY PRECAUTIONS......................................................................................................................................5
SECTION 1
1.1
1.2
1.3
INTRODUCTION....................................................................................................................17
General.................................................................................................................................................................... 17
Features................................................................................................................................................................... 17
Component Description................................................................................................................................... 18
SECTION 2
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
INSTALLATION.......................................................................................................................23
General.................................................................................................................................................................... 23
System Component Location.......................................................................................................................... 23
System Connections........................................................................................................................................... 24
Torch Components.............................................................................................................................................. 30
Installing Air Curtain........................................................................................................................................... 31
Bubble Muffler Installation............................................................................................................................... 32
WATER MUFFLER SYSTEM FOR THE PT-19XLS........................................................................................... 33
AIR CURTAIN/BUBBLE MUFFLER CONTROL BOX INSTALLATION......................................................... 33
WATER INJECTION PUMP.................................................................................................................................. 33
INSTALLATION OF THE SECONDARY GAS METERING BOX.................................................................... 34
SECTION 3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
OPERATION.......................................................................................................................................................... 39
General.................................................................................................................................................................... 39
Controls and Indicators..................................................................................................................................... 39
Pre-Operation Test and Checkout................................................................................................................. 41
Oxygen Cutting with PT-15XL......................................................................................................................... 44
Nitrogen Cutting with PT-15XL....................................................................................................................... 49
H-35 Cutting with PT-15XL............................................................................................................................... 51
CUTTING WITH THE PT-19XLS and PT-600 TORCHES............................................................................. 52
High Current Cutting with PT-19XLS............................................................................................................ 55
PT-19XLS Cutting Tables.................................................................................................................................... 56
Operating Techniques........................................................................................................................................ 70
SECTION 4
4.1
4.2
4.3
4.4
TROUBLESHOOTING........................................................................................................................................ 75
Programmable Logic Controller..................................................................................................................... 75
Sequence Description........................................................................................................................................ 75
Operating Information...................................................................................................................................... 77
Troubleshooting Guide..................................................................................................................................... 78
3
TABLE OF CONTENTS
4
safety precautions
Safety Precautions
Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize
precautionary information from the
references listed in Additional Safety
Information section. 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.
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 protective 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
hidden 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 work piece has been completely cleaned so
that there are no substances on the work piece
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
example, 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 Protection Association, Battery march Park,
Quincy, MA 02269.
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 operating 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 protection 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.
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.
5
safety precautions
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
3. Welders should use the following procedures to
minimize exposure to EMF:
2. Connect the work piece to a good electrical
ground.
A.Route the electrode and work cables together.
Secure them with tape when possible.
3. Connect the work cable to the work piece. A poor
or missing connection can expose you or others
to a fatal shock.
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.
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.
D.Connect the work cable to the work piece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
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.
Therefore:
9. Turn off the power before removing your gloves.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
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, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specific grounding recommendations. Do not mistake the work lead for a ground
cable.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric current flowing through any conductor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
3. If you develop momentary eye, nose, or throat irritation 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 discomfort persists.
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
2. Exposure to EMF may have other health effects which
are unknown.
6
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.)
1. Always have qualified personnel perform the installation, 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.
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
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.
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 instructions for mounting regulator to a compressed gas
cylinder.
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.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure
cylinders to work tables or fixtures where they may
become part of an electrical circuit.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equipment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not connected. 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.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
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.
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"
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
7
safety precautions
5. AWS C5.5 - "Recommended Practices for Gas Tungsten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
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 Attention! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in immediate, 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.
8
sEGURIDAD
Safety - Spanish
La escoria puede estar caliente y desprenderse
con velocidad. Personas cercanas deberán usar
gafas de seguridad y careta protectora.
ADVERTENCIA: Estas Precauciones de
Seguridad son para su protección. Ellas
hacen resumen de información proveniente de las referencias listadas en la sección
"Información Adicional Sobre La Seguridad". Antes
de hacer cualquier instalación o procedimiento
de operación , asegúrese de leer y seguir las precauciones de seguridad listadas a continuación
así como también todo manual, hoja de datos de
seguridad del material, calcomanias, etc. El no
observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.
FUEGO Y EXPLOSIONES -- El calor de
las flamas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:
1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases flamables, solventes,
pinturas, papel, etc.
2. Chispas y partículas de metal pueden introducirse
en las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.
3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté totalmente
limpia y libre de substancias que puedan producir
gases inflamables o vapores tóxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inflamables.
4. Tenga siempre a la mano equipo extintor de fuego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.
5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en los
cables de soldar pueden ocasionar un fuego.
6. Después de termirar la operación del equipo, inspeccione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.
7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.
PROTEJASE USTED Y A LOS DEMAS-Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco, como
el sol , emite rayos ultravioleta (UV) y otras radiaciones
que pueden dañar la piel y los ojos. El metal caliente
causa quemaduras. EL entrenamiento en el uso propio
de los equipos y sus procesos es esencial para prevenir
accidentes. Por lo tanto:
1. Utilice gafas de seguridad con protección a los lados
siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.
2. Use una careta que tenga el filtro correcto y lente
para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las personas cercanas de no mirar el arco y no exponerse a
los rayos del arco eléctrico o el metal fundido.
3. Use guantes de cuero a prueba de fuego, camisa
pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido. En
ocaciones un delantal a prueba de fuego es necesario
para protegerse del calor radiado y las chispas.
4. Chispas y partículas de metal caliente puede alojarse
en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.
5. Proteja a otras personas de los rayos del arco y chispas calientes con una cortina adecuada no-flamable
como división.
6. Use careta protectora además de sus gafas de seguridad cuando esté removiendo escoria o puliendo.
CHOQUE ELECTRICO -- El contacto con
las partes eléctricas energizadas y tierra
puede causar daño severo o muerte.
NO use soldadura de corriente alterna
(AC) en áreas húmedas, de movimiento
confinado en lugares estrechos o si hay
posibilidad de caer al suelo.
9
sEGURIDAD
1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.
2. Conecte la pieza de trabajo a un buen sistema de
tierra física.
3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.
4. Use el equipo solamente si está en buenas condiciones. Reemplaze cables rotos, dañados o con
conductores expuestos.
5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.
6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.
7. No se pare directamente sobre metal o tierra mientras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.
8. Use guantes secos y sin agujeros antes de energizar
el equipo.
9. Apage el equipo antes de quitarse sus guantes.
10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones específicas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
3.Los soldadores deberán usar los siguientes procedimientos para minimizar exponerse al EMF:
A.Mantenga el electrodo y el cable a la pieza de
trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.
B. Nunca envuelva los cables de soldar alrededor
de su cuerpo.
C.Nunca ubique su cuerpo entre la antorcha y el
cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.
D.Conecte el cable de trabajo a la pieza de trabajo
lo más cercano posible al área de la soldadura.
E. Mantenga la fuente de poder y los cables de soldar
lo más lejos posible de su cuerpo.
HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios
sin ventilación. No inhale el humo
o gases. El gas de protección puede
causar falta de oxígeno. Por lo tanto:
1. Siempre provea ventilación adecuada en el área
de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cadmio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique substancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.
3. Si momentáneamente desarrolla inrritación de
ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico persiste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomendaciones específicas en la ventilación.
CAMPOS ELECTRICOS Y MAGNETICOS - Son peligrosos. La corriente
eléctrica fluye através de cualquier
conductor causando a nivel local
Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:
1. Soldadores u Operadores que use marca-pasos para
el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.
2.Exponerse a campos electromagnéticos (EMF) puede
causar otros efectos de salud aún desconocidos.
10
sEGURIDAD
5. ADVERTENCIA-- Este producto cuando se utiliza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos conocidos por el Estado de California de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
1. Siempre tenga personal cualificado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualificado para hacer el
trabajo.
2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.
3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.
4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.
5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.
6. Use el equipo sólo para el propósito que fue
diseñado. No modifique el equipo en ninguna
manera.
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romperse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:
1. Utilize el gas apropiado para el proceso y utilize
un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adaptadores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.
INFORMACION ADICIONAL DE SEGURIDAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablilleros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
3. Cuando el cilindro no está en uso, mantenga la
válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
11
sEGURIDAD
SIGNIFICADO DE LOS sImbolOs
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Significan ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Significa riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Significa el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Significa el posible riesgo que
puede resultar en menores daños
a la persona.
12
sÉCURITÉ
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des flammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de précaution provenant des références dans
la section des Informations de sécurité supplémentaires. Avant de procéder à l'installation ou d'utiliser
l'unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les
fiches d'information sur la sécurité du matériel et
sur les étiquettes, etc. Tout défaut d'observer ces
précautions de sécurité peut entraîner des blessures
graves ou mortelles.
1. Éloignez suffisamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininflammable. Les
matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les
solvants, les peintures et les revêtements, le papier,
etc.
2. Les étincelles et les projections de métal incandescent
peuvent tomber dans les fissures dans les planchers
ou dans les ouvertures des murs et déclencher un
incendie couvant à l'étage inférieur Assurez-vous que
ces ouvertures sont bien protégées des étincelles et
du métal incandescent.
3. N'exécutez pas de soudure, de coupe ou autre travail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire des
vapeurs inflammables ou toxiques. N'exécutez pas
de travail à chaud sur des contenants fermés car ces
derniers pourraient exploser.
4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.
5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projection
de métal incandescent ne risque de provoquer un
incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.
7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage
produisent un niveau de bruit élevé et exige l'emploi d'une
protection auditive. L'arc, tout comme le soleil, émet des
rayons ultraviolets en plus d'autre rayons qui peuvent
causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à
l'usage des processus et de l'équipement est essentielle
pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d'écrans latéraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de
plaques protectrices appropriées afin de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas regarder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise
épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes afin de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé de
porter un tablier ininflammable afin de vous protéger
des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent
risquent de se loger dans les manches retroussées, les
rebords de pantalons ou les poches. Il est recommandé
de garder boutonnés le col et les manches et de porter
des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des
étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de
sécurité lors des opérations d'écaillage ou de meulage
du laitier. Les écailles de laitier incandescent peuvent
être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également
porter des lunettes étanches par dessus leur lunettes
de sécurité.
CHOC ÉLECTRIQUE -- Le contact avec des
pièces électriques ou les pièces de mise
à la terre sous tension peut causer des
blessures graves ou mortelles. NE PAS
utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint
ou si un danger de chute se pose.
13
sÉCURITÉ
1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.
2. Branchez la pièce à traiter à une bonne mise de
terre électrique.
3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion afin d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endommagés. 5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porteélectrode/torche et la source d'alimentation.
6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.
7. Si vous devez effectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.
9. Mettez l'équipement hors tension avant d'enlever
vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spécifiques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :
A.Acheminez l'électrode et les câbles de masse
ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse
autour de votre corps.
C.Ne jamais vous placer entre la torche et les câbles
de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D.Branchez le câble de masse à la pièce à traiter le
plus près possible de la section à souder.
E. Veillez à garder la source d'alimentation pour le
soudage et les câbles à une distance appropriée
de votre corps.
LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages
corporels, plus particulièrement
dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :
1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventilation naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation efficaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'effectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lorsque la chaleur
ou le rayonnement de l'arc entre en contact avec les
vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ventilation n'est pas adéquate. Cessez votre travail afin
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spécifiques
concernant la ventilation.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conducteur produit des champs électriques
et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit
consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour
la santé.
14
sÉCURITÉ
5.AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques considéres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualifié. N'effectuez aucune réparation
électrique à moins d'être qualifié à cet effet.
2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.
3. Maintenez les câbles, les fils de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez jamais un équipement s'il présente une défectuosité
quelconque.
4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des flaques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.
6. Utilisez l'équipement conformément à son usage
prévu et n'effectuez aucune modification.
MANIPULATION DES CYLINDRES -La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un
échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des blessures graves ou mortelles. Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération
et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à
l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne fixez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les
soupapes fermées. Si le détendeur n'est pas branché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée
de toute source de chaleur, des étincelles et des
flammes. Ne jamais amorcer l'arc sur un cylindre.
5. Pour de l'information supplémentaire, consultez
CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre disposition par le Compressed Gas Association, 1235
Jefferson Davis Highway, Arlington, VA 22202.
INFORMATIONS SUPPLÉMENTAIRES RELATIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
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"
15
sÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signifie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signifie un danger qui peut entraîner des blessures
corporelles mineures.
Additional Safety Information for Mechanized Plasmarc Cutting Systems:
Electrical Shock can kill or cause severe burns. Plasmarc cutting uses DC currents at dangerously high voltages.
• Do not touch the torch or change the consumables if input power to the Plasmarc power source has not been disconnected.
• Do not stand on, touch, or in any way contact the plate while cutting voltages are present.
• The workpiece must be electrically connected to the power source work terminal for safe operation of the system.
• Do not perform maintenance on any part of the Plasmarc system unless all power inputs have been disconnected
and locked out. This includes 115vac inputs as well as high voltage inputs.
• Troubleshooting requiring power to be on should only be done by qualified personnel.
Hydrogen Explosions can cause injury or death.
• See page ????? .
Fumes and Gases can cause discomfort or death. Do not breath fumes or gases.
• Do not cut containers of toxic materials or containers that have held toxic materials. Clean such containers thoroughly before cutting.
• Before cutting a coated material, consult with its manufacturer for proper safety precautions.
Noise and Ultraviolet Light
• The noise level of plasmarc cutting can be greater than 110 db at a distance of 6 feet from the torch. Wear proper
hearing protection.
• Reflection of ultraviolet light from areas walls close to the cutting arc can be minimized by selecting paints having a
high percentage of ZnO and TiO2 pigments. Do not use paints containing metallic flakes. Refer to “Ultraviolet Reflectance of Paint” from the American Welding Society.
• Underwater cutting is a well accepted technique for reducing the noise, fumes, and UV radiation of the Plasmarc cutting process. Often an air curtain or bubble muffler is required for underwater cutting. Above water cutting with a
water muffler can also achieve much of the benefits of underwater cutting.
16
section 1description
1.1 GENERAL
plumbing box, power source provides maximum
flexibility for system layout tailored to your
needs.
The ESP-1000 is a full capability plasmarc cutting system
that offers a wide variety of plasma cutting processes
and applications. The system is designed specifically for
computer controlled mechanized cutting applications
with expanded interfacing, flexible configuration from a
selection of packages and versatile ease of operation. By
selecting the components that best suit your needs the
ESP system can fully automate your cutting process.
•
Selection from a variety of power sources and
the paralleling capability allows a wide range
of available cutting power to meet virtually any
cutting condition.
•
Patented ESAB technology allows underwater
cutting and beveling with excellent results.
•
The system is capable of water injection cutting
with the PT-15XL torch and gas shielded underwater cutting can be accomplished at most
current levels with appropriate accessories with
the PT-19XLS torch.
The ESP-1000 uses simple switch settings to setup
process parameters for flow control and cutting
power eliminating the difficulty of adjustment
associated with needle valves.
•
The shielded construction of the plasma torches
and versatility of component location minimizes
electrical interference with surrounding equipment.
•
The ESP-1000 can accommodate all major cutting
gases including; oxygen, air, nitrogen or argon/
hydrogen mixture.
•
•
The separate component design, flow control,
The ESP system uses advanced technology for
high quality cutting for a variety of common
metals while keeping the operating costs at a
minimum.
1.2 FEATURES
•
PLUMBING
BOX
FLOW
CONTROL
COOLANT
CIRCULATOR
SECONDARY
GAS METERING
BOX
CUT WATER
PUMP
TORCH
(PT-15XL or PT-19XLS)
Figure 1-1. ESP-1000 Major Components
17
POWER SOURCE
(ULTRA LIFE 300, ESP400 or ESP-600C)
section 1description
1.3 COMPONENT DESCRIPTION
The components that make up an ESP-1000 are designed
specifically to interface into a system for use in automated
plasma cutting applications.
Refer tothe specific equipment manual for detailed
information.
400
300
500
OUT P UT
600
MA X
200
A MP S
100
50
MIN
V O L TS
A C TU A L A MP S
P R E S E T A MP S
P IL O T
HIG H
AR C
LOW
0
C U R R E NT
MA IN
P OWE R
P A NE L
OVE R
TE MP
R E MO TE
C O NTA C TO R
ON
4 0 0 C
FA ULT
P OWE R
RESET
FA ULT
Ultra Life 300 Power Source
Designed for high speed plasma cutting, the Ultra Life 300
is basically a silicon controlled rectifier (SCR) DC unit with
solid state circuitry. The unit can be operated from 50 to
300 amperes output (cutting) current.
Figure 1-3 ESP-400C Power Source
The design of the solid state circuitry produces stable
cutting current and eliminates changes in output current
as components heat up to operating temperature and/or
fluctuations in line voltages within + or - 10% of nominal.
If cutting currents above the rating is required, two ESP400C units can be paralleled.
Figure 1-2. Ultra Life 300 Power Source
Refer to the power source manual for installation instructions.
The solid state circuitry of the Ultra Life 300 produces
stable cutting current and eliminates changes in output
current as components heat up to operating temperature. Fluctuations in line voltage within +/- 10% of normal
and/are extremely low ripple output current is produced,
which results in longer consumable life.
ESP-600C Power Source
The ESP-600C is normally used in mechanized cutting applications for high speed cutting. The ESP-600C is a solid
state DC power source capable of producing 100 to 600
amperes of cutting current at 100% duty cycle (no cool
down requirements). The extremely low ripple current is
produced by a ripple cancellation technique and results
in increased life of plasma consumables. "Current slope
up" is also featured with the ESP-600C.
Refer to Instruction Manual F-15-141 for specific details
for the Ultra Life 300.
ESP-400C Power Source
The ESP-400C Power Source is a solid state DC pwoer source
capable of producing up tp 400 amperes.
18
section 1description
Connections to the flow control are Oxygen In, Nitrogen
In, Start Gas Out, Cut Gas Out, Cut Water In and Cut Water
Out.
Plumbing Box
The ESP Plumbing Box is an interconnecting device
between the torch and other system components. It
also contains the arc starting high frequency generator. Connection of functions through the plumbing box
include; cut gas, start gas, cut water, torch coolant, pilot
arc, cutting current and height control.
Figure 1-4. ESP-600C Power Source
For currents beyond the ESP-600C capability 2 units can be
connected in a parallel configuration. Refer to Instruction
Manual for specific details of the ESP-600C.
Flow Control
The Flow Control is a programmable Logic Control (PLC)
based unit. This device provides all the necessary control
functions for various fluids and signals to and from other
components of the system. Control Inputs/Outputs are
connected to the power source, cut water pump, plumbing box, coolant circulator, air curtain and the cutting
machine control.
Figure 1-6. Plumbing Box Assembly
Coolant Circulator
TE
ST
RU
N
The WC-7C circulator is a radiator type cooler for circulating a coolant fluid through the plasma torch providing
heat exchanger action for the internal parts of the torch.
Though the system refers to water, it is not recommended
that water be used. For the protection of internal parts
and lines a specially formulated coolant liquid is available that prevents production of corrosion and mineral
buildup. Refer to Instruction Manual F-15-138 for detailed
information on the WC-7C unit.
CU
TW
AT
ER
H I GH
LO W
CU
TG
AS
H I GH
LO W
Figure 1-5. Flow Control Assembly
19
section 1description
PT-15XL Plasma Torch
Secondary Gas Metering Box
The PT-15XL is designed for high current plasma cutting with water injection. Cutting is accomplished with
nitrogen cut gas up to 750 amps, oxygen cut gas up to
360 amps. Use of H-35 mixture for cut gas extends current capability up to 1000 amps. Each condition requires
specific torch components for the type of cut gas and
current level.
PLASMARC
SECONDARY SHIELD
GAS FLOW CONTROL
FLOW
READ TOP
OF BALL
PRESSURE
10
9
8
7
6
5
4
3
2
1
0
50
0
100
FLOW
ADJUSTMENT
OFF
ON
AUTO
PRESSURE
ADJUSTMENT
Figure 1-8. PT-15XL Plasma Torch
The PT-15XL is designed to eliminate double arcing, high
frequency leakage, and electrolytic corrosion of parts.
The electrode cooling and nozzle concentricity makes arc
ignition more reliable, longer life of the nozzle, electrode
and other consumable parts. Operating details for specific
cutting conditions are presented in later sections of this
manual. Refer to Form F-15-031 for detailed information
of the PT-15XL torch.
INLET
OUTLET
Figure 1-7A
The secondary shield/PT-19XLS improves the cut squareness. The secondary gas metering box measures the flow
rate of shield gas (nitrogen or air).
PT-19XLS Plasma Torch
The PT-19XLS Torch is designed with all the quality standards and feature characteristics of the PT-15XL. The
differences are primarily in applications and conditions
for which the PT-19XLS is to be used. The PT-19XLS is a
mechanized torch designed for high speed, high current
cutting using gas shielding instead ofwater injection.
Adaptor: PT-19XLS to Plumbing Box for shield gas connection to torch.
Figure 1-9. PT-19XLS Plasma Torch
PT-600 Plasma Torch
The PT-600 torch is a PT-19XLS with reduced manufacturing tolerances. The result is improved torch
component concentricity and cut accuracy. Connections, mounting and process data are identical.
Figure 1-7A
20
section 1description
The PT-19XLS is intended for applications of dry cutting
using air (clean & dry) for the cut gas at current levels up
to 200 amps. Oxygen (to 360A) or H-35 (to 600A) can be
used with the PT-19XLS, however these gases are not
recommended for some materials. Use of an air curtain
kit permits the PT-19XLS to be used for underwater cutting. Further details of the PT-19XLS are contained in
Form F-15-430.
Water Pump
The Water Pump is used to supply de-ionized cut water
to the PT-15XL torch for water injected cutting.
Figure 1-11. Bubble Muffler Assembly
Air Curtain
PT-19XLS Water Muffler
The Air Curtain assembly provides improved cutting
performance of the PT-15XL and PT-19XLS plasma torches
when cutting underwater. A source of oil free air at 80
psig is required to the air curtain control box. A curtain
(wall) of air is created around the plasma arc area allowing
operation in a relatively dry zone, even with the end of
the torch submerged 2 - 3 inches.
PT15XL H.D.
AIR CURTAIN
The PT-19XLS water muffler works much as the bubble
muffler described above.
PT-19XLS
AIR CURTAIN
Figure 1-10. Air Curtain Assembly
Underwater Cut quality and speed are enhanced when
using the air curtain for all PT-19XLS cutting applications
and PT-15XL O2/water injection cutting.
Bubble Muffler
Figure 1-12. PT-19XLS Water Muffler Assembly
The Bubble Muffler system creates a bubble of air surrounded by water that allows the PT-15XL torch to be
used underwater with oxygen cut gas and water injection
cutting without significant loss of cut quality.
This device also allows above water cutting with reduced
fume, noise and UV radiation from the arc by the flow
of water through the bubble muffler. A separate water
pump recycles filtered water from the water cutting table
through the bubble muffler.
21
section 1description
TABLE 1-1. ESP 1000 COMPONENTS
DESCRIPTION
PART NUMBER
INSTRUCTION MANUAL
Power Sources
Ultra Life 300
460/575 V, 3-Phase, 60 Hz
ESP-400C 460 V, 3-Phase, 60 Hz
400 V, 3-Phase, 50 Hz CE
575 V, 3-Phase, 50 Hz
ESP-600C 460 V, 3-Phase, 60 Hz
400 V, 3-Phase, 50 Hz CE
575 V, 3-Phase, 60 Hz
Plasma Torches:
33520
0558001729
0558001730
0558001731
35609
35610
35611
F-15-141
F-15-657
F-15-681
F-15-657
F-15-656
F-15-682
F-15-656
The basic torch body can be supplied in seven lead lengths between the plumbing box and torch. The replaceable
torch components are selected for the type of cut gas and current level used.
PT-15XL - 4.5 ft.
PT-15XL - 6 ft.
PT-15XL - 12 ft.
PT-15XL - 15 ft.
PT-15XL - 17 ft.
PT-15XL - 20 ft.
PT-15XL - 25 ft.
21307
21304
21305
21301
21306
21302
21303
F-15-031
PT-19XLS - 4.5 ft.
PT-19XLS - 6 ft.
PT-19XLS - 12 ft.
PT-19XLS - 15 ft.
PT-19XLS - 17 ft.
PT-19XLS - 20 ft.
PT-19XLS - 25 ft.
37086
37087
37088
37089
37090
37091
37092
F-15-430
PT-600 - 4.5 ft.
PT-600 - 6 ft.
PT-600 - 12 ft.
PT-600 - 15 ft.
PT-600 - 17 ft.
PT-600 - 20 ft.
PT-600 - 25 ft
0558001827
F-15-646
0558001828
0558001829
0558001830
0558001831
0558001832
0558001833
Flow Control:
Provides interface for fluids, gases and
power.
21294
F-15-106
Plumbing Box:
Provides interconnection between torch
and rest of system includes adaptor for
shield gas connection.
21295
F-15-107
WC-7C Water Recirculator: Circulates coolant for the torch
33859
F-15-138
Cut Water Pump:
Supplies cut water to torch for water injection cutting
33772
F-15-131
Air Curtain:
PT-19XLS and PT-600
Heavy Duty PT-15XL
PT-15XL Beveling (PT-19XL and PT-600)
37440
21856
34752
F-15-475
F-15-189
F-15-189
Bubble Muffler System
2232615
F-15-127
PT-19XLS (and PT-600) Water Muffler
37439
F-15-474
Secondary Gas Metering Box (for PT-19XLS)
22178
22
See pages 28 - 32 of this manual.
section 2installation
ing. In relationship to a cutting machine, the power
source can be positioned virtually anywhere that will
not interfere with machine travel. Accessories on the
cutting machine are available to carry hoses and cables
without interference with machine travel.
WARNING
READ THIS MANUAL COMPLETELY PRIOR TO
INSTALLING AND OPERATING THE ESAB SMART
PLASMA (ESP) 1000 SYSTEM.
Flow Control
2.1 General
The Flow Control can be placed on the Power
Source or mounted onto the cutting machine. It connects to the Power Source by a control cable from 6' to
125' long. The Flow Control needs to be accessible for
setting various cutting parameters. After setting the
cutting conditions, access to the Flow Control is not
required during the cutting operation.
Proper installation substantially contributes to the
satisfactory and trouble-free operation of the ESP-1000
System components. Each step in this section should
be studied carefully and followed as closely as possible.
Immediately upon receipt of the ESP components,
each should be inspected closely for damage which
may have occurred in transit. Notify the carrier of any
damage or defects immediately. Instruction manuals for
each component of the system are included in the package. It is recommended that these manuals be collected
and compiled in a common location.
Plumbing Box
The Plumbing Box is normally located on the
cutting machine in close proximity to the torch station.
Since the torch can be equipped with various standard
lengths of cable and hose, the exact location is determined by the configuration and station load capacity of
the machine.
NOTE
If the components are not to be immediately
installed, store them in a clean, dry, and well ventilated
area.
Access to the Plumbing Box is not required during
the standard operating procedures, location near the
operator is not required. Two important considerations
pertain to the location of the plumbing box:
2.2 System Component Locations
Power Source
WARNING
When lifting the Power Source using the lifting
lugs, ensure the lifting means is securely connected
to BOTH lifting lugs to prevent damage to the unit or
injury to personnel. DO NOT USE ANY LEVER DEVICE
WHICH COULD DAMAGE THE UNIT.
1.
There should be space for the box door to be
opened fully .
2.
Sufficient space should be provided on all
sides to permit easy connection of gas/water
hoses and electrical cables to the box.
Secondary Gas Metering Box
The gas metering box can be mounted on the cutting machine or a convenient wall with the flowmeter
vertical. The hose supplied is used to connect metering
box to torch shield gas using the adaptor supplied with
the plumbing box. The gas metering box must be connected to a source of dry oil free shop air or N2 capable
The location of the Power Source should be carefully selected to ensure satisfactory and dependable
service. The Power Source components are maintained
at the proper operating temperatures by forced air that
is drawn through the cabinet by the fan units. For this
reason, it is important that the Power Source be located
in an indoor-open area where air can circulate freely at
the front, bottom, and rear openings of the cabinet. If
space is a premium, leave at least two feet of clearance
at the rear of the cabinet.
The location should be such that a minimum of
dirt, dust, or moisture will be drawn into the air stream.
It is desirable to locate the unit so that the top and side
panels can be removed for cleaning and troubleshoot23
section 2installation
2.3. SYSTEM CONNECTIONS
Power Source
WARNING
Before making any connections to the output bus bars,
make sure the power source is de-energized by opening
the line (wall) disconnect switch. To be doubly safe, have a
qualified person check the output bus bars with a voltmeter
to be sure all power is off.
Fluid Hookups (See Table 2-1 for hose assemblies)
Input Power Connections
1. OXYGEN (O2) IN - This is a "B" size CGA oxygen
fitting. Connect the supply hose from the oxygen
regulator to this point.
2. NITROGEN (N2) IN - This is a "B" size IAA fitting.
Connect the supply hose from the nitrogen
regulator to this point.
3. START GAS OUT - This is a "B" size IAA fitting. From
this point connect the hose to Start Gas INPUT on
the Plumbing Box.
4. CUT GAS OUT - This is a "B" size oxygen fitting.
The hose is connected from this point to the Cut
Gas INPUT on the Plumbing Box.
The power sources (ESP-600C, ESP-400 or Ultra Life 300) used
with the ESP-1000 system are 3-phase units and must be connected to a 3-phase power line. Although designed with line
voltage compensation, it is suggested that the unit be operated
on a separate line to ensure the performance of the power
source is not impaired due to an overloaded circuit.
A line (wall) disconnect switch, with fuses or circuit breakers,
shall be used at the main power panel. The primary power input
must have four insulated power leads (three power leads and
one ground wire). The wires may be a heavy rubber covered
cable or may run in a solid or flexible conduit.
Electrical Hookups (See Table 2-2 for cables)
NOTE
The ground wire must be approximately six inches longer than
the power leads. This is a safety measure to ensure that in the
event the power lines are accidently pulled out the ground wire
will remain connected.
Input conductors must be terminated with ring terminals sized
for 1/2 inch hardware before being connected.
NOTE: Refer to the specific equipment manual for
detailed installation instructions.
Flow Control Connections
The Flow Control serves as a form of interface between the
various process utilities to enable a central location for setup
adjustments. Connections are made to receptacles on the rear
panel and are grouped into two sections, the bottom row is for
gas and water connections while the top row is for electrical
connections. The fluid connections should be made first.
24
1. PARALLELED POWER SOURCE - A cable from a
second power source connects to this receptacle
whenever two power sources are used in parallel. It parallels all control connections between
the power source and flow control.
2. AIR CURTAIN - This is used to connect the coil of
a solenoid valve in the air curtain control (when
used) or to control a relay coil in the water muffler
pump unit.
3. CUT WATER PUMP - Provides connection to a relay
coil in the cut water pump unit
4. WATER COOLER - This point is used to connect to
the relay coil in the water cooler.
5. PLUMBING BOX - This cable connection goes to
the gas solenoid valves, flow switch, interlock
switch and provides power to the primary of
the high frequency transformer in the plumbing
box.
6. CUTTING MACHINE NUMERICAL CONTROL (CNC)
- This connection provides a current reference
signal to the plasma power source and provides
control signals to and from the flow control circuits, Start Process Command, Arc On, Process
Fault, and E-Stop Interlock.
7. 115 VAC AUXILIARY POWER - This optional connection allows the Flow Control to be energized
without powering up the system. Disconnect
after test function is completed.
section 2installation
Wall Box
Gas Regulators
(+) Work
Input
Power
Power Source
(-) Electrode
Pilot Arc
Oxygen
Coolant Return
Cooler and
Pump
Nitrogen
Cut
Water
Coolant Output
Start Gas Solenoid
Cut Gas Solenoid
Pump
High Freq. On-Off
On-Off
Interlocks
Injection Water
Start Gas
Plumbing Box
Flow Control
Cut Gas
Voltage Feedback
Workpiece
Voltage
Gas
Metering
Box
Process OK
Interlocks
Current Ref.
E-Stop
Process
Off
Cutting Machine Control
Height
Control
Shield
Gas*
Air Supply
Secondary
Shield Gas
Torch
PT-15XL or
PT-19XLS or
PT-600
Height
Reference
Legend
Electrical Connections
Fluid Lines
*For use on the PT-19XLS and PT-600 only. For
dry cutting the cut water switch on the flow
control must be in the "OFF" position.
Cut Gas
Pilot Arc High Freq.
Water Injection
Coolant To
(-) Current To
Coolant From
(-) Current To
Work Piece
Figure 2-2. ESP-1000 Interface Block Diagram
25
section 2installation
TO PARALLEL
POWER SOURCE
115 VAC
AUXILIARY POWER
FOR TESTING
(DISCONNECT FOR
CUTTING OPERATION)
TO AIR
CURTAIN
TO CUT WATER
PUMP
POWER
SOURCE
TO WATER
COOLER
O2 IN
FROM
REGULATOR
TO PLUMBING
BOX
N2 IN
FROM
REGULATOR
START GAS
OUT TO
PLUMBING
BOX
CUT GAS
OUT TO
PLUMBING
BOX
TO CUTTING
MACHINE CNC
CUT WATER
OUT TO PLUMBING
BOX
CUT WATER
IN FROM CUT
WATER PUMP
Figure 2-4. Flow Control Connections
26
section 2installation
TABLE 2-1. HOSE ASSEMBLIES
CABLE LENGTH
CUT WATER HOSE
COOLING WATER
START GAS HOSE
CUT GAS HOSE
25 FT.
33127
21588
33122
33117
50 FT.
33128
21574
33123
33118
75 FT.
33129
1575
33124
33119
100 FT.
33130
21576
33125
33120
125 FT.
33131
21577
33126
33121
TABLE 2-2. COOLING WATER HOSE ASSEMBLIES
CUT GAS HOSE
Hose Assembly
25 FT.
33132
50 FT.
33133
75 FT.
33134
100 FT.
33135
125 FT.
33136
TABLE 2-3. INTERCONNECTION CABLES
CABLE
LENGTH
FLOW CONTROL PLUMBING BOX
(Cable, 18 AWG,
8 conductor)
FLOW CONTROL
- CNC
(Cable, 16 AWG
12 conductor)
FLOW CONTROL
- WATER COOLER
(Cable, 18 AWG
3 conductor)
POWER SOURCE PLUMBING BOX
(Cable, Pilot Arc)
AIR
CURTAIN
(Cable, 18 AWG
3 conductor)
25 FT.
33219
33224
33253
33303
33253
50 FT.
33220
33225
33254
33304
33254
75 FT.
33221
33226
33255
33305
33255
100 FT.
33222
33227
33256
33306
33256
125 FT.
33223
33228
33257
33307
33257
Flow Control Remote Location- Flow Control to Power Source cable:
30 Ft. - 34378
60 Ft. - 34377
27
section 2installation
TABLE 2-3. RECOMMENDED REGULATORS
DESCRIPTION
PART NUMBER
Station Regulator, O2, R-76-150-024*
19151
Station Regulator, N2, R-6703
22236
Two Stage Cylinder Regulator, O2, R-77-150-540**
998337
Two Stage Cylinder Regulator, N2, R-77-150-580**
998344
Two Stage Cylinder Regulator, H-35, R-77-150-350
998342
Liquid Cylinder Regulator, O2, R-76-150-540LC
19777
Liquid Cylinder Regulator, N2, R-76-150-580LC
19977
Water to Injection pump use Regulator R-6702
22235
* Station (line) regulators connect to station outlets of piping systems that transport gas to welding or cutting stations. These regulators are
intended for inlet pressures of less than 200 psig. When used with plasma cutting systems, minimum inlet pressure should be 120 psig.
** Two stage cylinder regulators provide a more constant delivery pressure than single stage cylinder regulators. The delivery pressure of a
single stage varies about 1 psig per 10 psi of change in the inlet pressure as the cylinder empties.
28
section 2installation
Plumbing Box Connections
WARNING
Make sure that all connections are properly made to
prevent any leaks. Any leakage during actual operation could lead to a hazardous situation because of
the high voltages involved.
NOTE
B. Connect the Pilot Arc cable from the torch bundle
to the stud marked PILOT ARC TORCH (TB1) located inside the Plumbing Box.
C. Connect the Cut Water hose to the CUT WATER
TO TORCH connector on the top section of the
Plumbing Box.
D. Connect the Cut Gas hose to the GAS TO
TORCH connector on top section of Plumbing
Box.
To make the following connections, the door must be
opened and the cover removed.
Cut Gas to Torch
Cut Water
To Torch
Start Gas
Cut Gas
Coolant Out
Coolant In
Control Cable
(from Flow
Control)
Pilot Arc
from Power
Source
4/0 Power
Cables
from Power
Source
To Height Control
Figure 2-5. Plumbing Box Connections
To Torch
To Power Source
1. Connect the torch bundle to the plumbing box. Check
that the box location permits torch movement as
required.
2. Connect the 4/0 power cable(s) to the studs on the
main power bus bar TB3 (see Figure 2-6). The number
of cables depends on the maximum cutting thickness
capacity for the installation. Three cables must b e
connected to carry the full 1000 amperes.
A. Connect the cooling water (coolant) in and out
(with the internal power cable) to the connectors on the main power junction bus bar inside
the plumbing box. Refer to Figure 2-6. One connection has right-hand threads and the other
has left-hand threads. Left-hand threads are
indicated by a groove or notch on the hex of the
fitting.
29
Select plasma cutting output cables on the basis of
one 4/0 AWG, 600 volt insulated copper cable for each
400 amperes of output current. Do not use ordinary
100 volt insulated welding cable.
Each 4/0 cable must be terminated with the correct
lug prior to attempting connection to the bus bar.
section 2installation
FRONT BODY
INSULATOR
ASSEMBLY
Each cable goes through one of three strain reliefs on
the box. Ensure neither lugs nor bare wires touch
the sheet metal of the box.
3. Connect the Pilot Arc cable from the power source through its strain relief (PILOT CURRENT) to the stud
TORCH PILOT
ARC
CABLE STUD
NOZZLE
RETAINING
CUP
PILOT
CURRENT STUD
(FROM POWER
SOURCE)
BODY
ASSEMBLY
ELECTRODE
TIP (N2)
GAS SWIRL
BAFFLE
ELECTRODE
HOLDER
NOZZLE
ASSEMBLY
Figure 2-7. PT-15XL Plasma Torch Components
WARNING
COOLANT
IN AND OUT
CONNECTORS
Electric shock can kill! Before touching the torch, be
sure the power source is shut off by turning off the
3-phase power input to the power source.
4/0 POWER CABLE
CONNECTING STUDS
WARNING
Never use oil or grease on this torch. Handle parts only
with clean hands and lay parts only on a clean surface.
Oil and grease are easily ignited and burn violently in
the presence of oxygen under pressure. Use silicone
lubricate only where indicated.
Figure 2-6. Plumbing Box Internal Connections
(TB2) on the side of the high frequency box inside the
Plumbing Box. This cable runs uninterrupted from the
power source to the termination in the plumbing box,
so it is essential that it be the proper length. Use # 6
AWG 600 volt wire with ring terminals to fit the 1/4inch stud.
PT-19XLS
The PT-19XLS is a water-cooled plasma arc torch designed
for mechanized cutting at currents up to 350 Amps with
oxygen and up to 600 Amps with nitrogen or H-35.
2.4 TORCH COMPONENTS
Refer to your torch manual for detailed
installation instructions.
ELECTRODE HOLDER GAS BAFFLE
ELECTRODE
PT-15XL
NOZZLE BASE
The PT-15XL torch is supplied with front end parts for water
injection cutting using nitrogen cutting gas at currents
up to 400 amps DCSP. Nozzles for other applications are
available and are referenced in the Cutting Data Tables
in Section 3.
NOZZLE TIP
NOZZLE RETAINING CUP
NOZZLE RETAINING CUP, AIR CURTAIN
DIFFUSER
SHIELD
SHIELD RETAINER
30
Figure 2-8. PT-19XLS Components
section 2installation
WARNING
Make sure that the heat shield, shield retainer,
and other front end parts are cool before handling.
2.5. INSTALLING AIR CURTAIN
The Air Curtain is a device used to improve performance
of the PT-15XL and PT-19XLS when cutting underwater.
Cut quality and cutting speed are enhanced when using the air curtain with all PT-19XLS cutting and PT-15XL
oxygen/water injection cutting. The device mounts onto
the torch and produces a curtain of air around the cutting
area producing a relatively dry area.
Installation procedures of the air curtain for the PT-15XL
and PT-19XLS are very similar with slight differences in the
nozzle clearance positioning.
1. Remove the torch nozzle retaining cup.
2. Slide the chrome plated Air Curtain Body.
NOTE: It will ease assembly if all O-rings in the air curtain
body are lightly lubricated with silicone grease,
77500101 (5.3 oz.) or 17672 (1 oz.).
6. Adjust the position of the air curtain on the torch
until:
A. PT-15XL - a gap from 0.040 to 0.060 inch is obtained between the air curtain sleeve and the
nozzle retaining cup.
B. PT-15XL - the nozzle is recessed 0.10 inch from
the end of the air curtain sleeve.
C. PT-19XLS - the nozzle extends 0.06 inch from the
end of the air curtain sleeve.
7. Lock the air curtain into place by tightening the allen screw on the air curtain body. Refer to Figure
2-9.
NOTE: The air curtain sleeve must remain completely bottomed in the air curtain body for the adjustment in
step 6 to be correct.
3. Replace the nozzle retaining cup and any front-end
parts that may have removed from the torch.
4. Install the air curtain sleeve over the assembled torch
and snap it into place.
5. Secure the air curtain sleeve by installing the air curtain retainer. The Retainer rotates to lock in place with
the locking pins.
After tightening the allen screw, the gap between
the sleeve and torch cup should be uniform all the
way around.
With PT-15XL torches, verify that the Bubble Muffler/Air
Curtain air does not excessively interfere with the injection
spray pattern. A small interference is normal, as long as it
is uniform. If not uniform, try turning the sleeve. This will
at times correct the problem. Turn off muffler water when
checking for this interference.
TORCH
BODY
BUSHING
TORCH
BODY
BUSHING
ALLEN
SCREW
AIR CURTAIN
BODY
AIR
CURTAIN
BODY
AIR
INLET
AIR
INLET
ALLEN
SCREW
AIR
INLET
RETAINER
RETAINER
0.06"
0.10"
.040 - .062
PT-15XL
PT-15XL BEVEL
Figure 2-9. Air Curtain Installation
31
PT-19XLS
section 2installation
ALLEN
SCREW
2.6. BUBBLE MUFFLER INSTALLATION
The bubble Muffler creates a bubble of air surrounded
by water so that a PT-15XL plasma torch can be used
underwater with oxygen/water injection cutting without
significant sacrifice of cut quality. This system also permits
operation above water as the flow through the muffler
reduces fumes, noise and arc UV radiation.
CLAMP
MAIN
BODY
Installation and Adjustment
SLEEVE
1. Remove the brass nozzle retaining cup from the
torch.
TORCH
RETAINING
CUP
.040 - .060
NOTE: Lubrication of O-rings in the bubble muffler is recommended for ease of installation.
Figure 2-10. Bubble Muffler Assembly
2. Slide the chrome plated bubble muffler clamp onto
the torch about 1/2 inch up the torch sleeve (body).
3. Replace the nozzle retaining cup and any front-end
torch parts that may have removed from the torch.
4. Install the bubble muffler sleeve in the bubble muffler
main body. Maker sure it bottoms completely.
The sleeve must remain completely bottomed in
the Bubble Muffler body for the adjustment in step 6 to
be correct.
After tightening the allen screw, the gap between
the sleeve and torch cup should be uniform all the way
around.
5. Install the bubble muffler main body (with sleeve)
over the assembled torch and snap it into place on
the bubble muffler clamp.
6. Adjust the position of the bubble muffler on the torch
until a gap of .040 to .060 (use 1/16 inch allen wrench
for gapping) is obtained between the inside wall of
the muffler sleeve and the torch retaining cup.
7. Lock the bubble muffler into position by tightening
the allen screw on the bubble muffler clamp.
With PT-15XL torches, verify that the Bubble Muffler air does not excessively interfere with the injection
spray pattern. A small interference is normal, as long as
it is uniform. IF not uniform, try turning the sleeve. This
will at times correct the problem. Turn off muffler water
when checking for this interference.
Better centering of the bubble muffler sleeve can
be obtained by putting 3 evenly spaced (120" interval)
pads of tape of electrical tape on the nozzle retaining
cup.
A helpful hint for adjusting the Air Curtain or bubble Muffler for proper location on the PT-15XL:
1. Mark the nozzle retaining cup and back it up 3/4 to 1
turn from fully tight.
2. Install the Air Curtain or Bubble Muffler sleeve and
push the assembly up the torch until the sleeve bottoms out against the nozzle retaining cup.
3. Lock into position with the allen screw.
4. Retighten the nozzle retaining cup.
NOZZLE
RETAINING
CUP
2-3 LAYERS ELECTRICAL
TAPE AT 3 PLACES
SPACED 120o
Figure 2-11. Centering Tape on Retaining Cup
32
section 2installation
2.9. WATER INJECTION PUMP
2.7 WATER MUFFLER SYSTEM FOR THE PT19XLS
The Water Injection Pump is intended to supply cut water
to the PT-15XL water injection torch. It may be used in
other applications where water requirements do not exceed the pump capacity of 0.5 gpm @ 200 psig. See Figure
2-13 for Installation Diagram.
This system is similar to the PT-15XL
Bubble Muffler.
2.8. AIR CURTAIN/BUBBLE MUFFLER
CONTROL BOX INSTALLATION
1. Mount the Control Box at a convenient location and use the
hose supplied to connect the box with the unit mounted
on the torch.
2. Connect the Control Box to a source of oil free shop air
capable of delivering at least 20 scfm at 80 psig. The hose
used should be at least 3/8 inch inside diameter. Refer to
Figure 2-12 for plumbing hookup.
3. Use SJO wire to connect the control to the cutting machine
control. If the ESP system is used, the connection may be
made to the appropriate amphenol connector on the
back of the Flow Control. The connection of the control is
made at terminals marked FC. An appropriate cable may
be selected from the table of optional accessories.
CONTROL CABLE
PUMP
APPROPRIATE AMPHENOL
CONNECTOR ON FLOW
CONTROL OR CNC
POWER
AIR CURTAIN
CONTROL BOX
CONTROL CABLE
115VAC
OPTIONAL
Figure 2-12. Electrical Connections for Water Pump
3/8" ID
HOSE
4. The user supplied 115 volt AC may be connected to the
terminals so marked. This will allow manual operation of
the air curtain control.
3/8" ID
HOSE
5. Connect a ground wire to the stud provided in the control
box.
6. Provide air to the control box. Energize solenoid in control
box and adjust regulator screw from 15 - 30 psig delivery.
Adjust within range for best cut quality.
AIR CURTAIN
CONTROL BOX
TORCH
BUBBLE MUFFLER
3/4" ID
HOSE
PUMP
WATER
TABLE
WATER
7. Place switch in AUTO. The system should turn on when the
preflow begins. The pump will recirculate approximately
20 gpm from the water table.
Further details and replacements parts for the air curtain and
bubble muffler are depicted in instruction manuals, F-15-189
& F-15-127, 15-474 & 15-475.
33
AIR
INLET
STRAINER
Figure 2-13. Plumbing Connections for Water Pump
To prevent damage to pump, do not operate water injection pump with delivery pressure above 220 psig. Do not
operate for more than 2 minutes without flow (with the
pump deadheaded). Do not operate for extended periods
of time with less than 0.2 gpm flow.
section 2installation
INTERMEDIATE
WATER QUALITY INDICATOR
LIGHT (50,000 OHM RATING)
FILTER TO
PROTECT
TANKS
TAP
WATER
IN
CATION
TANK
MIXED
BED
TANK
ANION
TANK
R-5702 REGULATOR
(PN 639629) SET TO
DELIVER 25-30 PSIG
TO
CUT WATER
PUMP
30 MICRON FILTER
TO PROTECT SYSTEM
WHEN TANKS ARE
CHANGED
FINAL WATER
QUALITY INDICATOR
LIGHT
(200,000 OHM RATING)
Figure 2-14. Deionizer System for Plasma Cut Water
2.10 INSTALLATION OF THE SECONDARY GAS
METERING BOX
The PT-19XLS incorporates arrangements for secondary gas shielding to improve cut squareness. A secondary gas metering box and accessories are required.
The adaptor for torch to gas metering box is supplied
with the plumbing box.
1. Mount the gas metering box at a convenient location
with the flowmeter vertical and use the hose supplied
to connect the box with the unit mounted on the
torch.
2. Connect the gas metering box to a source of dry oil
free shop air capable of delivering at least 11 scfm at
80 psig. The hose used should be at least 3/8" ID.
3. Use SJO wire to connect the gas metering box to the
cutting machine control. If the ESP system is used,
then the connection may be made to the "Air Curtain"
amphenol connector on the back of the flow control.
See Figure 2-16 if Air Curtain is already installed. The
connection of the gas metering box is made at the
terminals marked F. C. An appropriate cable may be
selected from the table of required accessories.
4. User supplied 115 V ac may be connected to the terminals so marked. This will allow manual operation
of the gas metering box assembly.
5. Connect a ground wire to the stud provided in the
control box.
The installation, operation and replacement parts
for the secondary gas metering box will be covered in
this section.
Required Accessories
Item
Part No.
Length
Cable, 18 GA 3-Cond.
P/N 33253
25 ft.
Cable, 18 GA 3-Cond.
P/N 33254
50 ft.
Cable, 18 GA 3-Cond.
P/N 33255
75 ft.
Cable, 18 GA 3-Cond.
P/N 33256
100 ft.
Cable, 18 GA 3-Cond.
P/N 33257
125 ft.
ITEM
Part No.
Quantity
Secondary Gas Metering
Box
22178
1
Hose Assy., 50 ft. w/
5/8" 18f Fittings
34033
1
Note: For dry cutting, turn off the "cut water switch" on flow
control.
34
section 2installation
Plumbing Box Connections
Operation
Remove the hose nut from adaptor assembly. Place the
adaptor over the "cut water" fitting as shown in figure 2-15
and screw the hose nut previously removed onto the "cut
water" fitting and assemble as shown.
1. Provide gas metering box with oil free air at 80 psig
minimum. Energize solenoid in control box and adjust
regulator screw to the desired pressure and throttle
valve to set the desired flow. Refer to the appropriate
cutting parameter charts starting on page 49.
2. Place switch to AUTO. The system should turn on when
the preflow begins.
3. Cutting standoff (Torch to Work Distance) must now
be measured from the bottom of the Secondary Shield
Assembly. Refer to appropriate tables for proper
standoffs.
Note: Set piercing standoff as specified in the appropriate parameter chart.
WARNING
Electric shock can kill. Disconnect power from power
source before touching or servicing the Secondary
Shield at the torch. Disconnect power to the Control
Box before servicing.
Figure 2-15 Plumbing Box Connections
Terminal
Strip
AIR CURTAIN
AMPHENOL
Figure 2-16. Air Curtain, Secondary Gas Metering Box and Pump Motor
35
section 2installation
1
16
14
12
13
2
8
6
15
7
11
10
ITEM NO.
QTY REQ.
PART NO.
DESCRIPTION
1
1
22174
FLOWMETER ASSEMBLY (See Fig.4)
2
3
10Z30
ADAPTOR B-A/W X 1/4 NPTM
3
1
19Z99
ADAPTOR 1/4 NPTM X .69 - 24F
4
1
82Z46
WASHER FLAT .61 X .32 X .06 NYLATRON
5
1
19906
VALVE RELIEF ASSEMBLY
6
1
22220
GAUGE 2.50, 100PSI
7
1
22181
HOSE ASSEMBLY FOR PRESSURE GAUGE
8
2
22182
HOSE ASSEMBLY FOR GAS IN & OUT
9
1
632904
VALVE NEEDLE 1/4PF X 1/4PF 3000PSI
10
2
11N16
ADAPTOR B/A-WF X 1/4 NPTM
11
1
522368
AIR REGULATOR (Discard Gauge)
12
3
639501
ADAPTOR 1/4-18NPT x 1/4 NPTM
13
1
636387
VALVE SOL. 1/4P
14
1
96W85
STRAIN RELIEF
15
1
951041
TERM BLOCK 4 POS.
16
1
636702
SWITCH TOGGLE DPDT 3 POS 15A
Figure 2-15. Secondary Gas Metering Box. P/N 22178
36
2,12,3,4,5
9
section 2installation
8
9
11
12
13
7
6
10
5
4
1
3
2
ITEM NO.
1
QTY REQ.
1
PART NO.
22168
DESCRIPTION
FLOWMETER BODY
2
2
86W62
O-RING 1.239ID X .070W NEOPR 70A
3
1
85W10
O-RING .239ID X .070W NEOPR 70A
4
1
639571
TUBE METER 1.4-33-G-5 GLS
5
1
53A61
BALL 0.250 DIA STAINLESS STEEL
6
1
22169
FLOAT STOP FLOWMETER
7
1
12N29
SPRING 0.75 X 0.63D
8
1
22170
CAP
9
8
61340006
10
1
22171
SCREW STLZPC 0.190-32 X 0.50 (#10-32 X .5)
11
8
64302920
12
2
22172
FRAME
13
1
22173
OUTER TUBE
SPIDER
WSR 52002 STLZPC 0.190 (WASHER #10)
Figure 2-16. Flowmeter Assembly, Secondary Gas, P/N 22174
37
Flowmeter Reading (Measured At Top Of Ball)
4.0
3.0
4.0
3.0
38
1.0
1.0
Figure 5. Flowmeter Calibration Curves
SCFH N2
2.0
2.0
0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700
5.0
5.0
8.0
6.0
100 PSIG
6.0
80 PSIG
9.0
10.0
7.0
60 PSIG
7.0
8.0
9.0
10.0
Pressures Shown Are Measured At Flowmeter Outlet
section 2installation
section 3operation
3.1. GENERAL
A. TEST/RUN
Operating with a plasma system such as the ESP-1000
contains a great number of variables to achieve quality
cutting over a wide range of applications. The setup and
operating characteristics for specific applications depend
on, type of material, thickness of material, type of cut gas,
dry cutting, water injection cutting or underwater cutting.
The information in this section will provide standard procedures and general guidelines for application.
This area includes a 5-position switch, the CUT WATER FLOW meter and the CUT WATER PRESSURE SET regulator. The functions are:
WARNING
Electric shock can kill! Do not operate this equipment
with any covers removed. Take all precautions to remove power before attempting any service or maintenance inside cabinets or torch.
1. CUT GAS position permits testing the cut gas flow
or purging the system without actually cutting.
2. START GAS permits testing the start gas flow or
purging the system without cutting.
3. RUN 1 position is used when cutting is to start with
the start gas, and after arc transfer occurs to switch
automatically to cut gas. This is one of two positions for actual cutting to occur. (Oxygen cutting is
normally performed in this position.)
4. RUN 2 position is used when the start of the process
is done with the same gas and flow as the cutting
process. (This position is normally used when Nitrogen and Argon-Hydrogen cutting is performed.
5. HF position permits testing of the high frequency
without cutting.
Arc rays can burn eyes and skin, noise can damage
hearing! Wear welding helmet with appropriate filter.
Wear ear and body protection.
3.2. CONTROLS AND INDICATORS
B. CUT WATER
FLOW CONTROL
All controls are located on the front of the Flow Control.
The control panel is laid out in three sections, TEST/RUN,
CUT WATER, CUT GAS, plus, the Power Switch.
This area pertains to control of the cut water flow for PT15XL only. The approximate flow rates for each position
are given in Table 3-1.
Figure 3-1. Flow Control Front Panel
39
section 3operation
C. CUT GAS
1. The ON/OFF switch is used to select whether or
not cut water is to be used. If ON, the flow rate is
determined by the setting of the flow rate switches.
This switch should always be ON for cutting with
the PT-15XL torch and off with the PT-19XLS (PT600).
This area includes the O2/N2 switch, Flow Rate that is an
8-position switch and HI/LOW toggle switch. Refer to Table
3-2 for approximate flow rate for specific settings.
2. FLOWRATE switches. The 8-position rotary switch
and two position toggle switch are used to set the
cut water flow rate. The 8-position switch (0-7) is
used for inputs within the flow control that determines the water flow rates. The switch operates
a combination of three of four solenoid valves in
parallel. The fourth valve is operated by the HIGH/
LOW switch. The cut water flows through measuring orifices in each line of the four solenoid valves.
The orifices vary in size so that each is capable of
doubling the flow, the largest orifice delivers eight
times the flow as the smallest.
1. The O2/N2 switch selects the type of cut gas being
used for cutting.
2. FLOWRATE switches. The 8-position rotary switch and
two position toggle switch are used to set the cut
gas flow rate. The 8-position switch (0-7) is used for
inputs within the flow control that determines the
gas flow rates. The switch operates a combination of
three of four solenoid valves in parallel. The fourth
valve is operated by the HIGH/LOW switch. The cut
gas flows through measuring orifices in each line of
the four solenoid valves. The orifices vary in size so
that each is capable of doubling the flow, the largest
orifice delivers eight times the flow as the smallest.
In the 0/ LOW setting no solenoid is energized. Position 1 energizes the solenoid valve in the smallest
orifice line. Position 2 energizes the valve next in
line of flow rate. Position 3 energizes both of these
valves. The progression continues to provide more
flow at each higher numbered position in equal
increments. In combination the four valves are
capable of providing different flows but the switch
limit is eight settings. The HIGH/LOW switch is used
to energize the solenoid with the largest orifice that
allows using the remainder of the flows.
In the 0/ LOW setting no solenoid is energized. Position 1 energizes the solenoid valve in the smallest
orifice line. Position 2 energizes the valve next in
line of flow rate. Position 3 energizes both of these
valves. The progression continues to provide more
flow at each higher numbered position in equal
increments. In combination the four valves are
capable of providing different flows but the switch
limit is eight settings. The HIGH/LOW switch is used
to energize the solenoid with the largest orifice that
allows using the remainder of the flows.
TABLE 3-2. CUT GAS FLOW RATES
TABLE 3-1. CUT WATER FLOW RATES
SWITCH SETTING/
FLOW RATE
CUT WATER GPM
SWITCH SETTING/
FLOW RATE
CUT GAS (O2/N2)
SCFH
0/LOW
0
0/LOW
0
1/LOW
0.03
1/LOW
20
2/LOW
0.07
2/LOW
40
3/LOW
0.10
3/LOW
60
4/LOW
0.14
4/LOW
80
5/LOW
0.17
5/LOW
100
6/LOW
0.21
6/LOW
120
7/LOW
0.24
7/LOW
140
0/HIGH
0.28
0/HIGH
160
1/HIGH
0.31
1/HIGH
180
2/HIGH
0.35
2/HIGH
200
3/HIGH
0.38
3/HIGH
220
4/HIGH
0.41
4/HIGH
240
5/HIGH
0.45
5/HIGH
260
6/HIGH
0.48
6/HIGH
280
7/HIGH
0.51
7/HIGH
300
40
section 3operation
POWER SOURCE (ESP-600C)
F. AMMETER displays the arc current level when cutting.
All control functions are provided through one receptacle
located on the front panel of the power source. A 19-pin receptacle allows plugging in the cable from the flow control.
All control signals are routed through this connection.
For control descriptions pertaining to the ESP-400
and Ultra Life 300 refer to the appropriate instruction
manual.
A. The current control mode for the power source is set using the PANEL/REMOTE switch.
3.3. PRE-OPERATION TEST/CHECKOUT
1. With the switch in the PANEL position, output current
is controlled by setting the power source current
control potentiometer (CCP).
The pre-operation testing and checking offers the advantage of having the parameters set and established in
proper order before starting to cut actual material.
2. With the switch in the REMOTE position, output
current is controlled from a remote device such as
a cutting machine CNC.
A. TEST FUNCTIONS
B. When using an ESP-600C power source, the LED indicator lights on the front panel are used to help check for
proper operation of the unit.
B. RUN MODES
1. OVER TEMP - illuminates should the power source
become over heated.
2. CONTACTOR ON - This light indicates that the main
power contactor has been energized and voltage is
being applied to the cutting circuit.
3. FAULT INDICATOR - illuminates should abnormalities
occur in the cutting process or if the input line voltage falls outside of the nominal value by +/- 10%.
4. POWER RESET FAULT - illuminates when a serious
fault is detected. Input power must be disconnected
far at least 5 seconds and then reapplied.
The TEST/RUN portion of the Flow Control front panel
allows the user to test parts of the system, purge gas,
water lines and to select between two different RUN
modes.
The first run mode (RUN 1) starts with start gas (at start
gas flow) and switches over to cut gas when the arc
transfers.
The start gas is taken from the N2 gas input on the back
of the flow control box. The cut gas is taken either from
the N2 or the O2 input on the back of the flow control
box. The selection of the cut gas is accomplished with
the O2/N2 selector switch on the front panel.
The second run mode (RUN 2) starts directly with cut
gas flow. In this case the gas used for cutting must
be connected to the N2 input on the back of the flow
control.
C. MAIN POWER indicator illuminates when input power is
applied to the Power Source.
NOTE
D. PILOT ARC HIGH/LOW switch allows selection of the
pilot arc range HIGH or LOW.
Purging of gas leads should be possible even if insufficient
gas pressure exists on incoming gas pressure switches.
E. VOLTMETER displays the arc voltage value when cutting.
TABLE 3-3. TEST/RUN SELECTION DESCRIPTION
TEST POSITIONS
ACTIVATED FUNCTION
START GAS
CUT GAS
CUT WATER
HF
CUT GAS
NO
YES
YES (if on)
NO
START GAS
YES
NO
YES (if on)
NO
HF
YES
NO
NO
YES
41
section 3operation
CUT WATER
C. TEST FUNCTIONS
A. Basic Requirements
The tests are used to test and purge gas and water. The
test of the HF unit is made without activating the main
contactor of the power source. Since water is tested
at the same time, some of the tests are combined to
reduce the number of positions on the switch.
The PT-15XL requires a supply of clean cut water with
high electrical resistance.
1. To adjust the delivery pressure of the water injection
pump, remove the acorn nut located on top of the
pump and turn screw "in" to increase pressure or "out"
to reduce pressure. After adjusting replace the acorn
nut.
WARNING
Never operate the power source with the cover removed. In addition to the safety hazard, improper
cooling may cause damage to internal components.
Keep side panels closed when unit is energized. Also,
make sure you are adequately protected before you
start to cut.
2. The water injection pump must be supplied with
water from a source capable of delivering at least 1/2
gpm @ 25 psig minimum. The water injection pump
boosts this pressure to 190 to 200 psig for delivery to
the flow control.
Ensure that the power cable connections are properly
made to prevent water leaks. Any leakage during operation could be hazardous because of high voltage
and current.
3. Cut water must have a high electrical resistance (at
least 200,000 ohm-cm is recommended) and low
hardness (0.5 grains per gallon maximum). Conductive water can cause problems with starting reliability, high frequency noise problems with the cutting
machine or height control, and can cause corrosion of
torch parts such as; cups, nozzles. These deposits will
reduce cooling, lower cut quality by disrupting flow
through the nozzle, and can clog the flow control.
CUT GASES
A. Set the delivery pressure of the gas supply regulators according to the Table 3-4 (with gas flowing).
For example, the recommended delivery pressure
for nitrogen cut gas and 50 feet of 1/4 inch ID hose is
104 psig. Delivery gauge mounted on regulator must
not read greater than 200 psig. Refer to Table 2-3 for
recommended gas regulators.
Tribed deionizer systems have generally proved to be the
best solution to supplying good quality cut water. Some
sources of deionizer systems are:
Culligan Water Treatment
ECO Water Systems
Master Chemical Corporation
NOTE
Do not use hoses less than 1/4 inch ID in
the system.
708-205-6000
513-423-9421
419-874-7902
Local distributors can be found in the phone book or by
calling one of the above numbers.
TABLE 3-4. RECOMMENDED REGULATOR PRESSURE SETTINGS (PSIG)
CUT
GAS
TYPE
1/4-IN. ID HOSE
LENGTH IN FEET
5/16-IN. ID HOSE
LENGTH IN FEET
3/8-IN. ID HOSE
LENGTH IN FEET
12.5
25
50
100
12.5
25
50
100
12.5
25
50
100
O2
100
100
100
100
100
100
100
100
100
100
100
100
N2
100
103
104
105
100
100
100
102
100
100
100
100
H-35 For PT-15XL
138
139
141
144
135
135
137
138
135
135
135
135
42
section 3operation
CUT WATER BLOWDOWN
After deionizing, water should pass through a 30-micron filter
before going to the cut water pump. Refer to Figure 2-13 for
further details of installation.
B. Cut Water Flow System Calibration
This is done to calibrate the cut water system when used
with the PT-15XL torch. Once it is completed, the cut
water flow is set with the flow rate switches for each case
according to the different cutting cable sizes.
1. Make sure that the Flow Control is turned on, the ON/
OFF switch is in the ON position and the indicator
light is lighted.
2. Set TEST/RUN selection switch to either CUT GAS or
START GAS position.
3. Set CUT WATER ON/OFF switch to ON.
4. Set CUT WATER HIGH/LOW switch to HIGH.
5. Set FLOW RATE switch to position 5.
6. Adjust CUT WATER pressure adjusting screw until the
CUT WATER FLOW gauge reads 0.45 gpm at the top
of the ball. Ensure that cut water pump gauge reads
no more than 220 psig. The preferred reading is 190
to 200 psig.
7. Toggle the CUT WATER ON/OFF switch a few times to
ensure any creep is out of the regulator adjustment.
Readjust if necessary.
The cut water system is now calibrated. This calibration
should be checked occasionally.
If the equipment is to be exposed to freezing temperatures
(while during non-operative time), water lines should be
blown out to prevent freeze damage to torch and equipment.
NOTE
Blowdown of the coolant system is not required if Plasma
Torch Coolant is used.
To blowdown the water injection system, disconnect water
supply to the Water Injection Pump and connect a supply
of nitrogen or clean air at 130 to 150 psig. Set the system
in test and set cut water flow to HIGH 7. Let the gas flow
until water stops coming out the front of the torch. It is
important that the Start Gas or Cutting Gas continues to
be supplied (at the same time as the purging air/nitrogen),
to prevent water feedback into the gas lines.
To blowdown the cooling system, disconnect the hose
from the cooler or pump and connect it to nitrogen or
clean air at 20 psig. The return hose should be connected
to drain. Blow gas through the system until coolant no
longer comes out the drain line. Do Not operate the coolant circulator without using plasma coolant 156F05 . The
coolant provides lubrication of the internal pump parts.
Algae growth and damage to the pump may occur if plain
water is substituted.
NOTE
Contact the supplier of the deionizer to discuss freezing
of the deionizing system.
POWER SOURCE
WARNING
COOLANT
Cooling of the plasma torch is usually accomplished with a
coolant circulator. This circulator should be filled with plasma
torch coolant. Always use torch coolant, it lubricates the internal parts of the pump.
WARNING
Settings over 150 psig will cause premature failure of the
pump and/or motor-to-pump coupling.
Check out the coolant flow with the power source ON, by
observing the return water at the cooler. Coolant flow with N2
consumables should be 1.4 to 1.6 gpm. Coolant flow with O2
consumables should be 1.25 gpm. Coolant can be conveniently
checked at the return line by using a suitable container.
43
Never operate the power source with the cover removed, in addition to the safety hazard, improper
cooling can cause damage to internal components.
Keep side panels closed when unit is energized. Also,
make sure you are adequately protected before you
start to cut.
The Power Source controls and their functions are described in the following sequence.
A. Check the secondary output connections to the positive and negative output bus bar terminals.
B. Verify that the control connections have been properly made.
section 3operation
C. Determine the current control mode the power source is
to be operated in and set the Control Switch in the desired
position. With this switch in the PANEL position, output
current is controlled by setting the power source current
potentiometer. When the power source output current
is controlled by a cutting machine control system, place
this switch in the REMOTE position.
D. If the primary electrical input connections to the power
source have been installed correctly, close the main line
(wall) disconnect switch. Power will be applied and the
Pilot Light on the front panel will be on. The cooling fans
will come on when cutting starts.
E. Adjust the desired output current level at the power
source or at the remote control location.
F. Operate the starting switches on the cutting control to
energize the power source main contactor. Power will
appear at the power source output bus bar terminals.
G. After cutting has started, observe the ammeter, voltmeter
and/or the cutting operation. If necessary readjust the
current control as required.
H. The cutting arc will extinguish and the power source will
shut off automatically when the torch travels beyond the
edge of the work piece. The nozzle and electrode will
experience excessive wear (especially with O2). Therefore,
extinguishing the arc with an Arc Stop Signal before running off the work piece is recommended.
A properly installed and operating power source should function as follows:
A. After energizing the power source (at the disconnect
switch), the Main Power light (on the front panel) will illuminate and the Fault Indicator light will flash and then
go out.
B. When the contactor signal is received ( the "Contactor
On" indicator will light) and power is applied to the main
transformer, Open Circuit Voltage is available at the power
source output terminals as indicated on the voltmeter.
C. Upon transfer of the main arc to the work, a current detector circuit senses the current and sends an "ARC ON"
signal to the Flow Control.
44
3.4. OXYGEN CUTTING WITH PT-15XL
The procedures presented in this section pertain to use of
Oxygen as the cutting gas in conjunction with the PT-15XL
plasma cutting torch. The information is relative to setting
parameters for various types and thicknesses of materials.
Refer to the torch instruction manual F-15-031 for details
of the torch assembly.
WARNING
Electric shock can kill! Before touching the torch, be
sure the power source is shut off by removing the
3-phase power input to the power source.
A. Ensure that the torch is assembled correctly for oxygen cutting. Internal parts of torch must be clean and
dry.
B. If using an air curtain or bubble muffler, be sure installation and setup are correct.
C. Set Flow Control O2/N2 switch to O2 position.
D. Set the Flow Control CUT WATER ON/OFF switch to
ON.
E. Set the Cut Water and Cut Gas flow as indicated in
Table 3-6.
NOTE
Cut Water must be calibrated as described on Page 27.
F. Set Flow Control TEST/RUN switch to CUT GAS TEST
position.
1. Ensure that O2 regulator is set to 100 psig.
2. Observe torch spray pattern. It should be rela-
tively even, regular and steady.
G. Set Flow Control TEST/RUN switch to START GAS TEST
position.
H. Set start gas regulator on Plumbing Box to 26 psig.
Check N2 regulator setting per Table 3-4.
I.
After changing consumables or a substantial break in
cutting operations, purge the torch in CUT GAS TEST
position for at least 60 seconds before cutting.
J.
Set the TEST/RUN switch in the RUN 1 position. The
system is ready to cut.
section 3operation
OXYGEN
ELECTRODE
GAS
BAFFLE
BODY
ASSEMBLY
FRONT BODY
INSULATOR
ASSEMBLY
NOZZLE
NOZZLE RETAINING
CUP
OXYGEN
ELECTRODE
HOLDER
NOTE: Refer to F-15-031 for part
numbers and options.
Figure 3-2. PT-15XL Torch Components for Oxygen Cutting
TABLE 3-5. COMPONENTS FOR OXYGEN CUTTING WITH PT-15XL
ELECTRODE
HOLDER
20398
ELECTRODE
20763XL
35666XL
(FLAT)
NOZZLE ASSEMBLY
SWIRL BAFFLE
Diameter
RATING
P/N
standard
optional
0.099
260A
20751
8-HOLE
CERAMIC
2075586
4-HOLE
CERAMIC
948142
0.099
REV.
260A
20920
8-HOLE
CERAMIC
REVERSE
20918
4-HOLE
CERAMIC
REVERSE
948143
0.116
0.120
300A
340A
35662
35664
8-HOLE
CERAMIC
35660
0.116
REV.
300A
35663
0.120
REV.
340A
35665
8-HOLE
CERAMIC
REVERSE
35661
45
N/A
section 3operation
TABLE 3-6. OXYGEN CUTTING CONTROL SETTINGS WITH PT-15XL
MATERIAL
THICKNESS
(CARBON
STEEL)
CURRENT
AMPS
VOLTAGE
SETTING
OXYGEN
CUT GAS
FLOW
CUT
WATER
FLOW
CUT
SPEED
(Inches
per minute)
STANDOFF
(TORCH TO
WORK - inches)
1/8
200
120-125
LOW 5
HIGH 7
175-200
1/2" FOR
1/4
260
120-125
LOW 5
HIGH 7
150-170
PIERCING
1/2
260
125-130
LOW 5
HIGH 7
90-100
1/8-5/32"
3/4
260
130-135
LOW 5
HIGH 7
60-70
FOR
*1
260
135-140
LOW 5
HIGH 7
40-50
CUTTING
Higher speed is sometimes obtained on thicker plate by increasing gas setting to LOW 6.
* Dross free conditions on 1" are more easily obtained at 300 to 340 amps.
NOTES
•
Cutting speeds given are average. They may vary with material composition and surface condition.
•
Only ceramic baffles may be used with oxygen cutting.
•
Use of more than 260 amps when cutting with oxygen will reduce electrode and nozzle life.
•
The nozzles for oxygen service, PN 20751 and 20920, are factory assembled and should not be taken apart. It must
be replaced as a complete unit.
•
The nozzles for oxygen service, PN 21206B and 21207B, have a replaceable insulator, PN 21193.
•
Replace electrode, PN 20763XL, when the cavity in the hafnium insert reaches 0.09" in depth or 0.12" in diameter.
•
Removing the nozzle from the torch to check electrode wear greatly reduces electrode life. Remove nozzle only when
changing electrode or cut quality has deteriorated.
•
Reverse nozzle and swirl baffles are useful in applications where two plasma torches are cutting with one cutting
mirror images.
•
8-Hole baffles are recommended for ESP systems. Consumable life is extended.
•
Cutting conditions have been developed up to 360 amps.
46
section 3operation
TABLE 3-7. HIGH CURRENT OXYGEN CUTTING WITH PT15XL
MATERIAL
THICKNESS
(CARBON
STEEL)
CURRENT
AMPS
VOLTAGE
SETTING
OXYGEN
CUT GAS
FLOW
CUT
WATER
FLOW
CUT
SPEED
(Inches
per minute)
STANDOFF
(TORCH TO
WORK - inches)
1/4
300
126
HIGH 1
HIGH 7
225-250
5/32
3/8
300
128
HIGH 1
HIGH 7
165-180
5/32
1/2
300
130
HIGH 1
HIGH 7
135-145
5/32
3/4
300
144
HIGH 1
HIGH 7
75-85
1/4
1
300
148
HIGH 1
HIGH 7
50-60
1/4
3/4
340
130-132
LOW 6
HIGH 7
85-100
5/32-3/16
1
340
128-135
LOW 6
HIGH 7
59-65
5/32-1/4
1-1/4
340
140
LOW 6
HIGH 7
40-45
1/4
1-1/4
360
140
LOW 6
HIGH 7
45-50
1/4
Cut water flow setting should be HIGH 7
TABLE 3-8. OXYGEN UNDERWATER CUTTING WITH PT-15XL
MATERIAL
THICKNESS
(CARBON
STEEL)
CURRENT
AMPS
VOLTAGE
SETTING
OXYGEN
CUT GAS
FLOW
CUT
SPEED
(Inches per
minute)
STANDOFF
(TORCH
TO
WORK inches)
AIR CURTAIN
PRESSURE
(PSIG)
1/4
300
126
HIGH 1
225-250
5/32
20
3/8
300
127
HIGH 1
165-180
5/32
20
1/2
300
132
HIGH 1
135-145
5/32
30
3/4
300
144
HIGH 1
75-85
1/4
30
1
300
148
HIGH 1
50-60
1/4
30
3/4
340
131
LOW 6
75-95
5/32
20
1
340
130
LOW 6
59-65
5/32
20
1-1/4
340
140
LOW 6
40-45
1/4
30
1-1/4
360
140
LOW 6
45-50
1/4
30
Cut water flow setting should be at HIGH 7.
NOTES
Nitrogen Start Gas setting should be at 26 psig for both above and under water cutting.
Torch components for both above and underwater oxygen cutting with a PT-15XL are:
Nozzle - PN 35662 or 35663 reverse up to 300 amps
PN 35664 or 35665 reverse for over 340 to 360 amps
Swirl Baffle - PN 35660 or 35661 reverse
Electrode - PN 35666XL
47
section 3operation
Table 3-9. Low Current Cutting Conditions with PT-15 (Above Water)
MATERIAL
TYPE/
THICKNESS
CURRENT
AMPS
VOLTAGE
SETTING
cut gas
flow
CUT WATER
FLOW
CUT SPEED
IPM
STANDOFF
(TORCH TO
WORK - IN.)
CS/ 0.078
70
125
OXY - LOW 5
LOW 5
240
0.156
CS/0.125
70
129
OXY - LOW 5
LOW 5
165
0.156
CS/0.188
90
129
OXY - LOW 5
LOW 5
140
0.156
CS/0.250
90
134
OXY - LOW 5
LOW 5
120
0.156
CS/0.312
125
134
OXY - LOW 5
LOW 5
120
0.156
SS/0.062
60
128
OXY - LOW 5
LOW 5
150
0.156
SS/0.125
65
130
OXY - LOW 5
LOW 5
100
0.156
SS/0.188
75
132
OXY - LOW 5
LOW 5
125
0.156
SS/0.250
90
136
OXY - LOW 5
LOW 5
100
0.156
SS/0.312
125
137
OXY - LOW 5
LOW 5
90
0.156
AL/0.062
100
136
OXY - LOW 5
LOW 5
175
0.156
AL/0.125
100
128
OXY - LOW 5
LOW 5
125
0.156
AL/0.250
100
135
OXY - LOW 5
LOW 5
75
0.156
AL/0.312
125
136
OXY - LOW 5
LOW 5
75
0.156
AL/0.375
125
149
OXY - LOW 5
LOW 5
50
0.156
SS/0.062
80
155
NIT - LOW 5
LOW 4
275
0.156
SS/0.125
100
150
NIT - LOW 5
LOW 4
150
0.156
SS/0.188
125
155
NIT - LOW 5
LOW 5
100
0.156
SS/0.250
125
156
NIT - LOW 5
LOW 5
90
0.156
SS/0.312
125
162
NIT - LOW 5
LOW 5
75
0.156
AL/0.062
65
160
NIT - LOW 5
LOW 5
150
0.156
AL/0.125
65
160
NIT - LOW 5
LOW 5
100
0.156
AL/0.250
125
160
NIT - LOW 5
LOW 5
100
0.156
AL/0.312
125
167
NIT - LOW 5
LOW 5
50
0.156
AL/0.375
125
179
NIT - LOW 5
LOW 5
45
0.156
notes:
1. Nitrogen generally produces smoother cut surfaces on stainless steel and aluminum, but with
somewhat more bevel and top edge rounding than oxygen. Oxygen generally has a wider
dross free speed range.
2. When using the ESP-300 power supply, low range must be used for current under 80 amps. High range
will produce less ripple on the cut face and can usually be user at current over 80 amps. The cut face
ripple is most noticeable on stainless steel cut with nitrogen.
3. Gas Baffle:
Electrode:
Nozzle:
948142 "4x030"
948143 "4x30 Rev."
35666XL
37317 "Nozzle low current PT-15XL"
37318 "Nozzle low current PT-15 Rev."
48
section 3operation
3.5. NITROGEN CUTTING WITH PT-15XL
B. Set Flow Control switch O2/N2 in the N2 position.
WARNING
C. Set Flow Control CUT WATER ON/OFF switch to ON
position.
Electric shock can kill! Before touching the torch, be
sure the power source is shut off by turning off the
3-phase power input to power source.
D. Set CUT WATER and CUT GAS flow per Table 3-10.
NOTE
Cut water must be calibrated as described on page 26.
The procedures presented in this section pertain to use
of Nitrogen as the cutting gas in conjunction with the
PT-15XL plasma cutting torch. The information is relative
to setting parameters for various types and thicknesses of
materials. Refer to the torch instruction manual F-15-031
for details of the torch assembly.
E. Set Flow Control TEST/RUN switch in CUT GAS TEST
position.
A. Ensure that the torch is correctly assembled for nitrogen cutting. (Refer to Table 3-9 for components.)
1. Ensure that N2 regulator is set per Table 3-4.
2. Observe spray pattern. It should be relatively
even, regular and steady.
TABLE 3-10. COMPONENTS FOR NITROGEN CUTTING WITH PT-15XL
ELECTRODE
HOLDER
ELECTRODE
NOZZLE ASSEMBLY
Diameter
2075343
600236
RATING
SWIRL BAFFLE
P/N
standard
optional
.125
250A
2075691
2075341
948142
.156
400A
2075611
4-HOLE
4-HOLE
.200
600A
2075612
PLASTIC
CERAMIC
.230
750A
2075613
REVERSE
.125
250A
2075692
2075360
948143
.156
400A
2075614
4-HOLE
4-HOLE
.200
600A
2075615
PLASTIC
CERAMIC
.230
750A
2075690
ELECTRODE
HOLDER
BODY
ASSEMBLY
NOZZLE
ASSEMBLY
NOZZLE RETAINING
CUP
SWIRL
BAFFLE
FRONT BODY
INSULATOR
ELECTRODE
Figure 3-3. Nitrogen Components for PT-15XL
49
section 3operation
TABLE 3-11. PARAMETERS FOR NITROGEN CUTTING WITH PT-15XL
MATERIAL
THICKNESS
1/32
CURRENT
AMPS
250
NA
NITROGEN
CUT GAS
LOW 6
CUT WATER
FLOW
LOW 6
1/4
CUT SPEED (IPM)
carbon
steel
stainless
steel
aluminum
500
550
600
NA
350
385
400
1/8
150-155
265
290
340
3/16
155-160
200
220
270
1/4
160-165
140
155
200
-----
-----
180
450
490
500
165-1170
1/16
400
NA
LOW 7
HIGH 0
3/8
1/8
NA
330
360
400
3/16
NA
250
280
320
1/4
145-150
160
180
240
3/8
150-155
135
145
210
1/2
155-165
110
120
170
3/4
165-175
60
70
110
1
175-180
1/2
600
140-150
HIGH 1
HIGH 3
3/8
45
50
60
130
140
190
3/4
155-160
75
80
130
1
160-170
65
75
100
1-1/2
175-185
33
36
50
2
180-190
22
24
38
3/4
750
160
1/2
90
98
-----
1
170
HIGH 4
HIGH 7
75
80
-----
1-1/2
185
40
44
-----
2
190
28
30
45
3
210
13
14
30
NOTE
When changing consumables always wipe any water
or coolant from new parts before restarting a torch.
The electrode removal nut driver must be clean. It
must not leave any contamination on the electrode.
5/8
Underwater Nitrogen Cutting
When cutting plates up to 1 inch thick using N2 underwater, cutting speeds and cut surface appearance are not
appreciably affected. Therefore, the data in Table 3-10 are
suitable for both above and underwater cutting.
F. After changing consumables or any substantial break
in cutting operations, purge the torch in START GAS
TEST for at least 60 seconds before cutting.
STANDOFF
(INCH)
1/16
3/8
VOLTAGE
SETTING
Cut quality and cutting speed diminish when cutting
1-to-3 inch thick materials underwater, particularly aluminum. The 0.230 inch nozzle is not recommended for cutting under water; however, the 0.200 inch nozzle assembly
may be used for cutting up to 3 inch thick aluminum at
600 amps and still give a reasonable appearing cut. The
approximate cutting speeds for underwater cutting of materials 1-to-3 inches are given in Table 3-12. Flow settings
for each nozzle are the same as given in Table 3-11.
caution
Purge the gas line with the Flow Control TEST/RUN
switch in the CUT GAS position for three minutes when
switching from O2 to ArH2 or N2 cutting. This will ensure
that no O2 exists in the cut gas lines. Small amounts of
O2 will cause rapid erosion of the tungsten electrode
that is used for cutting with N2 or ArH2.
danger
G. Set Flow Control TEST/RUN switch in the RUN 2 position.
Hydrogen explosion hazard! Read the precautions on
page 42 before starting under water cutting.
The system is now ready to cut.
50
section 3operation
TABLE 3-12. UNDERWATER CUTTING SPEEDS
MATERIAL
THICKNESS
(inches)
1
1-1/2
2
2-1/2
3
1-1/2
2
3
NOZZLE
ASSEMBLY
DIA./ PN
0.200
2075612
CURRENT
AMPS
600
0.200
REVERSE
2075615
0.230
2075613
750
0.230
REVERSE
2075690
CUT SPEED (IPM)
STANDOFF
carbon stainless alumi(INCH)
steel
steel
num
VOLTAGE
SETTING
160-170
1/2
50
65
80
175-185
1/2
30
33
50
180-190
1/2
15
18
35
190
5/8
----
----
28
210
5/8
----
----
20
185
5/8
35
35
----
190
5/8
20
20
----
210
5/8
8
8
----
NOTE
3.6. H-35 CUTTING WITH THE PT-15XL
H-35 is a mixture of hydrogen and argon that is used
for cutting material thicknesses of 3 to 6 inches. The
hydrogen component of the gas is flammable, requiring
certain precautions. Underwater cutting with H-35 is not
recommended. Table 3-14 provides the control settings
for cutting conditions.
When changing consumables, always wipe any water or
coolant from parts before installing and restarting torch.
The electrode removal nut driver must be clean. It must
not leave any contamination on the electrode.
A. Install high current parts in torch per Table 3-13.
C. Set Control CUT WATER ON/OFF to ON.
ELECTRODE
HOLDER
NOZZLE
RETAINING
CUP
B. Set Flow Control O2/N2 switch to N2.
BAFFLE
ELECTRODE
Figure 3-4. PT-15XL Front End Assembly for H-35 Cutting
TABLE 3-13. COMPONENTS FOR H-35 CUTTING WITH PT-15XL
ELECTRODE
HOLDER
2075343
ELECTRODE
600236
NOZZLE ASSEMBLY
SWIRL BAFFLE
Diameter
RATING
P/N
standard
optional
.250
875A to
1000A
2075587
2075586
8-HOLE
CERAMIC
NONE
51
section 3operation
TABLE 3-14. CONTROL SETTINGS FOR H-35 CUTTING
MATERIAL
THICKNESS
(inches)
3
CURRENT
AMPS
875
4
VOLTAGE
SETTING
215
H-35
CUT GAS
CUT WATER
FLOW
CUT SPEED (IPM)
STANDOFF
carbon stainless alumi(INCH)
steel
steel
num
HIGH 7
HIGH 7
3/4
HIGH 7
HIGH 7
3/4
220
5
1000
230
13
13
27
10
10
15
5
6
10
5-1/2
235
4
5
9
6
240
3
4
8
D. Purge cut gas lines.
1. Disconnect O2. Place the Flow Control TEST/RUN
switch in the CUT GAS TEST position. Purge with
N2 for three minutes.
2. Connect H-35 to the Flow Control N2 IN connector
and purge N2 from the lines for 60 seconds.
3.7. CUTTING WITH THE PT-19XLS and
PT-600 TORCHES
The PT-19XLS and PT-600 are mechanized plasma cutting
torches designed for cutting without water injection. Cutting can be performed using air, oxygen, nitrogen or H-35
as the cut gas at currents ranging from 50 to 360 amperes.
Underwater cutting can be performed with the PT-19XLS
by using an Air Curtain at 150 amps or higher. Refer to
your torch manual.
E. Set H-35 regulator in accordance with Table 3-4.
F. Set Flow Control TEST/RUN switch to RUN 2 posi-
tion. The system is now ready for cutting.
Nozzle Retainer Cup 37082
Nozzle Assembly
250A - 21822
360A - 35885
400A - 22195
600A - 22401
Shield Retainer 37081
Shield
50A - 21795
100-250A - 21802
250-600A - 21945
Diffuser
50A - 21796
100-600A - 21944
100-600A Rev - 22496
Nozzle Tip
50A - 22026
100A - 22029
150A - 22030
200A - 22031
Electrode
O2/N2/Air - 34086XL
H-35 - 34557
400A, O2, N2, Air, H-35 - 22196
600A, N2, H-35 - 22403
Nozzle Base
50A - 22027
100-200A - 22028
Gas Baffle
50-200A - 948142
250-600A - 35660
400A, O2 - 22194
Electrode Holder 37068
Figure 3-5. PT-19XLS Components
Reference only. Refer to your torch manual for specific or updated instructions
52
section 3operation
Table 3-15 COMPONENT SELECTION FOR PT-19XLS
Application
Current &
Plasma Gas
Recommended Replacement Parts
Thickness
Shield
Diffuser
& Material
Nozzle
Electrode
Gas Baffle
50-65A
1.16 to 6mm
50A
50A
Tip-22026
34086XL
Air & N2
CS, SS, AL
21795
21796
Base-22027
100A
4 to 19mm
100A-250A
100-360A
Tip 22029
34086XL
CS, SS, AL
21802
21944
Base 22028
Air, N2, O2
22496Rev.
948142
4 Hole STD
150A
6 to 25mm
100A-250A
100 -360A
Tip 22030
34086XL
Air, N2, O2
CS, SS, AL
21802
21944
Base 22028
22496Rev.
948142
4 Hole STD
948143
4 Hole Rev.
150A
6 to 25mm
100A-250A
100-360A
Tip 22030
22403
N2, H35
SS, AL
21802
21944
Base 22028
22496Rev.
948142
4 Hole STD
948143
4 Hole Rev.
200A
6 to 50mm
100A - 250A
100 - 360A
Tip 22031
34086XL
Air, N2, O2
CS, SS, AL
21802
21944
Base 22028
22496Rev.
948142
4 Hole STD
948143
4 Hole Rev.
200A
6 to 38mm
100A-250A
100-360A
Tip 22031
22403
N2, H35
SS, AL
21802
21944
Base 22028
22496Rev.
948142
4 Hole STD
948143
4 Hole Rev.
250A
6 to 50mm
100A-250A
100-360A
21822
34086XL
Air, O2
CS, SS, AL
21802
21944
(1-Piece)
22496Rev.
35660
8 x .047
35661
8 x .047 Rev.
250A
6 to 50mm
100A-250A
100-360A
21822
22403
N2, H35
SS, AL
21802
21944
(1-Piece)
22496Rev.
35660
8 x .047
35661
8 x .047 Rev.
325-360A
13 to 50mm
360A
100-360A
35885
35886XL
Air, N2, O2
CS, SS, AL
21945
21944
(1-Piece)
22496Rev.
35660
8 x .047
35661
8 x .047 Rev.
325-360A
13 to 50mm
360A
100A-360A
35885
22403
N2,H35
CS, SS, AL
21945
21944
(1-Piece)
22496Rev.
35660
8 x .047
35661
8 x .047 Rev.
400-450A
O2
22194
32 x .023
19 to 50mm
CS, SS, AL
360A
21945
100A-360A
21944
22195
22196
(1-Piece
948142
4-Hole STD
948143
4 Hole Rev
400-450A
19 to 50mm
360A
100A-360A
22195
22403
AL, SS
21945
21944
(1-Piece)
N2, H35
22496Rev.
35660
8 x .047
35661
8 x .047Rev.
600A
25 to 75mm
360A
100-360A
22401
22403
N2, H35
CS, SS, AL
21945
21944
(1-Piece)
22496Rev.
35660
8 x .047
35661
8 x .047Rev.
53
section 3operation
NOTE
For expanded details of the PT-19XLS (PT-600) refer to the
your torch manual.
4. Set the O2/N2 switch to N2 position.
5. Place CUT WATER switch to OFF.
LOW CURRENT CUTTING WITH AIR AND PT-19XLS (50
to 100 Amps)
6. Set CUT GAS Flow Rate as shown in Table 3-14.
7. Position TEST/RUN switch to RUN 1.
1. Ensure that the correct components are assembled
in the PT-19XLS (PT-600) for the cutting conditions.
Refer to Table 3-15.
CHECK VALVE
ADAPTOR
ASSEMBLY - 21124
999304
1/4 NPTM*
AIR REGULATOR
ASSEMBLY -522368
HEX. NIPPLE
639501
CONNECTOR
3389
B-OXY -F*
1/4 NPTM*
1/4 NPTF*
(2) 1/8" NPT
PIPE PLUGS
643792
* Use Locktite pipe sealant on threads, DO NOT use
Teflon tape.
1/4 NPTF*
1/4 NPTM*
Figure 3-5. PT-19XLS (PT-600) Regulator Assembly
B-OXY-M*
8. Set start gas pressure as follows:
2. To cut with air, disconnect N2 supply from the Flow
Control. Connect a supply of clean, filtered air (approximately 100 psig to the N2 inlet on the Flow
Control.
3. For low current cutting with the PT-19XLS (PT-600)
and ESP-1000 a cut gas regulator system is required
for air. See figure 3-5 for assembly details.
A. TEST/RUN switch to START GAS TEST.
B. Adjust start gas regulator to 30 psig.
C. Return TEST/RUN switch to RUN 1.
9. Set cut gas pressure as follows:
54
A. TEST/RUN switch to CUT GAS TEST
B. Adjust cut gas regulator to 60 psig.
C. Return TEST/RUN switch to RUN 1 position.
section 3operation
WARNING
PT-19XLS (PT-600) H-35 CUTTING AT 150 TO 300
AMPS
Electric shock can kill! Before touching torch, be sure
power source is shut off by turning off the 3-phase
power input to the power source.
H-35 is a mixture of hydrogen and argon that can be
used with the PT-19XLS (PT-600) for cutting stainless and
aluminum. This mixture is flammable requiring certain
precautions. Underwater cutting with H-35 is not recommended.
OXYGEN AND AIR CUTTING WITH PT-19XLS (PT-600)
(100 - 360 AMPS)
1. Install H-35 torch parts for the chosen current level
per Table 3-15.
2. Set the Flow Control O2/N2 switch in the N2 position.
3. Set Flow Control CUT WATER ON/OFF switch to OFF.
4. Purge gas lines:
1. Ensure that the torch is assembled correctly for oxygen or air cutting at the selected current level. See
Table 3-15 for parts and setup information.
2. If using PT-19XLS air curtain, see Form 15-475 for correct installation and setup.
3. Set Flow Control O2/N2 switch to O2 position.
4. Set Flow Control Cut Water ON/OFF switch to OFF.
5. Set CUT GAS Flow per Cutting Tables starting on page
50.
6. Set Flow Control TEST/RUN switch to CUT GAS TEST.
Check that O2 regulator is set at 100 psig.
7. Set Flow Control TEST/RUN switch to START GAS TEST
switch. Adjust Start Gas regulator, on Plumbing Box, to
25 psig. Check that N2 regulator is set to 100 psig.
8. Purge torch in START GAS TEST position for at least
60 seconds before cutting after changing consumables.
9. Set Flow Control TEST/RUN switch in the RUN 1 position. The system is ready for cutting.
A. Disconnect O2, with the Flow Control in the CUT
GAS TEST position, purge with N2 for three minutes.
B. Connect H-35 to the Flow Control N2 Inlet con-
nection and purge N2 from the lines for 60 sec-
onds.
5. Check H-35 regulator for setting of 100 psig.
6. Adjust gas setting per Cutting Tables. The system is
now ready to cut.
3.8. HIGH CURRENT CUTTING CONDITIONS
PT-19XLS (PT-600)
By using special components in the front end assembly
of the PT-19XLS (PT-600) cutting can be accomplished at
higher current and faster speeds. Cutting carbon steel
can be performed either above water of underwater,
cutting stainless steel and aluminum underwater is not
recommended.
The cutting speeds listed in the following tables are average values. Variations may occur depending on material
composition, surface conditions, etc. Practice cuts in a
scrap area of new material are recommended before
starting production cuts.
PT-19XLS (PT-600) NITROGEN CUTTING AT 150 AND
250 AMPS
1. Ensure that the torch is assembled correctly for nitrogen cutting at the selected current level. See Table
3-15 for parts and setup information.
2. If using a PT19XLS air curtain, see Form F-15-475 for
correct installation and setup.
3. Set Flow Control O2/N2 switch to N2 position.
4. Set Flow Control CUT WATER ON/OFF switch to OFF
position.
5. Set CUT GAS flow per Cutting Tables starting on page
50.
6. Set Flow Control TEST/RUN switch to START GAS TEST.
Adjust Start Gas Regulator, on Plumbing Box, to 26
psig. Check that N2 regulator is set to 100 psig
7. Purge torch in CUT GAS TEST position for at least 60
seconds after changing consumables before cutting.
8. Set Flow Control TEST/RUN switch to RUN 1. The system is now ready to cut.
TORCH COMPONENTS FOR HIGH CURRENT
CUTTING
55
NOZZLE
360A
P/N 35885
ELECTRODE
360A
P/N35886XL
HEAT SHIELD
360A
P/N 21945
DIFFUSER
360A
P/N 21944
BAFFLE
8-HOLE
P/N 35660
START GAS
N2 @ 25 PSIG
section 3operation
Cutting Tables FOR PT-19XLS and PT-600
A. To use the 50A or 100A nozzles with the ESP-1000 System, you must install a regulator at the Cut Gas connection on
the Plumbing Box. See Figure 3-5.
B. Cut Gas & Start Gas input pressures to the flow control should be 100 psig (6.9 Bar) for all Nozzles and Gases.
c. Refer to torch manual for recommended torch parts for these cutting conditions.
50-65 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
30/2.1
60/4
2.2
MM
.063
1.6
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
50
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
IN
MM
.250
IN
6
ARC
CURRENT
AIR
AIR
AIR
TRAVEL
SPEED
IPM
MM/
MIN
50
180
4572
MM
.125
3
115
.125
3
30/2.1
60/4
2.2
.250
6
.125
3
115
50
110
2294
.250
6
30/2.1
60/4
3.5
.250
6
.156
4
128
65
65
165
START GAS
CUT GAS
SHIELD GAS
N2
N2
N2
Cutting Data:
50
NOZZLE
MATERIAL ALUMINUM
50-65 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.063
1.6
30/2.1
60/4
2.2
.250
6
.125
3
118
50
180
4572
.125
3
30/2.1
60/4
2.2
.250
6
.125
3
117
50
120
3048
.250
6
30/2.1
60/4
3.5
.250
6
.125
3
125
65
70
1778
Cutting Data:
50
NOZZLE
MATERIAL STAINLESS STEEL
50-65 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.063
1.6
30/2.1
60/4
2.2
.250
6
.156
4
111
50
180
4572
.125
3
30/2.1
60/4
2.2
.250
6
.156
4
119
65
80
2032
.250
6
30/2.1
60/4
3.5
.250
6
.156
4
118
65
60
1524
56
section 3operation
Cutting Tables for PT-19xls and PT-600
NOZZLE
MATERIAL
50-65 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
50
ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
N2
N2
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.063
1.6
30/2.1
60/4
2.2
.250
6
.156
4
119
50
180
4572
.125
3
30/2.1
60/4
2.2
.250
6
.156
4
125
65
80
2032
.250
6
30/2.1
60/4
3.5
.250
6
.156
4
127
65
55
1397
START GAS
CUT GAS
SHIELD GAS
AIR
AIR
AIR
Cutting Data:
50
NOZZLE
MATERIAL CARBON STEEL
50-65 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.063
1.6
30/2.1
60/4
2.2
.250
6
.156
4
115
50
220
5588
.125
3
30/2.1
60/4
2.2
.250
6
.125
3
112
50
120
3048
.125
3
30/2.1
60/4
2.2
.250
6
.125
3
110
65
120
3048
.187
5
30/2.1
60/4
2.2
.250
6
.156
4
118
65
95
2413
.250
6
30/2.1
60/4
3.5
.250
6
.156
4
120
65
80
2032
100 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
100
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
45/3.1
3.5
.375
10
.187
5
154
100
100
2540
.375
10
25/1.7
45/3.1
4.4
.375
10
.250
6
174
100
70
1778
.500
13
25/1.7
45/3.1
4.4
.375
10
.312
8
183
100
50
1270
.750
19
25/1.7
45/3.1
3.5
.500
13
.312
8
189
100
30
762
57
section 3operation
Cutting Tables for PT-19xls and PT-600
Cutting Data:
100
NOZZLE
MATERIAL STAINLESS STEEL
100 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
45/3.1
4.4
.375
10
.125
3
154
100
55
1397
.375
10
25/1.7
45/3.1
4.4
.375
10
.187
5
165
100
35
889
.500
13
25/1.7
45/3.1
3.5
.375
10
.312
8
180
100
25
635
.750
19
25/1.7
45/3.1
3.5
.500
13
.312
8
189
100
10
254
START GAS
CUT GAS
SHIELD GAS
N2
N2
N2
Cutting Data:
100
NOZZLE
MATERIAL STAINLESS STEEL
100 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
35/2.4
4.4
.375
10
.125
3
153
100
55
1397
.375
10
25/1.7
35/2.4
4.4
.375
10
.187
5
157
100
45
1143
.500
13
25/1.7
35/2.4
4.4
.375
10
.187
5
162
100
35
889
.750
19
25/1.7
35/2.4
3.5
.500
13
.312
8
185
100
13
330
Cutting Data:
100
NOZZLE
MATERIAL STAINLESS STEEL
100 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
35/2.4
4.4
.375
10
.125
3
153
100
55
1397
.375
10
25/1.7
35/2.4
4.4
.375
10
.187
5
157
100
45
1143
.500
13
25/1.7
35/2.4
4.4
.375
10
.187
5
162
100
35
889
.750
19
25/1.7
35/2.4
3.5
.500
13
.312
8
185
100
13
330
58
section 3operation
Cutting Tables for PT-19xls and PT-600
100 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
100
NOZZLE
MATERIAL CARBON STEEL
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
25/1.7
45/3.1
5.2
.375
10
.125
3
148
100
150
3810
.250
6
25/1.7
45/3.1
4.4
.375
10
.156
4
154
100
120
3048
.375
10
25/1.7
45/3.1
4.4
.375
10
.187
5
159
100
65
1651
.500
13
25/1.7
45/3.1
3.5
.375
10
.187
5
162
100
50
1270
.625
16
25/1.7
45/3.1
3.5
.500
13
.281
7
175
100
35
889
.750
19
25/1.7
45/3.1
3.5
.500
13
.312
8
184
100
20
508
START GAS
CUT GAS
SHIELD GAS
N2
O2
AIR
Cutting Data:
100
NOZZLE
MATERIAL CARBON STEEL
100 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
25/1.7
45/3.1
4.4
.375
10
.156
4
135
100
150
3810
.250
6
25/1.7
45/3.1
4.4
.375
10
.156
4
133
100
120
3048
.375
10
25/1.7
45/3.1
4.4
.375
10
.250
6
149
100
80
2032
.500
13
25/1.7
45/3.1
3.5
.375
10
.187
5
141
100
60
1524
.625
16
25/1.7
45/3.1
3.5
.500
13
.312
8
159
100
37
940
.750
19
25/1.7
45/3.1
3.5
.500
13
.312
8
162
100
20
508
150 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
150
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
20/1.4
LOW 3
4.4
.375
10
.187
5
148
150
200
5080
.250
6
20/1.4
LOW 3
4.4
.375
10
.187
5
149
150
140
3556
.375
10
20/1.4
LOW 3
3.5
.375
10
.250
6
159
150
105
2667
.500
13
20/1.4
LOW 3
4.4
.375
10
.312
8
174
150
80
2032
.750
19
20/1.4
LOW 3
3.5
.500
13
.312
8
180
150
45
1143
1
25
20/1.4
LOW 3
3.5
.500
13
.312
8
184
150
30
762
59
section 3operation
Cutting Tables for PT-19xls and PT-600
Cutting Data:
150
NOZZLE
MATERIAL ALUMINUM
150 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
START GAS
CUT GAS
SHIELD GAS
ARC
VOLTAGE
PIERCE
CUT
N2 OR H-35
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
20/1.4
LOW 4
3.5
.375
10
.187
5
136
150
200
5080
.250
6
20/1.4
LOW 4
3.5
.375
10
.250
6
141
150
150
3810
.375
10
20/1.4
LOW 4
3.5
.375
10
.250
6
145
150
110
2794
.500
13
20/1.4
LOW 4
3.5
.375
10
.312
8
155
150
90
2286
.750
19
20/1.4
LOW 4
3.5
.500
13
.375
10
166
150
50
1270
1
25
20/1.4
LOW 4
3.5
.500
13
.375
10
171
150
30
762
Cutting Data:
150
NOZZLE
MATERIAL STAINLESS STEEL
150 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
20/1.4
LOW 3
4.4
.375
10
.187
5
138
150
200
5080
.250
6
20/1.4
LOW 3
3.5
.375
10
.187
5
146
150
165
4191
.375
10
20/1.4
LOW 3
3.5
.375
10
.250
6
155
150
95
2413
.500
13
20/1.4
LOW 3
3.5
.375
10
.312
8
163
150
60
1524
.750
19
20/1.4
LOW 3
3.5
.500
13
.375
10
175
150
25
635
1
25
20/1.4
LOW 3
3.5
.500
13
.375
10
185
150
15
381
Cutting Data:
150
NOZZLE
MATERIAL STAINLESS STEEL
150 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
20/1.4
LOW 3
4.4
.375
10
.125
3
132
150
200
5080
.250
6
20/1.4
LOW 3
4.4
.375
10
.187
5
140
150
130
3302
.375
10
20/1.4
LOW 3
4.4
.375
10
.187
5
143
150
85
2159
.500
13
20/1.4
LOW 3
4.4
.375
10
.250
6
154
150
60
1524
.750
19
20/1.4
LOW 3
3.5
.500
13
.250
6
164
150
18
457
1
25
20/1.4
LOW 3
3.5
.500
13
.312
8
179
150
10
254
60
section 3operation
Cutting Tables for PT-19xls and PT-600
150 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
150
NOZZLE
MATERIAL CARBON STEEL
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
N2
O2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
20/1.4
LOW 3
4.4
.375
10
.125
3
127
150
160
4064
.250
6
20/1.4
LOW 3
2.6
.375
10
.187
5
130
150
150
3810
.375
10
20/1.4
LOW 3
3.5
.375
10
.187
5
134
150
90
2286
.500
13
20/1.4
LOW 3
3.5
.375
10
.250
6
142
150
75
1905
.625
16
20/1.4
LOW 3
4.4
.500
13
.312
8
151
150
55
1397
.750
19
20/1.4
LOW 3
3.5
.500
13
.375
10
157
150
45
1143
1
25
20/1.4
LOW 3
3.5
.500
13
.312
8
160
150
25
635
150 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
150
NOZZLE
MATERIAL CARBON STEEL
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.188
4
20/1.4
LOW 3
4.4
.375
10
.125
3
143
150
160
4064
.250
6
20/1.4
LOW 3
3.1
.375
10
.125
3
145
150
140
3556
.375
10
20/1.4
LOW 3
3.1
.375
10
.187
5
156
150
90
2286
.500
13
20/1.4
LOW 3
3.5
.375
10
.250
6
160
150
75
1905
.625
16
20/1.4
LOW 3
3.5
.500
13
.250
6
164
150
50
1270
.750
19
20/1.4
LOW 3
3.5
.500
13
.375
10
179
150
45
1143
1
25
20/1.4
LOW 3
3.5
.500
13
.375
10
184
150
25
635
Cutting Data:
200
NOZZLE
MATERIAL ALUMINUM
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
START GAS
CUT GAS
SHIELD GAS
ARC
VOLTAGE
PIERCE
CUT
N2 or H-35
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 4
3.5
.375
10
.312
8
146
200
155
3937
.375
10
25/1.7
LOW 4
2.6
.375
10
.250
6
148
200
120
3048
.500
13
25/1.7
LOW 4
2.6
.375
10
.312
8
155
200
110
2794
.750
19
25/1.7
LOW 4
4.4
.500
13
.375
10
166
200
60
1524
1
25
25/1.7
LOW 4
4.4
.500
13
.375
10
169
200
40
1016
1.25
32
25/1.7
LOW 4
4.4
NR
NR
.375
10
175
200
26
660
61
section 3operation
Cutting Tables for PT-19xls and PT-600
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
200
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 4
4.4
.375
10
.187
5
155
200
125
3175
.375
10
25/1.7
LOW 4
4.4
.375
10
.250
6
165
200
110
2794
.500
13
25/1.7
LOW 4
4.4
.375
10
.250
6
167
200
85
2159
.750
19
25/1.7
LOW 4
4.4
.500
13
.375
10
182
200
60
1524
1
25
25/1.7
LOW 4
4.4
.500
13
.375
10
189
200
40
1016
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
200
NOZZLE
MATERIAL ALUMINUM
200 AMP
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 4
3.5
.375
10
.187
5
151
200
180
4572
.375
10
25/1.7
LOW 4
3.5
.375
10
.187
5
155
200
110
2794
.500
13
25/1.7
LOW 4
3.5
.375
10
.187
5
159
200
70
1778
.750
19
25/1.7
LOW 4
3.5
.500
13
.250
6
170
200
55
1397
1
25
25/1.7
LOW 4
3.5
.500
13
.250
6
177
200
30
762
Cutting Data:
200
NOZZLE
MATERIAL STAINLESS STEEL
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
START GAS
CUT GAS
SHIELD GAS
ARC
VOLTAGE
PIERCE
CUT
N2 OR H-35
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.500
13
25/1.7
LOW 4
4.4
.500
13
.375
10
163
200
50
1270
.625
19
25/1.7
LOW 4
4.4
.500
13
.312
8
162
200
47
1194
.750
19
25/1.7
LOW 4
4.4
.500
13
.375
10
169
200
32
813
1
25
25/1.7
LOW 4
4.4
.500
13
.375
10
175
200
17
432
1.25
32
25/1.7
LOW 4
3.5
NR
NR
.500
13
191
200
10
254
1.50
38
25/1.7
LOW 4
3.5
NR
NR
.625
16
203
200
8
203
62
section 3operation
Cutting Tables for PT-19xls and PT-600
Cutting Data:
200
NOZZLE
MATERIAL STAINLESS STEEL
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 4
4.4
.375
10
.125
3
142
200
140
3556
.375
10
25/1.7
LOW 4
4.4
.375
10
.187
5
150
200
125
2667
.500
13
25/1.7
LOW 4
4.4
.375
10
.187
5
154
200
85
2159
.750
19
25/1.7
LOW 4
4.4
.500
13
.375
10
174
200
55
1397
1
25
25/1.7
LOW 4
4.4
.500
13
.375
10
180
200
20
508
Cutting Data:
200
NOZZLE
MATERIAL STAINLESS STEEL
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 4
4.4
.375
10
.250
6
158
200
165
4191
.375
10
25/1.7
LOW 4
4.4
.375
10
.187
5
149
200
105
2667
.500
13
25/1.7
LOW 4
3.5
.375
10
.187
5
150
200
90
2286
.750
19
25/1.7
LOW 4
2.6
.500
13
.250
6
159
200
45
1143
1
25
25/1.7
LOW 4
3.5
.500
13
.250
6
169
200
20
508
Cutting Data:
200
NOZZLE
MATERIAL CARBON STEEL
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
START GAS
CUT GAS
SHIELD GAS
AIR
AIR
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 4
3.5
.375
10
.125
3
143
200
150
3810
.375
10
25/1.7
LOW 4
3.5
.375
10
.125
3
146
200
100
2540
.500
13
25/1.7
LOW 4
3.5
.375
10
.218
5.5
158
200
95
2413
.625
16
25/1.7
LOW 4
3.1
.500
13
.218
5.5
160
200
75
1905
.750
19
25/1.7
LOW 4
3.1
.500
13
.250
6
165
200
65
1651
1
25
25/1.7
LOW 4
3.5
.500
13
.375
10
180
200
35
889
1.25
32
25/1.7
LOW 4
2.2
NR
NR
.375
10
182
200
25
635
1.50
38
25/1.7
LOW 4
2.2
NR
NR
.375
10
189
200
15
380
1.75
45
25/1.7
LOW 4
2.2
NR
NR
.375
10
201
200
10
255
2
50
25/1.7
LOW 4
2.2
NR
NR
.375
10
211
200
6
152
63
section 3operation
Cutting Tables for PT-19xls and PT-600
Cutting Data:
NOZZLE
200
MATERIAL CARBON STEEL
200 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
MM
STANDOFF
SHIELD
@ 60 PSI / 4
BAR
START GAS
CUT GAS
SHIELD GAS
ARC
VOLTAGE
PIERCE
CUT
IN
MM
IN
ARC
CURRENT
N2
O2
AIR
TRAVEL
SPEED
IPM
MM
MM/
MIN
.250
6
25/1.7
LOW 4
3.5
.375
10
.125
3
129
200
170
4318
.375
10
25/1.7
LOW 4
3.5
.375
10
.187
4
133
200
110
2794
.500
13
25/1.7
LOW 4
3.5
.375
10
.218
5.5
136
200
95
2413
.625
16
25/1.7
LOW 4
3.1
.500
13
.218
5.5
139
200
75
1905
.750
19
25/1.7
LOW 4
3.1
.500
13
.250
6
142
200
55
1397
1
25
25/1.7
LOW 4
3.5
.500
13
.375
10
155
200
40
1016
1.25
32
25/1.7
LOW 4
2.2
NR
NR
.375
10
164
200
25
635
1.50
38
25/1.7
LOW 4
2.2
NR
NR
.375
10
166
200
20
508
1.75
45
25/1.7
LOW 4
2.2
NR
NR
.375
10
185
200
10
255
2
50
25/1.7
LOW 4
2.2
NR
NR
.500
13
205
200
5
127
START GAS
CUT GAS
SHIELD GAS
N2
O2
AIR
Cutting Data:
250
NOZZLE
MATERIAL CARBON STEEL
250 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 5
4.0
.375
10
.125
3
130
250
170
4318
.375
10
25/1.7
LOW 5
4.0
.375
10
.187
5
135
250
125
3175
.500
13
25/1.7
LOW 5
4.0
.500
13
.219
5.6
138
250
100
2540
.750
19
25/1.7
LOW 5
4.0
.500
13
.250
13
142
250
65
1650
1
25
25/1.7
LOW 5
4.0
.500
13
.375
10
155
250
50
1270
START GAS
CUT GAS
SHIELD GAS
N2
O2
AIR
Cutting Data:
360
NOZZLE
MATERIAL CARBON STEEL
325 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.500
13
25/1.7
LOW 5
6.7
.625
16
.187
4
130
325
130
4572
.750
19
25/1.7
LOW 5
6.7
.625
16
.187
4
132
325
90
2286
1
25
25/1.7
LOW 5
7.5
.625
16
.250
6
141
325
55-65
1.25
32
25/1.7
LOW 5
7.5
.625
16
.250
6
146
325
35-40
64
section 3operation
Cutting Tables for PT-19xls and PT-600
360 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
360
NOZZLE
MATERIAL CARBON STEEL
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
3556
.500
13
25/1.7
LOW 5
6.7
.625
16
.187
4
132
360
140
.750
19
25/1.7
LOW 5
6.7
.625
16
.187
4
135
360
90-100
1
25
25/1.7
LOW 5
8.7
.625
16
.250
6
141
360
65-70
1.25
32
25/1.7
LOW 5
8.7
.625
16
.250
6
146
360
45
1.50
38
25/1.7
LOW 5
8.7
.625
16
.312
8
153
360
30-35
360 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
360
NOZZLE
MATERIAL STAINLESS STEEL
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
N2
O2
AIR
1143
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
HIGH 5
8.7
.500
13
.250
6
160
360
230
5842
.500
13
25/1.7
HIGH 5
7.5
.625
16
.250
6
163
360
110
2794
.750
19
25/1.7
HIGH 5
8.7
.625
16
.375
10
176
360
80
2032
1
25
25/1.7
HIGH 5
8.7
.625
16
.500
13
192
360
45
1143
Cutting Data:
360
NOZZLE
MATERIAL STAINLESS STEEL
360 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
25/1.7
HIGH 5
8.7
.625
16
.625
16
1
MM
25
STANDOFF
START GAS
CUT GAS
SHIELD GAS
ARC
VOLTAGE
PIERCE
CUT
65
190
H-35 or N2
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
360
30
762
section 3operation
Cutting Tables for PT-19xls and PT-600
360 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
360
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
N2
N2
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.250
6
25/1.7
LOW 7
9.5
.500
13
.375
10
158
360
250
6350
.500
13
25/1.7
LOW 7
9.5
.625
16
.375
10
160
360
160
4064
.750
19
25/1.7
LOW 7
9.5
.625
16
.375
10
164
360
90
3386
1
25
25/1.7
LOW 7
9.5
.625
16
.375
10
171
360
60
1524
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
360
NOZZLE
MATERIAL ALUMINUM
360 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
H-35 or N2
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.500
13
25/1.7
HIGH 1
9.5
.625
16
.375
10
157
360
150
3810
.750
19
25/1.7
HIGH 1
9.5
.625
16
.375
10
176
360
90
2286
1
25
25/1.7
HIGH 1
9.5
.625
16
.375
10
180
360
60
1524
START GAS
CUT GAS
SHIELD GAS
N2
O2
AIR
Cutting Data:
400
NOZZLE
MATERIAL CARBON STEEL
400 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.750
19
25/1.7
LOW 7
7
.625
16
.188
4
134
400
110
2794
1
25
25/1.7
LOW 7
7
.625
16
.250
6
140
400
80
2032
1.25
32
25/1.7
LOW 7
4.5
.625
16
.438
11
150
400
60
1524
1.50
38
25/1.7
LOW 7
3
.625
16
.438
11
155
400
42
1067
66
section 3operation
Cutting Tables for PT-19xls and PT-600
410 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
400
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
H-35
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.750
19
25/1.7
HIGH 0
6.5
.625
16
.312
8
132
410
140
3556
1
25
25/1.7
HIGH 0
6.5
.625
16
.438
11
135
410
110
2794
1.25
32
25/1.7
HIGH 0
6.5
.625
16
.500
13
141
410
85
2159
1.50
38
25/1.7
HIGH 0
6.5
.625
16
.500
13
146
410
65
1651
2
50
25/1.7
HIGH 0
6.5
.625
16
.500
13
153
410
45
1143
START GAS
CUT GAS
SHIELD GAS
N2
N2
AIR
Cutting Data:
450
NOZZLE
MATERIAL STAINLESS STEEL
450 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.750
19
25/1.7
LOW 7
7
.625
16
.375
10
160
450
100
2540
1
25
25/1.7
LOW 7
7
.625
16
.250
6
163
450
70
1778
1.25
32
25/1.7
LOW 7
4.5
.625
16
.375
10
176
450
52
1321
1.50
38
25/1.7
LOW 7
3
.625
16
.500
13
192
450
33
838
Cutting Data:
600
NOZZLE
MATERIAL ALUMINUM
600 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
H-35
H-35
N2
ARC
VOLTAGE
PIERCE
CUT
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
1
25
RUN 2
HIGH 4
8*
.750
19
.625
16
172
600
80*
2032*
1.50
38
RUN 2
HIGH 4
8*
.750
19
.625
16
177
600
65*
1651*
2
50
RUN 2
HIGH 4
8*
moving
.750
19
192
600
30*
762*
3
75
RUN 2
HIGH 4
8
moving
.750
19
212
600
15
381
67
section 3operation
Cutting Tables for PT-19xls and PT-600
600 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
.750
MM
STANDOFF
1.50
38
RUN 2
HIGH 4
8
2
50
RUN 2
HIGH 4
6
3
75
RUN 2
HIGH 4
8
ARC
VOLTAGE
PIERCE
ing
ing
CUT
MM
IN
MM
19
H-35
H-35
Air
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
.625
16
172
600
75
1905
mov-
.750
19
192
600
40
1016
mov-
.750
19
205
600
20
508
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
600
NOZZLE
MATERIAL ALUMINUM
600 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
START GAS
CUT GAS
SHIELD GAS
Cutting Data:
600
NOZZLE
MATERIAL ALUMINUM
STANDOFF
ARC
VOLTAGE
PIERCE
CUT
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
1
25
RUN 2
HIGH 0
8
.625
16
.375
10
158
600
100
2540
1.50
38
RUN 2
HIGH 0
7
.625
16
.375
10
168
600
60
1524
Cutting Data:
600
NOZZLE
MATERIAL STAINLESS STEEL
600 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
19
.500
13
19
MM
STANDOFF
1
25
RUN 2
HIGH 4
8
.750
1.50
38
RUN 2
HIGH 4
8
.750
2
50
RUN 2
HIGH 4
6
3
75
RUN 2
HIGH 4
8
ing
ing
H-35
H-35
N2
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
163
600
40
1016
ARC
VOLTAGE
PIERCE
START GAS
CUT GAS
SHIELD GAS
CUT
.625
16
186
600
18
457
mov-
.750
19
204
600
12
305
mov-
.750
19
206
600
9
229
68
section 3operation
Cutting Tables for PT-19xls and PT-600
Cutting Data:
600
NOZZLE
MATERIAL STAINLESS STEEL
600 AMP
MATERIAL THICKNESS
GAS SET UP
IN
START
PSI/BAR
CUT
PSI/BAR
SHIELD
@ 60 PSI / 4
BAR
IN
MM
IN
MM
MM
STANDOFF
START GAS
CUT GAS
SHIELD GAS
ARC
VOLTAGE
PIERCE
CUT
N2
N2
AIR
ARC
CURRENT
TRAVEL
SPEED
IPM
MM/
MIN
1
25
RUN 2
HIGH 0
8
.625
16
.500
13
160
600
70
1778
1.5
38
RUN 2
HIGH 0
8
.625
16
.500
13
163
600
40
1016
Notes on 600A Cutting
H‑35 plasma gas/nitrogen shield produces good to excellent cut quality on 1" to 3" aluminum. H­-35 plasma gas/air shield
produces cut quality nearly as good on 1-1/2" to 3" aluminum. Nitrogen plasma gas/air shield produces fair quality cuts on
1“ to 1-1/2 “ aluminum.
H‑35 plasma gas/nitrogen shield yields the best quality on 1“ to 3“ stainless steel, with smooth surfaces and moderate
quantities of dross. Nitrogen plasma gas/air shield may be used to achieve good cuts on 1“ and fair cuts on 1-1/2“ stainless
steels at higher speeds than H‑35.
Piercing of plate 2" to 3" thick is best accomplished with the moving pierce technique: Start the arc at 3/4" standoff, 250
amps, and 35 to 40 ipm. Immediately upon arc transfer, raise the standoff to a cutting voltage of 225 to 240 volts. After the
arc has been on about one second, ramp the current up to 600 amps over a two second interval. After another two second
delay, reduce the speed to about half the recommended cutting speed until the arc burns through the plate.
69
section 3operation
3.9. OPERATING TECHNIQUES
PT-15XL Bevel Angles
Mirror Image Cutting
If desiring to cut with two torches simultaneously, with one
moving in the mirror image of the other, the standard gas
baffle can be replaced by their reverse swirl counterparts
so that the right-edge remains square.
Bevel Cutting with Standard Parts
Bevel cutting requires the same setup considerations
as standard straight cutting with a few exceptions. The
thickness of the cut is longer than the material thickness
therefore the nozzle assembly and cutting speed must
be selected accordingly. Illustrated in Figure 3-5 are the
maximum bevel angles that can provide good quality cuts
with each nozzle based on 1/8 inch clearance (not standoff) between torch and work piece. Large bevel angles can
be made by reducing the clearance and increasing the arc
length if cut quality can be sacrificed.
PLATE
THICKNESS
(IN.)
XR NOZZLE
ASSEMBLY
PART NO.
MAXIMUM
BEVEL ANGLE
(A)
1/4
2075691 (0.125)
35o
3/4
2075611 (0.156)
40o
1-1/2
2075612 (0.200)
45o
2
2075613 (0.230)
40-45o
The resulting bevel angle setting, particularly on thin materials, may be 5 degrees greater than the torch angle. The
bevel retaining cup has smaller feet and steeper sloped
sides required to angle the torch without hitting the work
piece. The bevel retaining cup is also usable for straight
cutting required with an air curtain or bubble muffler
although there is less protection than with the standard
cup. Normally used with oxygen.
Special nozzles for oxygen beveling are available. See Form
F-15-031 Instructions or PT-15XL Plasmarc torch.
Piercing
A
Piercing can be accomplished on plates up to about 1-1/2
inches thick by delaying carriage movement until the arc
penetrates through the plate. The following are typical
delay timer settings:
ARC LENGTH
1/8"
PLATE
THICKNESS
1/2 IN.
SET CARRIAGE
DELAY TO
1/4 SEC.
1 IN.
3/4 SEC.
1-1/2 IN.
1-1/2 SEC.
When piercing plate 1-1/2 to 3 inches thick, allow the
carriage to move (no delay) at about 1/2 the normal cutting speed. Permit the arc to slice through the plate and
produce a rooster-tail effect of molten spray. As soon as
the arc penetrates through the plate, adjust the carriage
travel to the normal cutting speed. Piercing requires practice and skill. Piercing is made at a higher standoff than
actual cutting. This helps prevent spatter from destroying
the nozzle.
Figure 3-6. Bevel Cutting Characteristics
70
section 3operation
a
c
b
1/4 SPEED
FULL
SPEED
d
1"
REDUCE
SPEED
LAG
2/3 OF
THICKNESS
Figure 3-7. High Current Cutting Thick Plate
PT-15XL Cutting with High Current Nozzles (4 to 6
inch Plates)
1. Underwater Cutting: PT-15XL & N2 Plasma Gas
Normally, only a slight carriage delay (1/2 to 2 seconds depending on plate thickness) is required to allow cutting arc
to penetrate through a plate, then cutting can continue at
the recommended speed. However, when cutting plate 4
inches or more thick, a little more consideration is required
for starting and ending a cut. The following procedures are
recommended (refer to Figure 3-6).
a. Start at edge of plate as normal.
b. Delay carriage movement until arc penetrates
about two-thirds of the plate thickness. (2-1/2 to
3 seconds.)
c. Start carriage movement about 1/4 of the recommended speed until arc cuts through the lower
corner of the plate edge and then cut at the
recommended speed. The molten spray from the
bottom of the plate should be lagging slightly
behind the arc cutting at the top of plate.
It has been found that an effective means of reducing
the cutting noise level to 85 db or lower is by cutting
under 2 to 3 inches of water. Fumes and UV radiation
are substantially reduced. No plasma arc equipment
change or accessory is required for underwater cutting. However, an automatic cutting system requires
controlling the initial standoff when starting the cut.
In cutting materials up to 1-inch thick underwater,
neither cutting speed nor cut surface appearance is
appreciably affected. Cutting speed and cut surface
quality diminishes when cutting plates between 1 and
3 inches thick. Underwater cutting of plates 3-inches
or thicker is not recommended. Underwater cutting
with oxygen requires the use of an air curtain or bubble
muffler.
NOTE
d. When about 1 inch from end of cut, reduce the
speed slowly, allowing the molten spray to catch
up to the arc cutting at the top.
When cutting underwater, care must be taken when
a rust inhibitor is used in the water. Some inhibitors
contain enough conductive materials to prevent
arc starting. CM-1000S (manufactured by Chemicals
Methods, Inc.) is one satisfactory inhibitor.
2. Water Muffler (Option) PT-15XL & N2 Plasma Gas
Noise, Fume and UV Radiation Considerations
The noise level of plasma cutting is greater than 110 db 6
ft. or 1.8 m from torch and depending on location of torch
with respect to sound reflecting surfaces and the power
level used for cutting. OSHA allows exposure to 95 db on
a 50% duty cycle (4 hours out of an 8 hour shift) and to
90 db on a 100% duty cycle.
Another method of fume control is to use the water
muffler, above or underwater. For maximum effectiveness, the water muffler is recommended for use
in conjunction with a water table to eliminate 99.5%
of noxious gases and particulate emissions from the
plasma arc cutting operation. The water muffler is less
effective in controlling noise and UV radiation than
underwater cutting. The water muffler is not recommended for use with oxygen cutting.
3. Air Curtain (Option) PT-15XL & PT-19XLS
There are currently several methods of attenuating noise,
fumes and UV radiation of the plasma arc process; underwater cutting, underwater cutting with bubble muffler,
underwater cutting with air curtain or cutting with a
water muffler.
71
The air curtain uses air to provide a "dry" area around
the arc during underwater cutting. The air curtain is
recommended for use with oxygen cutting as the most
economical approach to fume and noise control.
section 3operation
4. Bubble Muffler (Option) PT-15XL & Water Muffler
(Option) PT-19XLS
The bubble muffler can be viewed as a combination air
curtain and water muffler. It is recommended for use
with oxygen when both underwater and above water
cutting are to be used.
WARNING
4. Follow these practices to reduce hydrogen generation and accumulation:
Hydrogen explosion hazard! Read the following before
attempting to cut with a water table.
A hazard exists whenever a water table is used for plasma
arc cutting. Severe explosions have resulted from the
accumulation of hydrogen beneath the plate being cut.
Thousands of dollars in property damage has been caused
by these explosions. Personal injury or death could result
from such an explosion.
A. Clean the slag (especially fine particles) from the
bottom of the table frequently. Refill the table
with clean water.
B. Do not leave plates on the table overnight or a
weekend.
C. If a water table has been unused for several hours,
vibrate it in some way before the first plate is laid
in position. This will allow accumulated hydrogen
in the refuse to break loose and dissipate before
it is confined by a plate on the table. This might
be accomplished by laying the first plate onto
the table with a slight jolt, then raising the plate
to permit hydrogen to escape before it is finally
set down for cutting.
D. If cutting above water, install fans to circulate air
between the plate and the water surface.
E. If cutting underwater, agitate the water under
the plate to prevent accumulation of hydrogen.
This can be done by aerating the water using
compressed air.
F. If possible, change the level of the water between
cuts to dissipate accumulated hydrogen.
G. Maintain pH level of the water near 7 (neutral).
This reduces the rate of chemical reaction between water and metals.
H. Programmed part spacing should be a minimum
of twice the kerf width to ensure material is aluminum under the arc.
The best available information indicates that three possible sources of hydrogen exists in water tables:
1. Molten Metal Reaction
Most of the hydrogen is liberated by a fast reaction of
molten metal from the kerf in the water to form metallic oxides. This reaction explains why reactive metals
with greater affinity for oxygen, such as aluminum
and magnesium, release greater volumes of hydrogen
during the cut than does iron or steel. Most of this
hydrogen will come to the surface immediately, but
some will cling to small metallic particles. These particles will settle to the bottom of the water table and
the hydrogen will gradually bubble to the surface.
2. Slow Chemical Reaction
Hydrogen may also result from the slower chemical
reactions of cold metal particles with the water, dissimilar metals, or chemicals in the water. The hydrogen
gradually bubbles to the surface.
3. Plasma Gas
Regardless of the source, the hydrogen gas can collect
in pockets formed by the plate being cut and slats on
the table, or pockets from warped plate. There can also
be accumulation of hydrogen under the slag tray or
even in the air reservoir, if these are part of the table
design. The hydrogen, in the presence of oxygen or
air, can then be ignited by the plasma arc or a spark
from any source.
Hydrogen may come from the plasma gas. At currents
over 750 amps, H-35 is used as cut gas. This gas is 35%
hydrogen by volume and a total of about 125 cfh of
hydrogen will be released.
72
section 3operation
danger
Possible explosion hazard from plasma cutting aluminum-lithium alloys!
Aluminum-Lithium (Al-Li) alloys are used in the aerospace
industry because of 10% weight savings over conventional
aluminum alloys. It has been reported that molten Al-Li
alloys can cause explosions when they come into contact with water. Therefore, plasma cutting of these alloys
should not be attempted in the presence of water. These
alloys should only be dry cut on a dry table. Alcoa has
determined that "dry" cutting on a dry table is safe and
gives good cutting results. DO NOT dry cut over water. DO
NOT water injection cut.
The following are some of the Al-Li alloys currently available:
Alithlite (Alcoa)
X8192 (Alcoa)
Alithally (Alcoa)
Navalite (U. S. Navy)
2090 Alloy (Alcoa)
Lockalite (Lockhead)
X8090A (Alcoa)
Kalite (Kaiser)
X8092 (Alcoa)
8091 (Alcan)
For additional details and information on the safe use
from the hazards associated with these alloys, contact
your aluminum supplier.
73
section 3operation
74
section 4maintenance
4.1. PROGRAMMABLE LOGIC CONTROLLER (PLC)
TABLE 4-1 PLC INPUT/OUTPUT LEDs
LED
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
The PLC is located in the top section of the Flow Control and
is a device capable of providing predefined outputs depending on the state of the inputs. The precise conditions are
programmed and permanently stored in the PLC. Because
it is a solid state device the PLC is inherently very reliable. It
is also relatively compact.
The PLC will provide predefined outputs in response to inputs from external devices. This exchange of signals can be
confirmed by observing the LEDs on the top of the PLC while
troubleshooting. These indications are useful in isolating a
system failure to the most likely device. They can be seen
through window in the Flow Control top cover.
The LEDs are divided into two groups; Input (0-15) and Output (0-11). Input LEDs light when the corresponding signal is
detected by the PLC. Output LEDs light when the PLC issues a
signal to an external device. The fault LED (output 1) indicates
the PLC has detected an error within the ESP and has caused
the system to enter the not ready (fault) state.
INPUT
FUNCTION
Start/Stop
Current Detector
Nitrogen Pressure
Oxygen Pressure
Interlock Plumb.Box
Cooling Water Flow
Cut Water Flow
Cut Gas Pressure
Run 1
O2/N2 Select
Emergency Stop
Cut Water On/Off
Test Cut Gas
Test Start Gas
Run 2
Test HF
LED
0
1
2
3
4
5
6
7
8
9
10
11
OUTPUT
FUNCTION
Process Running
Fault Signal
Power Source On/Off
Cut Water On/Off
Air Curtain
Cut Gas Metering
Cut Gas On/Off
Start Gas On/Off
HF On/Off
4.2Sequence Description
The program controlling the plasma system sequence
is made with the help of a group of conditional states.
Inputs from sensors, and the cutting machine are continuously evaluated by the PLC to determine whether the
program stays in its present state or makes a transition to
another state.
LEDs are highly reliable indicators. It is not likely that one will
burn out. However, if the technician is not confident that the
LEDs are working the presence of a signal can be confirmed
by using a meter to measure the appropriate pin. Refer to
the schematic and wiring diagrams.
The different states are shown as rectangles in figure 4-2.
The function of the seven states are described in the following paragraphs.
The signal exchange between the PLC and external devices
are both time dependent and condition dependent. If a
required signal is not received in the proper sequence, the
PLC will discontinue the process and generate a fault signal
to the CNC.
0 - Ready state
The "Ready" state is the normal state for the system to be
in when not executing the cutting process. In this state,
the system awaits the start signal from the cutting machine and monitors the selection keys and safety switches.
While in this state it is possible to activate the gas flows
and cut water flow for testing and purging the system.
1 - Preflow state
The "Preflow" state is a fixed duration and is reached only
from state "0". Nitrogen is always the preflow gas in RUN 1
position. Selected cut gas type and flow is the preflow gas
in RUN 2 position. Cut water flow during preflow whenever a water injection torch is used and cut water is switched
on at the front panel. The air curtain output is energized
at this time also.
2 - Open Circuit Voltage State
The main contactor of the power source is activated after
the preflow, and a short time is allowed for the open circuit voltage to be reached.
Figure 4-1. PLC LED Panel (Partial View)
75
section 4maintenance
3 - PILOT ARC STATE
6 - FINAL POSTFLOW STATE
The Pilot Arc State is started by activating the high frequency unit. The time allowed between this and the requirement of a current flow signal from the power source
is a fixed time. If the signal from the power source is not
received during this time, the state is transferred to the
not ready state 7.
The Final Postflow State provides the time during which
nitrogen gas and cut water flow cools the torch. This state
immediately follows the Priority Postflow state, a restart is
possible during postflow.
When the time for postflow has elapsed, the program
transfers to the 0 Ready state. If a new start signal has been
given from the cutting machine control after it stopped
the process, a fast restart will be executed directly from the
Postflow state to state 2 that turns on the main contactor
in the power source.
4 - CUTTING STATE
In the Cutting State, the cut gas is turned on and the start
gas off if using RUN 1. A signal is sent to the cutting machine control indicating that the process is running. This
is the normal state to be in during cutting.
7 - NOT READY STATE
During the Not Ready State (fault state) the Programmable
Logic Controller (PLC) is sending a fault signal to the cutting machine.
5 - PRIORITY POSTFLOW STATE
The Priority Postflow State provides the minimum postflow of nitrogen gas and cut water flow necessary before
a restart is possible. The time is different depending upon
whether cutting with nitrogen or oxygen. This state is
reached when the START/STOP goes low or current flow
through the arc is lost.
It is possible to test gas/water flows in this state. The HF
unit can be run for test purposes in this state.
Figure 4-2. Plasma Sequence Flow Diagram
76
section 4maintenance
4.3. OPERATING INFORMATION
CLEANING OXYGEN NOZZLES
MAXIMIZING CONSUMABLE LIFE
As the electrode wears considerable deposits of hafnium
oxide and silver can build up in the nozzle. Calcium carbonate can also build up at he nozzle exit if the cut water
is not adequately treated. These deposits can sometimes
cause substantial reductions in cut quality, speed and
consumable life.
# OF STARTS
Plasma torch electrode and nozzle life is a function of many
factors, some of which are under control of the operator. When using oxygen as the plasma gas in a properly
operating system, electrode wear and life is a function of
the number of arc starts, the total duration of the cutting
time and the current level. The longer the cut time for a
part being cut, the fewer the number of arc starts on an
oxygen electrode before it must be replaced. The graph
below shows the relationship between the two.
Nozzle performance can be restored by removing these
deposits from the inside of the nozzle and the nozzle exit. A
twisted piece of very fine 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 have a heavier less easily damaged exit as
compared to the 260 and 300 amp nozzles.
Nozzle performance is also degraded by nicks and elongation of the orifice due to double arcs or mechanical damage. Cleaning will not restore a damaged nozzle.
Whenever a nozzle is removed for cleaning the electrode
should be inspected. If the wear is greater than 0.090 inch
or very irregular, the electrode should be replaced.
ELECTRODE LIFE
LINE
CUT QUALITY
Maximum attainable cut quality is highly dependent on
the material being cut. With the wide variety of commercial
metals and alloys being cut with plasma, optimum cut
quality can vary widely from situation to situation. Suggested cut parameters given in this manual are starting
points only for general cases. Fine tuning of the various
parameters may be required to get the best possible cut of
a specific material. Some materials, including certain steels,
are difficult, if not impossible to cut dross free. Likewise, in
carbon steels, variations in plate composition, treatment
while rolling, contaminants and other factors can cause the
dross generated to vary from heat to heat, plate to plate
and area to area on a plate. As a general rule, using oxygen
as a plasma gas produces less dross variation on carbon
steel as a result of these factors, but is not a guarantee that
"dross free" cuts will be produced.
DURATION OF CUT
Figure 4-3. Oxygen Electrode Life Graph
Oxygen electrode and nozzle life are also affected by the
current setting. If parts are operated above their recommended current level, life deteriorates quickly. Improper
cutting and parts programming can adversely effect oxygen consumable life, so it is important that proper techniques be used. Oxygen plasma nozzles and electrodes
are less forgiving of improper operation than nitrogen
nozzles and electrodes. When using nitrogen or argon/
hydrogen as a plasma gas, nozzle and electrode life are
primarily a function of current level. The higher the current
the shorter the life.
77
section 4maintenance
4.4. Troubleshooting
The following troubleshooting guide is primarily an operationally oriented guide. If a problem exists in one of the system
components, the guide will direct you to that manual. When directed to another manual, be sure a qualified maintenance technician is contacted.
TROUBLESHOOTING GUIDE
Problem
Probable Cause
1. Reduced consumable Excessive current.
(electrode) life (O2 and N2
cutting)
Gas settings - inlet pressure.
Remedy
Check Power Source ammeter (Refer to
Power Source Manual).
Check that settings are in accordance with
charts. Use gas flow check kit.
Gas or water leak.
Check for leaks.
Inadequate cooling.
Check water cooler for proper operation.
Single phasing of Power Source.
Refer to Power Source manual.
Wrong gas baffle (O2).
Install correct gas baffle (O2).
Moisture in system.
Purge system of moisture for a minimum of
30 seconds after long idle time.
Cut water setting.
If set to high, it can cause water to reach the
electrode.
Process factors:
Running off work.
Extinguish arc with Arc Stop Signal prior to
running off work or use a waste plate to run
off on. This is most important with O2 cutting.
Flipping or twisted parts hitting
torch.
Change program or fix table.
Skeleton cutting.
Cutting skeletons to facilitate their removal
from the table can adversely affect electrode
life by:
A. Causing the torch to run off the work. (see
above)
B. Causing multipop edge starts. (see below)
C. Greatly increasing the frequency of starts.
This is mainly a problem for O2 cutting and
can be alleviated by choosing a path with a
minimum number of starts or by bridging
gaps in the skeleton with water plates.
D. Increased likelihood that the plate will
spring up against the nozzle causing a
double arc. This can be mitigated by careful
operator attention and by increasing standoff and reducing cutting speeds.
78
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
Probable Cause
1. Reduced consumable (electrode) life
(O2 and N2 cutting) (cont)
Remedy
Since many of these problems are most severe with O2 cutting consumables, consider
when it may be practical to cut skeletons
with N2 consumables:
A. When you will be changing to N2
consumables for the next plate anyway.
B. When one plasma station on the
machine is not being used for part
cutting and could be used for cutting
skeletons with N2.
On machine with Oxweld or Purox torch,
it may be practical to use the gas torch for
skeleton cutting.
Height control problems.
See crashing/diving in item 2 below.
Piercing standoff too low.
Increase piercing standoff.
Starting on edges with multipop
starts.
Position torch more carefully or use a waster
plate to start on. This is most important for
O2 cutting.
Drawn arc from falling part.
Purity and dryness of gas.
Gas switching is not activating.
79
Change program.
Verify purity to be 99.55% O2 . Verify dew
point. Verify purity of N2 to be 99.995%.
This pertains to O2 cutting only. Check to
make sure that switch is in Run 1 mode so
that the arc begins in N2 and switches to O2.
This may be checked by installing the gas
test flow-meter first on the N2 line into the
flow control to see that N2 is flowing during
preflow and postflow only. Then install it
on the O2 line into the flow control to check
that O2 is flowing only during the cut. O2
should never flow when cutting with N2.
section 4maintenance
Problem
1.Reduced consumable
(electrode) life (O2 and
N2 cutting) - (cont)
Probable Cause
O2 present at start.
Remedy
When O2 cutting, check above for gas switching.
When N2 cutting, any presence of O2 will
result in rapid electrode wear. Make sure
system has been purged in cut gas test.
Check for gas or water leaks in torch or hoses.
Check gas quality. Ensure that O2 OSV in flow
control is not leaking by disconnecting O2
from the flow control purging system.
N2 cutting is done with a tungsten electrode.
Tungsten will turn blue or yellow in the presence of oxygen from any source.
2.Reduced nozzle life
(N2, O2 and ArH2)
Using non-genuine consumables.
Replace with genuine consumables.
Incorrect cut water sequence.
Correct cut water sequence. Cut water must
be on when arc starts. PT-15XL only.
Cut water quality.
See section 3.
Cut water settings.
Review and set proper cut water settings per
instructions in Section 3.
Improper pierce height.
Refer to appropriate application Table for
correct setting.
Contacting work:
Diving
Diving is usually caused by a change in arc
voltage when an automatic height control is
in use. Diving can result in loss of cut damage to the nozzle. Usually the voltage change
is as the result of a change of direction or
speed to negotiate a corner or as a result
of plate falling away from the arc. These
problems can be dealt with by disabling the
height control in such situations and by extinguishing the arc earlier when finishing the cut
on falling plate.
Diving may also be caused by a problem with
the height control or the signals fed to it.
Work flipping
The nozzle may sometimes be damaged if the
torch hits a flipped up part. This is difficult to
avoid entirely but careful part programming
can minimize the problem.
80
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
2. Reduced nozzle life
(N2, O2 and ArH2) (cont)
Probable Cause
Remedy
catching on piece
This refers to crashes or nozzle damaged
caused by the front end of the torch catching
on top spatter after a pierce. Hold the torch
at a high standoff for a longer lead-in to avoid
this problem.
Air curtain/bubble muffler
alignment
Refer to paragraphs 3.3.7 and 3.3.8 to make
necessary adjustments.
Excessive speed
Reduce speed to prevent rooster tailing
during cut. Reduce speed corners if rooster
tailing occurs only coming out of corners.
Excessive pilot arc on
time.
Process factors:
Same as for electrode above.
Cut water not at torch when arc
starts.
Inadequate initial delay.
Pierce not complete before
starting.
Excessive initial delay.
Check cut water system.
Increase delay time.
Decrease initial delay.
Improper torch assembly.
Improper piercing
technique.
Reassemble torch properly. Check for gas
and water leaks.
Refer to paragraph 3.3.6.
Running pilot arc without
transfer.
Running pilot arcs without transfer is very
damaging to nozzles. Check standoff and
work connections.
Using non-genuine
consumables.
Replace with genuine consumables.
Improper connection or inadvertent grounding of pilot
arc cable running from Power
Source to Plumbing Box.
Connect wire properly in the Power Source.
Make sure there are no breaks in the insulation.
Worn feet on retaining
Replace retaining cup.
81
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
3. Poor cut quality.
Probable Cause
Remedy
Dross and cut surface:
Varying characteristics of material No remedy.
being cut.
Incorrect speed
Adjust to correct speed.
Incorrect standoff
Refer to paragraph for applicable cutting
technique.
Incorrect gas or cut waterflow.
Refer to paragraph 3.1.1.
Incorrect alignment or improper
operation of air curtain or bubble Refer to paragraph 3.3.7 or 3.3.8.
muffler.
Damaged or worn consumables. Replace.
Using non-genuine consumable
part.
Replace with genuine consumable part.
Gas selection.
N2 produces smoother surfaces on Al and SS
than O2. O2 sometimes produces less dross on
C.S. than N2.
Torch alignment to work.
Verify and correct torch alignment.
Incorrect current.
Verify correct current. Refer to appropriate table
in section 3.
Cutting over slats.
Cutting over slats will cause some bottom dross.
If the cut runs along the slat, it can produce other
cut quality problems. The only solution is to try
to avoid running along the slats.
Cutting machine or torch
vibrates.
Make sure brackets and height control are rigid
and properly adjusted.
Mixing standard and
reverse swirl parts.
Check to be sure swirl is in the same direction.
Remove swirl parts that are marked with an "R".
Bevel Angle:
Same as Dross and Cut surface above
except varying characteristics of material being
cut and cutting machine or torch vibrations.
Standoff and speed have considerable effect
on bevel angle.
82
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
3. Poor cut quality (cont)
4. No pilot arc.
Probable Cause
Remedy
Damaged nozzle
Plate not level - ensure work is level. Torch
not perpendicular to work - ensure torch is
plumb (perpendicular) to work.
Wrong travel direction
(good angle on scrap side)
With standard swirl parts the most square
side of the cut is on the right side of the
direction of travel.
Plate shifting while being
cut.
Small, thin, or light weight plates can shift
while cutting. Clamp them down.
Slag buildup on cut table.
Clean slag from cut table.
Contaminated electrode.
Clean or replace electrode.
Excessively conductive
cut water (injection water).
Check injection water instructions in Section 3. PT-15XL only.
Insufficient spark gap
setting (in plumbing box).
Set spark gap to 0.040+.004".
Pilot Arc Contactor (PAC)
malfunctioning.
Refer to Power Source manual.
Blown fuse in P.A. or starting
circuit.
Refer to Power Source manual.
Improperly assembled torch
or broken torch pilot xar
cable.
Reassemble torch properly or replace torch
pilot arc cable.
Broken or improperly connected P.A. cable between
Plumbing Box and Power
Source.
Replace or verify connections between
Plumbing Box and Power Source.
Insufficient Open Circuit
Voltage (OCV).
Refer to Power Source manual.
Gas flow improperly set.
Refer to paragraph 3.1.1.
Improper clamping of stainless steel torch body.
Clamp onto nonconductive sleeve above
indicated mark.
Conductive water muffler
hoses.
Replace with nonconductive hoses.
Water leak in torch.
Determine cause of leak.
83
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
Probable Cause
Remedy
4. No pilot arc - (cont)
Cut Water Flow Switch (CWFS)
not activated (water injection
only).
Check for adequate cut water flow. Check
CWFS.
5. No arc transfer.
Blown fuse in P.A. or starting
circuits.
Refer to Power Source manual.
Insufficient Open Circuit Voltage (OCV).
Refer to Power Source manual.
Gas flow improperly set.
Refer to Section 3.
Standoff too high or torch
centered off edge of work.
Check cutting technique or position torch to be
over work.
Poor connection to workpiece.
Check connection.
Heavy mill scale or nonconductive surface on work.
Clean mill scale or ensure conductive surface
on work.
Power Source current setting
too low.
Refer to Power Source manual.
Defective power source.
See Power Source manual.
No start signal.
Check input 0 on PLC in Flow Control. Should
be lit when receiving start signal. Ensure
qualified technician performs this check.
Emergency stop signal open.
Check input 10 on PLC in Flow Control. Should
be lit to enable operation. Ensure qualified
technician performs this check.
6. No preflow.
Door opened on Plumbing
Box allowing interlock to
open.
Shorted, closed or jumpered
out CWFS.
No cooling water.
N2 pressure switch not activated.
Close door.
Check input 6 on PLC. Should be off before
start signal applied. Should be on when in
test. Ensure qualified technician performs
this check.
Check Flow Switch.
100 psig N2 (gas flowing) should be supplied to
the flow control.
O2 pressure switch not activated when N2/O2 switch is set 100 psig O (gas flowing) should be supplied to
2
to O2.
the flow control.
84
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
7. No cut water flow when in
Test Position.
8. Arc extinguishes during a
cut or shuts down immediately after transfer.
9. Bubble muffler air supply
does not come on.
10. Bubble muffler under
pump does not come on.
Probable Cause
Remedy
No power to pump.
Apply power.
Relay in pump not activated.
Check for 110 V ac from flow control.
Failed pump and/or motor.
Replace.
Insufficient or no water
supply.
Make sure pressure is set to 190 to 200
psig. Correct or provide water supply. 20
psig should be supplied to pump.
Back pressure regulator set
above 115 psig.
Reset to 90 to 115 psig.
Cut water regulator on Flow
Control set too low.
Adjust as necessary.
Loss of start signal.
Check signal from cutting machine.
Interlock not satisfied - loss
of gas pressure or water
flow.
Check PLC inputs.
Water hose kinked.
Straighten water hose.
Running across very large
kerf or off plate.
Check part program.
Speed too low.
Increase speed as necessary.
Switch on air curtain control
box in the OFF position.
Switch to AUTO.
Air curtain control box is not
receiving signal from flow
control.
Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of flow control. Check wiring.
Starting relay on bubble
muffler is not receiving signal from flow control.
Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of flow control. Check wiring.
Pump is not connected to
main power.
Check wiring and fuses.
Pump is running backwards.
Check wiring.
85
section 4maintenance
TROUBLESHOOTING GUIDE - (Cont)
Problem
11. Poor cut quality with
Bubble Muffler or Air
Curtain installed. (Cuts
are good above water
with Bubble Muffler or
Air Curtain turned off.
Cuts are bad under-water with device operating.)
12. Cut water flow inadequate. Cannot reach
proper flow setting.
Probable Cause
Remedy
Sleeve not bottomed out on the
Main Body.
Reseat Sleeve.
O-rings missing or broken.
Replace O-rings in Main Body.
Air Pressure set too high, or air shut Set air pressure between 15-30 psi. Some
trails should be made on scrap plate to find
off.
the optimum pressure for your conditions.
Sleeve spacing between Air Curtain or Bubble Muffler and Torch
Retaining Cup incorrect.
Adjust spacing. See Section 3.
Sleeve not centered in reference to
the Torch Retaining Cup.
Center Sleeve. Clamp may be cocked on
torch handle or O-rings may be damaged.
Dirt in Sleeve holes.
Remove sleeve and clean.
Holes in Sleeve align with air input
port.
Rotate Sleeve 5°.
Internal cut water filter (in Flow
Control) is clogged.
Replace internal filter of flow control. Check
all external water filters.
86
section 4maintenance
87
notes
88
revision history
1. Revision 07/2007 - RE-Formatted manual for German translation per R. Chico.
89
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548
Order Entry
Product Availability
Pricing
Hours: 8:00 AM to 7:00 PM EST
Order Information
Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693
Hours: 7:30 AM to 5:00 PM EST
Warranty Returns
Authorized Repair Stations
Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452
Part Numbers
Technical Applications
Specifications
Hours: 8:00 AM to 5:00 PM EST
Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates
Repair Status
Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
Visit us on the web at http://www.esabna.com
The ESAB web site offers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
F15-116-D
07/2007
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