ESAB PT-25 Plasma Arc Cutting Torch Manual de usuario
- Categoría
- Sistema de soldadura
- Tipo
- Manual de usuario
This manual provides maintenance instructions and replacement parts for the following PT-25 torch assemblies:
P/N 21648 - 90° head, 25-ft. service lines
P/N 21649 - 90° head, 50-ft. service lines
PT-25
Plasma Arc Cutting Torch
F15-266-C 07/2010
Instruction Manual
2
This equipment will perform in conformity with the description thereof contained in this manual and accompa-
nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-
tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme-
diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser-
vice facility designated by the manufacturer.
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions be-
fore installing or operating this equipment.
CAUTION
USER RESPONSIBILITY
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
3
SECTION 1 DESCRIPTION ....................................................................................................................................................................... 17
1.1 Introduction ......................................................................................................................................................................... 17
1.2 Specications ....................................................................................................................................................................... 17
SECTION 2 ACCESSORIES ....................................................................................................................................................................... 19
2.1 Spare Parts Kits .................................................................................................................................................................... 19
2.2 Optional Accessories ......................................................................................................................................................... 19
SECTION 3 INSTALLATION AND OPERATION................................................................................................................................... 21
3.1 Torch to Power Source Connection ............................................................................................................................. 21
3.2 Retrots .................................................................................................................................................................................. 22
3.3 Gas Selection ....................................................................................................................................................................... 22
3.4 Operating Parameters ...................................................................................................................................................... 22
3.5 Gas Connections ............................................................................................................................................................... 23
3.6 Assembling Front End Parts ........................................................................................................................................... 23
3.7 Gouging Guard & Stand-O Guide .............................................................................................................................. 24
3.8 Loose Consumables .......................................................................................................................................................... 24
3.9 Operation .............................................................................................................................................................................. 24
SECTION 4 MAINTENANCE .................................................................................................................................................................... 27
4.1 Disassembly of Front End ................................................................................................................................................ 27
4.2 General ................................................................................................................................................................................... 27
4.3 Dirt or Contamination ...................................................................................................................................................... 27
4.4 Removal and Replacement of Torch Head ................................................................................................................ 27
4.5 Removal and Replacement of Torch Cables ............................................................................................................. 28
4.6 Replacement of Flex Support, Switch Band or Handle ......................................................................................... 28
4.7 Replacement of Torch Switch ........................................................................................................................................ 28
4.8 Measuring Torch Gas Flows ............................................................................................................................................ 28
SECTION 5 REPLACEMENT PARTS ....................................................................................................................................................... 31
5.1 General ................................................................................................................................................................................... 31
5.2 Ordering ................................................................................................................................................................................ 31
TABLE OF CONTENTS
4
TABLE OF CONTENTS
5
SECTION SAFETY PRECAUTIONS
Safety Precautions
Safety - English
WARNING: These Safety Precautions are
for your protection. They summarize pre-
cautionary information from the references
listed in Additional Safety Information sec-
tion. Before performing any installation or operating
procedures, be sure to read and follow the safety
precautions listed below as well as all other manuals,
material safety data sheets, labels, etc. Failure to observe
Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:
1. Always wear safety glasses with side shields in any
work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield tted with the correct lter and
cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operat-
ing or observing operations. Warn bystanders not
to watch the arc and not to expose themselves to
the rays of the electric-arc or hot metal.
3. Wear ameproof gauntlet type gloves, heavy long-
sleeve shirt, cuess 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 ameproof apron may also be desirable as protec-
tion against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cus, 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-ammable partition or
curtains.
6. Use goggles over safety glasses when chipping slag
or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.
FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:
1. Remove all combustible materials well away from
the work area or cover the materials with a protec-
tive non-ammable 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 oors or wall openings and cause a hid-
den smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.
4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.
5. Do not use equipment beyond its ratings. For ex-
ample, overloaded welding cable can overheat and
create a re 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 re. Use re watchers when
necessary.
7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec-
tion Association, Batterymarch Park, Quincy, MA
02269.
ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.
6
SECTION SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is con-
nected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.
4. Use well-maintained equipment. Replace worn or
damaged cables.
5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.
6. Make sure that all parts of your body are insulated
from work and from ground.
7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the
power.
9. Turn o the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda-
tions. Do not mistake the work lead for a ground
cable.
ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur-
rent owing through any conduc-
tor causes localized Electric and
Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:
1. Welders having pacemakers should consult their
physician before welding. EMF may interfere with
some pacemakers.
2. Exposure to EMF may have other health eects which
are unknown.
3. Welders should use the following procedures to
minimize exposure to EMF:
A. Route the electrode and work cables together.
Secure them with tape when possible.
B. Never coil the torch or work cable around your
body.
C. Do not place your body between the torch and
work cables. Route cables on the same side of
your body.
D. Connect the work cable to the workpiece as close
as possible to the area being welded.
E. Keep welding power source and cables as far
away from your body as possible.
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain-
less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat ir-
ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom-
fort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.
7
SECTION SAFETY PRECAUTIONS
5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code
§25249.5 et seq.)
CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio-
lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:
1. Use the proper gas for the process and use the
proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instruc-
tions for mounting regulator to a compressed gas
cylinder.
2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar-
riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualied personnel perform the instal-
lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.
2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do
not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for
electric arc welding and cutting equip-
ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.
The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
8
SECTION SAFETY PRECAUTIONS
5. AWS C5.5 - "Recommended Practices for Gas Tung-
sten Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used
throughout this manual: Means Atten-
tion! Be Alert! Your safety is involved.
Means immediate hazards which,
if not avoided, will result in im-
mediate, serious personal injury
or loss of life.
Means potential hazards which
could result in personal injury or
loss of life.
Means hazards which could result
in minor personal injury.
9
SECTION SEGURIDAD
Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad son para su protección. Ellas hacen
resumen de información proveniente de las
referencias listadas en la sección "Información Adi-
cional 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.
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 ltro 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 per-
sonas 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 chis-
pas calientes con una cortina adecuada no-amable
como división.
6. Use careta protectora además de sus gafas de segu-
ridad cuando esté removiendo escoria o puliendo.
La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.
FUEGO Y EXPLOSIONES -- El calor de
las amas 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 amables, 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 to-
talmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
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, inspec-
cione 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.
CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
10
SECTION 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 condi-
ciones. 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 mien-
tras 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 especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.
CAMPOS ELECTRICOS Y MAGNETI-
COS - Son peligrosos. La corriente
eléctrica uye 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.
3. Los soldadores deberán usar los siguientes proced-
imientos 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 cad-
mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.
2. No opere cerca de lugares donde se aplique sub-
stancias 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 per-
siste.
4. Haga referencia a la publicación ANSI/ASC Standard
Z49.1 (Vea la lista a continuación) para recomen-
daciones especícas en la ventilación.
11
SECTION SEGURIDAD
5. ADVERTENCIA-- Este producto cuando se uti-
liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali-
fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)
MANEJO DE CILINDROS-- Los
cilindros, si no son manejados
correctamente, pueden romp-
erse 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 adapta-
dores. 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.
2. Asegure siempre los cilindros en posición vertical
y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tab-
lilleros, 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.
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
MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede cau-
sar daño o muerte. Por lo tanto:
1. Siempre tenga personal cualicado para efec-
tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado 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 modique el equipo en ninguna
manera.
INFORMACION ADICIONAL DE SEGU-
RIDAD -- 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.
Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:
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"
12
SECTION SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig-
nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
13
SECTION SÉCURITÉ
Safety - French
INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles
peuvent également provoquer un
incendie ou une explosion. Par conséquent :
1. Éloignez susamment tous les matériaux combus-
tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vête-
ments, 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 incan-
descent peuvent tomber dans les ssures 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 tra-
vail 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 inammables 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 surchauer et provoquer un in-
cendie.
6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec-
tion 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.
CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-
telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.
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-des-
sous, dans les manuels, les ches 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.
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 la-
téraux 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 ltrants et de
plaques protectrices appropriées an 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 re-
garder 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 an 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 ininammable an
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 recom-
mandé 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 ininammable.
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 égale-
ment porter des lunettes étanches par dessus leur
lunettes de sécurité.
14
SECTION SÉCURITÉ
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 re-
spirez 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 ventila-
tion naturelle ou à l'aide de moyens mécanique.
N'eectuez jamais de travaux de soudage, de coup-
age 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 ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 ven-
tilation n'est pas adéquate. Cessez votre travail an
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 spéciques
concernant la ventilation.
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 an d'éviter le risque
de choc électrique mortel.
4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom-
magés.
5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte-
électrode/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 eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe-
ment 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
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉ-
TIQUES — comportent un risque
de danger. Le courant électrique
qui passe dans n'importe quel con-
ducteur produit des champs élec-
triques 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 cer-
tains stimulateurs cardiaques.
2. L'exposition à des champs électriques et magné-
tiques peut avoir des eets néfastes inconnus pour
la santé.
15
SECTION SÉCURITÉ
1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
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 ls 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 quel-
conque.
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 aques
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'eectuez aucune modication.
INFORMATIONS SUPPLÉMENTAIRES RELA-
TIVES 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 "Precau-
tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.
Les publications suivantes sont également recomman-
dées 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"
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 consi-
déres 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.)
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 bles-
sures 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 xez
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 bran-
ché, 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
ammes. 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 dis-
position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe-
ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :
16
SECTION SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
Signie un danger qui peut entraîner des blessures
corporelles mineures.
DANGER
AVERTISSEMENT
ATTENTION
17
1.1 INTRODUCTION
The PT-25 is a dual gas manual torch with a 90° head de-
signed for use with certain plasma arc cutting packages.
These packages include the ESP-100i and properly retrot-
ted PCM-70's, PCM-100's and PCM-150's.
!
WARNING
The plasma arc cutting process employs extremely high
voltages. Contact with “live” parts of the torch and ma-
chine must be avoided. Also, the improper use of any of
the gases employed can present a safety hazard. Before
beginning operation with the PT-25 Torch, refer to the
safety precautions and operating instructions packed
with your power source package.
Using the torch on any unit not equipped with a mating
safety interlock circuit will expose operator to unex-
pected high voltage.
1.2 SPECIFICATIONS
Current Capacity (100% Duty) .......................................................................................150 A DCSP (N
2
, H-35, N
2
/H
2
Plasma)
..................................................................................................................................................................100 A DCSP (Air Plasma)
Approved Service Gases:
Plasma ............................................................................................................................................Air, N
2
, H-35, N
2
/H
2
Mixtures
Cooling ............................................................................................................................................................................Air, N
2
, CO
2
Length of Service Lines: ................................................................................................................................................ 25 ft or 50 ft.
Weight ...................................................................................................................................................................25 ft - 14 lbs. (6.3 kg)
.................................................................................................................................................................... 50 ft. - 25 lbs. (11.3 kg)
Min. Gas Flow Requirements: .........................................................................................................................See Subsection 4.8
1.38"
(35 mm)
1.60"
(41 mm)
4.48"
(114 mm)
12.15"
(309 mm)
1.22" (31 mm)
1.47" (37 mm)
Figure 1-1 PT-25 Dimensions
SECTION 1 DESCRIPTION
18
SECTION 1 DESCRIPTION
19
Quanity
5
2
5
2
2
1
1
Description
Electrode Air/N
2
Swirl Baes
Nozzle-100A
Nozzle-Gouging
Heat Shield
Gouging Guard
Stand-O Guide
Part No.
21595
21667
21597
21599
21654
21656
21943
PT-25/100 amp Spare Parts Kit, Part No. 21946
Quanity
5
2
5
2
2
1
1
Description
Electrode Ar/H
2
Swirl Baes
Nozzle-150A
Nozzle-Gouging
Heat Shield
Gouging Guard
Stand-O Guide
Part No.
21780
21667
21598
21599
21654
21656
21943
PT-25/150 amp Spare Parts Kit, Part No. 21947
2.1 SPARE PARTS KITS
2.2 OPTIONAL ACCESSORIES
Torch Guide Kit:
Deluxe: 1-3/4 in. (44.5mm) - 42 in. (106cm) Radius ...........................................................................................................0558003258
Basic: 1-3/4 in. (44.5mm) - 28 in. (71cm) Radius .................................................................................................0558002675
Plasmit Torch Head Protector ..................................................................................................................................................... 20801
Leather Sheath, 10 ft. (254 cm) length .................................................................................................................................. 20812
Plasma Flow Measuring Kit ......................................................................................................................................................... 19765
Retrot Kit for PCM-100/150:
Enables use of PT-25 with PCM-100/150 ........................................................................................................................... 21932
European Swirl Bae .......................................................................................................................................................0558001457
SECTION 2 ACCESSORIES
20
SECTION 2 ACCESSORIES
21
The torch switch connection is made with the 5-pin plug
on the torch switch lead. Insert the plug into the socket
on the power source and twist the locking ring to secure
it in place.
The torch front end components are designed to send a
gas pressure signal to the power source when the heat
shield and nozzle are properly installed. This gas pres-
sure operates in conjunction with circuitry provided
in the power source. This patented system provides
a safety interlock preventing the torch from being ac-
cidentally energized with high voltage when the heat
shield is removed and the torch switch is accidentally
closed. Occasionally check this system by removing the
heat shield. Turn on power source. Do NOT touch the
metallic parts on the torch front end. Close the torch
switch and place the electrode in contact with a prop-
erly grounded work piece. If the torch energizes and
arcing occurs between the electrode and work piece,
DO NOT USE. Do NOT tamper with the torch or power
source. Return torch and power source to your ESAB
distributor for repair.
!
WARNING
3.1
TORCH TO POWER SOURCE CONNECTIONS
Consult your power source instruction manual for access
to the torch connections.
Make sure the power switch on the console is in the o
position and the primary input power is deenergized.
The PT-25 torch uses a “C” sized left hand thread tting
for the negative terminal and the plasma gas connection.
Connect this tting to the corresponding female tting on
the power source and tighten it rmly with a wrench. After
tightening the tting, slide the rubber boot (49N83) on the
power cable over the connection. The “B” sized right hand
tting is used to make the positive terminal and cooling gas
connection. Tighten it rmly as well.
!
WARNING
The safety sensor tube plugs into the small bulkhead tting
or tube union at the power source. Simply push it into the
tting or union until it is fully seated.
SECTION 3 INSTALLATION AND OPERATION
22
Figure 3-2. PT-25 Cutting Data, H-35/N
2
3.4 OPERATING PARAMETERS
Recommended Gas Pressures
Plasma (Cutting) 65 - 75 psig
Plasma (Gouging) 40 - 45 psig
Cooling 65 - 80 psig
Recommended Stand-o
3/16" - 1/2"
Recommended Current Settings
Air Plasma - 100A maximum
N
2
, Ar- H
2
, N
2
- H
2
Plasma - 150 A maximum
Travel Speeds
Travel speeds for the PT-25 are given in the charts
shown in gures 3.1 and 3.2.
Nitrogen Plasma/Air Cooling
This combination provides improved parts life, especially
for the electrode. Cut speeds will usually be slightly slower
than with air plasma. It creates surface nitriding but provides
cleaner cut face on stainless steels. Nitrogen or CO
2
may be
substituted for air cooling.
H-35 Plasma/Nitrogen Cooling
This combination gives excellent parts life with minimum
amount of cut surface contamination, providing excellent
weldability. It is most often used for gouging on mild steel,
aluminum, and stainless steel. It gives poor cut quality on
mild steel, good cut quality on aluminum and stainless,
particularly on thicker sizes.
40% Hydrogen - 60% Nitrogen Plasma/Air Cooling
This combination is used on aluminum only for increased
speed and thickness capability. This combination oers no
real advantage on stainless and mild steels.
(See Section 1.2). Do not use Argon or Argon mixtures
as cooling gas in the PT-25 as internal arcing in the torch
head may occur. Do not use oxygen as cooling or plasma
gas as the torch may catch re.
Air Plasma/Air Cooling
Best overall combination for cut quality, cut speed and
economy on mild steel, stainless steel and aluminum. This
combination causes some surface nitriding at cut face and
some surface oxidation of alloying elements on stainless
steels. Always use clean, dry air. Moisture
or oil in the air supply will reduce torch parts life.
3.2 RETROFITS TO OLDER POWER SOURCES
The PT-25 torch uses a new type of safety mechanism for
added protection against accidental shock to the torch
operator. Some power sources which were built before the
introduction of the PT-25 torch can be retrotted so that this
safety mechanism will function properly. The retrot kit for
PCM-100 and PCM-150 power sources is P/N 21932.
3.3 GAS SELECTION
The PT-25 is a dual gas torch, allowing for one gas to be
used for plasma gas and another to be used for cooling
the torch as well as shielding the cut zone. Recommended
combinations of gases are listed below.
Use only those gases listed as approved in this manual.
!
CAUTION
Figure 3-1. PT-25 Cutting Data, Air/Air
PT-25 100 amp
PT-25 150 amp
SECTION 3 INSTALLATION AND OPERATION
23
Figure 3-3, Assembly of PT-25 Front End Parts
AIR, N
2
, N
2
/ H
2
- 21595
H-35 (Ar / H
2
) - 21780
ELECTRODE
NOZZLE
50 AMP - 21596
100 AMP - 21597
150 AMP - 21598
GOUGING - 21599
GOUGING GUARD - 21656
SWIRL BAFFLE - 21667
HEAT SHIELD - 21654
STAND-OFF GUIDE - 21943
0-RING - 344019
(Supplied With Torch Head)
ELECTRODE HOLDER
ASSEMBLY - 21657
3.5 GAS CONNECTIONS
After the gases for the job have been selected, connect the
gas supply hoses to the ttings at the back of the power
source. Note there are two ttings for each gas. Use the t-
ting which best matches your hose. Do not use oxygen as
plasma or cooling gas for the PT-25. Do not use argon or
argon mixtures for cooling gas. Make sure that the tting
not used for each gas is plugged with the plug attached to
the power source.
Thread the electrode holder assembly (21657) into the
torch body and tighten it securely in place using a 7/16"
nut driver. Avoid overtightening and rounding o the hex
on the electrode holder assembly.
Thread the electrode onto the electrode holder and tighten
securely using the thumb and forenger. The electrode is
tightened properly when a slight snapping action is felt as
one twists the electrode to remove it. Use electrode 21595
for plasma gases of air, nitrogen or nitrogen/hydrogen
mixtures. Use electrode 21780 for argon/hydrogen (H-35)
plasma gas.
Install the swirl bae (21667) by pressing it onto the torch
insulator. The grooved face of the swirl bae ts against
the torch insulator and it should snap into place on the
torch insulator.
NOTE:
Poor PT-25 plasma cutting performance will be caused by
improper bae positioning. Due to small tolerance varia-
tions, the bae might not seat squarely against the insulator
body when it is installed independent of the nozzle and heat
shield. This condition causes plasma gas leakage into the
shield gas causing generally poor cutting performance and
lower consumable life. To improved plasma cutting perfor-
mance assemble the consumables as shown in Figure 3-4.
Select the proper nozzle according to the cutting current
which will be used, or select the gouging nozzle for gouging
between 100 and 150 amps.
Drop the nozzle into the heat shield (21654) so that the
nozzle protrudes out of the shield's smaller end. Thread
the heat shield onto the torch body, tightening it rmly
by gripping it in the palm of the hand and twisting until
the nozzle is fully secure and further twisting is noticeably
more dicult.
!
WARNING
3.6 ASSEMBLING FRONT END PARTS
Make sure power switch on power source is in the OFF
position and primary input power is deenergized. Fail-
ure to install front end parts properly can expose you
to high voltage or re.
BE SURE:
• Electrode holder assembly is tight.
• Swirl bae is installed and fully snapped into place.
• Electrode is installed and tight.
• Nozzle is installed.
If the optional gouging guard (21656) or stand-o guide
(21943) is to be used, install it over the heat shield by push-
ing and twisting in the clockwise direction until it is fully
seated on the shield..
SECTION 3 INSTALLATION AND OPERATION
24
2. Make sure that the nozzle and swirl bae are securely
installed by fully tightening the heat shield. “Fully”
means at least 3/16" of rotation after the swirl bae
and nozzle make rm contact with each other. See
Subsection 3.6 and Figure 3.4.
Improperly installed front end parts will cause gas leaks
which may cause poor cutting or gouging performance and
may cause damage to the torch itself from internal arcing.
3.8 LOOSE CONSUMABLES
Proper performance of the torch will rely on proper and
secure installation of the front end consumable parts, par-
ticularly the electrode holder, electrode, and heat shield.
1. Make sure that the electrode holder is fully threaded
into the torch head and securely tightened using a
7/16" nut driver.
Fully tighten the electrode onto the electrode holder
using the thumb and forenger (wrenches or pliers are
not required). A correctly tightened electrode will come
loose with a "snapping" action when it is removed using
the thumb and forenger.
If desired, a metal gouging guard (21656) is available. It
is used during plasma gouging and protects the torch
by reecting radiant heat and spatter produced during
gouging.
The stand-o guide (21943) provides the operator with the
ability to hold a consistant stand-o by keeping the guide's
feet in contact with the work.
Install the guard or guide by sliding it onto the heatshield
(heatshield should be in place on torch) with a clockwise
twisting motion. Always install or adjust the guard or guide
on the shield with a clockwise twisting motion to prevent
loosening of the shield.
If the t of the guard or guide is too tight on the shield, open
the slot in the shield by twisting with a large at blade screw
driver. If the t is too loose, close the slot by squeezing the
guard or guide in a bench vise.
IMPORTANT - Do not twist the gouging guard or stand-o
guide in the counter-clockwise direction as this will loosen
the heat shield.
Follow all instructions in the appropriate booklet packed
with your power source package. Do NOT install or attempt
to operate this torch without following these instructions.
The torch front end design contains components which,
working together with power source circuitry, prevent the
torch from being accidently energized when the heat shield
is removed and the torch switch is closed.
3.7 GOUGING GUARD & STAND-OFF GUIDE
Figure 3-4, PT-25 Bae Assembly
SECTION 3 INSTALLATION AND OPERATION
25
3.9 OPERATION
Wear the usual protective gloves, clothing, ear protec-
tion and helmet. Read Safety Precautions covered in the
instruction manual packed with your power source.
The torch is now ready for cutting or gouging operation.
Refer to the instructions for your power source for making
any control adjustments.
Never touch any parts forward of the torch handle
(nozzle, heat shield, electrode, etc.) unless the power
switch on the power source is in the OFF position.
1. Turn the gas test or gas mode switch to the test or set-
up position.
2. Turn the power switch to the ON position. Gas should
now ow through the torch.
3. Adjust the gas pressure settings at the gas supply
regulators to the values given in the operating par-
!
CAUTION
ameters section. Turn the gas test or gas mode switch
to the operating position. Gas ow should now stop.
Adjust the current control to the correct setting for the
nozzle.
4. Bring the torch into the proper position for cutting
or gouging. For cutting, the torch stand-o (nozzle-
to-work distance) should be approximately 1/4". If
possible, start the cut from an edge on the workpiece.
If piercing must be done, tilt the torch at an angle to
deect the molten metal away from the torch and
operator until the pierce is complete, then bring the
torch back to 5° to 10° from the vertical and begin the
cut. For gouging, place the torch over the work at an
angle of 35° to 45° from the horizontal.
5. Lower your protective helmet.
6. Push down and hold the torch switch button. The
gas should start owing. Two seconds later, the main
contactor should close and the arc should transfer to
the workpiece.
!
WARNING
NOTE: Your power source may allow the preow time to
be extended longer than two seconds, usually up
to four or ve seconds. If, at the end of the preow
time, the pilot arc does not ignite, release the torch
switch and check the gas pressure settings. If the
pilot arc does ignite but does not transfer to the
work, release the torch switch and check to see
that the torch is in the proper distance from the
work and that the work clamp is rmly connected
to the work piece.
7. When cutting, maintain the torch stand-o at a distance
of between 3/16" and 1/2". When cutting thinner plates,
the stand-o should be closer to the lower end of
the range and it should be closer to the upper end of
the range for thicker plates. Maintain a cutting speed
which gives a cut of the desired quality and produces
a stream of molten metal emitting from the bottom of
the workpiece.
8. When gouging, maintain an angle and speed which
causes the desired amount of metal to be removed on
each pass. Maintain the torch angle so that all the mol-
ten metal is blown directly away from the torch, along
the top surface of the plate or down the groove of the
previous pass. Gouging at too steep of an angle will
cause molten metal to y directly back at the torch.
9. If the main arc is lost during the cut (or gouge), the pilot
arc will immediately reignite as long as the torch switch
is depressed. At this time the torch should quickly be
repositioned at the workpiece to re-establish the main
arc or else the torch switch should be released.
10. The main arc will automatically extinguish at the end of
the cut as the torch is moved away from the workpiece.
The torch switch should be released immediately to
keep the pilot arc from reigniting.
11. When cutting (or gouging) operations are completed,
wait a few minutes before placing the power switch on
the power source in the OFF position to allow the fan
to remove heat from the unit. After this time, shut o
the primary power at the main disconnect switch.
SECTION 3 INSTALLATION AND OPERATION
26
SECTION 3 INSTALLATION AND OPERATION
27
!
WARNING
4.2 GENERAL
Periodically check the heat shield, electrode holder as-
sembly and swirl bae. If any of these parts are damaged
or excessively worn, replace them.
Check the torch o-ring daily. If the o-ring has nicks, cuts or
other damage, replace it. If it is dry, lubricate it with a thin
lm of lubricant, P/N 17672. If no drag, caused by the o-ring,
is felt when installing the heat shield, replace the o-ring.
The torch cable sleeving should be inspected periodically.
If any damage to the sleeving is found, inspect the torch
power and pilot arc cables for damage. If gas leaks or
damage of any kind are found, replace the components
in question.
4.3 DIRT OR CONTAMINATION
Dirt or other contamination can cause premature failure
of the PT-25 torch through internal arcing. To avoid this,
do the following:
1. Insure that clean, dry, oil-free air is used for plasma
and/or cooling gas.
2. Avoid excessive use of the silicone o-ring grease on
the torch o-ring. A thin lm is sucient.
3. Wipe the torch body insulator clean with a cloth before
installing each fresh set of consumables. The ability of
the insulator to resist arc tracking over its surface is
reduced when dirt or other contamination is allowed
to collect there.
4. When the torch is not in use, store it with a full set of
front end parts installed. This will prevent dirt from
collecting in the torch and will help protect the torch
head if it is accidentally dropped.
4.4 REMOVAL AND REPLACEMENT OF THE
TORCH HEAD
Note the position of all components and tape locations
before performing disassembly to ensure proper position-
ing of components and tape during reassembly. Refer to
Figure 5.1.
1. Slide the ex support rearward, onto the cable sleeving
until it is approximately 18" to the rear of the handle.
2. Remove the tape near the end of the torch handle.
3. Slide the switch band and switch rearward and o of
the handle.
4. Slide the cable sleeving rearward to expose the tube
union for the safety sensor tube. Remove the torch end
of the tube by pressing on the end of the union and
pulling on the tube at the same time.
4.1 DISASSEMBLY OF FRONT END
Make sure power switch on power source is in the OFF
position and primary input power is deenergized.
If the gouging guard or stand-o guide is being used,
remove it by twisting clockwise and pulling it from the
heat shield.
With the torch head in the downward position, unscrew the
heat shield and remove it, allowing the nozzle to remain
inside.
Inspect the nozzle. The orice should be round at both the
entrance and the exit. Replace the nozzle if the orice is
oval shaped or is damaged at either the entrance or exit.
The nozzle may have grey to black deposits on the inside
surfaces. They may be cleaned with steel wool but care must
be taken to remove all traces of the steel wool afterward.
Inspect the heat shield. There should be no signs of arcing
anywhere inside the shield. The outer insulating jacket
should not be severely charred or worn. Replace the shield
if any of the above damage is found.
Inspect the electrode. If it has a pit more than 1/16" deep at
its center, replace it. Remove the electrode by unscrewing it
from the electrode holder assembly. After prolonged high
current use, the electrode may require the aid of pliers for
removal. (Do not use pliers for installation).
Inspect the swirl bae. If any signs of arcing are found,
replace it. The faces of the swirl bae must be kept clean
where they contact the torch insulator and nozzle. Dirt or
grit on these faces will aect torch performance.
Inspect the electrode holder. Replace it if it shows signs of
arcing or if the electrode threads are galled.
Inspect the o-ring (344019). If it is worn or damaged, re-
place it. If it is dry, lubricate it with a thin lm of silicone
lubricant (17672). Use just enough lubricant to make the
o-ring appear wet or shiny but do not leave clumps of
excess lubricant.
After all of the front end parts have been inspected and
replaced as needed, reassemble the torch as described in
the section “Assembling Front End Parts”.
SECTION 4 MAINTENANCE
28
5. Unthread the handle from the torch head and slide it
rearward to expose the torch cable connections.
6. Using two wrenches at each connection, unthread the
two torch connections. The wrench sizes required are
3/8" and 7/16".
7. Pull the torch head away from the cable assembly,
including the short piece of safety sensor tubing at-
tached. Position the new torch head and safety sensor
tube back into the assembly.
8. Using two wrenches at each connection, tighten the
two torch connections securely. The torque value used
at the factory for this step is 25-30 in-lbs.
9. Thread the handle back onto the torch head. Make sure
the safety sensor tube on the torch passes through the
handle.
10. Push the safety sensor tube into the union until it stops.
Slide the switch band and switch onto the handle until
it is two (2) inches from the torch head. The red splice
connections for the switch lead should be located just
behind the handle end.
11. Pull the cable sleeving forward and tape in place behind
the handle using vinyl electrical tape.
12. Slide the ex support back onto the handle until it
contacts the switch band.
4.5 REMOVAL AND REPLACEMENT OF TORCH
CABLES
1. Disconnect the torch cable assembly from the power
source. Refer to your power source instruction booklet
for detailed instructions.
2. Remove the torch head from the cable assembly as
described in steps 1 through 7 of the previous section.
Also remove the handle and ex support from the cable
assembly.
3. Lay the cable assembly out straight. This should be done
in an area about 1-1/2 times the length of the cables.
4. Using a piece of cord or sturdy twine about 1/2 the
length of the torch cables, secure one end of the cord
around all of the torch cables at the torch end and se-
cure the other end of the cord to a stationary object.
5. Remove the tape from the cable sleeving at the power
source end of the cables.
6. Push the switch out of the switch band and slide the
handle, switch band and ex support to the far end of
the cord used in step 4. Secure the power source end
of the cables and pull the cable sleeving completely
onto the cord.
7. Untie the cord from the cables and replace the dam-
aged cable or cables. Be sure to replace the rubber boot
on the power cable.
8. Resecure the torch ends of the cables with the cord and
pull the cable sleeving back onto the cables. Temporar-
ily secure the sleeving to the cables near the torch head
end with vinyl electrical tape.
9. Pull the ex support, switch band and handle back
o the cord and onto the cable sleeving. Remove the
tape.
10. Untie the cord from the cables and follow steps 7
through 12 of the previous section to secure the torch
head to the cable assembly.
11. Secure the cable sleeving to the cables at the power
source end with vinyl electrical tape.
4.6 REPLACEMENT OF FLEX SUPPORT, SWITCH
BAND OR HANDLE.
If damage to the ex support, switch band or torch handle
causes the need for replacement of any of these items, fol-
low the procedure in the section “Removal and Replacement
of the Torch Head” and replace the part(s) in question dur-
ing step 7 prior to reattaching the torch head. This process
will be made easier by temporarily securing the sleeving to
the cables with vinyl electrical tape.
4.7 REPLACEMENT OF TORCH SWITCH
1. Follow steps 1 through 3 of the section “Removal and
Replacement of the Torch Head”.
2. Clip the black and white leads of the old switch as close
as possible to the red splice connections. Strip 1/4" of
insulation from the black and white leads.
3. Strip 1/4" of insulation from the new switch leads (P/N
18224).
4. Attach the switch leads to the switch cable using the
two new splice connections included with the replace-
ment switch. Be sure to use a crimping tool made for
crimping this type of splice connection.
5. Reverse steps 1 through 3 of the section “Removal and
Replacement of the Torch Head” to nish.
4.8 MEASURING TORCH GAS FLOWS
If low gas ow is suspected of causing poor cutting perfor-
mance or short consumable life, the ow can be checked
by using Plasma Torch Flow Measuring Kit (P/N 19765).
The kit includes a hand held rotameter (owmeter) which
will indicate the gas ow rate exiting the torch. The kit also
includes a set of instructions which should be followed
exactly to insure safe and accurate use of the rotameter.
See form F-14-391.
SECTION 4 MAINTENANCE
29
Measure the ow rates using a new 100 amp nozzle (21597),
a new electrode (21595 or 21780) and a new heat shield
(21654). Make sure that all parts are properly installed and
that the torch o-ring (344019) is in good condition and not
leaking. Measure the ows individually if possible. If not
possible, measure the total ow.
Low gas ow rates (lower than those given here) indicate
a restriction or a leak in the gas plumbing of the torch or
power source.
Note:
Gas ow rates are given for a "no arc" condition and are not
representative of ow rates when the arc is on. Plasma ow
will reduce to < 60 cfh in the "arc on" condition. Shield gas
ow is not aected when the arc is on.
Nozzle
Plasma Flow
Cooling Flow
Total Flow
PT-25 Air or Nitrogen Flow Rate
should be as follows:
100A
162
396
558
150A
180
372
552
Gouging
144
264
408
@ 75 psig @ 45 psig
Swirl Bae - 21664 (4-slot)
( cu. ft. per hr. +/- 25% )
SECTION 4 MAINTENANCE
30
SECTION 4 MAINTENANCE
31
5.1 General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
5.2 Ordering
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
Note
SECTION 5 REPLACEMENT PARTS
32
Figure 5-1. Replacement Parts - PT-25 Torch Assembly
FLEX SUPPORT - 21647
SWITCH BAND - 21646
SAFETY SENSOR TUBE 25 FT - 21854
50 FT - 21855
SLEEVING (Ref.)
COOLING GAS / PILOT ARC CABLE 25 FT - 21783
50 FT - 21782
PLASMA GAS / POWER CABLE 25 FT - 18450
50 FT - 18449
Tighten ttings at two (2) places
using two (2) wrenches
Torque 25-30 IN-LBS.
UNION - 2210735
Push tubing securely into both ends of union.
HANDLE - 948177
25 FT - 995832
50 FT - 995826
SLEEVING
RUBBER BOOT - 49N83
TORCH HEAD
90
O
- 21625
(Includes O-Ring - 344019 and 14" of plastic tube.)
FRONT END PARTS - (See Fig. 3-3)
SWITCH & LEAD ASSY 25 FT - 948188
50 FT - 948189
INCLUDES:
SWITCH - 18224
PLUG - 997758
CABLE - 18 AWG/2 COND.
SECTION 5 REPLACEMENT PARTS
33
NOTES
34
NOTES
35
1. The "A" edition was printed to cover changes in (Minimum Gas Flow Requirements) on page 3.
2. Revision B - Removed Min. Flow Rate Requirements values in note on Page 5 and added reference to Sub-
section 4.8. Added Flow Rate Chart to Subsection 4.8 on Page 17.
3. Revision B - 04/2005 - Added Swirl Bae installation information on Pages 23 and 24 per Service Bulletin
P_05_006. Added Safety section.
4. Revision C - 06/2010 - Added Section 2.2 Optional Accessories from PAC-21000A per cust serv dept.
REVISION HISTORY
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4452
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing 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 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications 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 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
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
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
Transcripción de documentos
PT-25 Plasma Arc Cutting Torch Instruction Manual This manual provides maintenance instructions and replacement parts for the following PT-25 torch assemblies: P/N 21648 - 90° head, 25-ft. service lines P/N 21649 - 90° head, 50-ft. service lines F15-266-C 07/2010 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 1 1.1 1.2 DESCRIPTION........................................................................................................................................................................ 17 Introduction.......................................................................................................................................................................... 17 Specifications........................................................................................................................................................................ 17 SECTION 2 2.1 2.2 ACCESSORIES........................................................................................................................................................................ 19 Spare Parts Kits..................................................................................................................................................................... 19 Optional Accessories.......................................................................................................................................................... 19 SECTION 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 INSTALLATION AND OPERATION................................................................................................................................... 21 Torch to Power Source Connection.............................................................................................................................. 21 Retrofits................................................................................................................................................................................... 22 Gas Selection........................................................................................................................................................................ 22 Operating Parameters....................................................................................................................................................... 22 Gas Connections ............................................................................................................................................................... 23 Assembling Front End Parts............................................................................................................................................ 23 Gouging Guard & Stand-Off Guide............................................................................................................................... 24 Loose Consumables........................................................................................................................................................... 24 Operation............................................................................................................................................................................... 24 SECTION 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 MAINTENANCE..................................................................................................................................................................... 27 Disassembly of Front End................................................................................................................................................. 27 General.................................................................................................................................................................................... 27 Dirt or Contamination....................................................................................................................................................... 27 Removal and Replacement of Torch Head................................................................................................................. 27 Removal and Replacement of Torch Cables.............................................................................................................. 28 Replacement of Flex Support, Switch Band or Handle.......................................................................................... 28 Replacement of Torch Switch......................................................................................................................................... 28 Measuring Torch Gas Flows............................................................................................................................................. 28 SECTION 5 5.1 5.2 REPLACEMENT PARTS........................................................................................................................................................ 31 General.................................................................................................................................................................................... 31 Ordering................................................................................................................................................................................. 31 3 table of contents 4 section safety precautions Safety Precautions 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. 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 longsleeve 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. Safety - English 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 workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode. 4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use. 5. Do not use equipment beyond its ratings. For 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, Batterymarch Park, Quincy, MA 02269. ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. 5 section 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 workpiece 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 workpiece. 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 workpiece as close as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible. 6. Make sure that all parts of your body are insulated from work and from ground. 7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes. 8. Put on dry, hole-free gloves before turning on the power. 9. Turn off the power before removing your gloves. 10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable. 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: 1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers. 2. Exposure to EMF may have other health effects which are unknown. Therefore: 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. 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. 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. 4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations. 6 section safety precautions 5. WARNING: This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition. Follow manufacturer's operating instructions for mounting regulator to a compressed gas cylinder. 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. 4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather. 5. Keep all safety devices and cabinet covers in position and in good repair. 6. Use equipment only for its intended purpose. Do not modify it in any manner. 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. 5. For additional information, refer to CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore: The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting" 2. AWS C5.1 - "Recommended Practices for Plasma Arc Welding" 3. AWS C5.2 - "Recommended Practices for Plasma Arc Cutting" 4. AWS C5.3 - "Recommended Practices for Air Carbon Arc Gouging and Cutting" 7 section 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 section sEGURIDAD Safety - Spanish 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. 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. La escoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberán usar gafas de seguridad y careta protectora. 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. 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 section 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. 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. sEGURIDAD 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. 10 section 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.) 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. 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. 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 MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede causar daño o muerte. Por lo tanto: 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. 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. Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted: 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" 11 section 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 section 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. 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. 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 : 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. 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 section 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. 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. sÉCURITÉ 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. 14 section 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.) 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. sÉCURITÉ 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. 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 section 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. 16 section 1 description ! 1.1 INTRODUCTION WARNING The plasma arc cutting process employs extremely high voltages. Contact with “live” parts of the torch and machine must be avoided. Also, the improper use of any of the gases employed can present a safety hazard. Before beginning operation with the PT-25 Torch, refer to the safety precautions and operating instructions packed with your power source package. The PT-25 is a dual gas manual torch with a 90° head designed for use with certain plasma arc cutting packages. These packages include the ESP-100i and properly retrofitted PCM-70's, PCM-100's and PCM-150's. Using the torch on any unit not equipped with a mating safety interlock circuit will expose operator to unexpected high voltage. 1.2 SPECIFICATIONS Current Capacity (100% Duty)........................................................................................150 A DCSP (N2, H-35, N2/H2 Plasma) ..................................................................................................................................................................100 A DCSP (Air Plasma) Approved Service Gases: Plasma.............................................................................................................................................Air, N2, H-35, N2/H2 Mixtures Cooling............................................................................................................................................................................. Air, N2, CO2 Length of Service Lines: . ............................................................................................................................................... 25 ft or 50 ft. Weight....................................................................................................................................................................25 ft - 14 lbs. (6.3 kg) .................................................................................................................................................................... 50 ft. - 25 lbs. (11.3 kg) Min. Gas Flow Requirements: ..........................................................................................................................See Subsection 4.8 12.15" (309 mm) 4.48" (114 mm) 1.38" (35 mm) 1.60" (41 mm) 1.22" (31 mm) 1.47" (37 mm) Figure 1-1 PT-25 Dimensions 17 section 1 description 18 section 2 ACCESSORIES 2.1 SPARE PARTS KITS PT-25/100 amp Spare Parts Kit, Part No. 21946 Quanity 5 2 5 2 2 1 1 2.2 Description Electrode Air/N2 Swirl Baffles Nozzle-100A Nozzle-Gouging Heat Shield Gouging Guard Stand-Off Guide PT-25/150 amp Spare Parts Kit, Part No. 21947 Part No. Quanity 21595 21667 21597 21599 21654 21656 21943 5 2 5 2 2 1 1 Description Electrode Ar/H2 Swirl Baffles Nozzle-150A Nozzle-Gouging Heat Shield Gouging Guard Stand-Off Guide Part No. 21780 21667 21598 21599 21654 21656 21943 Optional Accessories Torch Guide Kit: Deluxe: 1-3/4 in. (44.5mm) - 42 in. (106cm) Radius . ..........................................................................................................0558003258 Basic: 1-3/4 in. (44.5mm) - 28 in. (71cm) Radius . ................................................................................................ 0558002675 Plasmit Torch Head Protector...................................................................................................................................................... 20801 Leather Sheath, 10 ft. (254 cm) length ................................................................................................................................... 20812 Plasma Flow Measuring Kit.......................................................................................................................................................... 19765 Retrofit Kit for PCM-100/150: Enables use of PT-25 with PCM-100/150 . .......................................................................................................................... 21932 European Swirl Baffle . ...................................................................................................................................................... 0558001457 19 section 2 ACCESSORIES 20 section 3 INSTALLATION AND OPERATION 3.1 TORCH TO POWER SOURCE CONNECTIONS Consult your power source instruction manual for access to the torch connections. ! ! WARNING Make sure the power switch on the console is in the off position and the primary input power is deenergized. The safety sensor tube plugs into the small bulkhead fitting or tube union at the power source. Simply push it into the fitting or union until it is fully seated. The PT-25 torch uses a “C” sized left hand thread fitting for the negative terminal and the plasma gas connection. Connect this fitting to the corresponding female fitting on the power source and tighten it firmly with a wrench. After tightening the fitting, slide the rubber boot (49N83) on the power cable over the connection. The “B” sized right hand fitting is used to make the positive terminal and cooling gas connection. Tighten it firmly as well. WARNING The torch front end components are designed to send a gas pressure signal to the power source when the heat shield and nozzle are properly installed. This gas pressure operates in conjunction with circuitry provided in the power source. This patented system provides a safety interlock preventing the torch from being accidentally energized with high voltage when the heat shield is removed and the torch switch is accidentally closed. Occasionally check this system by removing the heat shield. Turn on power source. Do NOT touch the metallic parts on the torch front end. Close the torch switch and place the electrode in contact with a properly grounded work piece. If the torch energizes and arcing occurs between the electrode and work piece, DO NOT USE. Do NOT tamper with the torch or power source. Return torch and power source to your ESAB distributor for repair. The torch switch connection is made with the 5-pin plug on the torch switch lead. Insert the plug into the socket on the power source and twist the locking ring to secure it in place. 21 section 3 INSTALLATION AND OPERATION 3.2 RETROFITS TO OLDER POWER SOURCES The PT-25 torch uses a new type of safety mechanism for added protection against accidental shock to the torch operator. Some power sources which were built before the introduction of the PT-25 torch can be retrofitted so that this safety mechanism will function properly. The retrofit kit for PCM-100 and PCM-150 power sources is P/N 21932. 3.3 GAS SELECTION The PT-25 is a dual gas torch, allowing for one gas to be used for plasma gas and another to be used for cooling the torch as well as shielding the cut zone. Recommended combinations of gases are listed below. Use only those gases listed as approved in this manual. ! CAUTION (See Section 1.2). Do not use Argon or Argon mixtures as cooling gas in the PT-25 as internal arcing in the torch head may occur. Do not use oxygen as cooling or plasma gas as the torch may catch fire. Air Plasma/Air Cooling Best overall combination for cut quality, cut speed and economy on mild steel, stainless steel and aluminum. This combination causes some surface nitriding at cut face and some surface oxidation of alloying elements on stainless steels. Always use clean, dry air. Moisture or oil in the air supply will reduce torch parts life. Nitrogen Plasma/Air Cooling This combination provides improved parts life, especially for the electrode. Cut speeds will usually be slightly slower than with air plasma. It creates surface nitriding but provides cleaner cut face on stainless steels. Nitrogen or CO2 may be substituted for air cooling. H-35 Plasma/Nitrogen Cooling This combination gives excellent parts life with minimum amount of cut surface contamination, providing excellent weldability. It is most often used for gouging on mild steel, aluminum, and stainless steel. It gives poor cut quality on mild steel, good cut quality on aluminum and stainless, particularly on thicker sizes. 40% Hydrogen - 60% Nitrogen Plasma/Air Cooling This combination is used on aluminum only for increased speed and thickness capability. This combination offers no real advantage on stainless and mild steels. 3.4 OPERATING PARAMETERS Recommended Gas Pressures Plasma (Cutting) 65 - 75 psig Plasma (Gouging) 40 - 45 psig Cooling 65 - 80 psig Recommended Stand-off 3/16" - 1/2" Recommended Current Settings Air Plasma - 100A maximum N2, Ar- H2, N2- H2 Plasma - 150 A maximum Travel Speeds Travel speeds for the PT-25 are given in the charts shown in figures 3.1 and 3.2. PT-25 150 amp PT-25 100 amp Figure 3-2. PT-25 Cutting Data, H-35/N2 Figure 3-1. PT-25 Cutting Data, Air/Air 22 section 3 INSTALLATION AND OPERATION 3.5 GAS CONNECTIONS After the gases for the job have been selected, connect the gas supply hoses to the fittings at the back of the power source. Note there are two fittings for each gas. Use the fitting which best matches your hose. Do not use oxygen as plasma or cooling gas for the PT-25. Do not use argon or argon mixtures for cooling gas. Make sure that the fitting not used for each gas is plugged with the plug attached to the power source. 3.6 ASSEMBLING FRONT END PARTS WARNING Make sure power switch on power source is in the OFF position and primary input power is deenergized. Failure to install front end parts properly can expose you to high voltage or fire. ! BE SURE: • Electrode holder assembly is tight. • Swirl baffle is installed and fully snapped into place. • Electrode is installed and tight. • Nozzle is installed. Thread the electrode holder assembly (21657) into the torch body and tighten it securely in place using a 7/16" nut driver. Avoid overtightening and rounding off the hex on the electrode holder assembly. Thread the electrode onto the electrode holder and tighten securely using the thumb and forefinger. The electrode is tightened properly when a slight snapping action is felt as one twists the electrode to remove it. Use electrode 21595 for plasma gases of air, nitrogen or nitrogen/hydrogen mixtures. Use electrode 21780 for argon/hydrogen (H-35) plasma gas. Install the swirl baffle (21667) by pressing it onto the torch insulator. The grooved face of the swirl baffle fits against the torch insulator and it should snap into place on the torch insulator. NOTE: Poor PT-25 plasma cutting performance will be caused by improper baffle positioning. Due to small tolerance variations, the baffle might not seat squarely against the insulator body when it is installed independent of the nozzle and heat shield. This condition causes plasma gas leakage into the shield gas causing generally poor cutting performance and lower consumable life. To improved plasma cutting performance assemble the consumables as shown in Figure 3-4. Select the proper nozzle according to the cutting current which will be used, or select the gouging nozzle for gouging between 100 and 150 amps. Drop the nozzle into the heat shield (21654) so that the nozzle protrudes out of the shield's smaller end. Thread the heat shield onto the torch body, tightening it firmly by gripping it in the palm of the hand and twisting until the nozzle is fully secure and further twisting is noticeably more difficult. If the optional gouging guard (21656) or stand-off guide (21943) is to be used, install it over the heat shield by pushing and twisting in the clockwise direction until it is fully seated on the shield.. 0-RING - 344019 (Supplied With Torch Head) NOZZLE 50 AMP - 21596 100 AMP - 21597 150 AMP - 21598 GOUGING - 21599 ELECTRODE HOLDER ASSEMBLY - 21657 HEAT SHIELD - 21654 ELECTRODE SWIRL BAFFLE - 21667 GOUGING GUARD - 21656 STAND-OFF GUIDE - 21943 Figure 3-3, Assembly of PT-25 Front End Parts 23 AIR, N2, N2 / H2 - 21595 H-35 (Ar / H2) - 21780 section 3 INSTALLATION AND OPERATION Figure 3-4, PT-25 Baffle Assembly IMPORTANT - Do not twist the gouging guard or stand-off guide in the counter-clockwise direction as this will loosen the heat shield. Follow all instructions in the appropriate booklet packed with your power source package. Do NOT install or attempt to operate this torch without following these instructions. The torch front end design contains components which, working together with power source circuitry, prevent the torch from being accidently energized when the heat shield is removed and the torch switch is closed. 3.8 LOOSE CONSUMABLES Proper performance of the torch will rely on proper and secure installation of the front end consumable parts, particularly the electrode holder, electrode, and heat shield. 1. Fully tighten the electrode onto the electrode holder using the thumb and forefinger (wrenches or pliers are not required). A correctly tightened electrode will come loose with a "snapping" action when it is removed using the thumb and forefinger. 3.7 GOUGING GUARD & STAND-OFF GUIDE If desired, a metal gouging guard (21656) is available. It is used during plasma gouging and protects the torch by reflecting radiant heat and spatter produced during gouging. 2. The stand-off guide (21943) provides the operator with the ability to hold a consistant stand-off by keeping the guide's feet in contact with the work. Install the guard or guide by sliding it onto the heatshield (heatshield should be in place on torch) with a clockwise twisting motion. Always install or adjust the guard or guide on the shield with a clockwise twisting motion to prevent loosening of the shield. Make sure that the electrode holder is fully threaded into the torch head and securely tightened using a 7/16" nut driver. Make sure that the nozzle and swirl baffle are securely installed by fully tightening the heat shield. “Fully” means at least 3/16" of rotation after the swirl baffle and nozzle make firm contact with each other. See Subsection 3.6 and Figure 3.4. Improperly installed front end parts will cause gas leaks which may cause poor cutting or gouging performance and may cause damage to the torch itself from internal arcing. If the fit of the guard or guide is too tight on the shield, open the slot in the shield by twisting with a large flat blade screw driver. If the fit is too loose, close the slot by squeezing the guard or guide in a bench vise. 24 section 3 INSTALLATION AND OPERATION 3.9 OPERATION ! NOTE: CAUTION Wear the usual protective gloves, clothing, ear protection and helmet. Read Safety Precautions covered in the instruction manual packed with your power source. The torch is now ready for cutting or gouging operation. Refer to the instructions for your power source for making any control adjustments. ! WARNING Never touch any parts forward of the torch handle (nozzle, heat shield, electrode, etc.) unless the power switch on the power source is in the OFF position. 1. 2. 3. 4. 5. 6. Turn the gas test or gas mode switch to the test or setup position. Turn the power switch to the ON position. Gas should now flow through the torch. Adjust the gas pressure settings at the gas supply regulators to the values given in the operating parameters section. Turn the gas test or gas mode switch to the operating position. Gas flow should now stop. Adjust the current control to the correct setting for the nozzle. Bring the torch into the proper position for cutting or gouging. For cutting, the torch stand-off (nozzleto-work distance) should be approximately 1/4". If possible, start the cut from an edge on the workpiece. If piercing must be done, tilt the torch at an angle to deflect the molten metal away from the torch and operator until the pierce is complete, then bring the torch back to 5° to 10° from the vertical and begin the cut. For gouging, place the torch over the work at an angle of 35° to 45° from the horizontal. Lower your protective helmet. Push down and hold the torch switch button. The gas should start flowing. Two seconds later, the main contactor should close and the arc should transfer to the workpiece. 7. Your power source may allow the preflow time to be extended longer than two seconds, usually up to four or five seconds. If, at the end of the preflow time, the pilot arc does not ignite, release the torch switch and check the gas pressure settings. If the pilot arc does ignite but does not transfer to the work, release the torch switch and check to see that the torch is in the proper distance from the work and that the work clamp is firmly connected to the work piece. When cutting, maintain the torch stand-off at a distance of between 3/16" and 1/2". When cutting thinner plates, the stand-off should be closer to the lower end of the range and it should be closer to the upper end of the range for thicker plates. Maintain a cutting speed which gives a cut of the desired quality and produces a stream of molten metal emitting from the bottom of the workpiece. 8. When gouging, maintain an angle and speed which causes the desired amount of metal to be removed on each pass. Maintain the torch angle so that all the molten metal is blown directly away from the torch, along the top surface of the plate or down the groove of the previous pass. Gouging at too steep of an angle will cause molten metal to fly directly back at the torch. 9. If the main arc is lost during the cut (or gouge), the pilot arc will immediately reignite as long as the torch switch is depressed. At this time the torch should quickly be repositioned at the workpiece to re-establish the main arc or else the torch switch should be released. 10. The main arc will automatically extinguish at the end of the cut as the torch is moved away from the workpiece. The torch switch should be released immediately to keep the pilot arc from reigniting. 11. When cutting (or gouging) operations are completed, wait a few minutes before placing the power switch on the power source in the OFF position to allow the fan to remove heat from the unit. After this time, shut off the primary power at the main disconnect switch. 25 section 3 INSTALLATION AND OPERATION 26 section 4 MAINTENANCE 4.1 DISASSEMBLY OF FRONT END ! WARNING Make sure power switch on power source is in the OFF position and primary input power is deenergized. If the gouging guard or stand-off guide is being used, remove it by twisting clockwise and pulling it from the heat shield. With the torch head in the downward position, unscrew the heat shield and remove it, allowing the nozzle to remain inside. Inspect the nozzle. The orifice should be round at both the entrance and the exit. Replace the nozzle if the orifice is oval shaped or is damaged at either the entrance or exit. The nozzle may have grey to black deposits on the inside surfaces. They may be cleaned with steel wool but care must be taken to remove all traces of the steel wool afterward. Inspect the heat shield. There should be no signs of arcing anywhere inside the shield. The outer insulating jacket should not be severely charred or worn. Replace the shield if any of the above damage is found. Inspect the electrode. If it has a pit more than 1/16" deep at its center, replace it. Remove the electrode by unscrewing it from the electrode holder assembly. After prolonged high current use, the electrode may require the aid of pliers for removal. (Do not use pliers for installation). Inspect the swirl baffle. If any signs of arcing are found, replace it. The faces of the swirl baffle must be kept clean where they contact the torch insulator and nozzle. Dirt or grit on these faces will affect torch performance. Inspect the electrode holder. Replace it if it shows signs of arcing or if the electrode threads are galled. Inspect the o-ring (344019). If it is worn or damaged, replace it. If it is dry, lubricate it with a thin film of silicone lubricant (17672). Use just enough lubricant to make the o-ring appear wet or shiny but do not leave clumps of excess lubricant. After all of the front end parts have been inspected and replaced as needed, reassemble the torch as described in the section “Assembling Front End Parts”. 4.2 GENERAL Periodically check the heat shield, electrode holder assembly and swirl baffle. If any of these parts are damaged or excessively worn, replace them. Check the torch o-ring daily. If the o-ring has nicks, cuts or other damage, replace it. If it is dry, lubricate it with a thin film of lubricant, P/N 17672. If no drag, caused by the o-ring, is felt when installing the heat shield, replace the o-ring. The torch cable sleeving should be inspected periodically. If any damage to the sleeving is found, inspect the torch power and pilot arc cables for damage. If gas leaks or damage of any kind are found, replace the components in question. 4.3 DIRT OR CONTAMINATION Dirt or other contamination can cause premature failure of the PT-25 torch through internal arcing. To avoid this, do the following: 1. 2. 3. 4. Insure that clean, dry, oil-free air is used for plasma and/or cooling gas. Avoid excessive use of the silicone o-ring grease on the torch o-ring. A thin film is sufficient. Wipe the torch body insulator clean with a cloth before installing each fresh set of consumables. The ability of the insulator to resist arc tracking over its surface is reduced when dirt or other contamination is allowed to collect there. When the torch is not in use, store it with a full set of front end parts installed. This will prevent dirt from collecting in the torch and will help protect the torch head if it is accidentally dropped. 4.4 REMOVAL AND REPLACEMENT OF THE TORCH HEAD Note the position of all components and tape locations before performing disassembly to ensure proper positioning of components and tape during reassembly. Refer to Figure 5.1. 1. 2. 3. 4. 27 Slide the flex support rearward, onto the cable sleeving until it is approximately 18" to the rear of the handle. Remove the tape near the end of the torch handle. Slide the switch band and switch rearward and off of the handle. Slide the cable sleeving rearward to expose the tube union for the safety sensor tube. Remove the torch end of the tube by pressing on the end of the union and pulling on the tube at the same time. section 4 5. Unthread the handle from the torch head and slide it rearward to expose the torch cable connections. 6. Using two wrenches at each connection, unthread the two torch connections. The wrench sizes required are 3/8" and 7/16". 7. Pull the torch head away from the cable assembly, including the short piece of safety sensor tubing attached. Position the new torch head and safety sensor tube back into the assembly. 8. Using two wrenches at each connection, tighten the two torch connections securely. The torque value used at the factory for this step is 25-30 in-lbs. 9. Thread the handle back onto the torch head. Make sure the safety sensor tube on the torch passes through the handle. 10. Push the safety sensor tube into the union until it stops. Slide the switch band and switch onto the handle until it is two (2) inches from the torch head. The red splice connections for the switch lead should be located just behind the handle end. 11. Pull the cable sleeving forward and tape in place behind the handle using vinyl electrical tape. 12. Slide the flex support back onto the handle until it contacts the switch band. MAINTENANCE 8. Resecure the torch ends of the cables with the cord and pull the cable sleeving back onto the cables. Temporarily secure the sleeving to the cables near the torch head end with vinyl electrical tape. 9. Pull the flex support, switch band and handle back off the cord and onto the cable sleeving. Remove the tape. 10. Untie the cord from the cables and follow steps 7 through 12 of the previous section to secure the torch head to the cable assembly. 11. Secure the cable sleeving to the cables at the power source end with vinyl electrical tape. 4.6 REPLACEMENT OF FLEX SUPPORT, SWITCH BAND OR HANDLE. If damage to the flex support, switch band or torch handle causes the need for replacement of any of these items, follow the procedure in the section “Removal and Replacement of the Torch Head” and replace the part(s) in question during step 7 prior to reattaching the torch head. This process will be made easier by temporarily securing the sleeving to the cables with vinyl electrical tape. 4.7 REPLACEMENT OF TORCH SWITCH 4.5 REMOVAL AND REPLACEMENT OF TORCH CABLES 1. 1. 2. 2. 3. 4. 5. 6. 7. Disconnect the torch cable assembly from the power source. Refer to your power source instruction booklet for detailed instructions. Remove the torch head from the cable assembly as described in steps 1 through 7 of the previous section. Also remove the handle and flex support from the cable assembly. Lay the cable assembly out straight. This should be done in an area about 1-1/2 times the length of the cables. Using a piece of cord or sturdy twine about 1/2 the length of the torch cables, secure one end of the cord around all of the torch cables at the torch end and secure the other end of the cord to a stationary object. Remove the tape from the cable sleeving at the power source end of the cables. Push the switch out of the switch band and slide the handle, switch band and flex support to the far end of the cord used in step 4. Secure the power source end of the cables and pull the cable sleeving completely onto the cord. Untie the cord from the cables and replace the damaged cable or cables. Be sure to replace the rubber boot on the power cable. 3. 4. 5. Follow steps 1 through 3 of the section “Removal and Replacement of the Torch Head”. Clip the black and white leads of the old switch as close as possible to the red splice connections. Strip 1/4" of insulation from the black and white leads. Strip 1/4" of insulation from the new switch leads (P/N 18224). Attach the switch leads to the switch cable using the two new splice connections included with the replacement switch. Be sure to use a crimping tool made for crimping this type of splice connection. Reverse steps 1 through 3 of the section “Removal and Replacement of the Torch Head” to finish. 4.8 MEASURING TORCH GAS FLOWS If low gas flow is suspected of causing poor cutting performance or short consumable life, the flow can be checked by using Plasma Torch Flow Measuring Kit (P/N 19765). The kit includes a hand held rotameter (flowmeter) which will indicate the gas flow rate exiting the torch. The kit also includes a set of instructions which should be followed exactly to insure safe and accurate use of the rotameter. See form F-14-391. 28 section 4 MAINTENANCE PT-25 Air or Nitrogen Flow Rate should be as follows: ( cu. ft. per hr. +/- 25% ) @ 75 psig Nozzle Plasma Flow Cooling Flow Total Flow 100A 162 396 558 150A 180 372 552 Swirl Baffle - 21664 (4-slot) @ 45 psig Gouging 144 264 408 Measure the flow rates using a new 100 amp nozzle (21597), a new electrode (21595 or 21780) and a new heat shield (21654). Make sure that all parts are properly installed and that the torch o-ring (344019) is in good condition and not leaking. Measure the flows individually if possible. If not possible, measure the total flow. Low gas flow rates (lower than those given here) indicate a restriction or a leak in the gas plumbing of the torch or power source. Note: Gas flow rates are given for a "no arc" condition and are not representative of flow rates when the arc is on. Plasma flow will reduce to < 60 cfh in the "arc on" condition. Shield gas flow is not affected when the arc is on. 29 section 4 MAINTENANCE 30 section 5 5.1 REPLACEMENT PARTS General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 5.2 Ordering To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment. The use of non-ESAB parts may void your warranty. Replacement parts may be ordered from your ESAB Distributor. Be sure to indicate any special shipping instructions when ordering replacement parts. Refer to the Communications Guide located on the back page of this manual for a list of customer service phone numbers. Note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. 31 32 25 FT - 18450 50 FT - 18449 25 FT - 21783 50 FT - 21782 COOLING GAS / PILOT ARC CABLE FLEX SUPPORT - 21647 SLEEVING 25 FT - 995832 50 FT - 995826 SLEEVING (Ref.) 25 FT - 21854 50 FT - 21855 Push tubing securely into both ends of union. UNION - 2210735 SAFETY SENSOR TUBE Figure 5-1. Replacement Parts - PT-25 Torch Assembly RUBBER BOOT - 49N83 Tighten fittings at two (2) places using two (2) wrenches Torque 25-30 IN-LBS. SWITCH BAND - 21646 PLASMA GAS / POWER CABLE INCLUDES: 25 FT - 948188 50 FT - 948189 SWITCH - 18224 PLUG - 997758 CABLE - 18 AWG/2 COND. SWITCH & LEAD ASSY FRONT END PARTS - (See Fig. 3-3) (Includes O-Ring - 344019 and 14" of plastic tube.) TORCH HEAD 90O - 21625 HANDLE - 948177 section 5 REPLACEMENT PARTS notes 33 notes 34 revision history 1. The "A" edition was printed to cover changes in (Minimum Gas Flow Requirements) on page 3. 2. Revision B - Removed Min. Flow Rate Requirements values in note on Page 5 and added reference to Subsection 4.8. Added Flow Rate Chart to Subsection 4.8 on Page 17. 3. Revision B - 04/2005 - Added Swirl Baffle installation information on Pages 23 and 24 per Service Bulletin P_05_006. Added Safety section. 4. Revision C - 06/2010 - Added Section 2.2 Optional Accessories from PAC-21000A per cust serv dept. 35 ESAB Welding & Cutting Products, Florence, SC COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Order Entry Product Availability Pricing B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 Warranty Returns Authorized Repair Stations Hours: 7:30 AM to 5:00 PM EST Welding Equipment Troubleshooting C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Part Numbers Technical Applications Specifications D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Repair Estimates Repair Status F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Training School Information and Registrations Hours: 8:00 AM to 7:00 PM EST Order Information Returns Hours: 8:00 AM to 5:00 PM EST Equipment Recommendations Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 3:30 PM EST 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) 664-4452 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-
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ESAB PT-25 Plasma Arc Cutting Torch Manual de usuario
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- Sistema de soldadura
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