Instructions for
F-15-189-B
March, 2010
PLASMARC
Air Curtain Kits
tm
P/N 22018 for PT-15XL Heavy Duty (H. D.)
P/N 34752 for PT-19XL and PT-15XL Beveling
21856 Air Curtain Assembly
PT-15XL H.D.
WARNING
21549 Air Curtain Assembly
PT-19XL
The Air Curtain CAN NOT be used when using H-35 or CH4 gas
mixes. The water level must be lowered 4 to 6 inches beneath the bottom of the plate.
Failure to comply to this warning can result in a hydrogen detonation.
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 / Title
Page
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.0 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3
table of contents
4
section 1
safety precautions
1.0Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1.
Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2.The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3.The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, flame proof
clothing, safety gloves.
- Do not wear loose fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualified electrician.
- Appropriate fire extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered.
CAUTION
If equipment is placed on a surface that
slopes more than 15°, toppling over may occur. Personal injury and / or significant damage to equipment is possible.
5
Maximum
Tilt Allowed
15°
section 1
safety precautions
WARNING
WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and filter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
FIRE HAZARD
- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
CAUTION
This product is solely intended for plasma cutting. Any other
use may result in personal injury and / or equipment damage.
CAUTION
To avoid personal injury and/or equipment
damage, lift using method and attachment
points shown here.
6
Section 2
installation
ELECTRIC SHOCK CAN KILL!
WARNING
DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCHING OR SERVICING THE Air Curtain AT THE TORCH.
DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.
The Air Curtain is a device used to improve the performance of the PT-19XL and the PT-15XL Plasmarc Cutting Torches when
cutting underwater. Cut quality and speed are enhanced when using the Air Curtain with all the PT-19 cutting and with PT-15
oxygen/water injection cutting. Very minor improvements may be seen with nitrogen/water injection cutting.
P/N 19X19
25 ft.
50 ft.
75 ft.
100 ft.
125 ft.
1
7
SIMILAR TO
ADAPT B-A/W*F B-A/W*M
ASSY 90
FLORENCE, SC 29501
TITLE
DATE
RELEASED FOR
3
4
63
MICROINCHES
ANGLES
REMOVE ALL BURRS
BREAK SHARP EDGES
2
CHAMFERS & C'SINKS
2
SURFACE ROUGHNESS IS IN
.015
.005
.XX
.XXX
TOL
ENGLISH DWG
UNLESS OTHERWISE
SPECIFIED, DIM ARE
IN INCHES.
A
A
DESCRIPTION
NUT HOSE B/A-W* .63-18F RH OLD
NPL B/SIZE .425ODX 0.81LG
BODY FOR 90 AIR WATER ADAPTOR
RING SSBAG-1 0.438KDX.03D STD
QTY
1
1
1
1
1 pc
1 pc
1 pc
FINISH:
BRIGHT DIP PER SPI 45.315.3 METHOD 6
Adapt B-A/W*F B-A/W*M
90 deg assy
P/N 33253
P/N 33254
P/N 33255
P/N 33256
P/N 33257
2
Cable, 18 GA 3-Cond.
Cable, 18 GA 3-Cond.
Cable, 18 GA 3-Cond.
Cable, 18 GA 3-Cond.
Cable, 18 GA 3-Cond.
P/N 21549
P/N 33383
P/N 34033
1
Optional Accessories
Air Curtain Assy.
Control Box Assy.
Hose Assy., 50 ft.
P/N
836Z40
03Z59
19Z48
6270869
1 pc
1 pc
1 pc
PT-19XL Air Curtain Kit, P/N 34752
1.
2.
3.
4.
P/N 21856
P/N 33383
P/N 34033
THIS DRAWING CONTAINS PROPRIETARY CONFIDENTIAL INFORMATION OF ESAB WELDING
&
CUTTING PRODUCTS AND IS LOANED WITH THE EXPRESS AGREEMENT THAT THIS DRAWING
(1) WILL NOT BE REPRODUCED OR COPIED, (2) WILL NOT BE USED OTHER THAN IN WORK
FOR ESAB WELDING & CUTTING PRODUCTS, AND (3) WILL NOT BE DISCLOSED EXCEPT
TO EMPLOYEES OF THE PARTY TO WHOM THIS DRAWING IS LOANED ON A CONFIDENTIAL
BASIS.
Air Curtain Assy.
Control Box Assy.
Hose Assy., 50 ft.
A-19X19
PT-15XL H.D. Air Curtain Kit, P/N 22018
INEER DWG.
MATERIAL:
Compressed Air Supply
(Air Curtain)
Source: 80 psi @ 1200cfh
(5.5 bar @ 34 m3h)
Clean, dry & oil-free shop air
ESAB WELDING & CUTTING PRODUCTS
The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone,
even though the torch has been submerged to reduce noise, fume, and are radiation.
Section 2
installation
A.Installation of PT-15XL H. D. Air curtain Assembly on PT-15XL
1. Remove the brass Nozzle Retaining cup from the
torch.
2. Slide the chrome plated Air Curtain Body, P/N 21550
onto the stainless steel body of the torch.
NOTE: It will ease assembly if all o-rings in the air curtain
body are lightly lubricated with silicone grease
77500101 (5.3 oz.) or 17672 (1 oz.).
ALLEN
SCREW
3. Replace Nozzle Retaining Cup, P/N 20758, and any
front-end parts you may have removed from the
torch.
4.Tighten the Nozzle Retaining Cup securely on the torch,
then mark the cup with a felt tip marker or pen. Loosen
the cup 3/4 to 1 full turn.
5. Install the PT-15XL H. D. Air Curtain Sleeve (P/N 21859)
over the completely assembled torch and snap it into
the air curtain body. Secure the sleeve by installing the
Air Curtain Retainer, P/N 21553.
The Retainer turns to engage or disengage with the locking pins.
TORCH
RETAINING
CUP
6. Push the Air Curtain Assembly up on the torch until the
inside of the Air Curtain Sleeve, P/N 21859, bottoms
against the Nozzle Retaining Cup, P/N 29758. Lock the
Air Curtain Assembly in place by tightening the Allen
screw on the Air Curtain body.
.O40 - .062
7. Remove the Retaining Ring and Air Curtain Sleeve.
Tighten the Nozzle Retaining Cup, P/N 20758, securely.
Reinstall the Air Curtain Sleeve and the Nozzle Retaining Cup.
Figure 1. Air Curtain Installation on PT-15XL
There should now be a gap of .040 to .062 inches between the Nozzle Retaining Cup, P/N 20758, and the
inside of the Air Curtain Sleeve, P/N 21859.
8
Section 2
installation
B.Installation of Air Curtain Assembly on PT-15XL
with P/N 21378 Sleeve for Beveling with standard length nozzles.
1. Remove the brass nozzle Retaining Cup from the
torch.
2. Slide the chrome plated Air Curtain Body, P/N 21550,
onto the stainless steel body of the torch.
NOTE: It will ease assembly of all O-rings in the air
curtain body are lightly lubricated with silicone
grease; P/N 77500101 (5.3 oz.) or 176772 (1
oz.).
ALLEN
SCREW
3. Replace Nozzle Retaining Cup, P/N 20758, and any
front-end parts you may have removed from the torch,
tightening securely, then mark the cup with a felt tip
marker or pen. Loosen the cup 3/4 to 1 full turn.
4. Install an Air Curtain Sleeve, P/N 21378, over the
complete assembled torch and snap it into the Air
Curtain Body. DO NOT use the Air Curtain Retainer, P/N
21553.
5. Push the Air Curtain Assembly up onto the torch until
the inside of the Air Curtain Sleeve, P/N 21378, bottoms
against the Nozzle Retaining cup, P/N 20758. Lock the
Air Curtain Assy. in place by tightening the Allen screw
on the Air Curtain Body.
SLEEVE
P/N 21378
NOTE: The Air Curtain Sleeve must remain completely
bottomed in the Air Curtain Body for the adjustment in step 5 to be correct.
.O40 - .062
6. Remove the Air Curtain Sleeve. Tighten the Nozzle
Retaining Cup 20758 securely. Reinstall the Air Curtain
Sleeve. There should be a gap of .040 to .062 inch between the inside of the Air Curtain Sleeve P/N 21378
and the Nozzle Retaining Cup, P/N 20758.
Figure 2. Air Curtain Installation on PT-15XL
(For Beveling with standard length nozzles)
9
Section 2
installation
C.Installation of Air Curtain Assembly on PT-19XL
or PT-15XL using Long Beveling Nozzles (Figure
3).
1. Remove the plastic nozzle Retaining Cup from the
torch.
PT-19XL or PT-15XL
Torch Body
BUSHING
2. Slide the chrome plated Air Curtain Body, P/N 29550,
onto the stainless steel body of the torch.
BODY
NOTE: It will ease assembly if all O-rings in the air
curtain body are lightly lubricated with silicone
grease.
AIR
INLET
3. Replace Nozzle Retaining Cup, P/N 34085, and any
front-end parts you may have removed from the torch.
Do not replace the heat shield, P/N 948186.
RETAINING
NUT
4. Install an Air Curtain Sleeve, P/N 12551, over the completely assembled torch and snap it into the Air Curtain
Body. Secure the sleeve by installing the air curtain
Retainer, P/N 21553. The Retainer turns to engage or
disengage with the locking pins.
REMOVE HEAT SHIELD,
SET DIMENSION @
.10, SET PRESSURE @
20 PSIG
5. Adjust the position of the Air Curtain Assembly on the
torch until the nozzle is recessed 0.10 inch from the end
of the air curtain sleeve as illustrated in Fig. 1. Lock the
Air Curtain in place by tightening the Allen screw on
the Air Curtain.
.10 INCH
Figure 3. Air Curtain Installation
On PT-19XL or PT-15XL Bevel
NOTE: The Air Curtain Sleeve must remain completely
bottomed in the Air Curtain Body for the adjustment in step 5 to be correct.
D.Installation of the Control Box Assembly (P/N 3383)
1. Mount the control box at a convenient location and use the hose supplied to connect the box with the unit mounted
on the torch.
2. Connect the control box to a source of oil free shop air capable of delivering at least 20 scfm at 80 psig. The hose used
should be at least 3/8" ID.
3. Use the SJO wire supplied to connect the control to the cutting machine control. If the ESP system is used, then the
connection may be made to the appropriate amphenol connector on the back of the flow control. The connection
of the control is made at the terminals marked F. C. An appropriate cable may be selected from the table of optional
accessories.
4.The user supplied 115 V ac may be connected to the terminals so marked. This will allow manual operation of the air
curtain control.
5. Connect a ground wire to the stud provided in the control box.
10
Section 3operation
E. Operation
1. Provide control box will oil free air at 80 psig minimum. Energize solenoid in control box and adjust regulator screw
on box to 20 psig delivery.
2. Place switch to AUTO. The system should turn on when the preflow begins.
F. PT-19 Operation Notes
Cutting standoff (Torch to Work Distance) must now be measured from the bottom of the Air Curtain Sleeve. This distance
is approximately 1/4".
NOTE: If piercing thick plate, increase standoff to 0.400" for 1/2" thick plate, 0.650" for 3/4" thick plate. Then return to 1/4" standoff
after completing the pierce and you are ready to cut.
Electric shock can kill. Disconnect power to power source before touching or servicing the air curtain at the torch.
Disconnect power to the control box before servicing.
11
Section 3operation
12
Section 4
replacement parts
5
4
1
1
7
6
3
5
2
2
3
Figure 4. Air Curtain Assembly, P/N 21549 for use W/ PT-19XL
and PT-15XL With Long Beveling Nozzle
ITEM
NO.
QTY
REQ.
PART
NO.
DESCRIPTION
1
2
3
4
5
6
7
1
1
1
1
1
2
1
21550
21551 21553
21380
2221978
21214 85W87
BODY, AIR CURTAIN
SLEEVE, AIR CURTAIN
RETAINER, AIR CURTAIN
BUSHING, SPLIT
'O' RING, 1.799ID X .103 SILICON, 60A
‘O’ RING, 2.484ID X .139 NEOPR, 70A
‘O’ RING, 1.984ID X .070 NEOPR, 70A
Note: Some spare o-rings are supplied with the Air Curtain assembly 21549
13
Section 4
replacement parts
4
4
1
7
1
6
3
5
8
2
2
5
3
Figure 5. H.D. Air Curtain Assembly, P/N 21856 for use W/ PT-15XL
ITEM
NO.
QTY
REQ.
PART
NO.
DESCRIPTION
1
1
21550
BODY, AIR CURTAIN
2
1
21859 SLEEVE ASSY, AIR CURTAIN
3
1
21553
RETAINER, AIR CURTAIN
4
1
21380
BUSHING, SPLIT
5
1
2221978
"O" RING, 1.799 ID X .103 SILC 60A
6
2
21214
"O" RING, 2.484 ID X .139 NEOPR, 70A
7
1
85W87
"O" RING, 1.984 ID X .139 NEOPR, 70A
8
1
952062
"O" RING. 1.989 ID X .070 NEOPR, 70A
NOT SHOWN, 1PC P/N 21378 SLEEVE BEVELING AIR CURTAIN
Note: Some spare o-rings are supplied with the Air Curtain assembly 21856
14
Section 4
replacement parts
8*, 9
6
4
7
10
11
1
5
3
2
*AIR REGULATOR AND PRESSURE GAGE ARE SUPPLIED TOGETHER AS ITEM 8. REGULATOR W/GAGE P/N 522368.
Figure 6. Air Curtain Control Box Assembly
ITEM NO.
QTY
REQ.
PART
NO.
1
2
3
4
5
6
7
8
9
10
11
2
1
1
2
2
1
1
1
2
1
1
8180W38 CONNECTOR, STRAIN RELIEF
951041TERMINAL, BLOCK, 4 POSITIONS
636702
SWITCH, DPDT 3 POSITIONS
858775
ADAPT. BULKHD. B SIZE, 1/4 NPT
182W82
ELBOW, STREET 90 BRASS
636387
SOLENOID VALVE
67101075
NIPPLE, CLOSED, 1/4 NPT BR. M TO M
522368
REGULATOR W/GAGE
60101025
PLUG, 1/8" NPT ALLEN HEAD
67100081 NIPPLE, 2"LG. 1/4NPT BRASS M TO M
68161103TEE, 1/4 NPT BRASS
15
DESCRIPTION
Section 4
replacement parts
CONTACT RING ASS'Y,
Includes: Setscrew, No. 6-32 X 3/16 lg. (Cup Point)
Screw, No. 6-32 X 1/2" lg.
Note:
All Set Screws Are Stainless Steel & Should Only Be
Replaced With Stainless Steel or Brass Screws.
13
8
12
11
O-RING - 996527
6
5
4
10
3
9
O-RING - 2064106
(1-5/16" I.D.)
2
NOT SHOWN:
O-RING - 86W85 (1/2" I.D.)
(2) O-RING - 996526 (5/32" I.D.)
Figure 7. PT-15XL Plasmarc Cutting Torch For Bevel Cut
ITEM NO.
2
3
4
5
6
8
9
10
11 12
13
QTY
REQ.
PART
NO.
DESCRIPTION
1
1
1
1
1
1
1
2
1
1
1
35570 21962
35886
34084
35660
996341
20755
996528
996242
20754 19483
CUP, NOZZLE RETAINING
NOZZLE PT-15 O2 BEVEL - 21963 REVERSE
ELECTRODE, HF
ELECTRODE HOLDER ASSY
8 X.047 HOLE BAFFLE, GAS SWIRL, CERAMIC - 35661 REVERSE
CONTACT RING ASSY
INSULATOR ASSY, FRONT BODY
O-RING
LOCATING PIN
REAR MAIN BODY ASSY
SLEEVE
OXYGEN - SET O2 FLOW AT 100 SCFH 100PSI SUPPLY
WATER - SET WATER FLOW AT 0.51 GPM
INLET TO TORCH PRESSURE - 35-42 PSI AT TORCH - CUTTING
15-20 PSI AT TORCH - STARTING
16
NOTES
17
NOTES
18
revision history
Revision 03/2010 - added 19X19 to optional accessories.
19
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
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
Part NumbersTechnical Applications
Specifications
Hours: 8:00 AM to 5:00 PM EST
Equipment Recommendations
D.
LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548
Hours: 7:30 AM to 4:00 PM EST
E.
WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557
Repair Estimates Repair Status
Hours: 7:30 AM to 3:30 PM EST
F.
WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations
Hours: 7:30 AM to 4:00 PM EST
G.
WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H.TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070
Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
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F15-189-B
03/2010