INSTRUCTIONS for
ADAPTOR KIT
PT-15XL TORCH TO HYPERTHERM PLASMA SYSTEM
P/N 17517
F-12-995-A
October, 1995
This kit permits connecting a plasma arc cutting torch to a
Hypertherm plasma arc system. The standard PT -15XL torch
(P/N 20762) may be used, but the service lines and sleeve
(or barrel) supplied with the torch is not used. A basic PT15XL torch that is supplied without service lines and sleeve is
available under P/N 16365, and made particularly for use with
this kit for connecting to a Hypertherm system.
These torches sre supplied with a nozzle assembly for 400
amps, N2 cutting. See Form F-15-031-B, "Instructions for PT15XL Plasma Arc Cutting Torch", which is packed with each
torch, and select the desired nozzle assembly. Also, read
and follow the installation instructions of the nozzle assembly
covered in Form F-15-031-B.
This adaptor kit (P/N 17517) containes the following components:
1 — Adaptor, Water Injection ................................ P/N 17501
1 — Adaptor, Water-In .......................................... P/N 17503
1 — Adaptor, Water-Out ....................................... P/N 17504
A nozzle ret aining cup (20793) without feet is available which
may work better with some Hypertherm installations.
INSTALLATION
If using the standard PT -15XL torch (20762), refer to Form F15-031-B, and remove the following components.
1. Remove clamp (996565) and boot hose (996647).
2. Unscrew sleeve (19483) and slide it back along with the
bushing (996342) far enough to clear the service line
connections.
3. Disconnect the service lines, and remove them (including
the pilot arc cable) from torch.
Y ou are now left with the basic torch assembly like P/N 16365.
To assemble the kit to the basic torch assembly (16365), pro-
ceed as follows (see Fig. 1 and Form F-15-031-B):
1. Connect the two 4-in. long adaptors (17503) and (17504) to
the short "watrer-in" and "water-out" fittings on the torch
body. Note that the "water-in" connection has left-hand
threads. Tighten the connecting nuts firmly with a wrench.
2. Connect the short adaptor (17501) to the long "WaterInjection" fitting on the torch body. Tighten the connection
firmly with a wrench.
Before installing the adaptor kit, make sure that all input
power to the system is deenergized (OFF).
INSULATOR - 20409
Water
Out
Water
Injection
ADAPTOR - 17504
Gas Hose
Connection
Water-In
Fig. 1 - Adapting PT-15XL Torch to Hypertherm Plasma System
RED BAND
ADAPTOR - 17501
GREEN BAND
ADAPTOR - 17503
Be sure this information reaches the operator.
You can get extra copies through your supplier.
3. Thread the hoses nad cables from the Hyperthern system
through the torch sleeve and then connect them to the
proper torch and adaptor fittings on the torch body. Tighten
all connections firmly using two wrenches.
HYPERTHERM
SERVICE LINES
RED
BAND
RED
SLEEVE - 17499
GREEN
GREEN
BAND
4. Cut the end of the Hypertherm pilot arc cable and strip
the insulation off 1/2" of wire.
6. Slide the HF connection insulator back over the HF
connector and secure with vinyl tape.
5. Slide the high freq. (HF) connection insulator (P/N
7. Assemble the sleeve to the torch body.
20409) over the stripped wire and insert the wire into
the H.F. connector (P/N 20408). Tighten the setscrew.
8. Install the desired nozzle assembly as directed in
Form F-15-031-B.
See Table 1 and 2 for operating data.
Table 1 - PT-15XL/Hypertherm Operating Data (Above Water)
PT-15XL
Nozzle Ass'y.
P/N
(orif. dia.)
2075961
(0.125 in.)
2075611
(0.156 in.)
2075612
(0.200 in.)
2075613
(0.230 in.)
Cut Gas (Nitrogen)
(Arc Off)
Current
Amps
250
400
600
750
Flowmeter
Reading
(110 cfh)
(140 cfh)
(180 cfh)
(220 cfh)
36%
42%
52%
62%
Cut Water
Flowmeter
Reading
(Arc On)
45%
(0.25 gpm)
63%
(0.33 gpm)
80%
(0.4 gpm)
100%
(0.5 gpm)
Standoff
(Torch-
to-work
distamce)
1/4-in.
3/8-in.
1/2-in.
5/8-in.
Plate
Thickness,
Inches
1/32
1/16
1/8
3/16
1/4
3/8
1/16
1/8
3/16
1/4
3/8
1/2
3/4
1
1/2
3/4
1
1-1/2
2
3/4
1
1-1/2
2
3
*Cutting speeds given are average. They may vary depending on material composition, surface conditions, etc. Practice cuts in
scrap area of new materials are recommended before starting cuts on production work.
Cutting Speed,
Inches Per Minute*
Stainless
Mild
Steel
500
350
265
200
140
——
450
330
250
160
135
110
60
35
130
75
65
33
22
90
75
40
28
13
Steel
550
385
290
220
255
——
490
360
280
180
145
120
140
70
50
80
75
36
24
98
80
44
30
14
Aluminum
600
400
340
270
200
180
500
400
320
240
210
170
110
60
190
130
100
50
38
——
——
——
45
30
Underwater Cutting Notes:
1. When cutting plates up to 1-in. thick under water, cutting speed and cut surface appearance are not appreciably affected.
Therefore, the above data given for cutting plates up to 1-in. thick are suitable for both normal and underwater cutting.
2. Cut quality and cutting speed diminish when cutting from 1 to 3 in. thick materials underwater, particulary aluminum. The 0.230
in. nozzle assembly (P/N 2075613) is not recommended for cutting aluminum underwater; however, the 0.200 in. nozzle
assembly can be used for cutting up to 3 in. thick aluminum and still obtain a reasonable appearing cut. The approximate cutting
speeds for underwater cutting of materials from 1 to 3 in. thick are given in Table 2 (current, pressure, flow, and standoff settings
of eash nozzle are the same as given above in Table 1, except where noted).
Table 2 - Underwater Cutting of Thick Materials
Cutting Speed,
Inches Per Minute*
Mild
Steel
50
30
15
——
——
35
20
8
Stainless
Steel
65
33
18
——
——
35
20
8
Aluminum
80
50
35
28*
20*
——
——
——
Nozzle Ass'y.
P/N 2075612
(0.200 in.orif.)
P/N 2075613
(0.230 in.orif.)
*Use 5/8-in. standoff.
F-15-995-A 9/95 1C Printed in U.S.A.
Plate
Thickness,
Inches
1
1-1/2
2
2-1/2
3
1-1/2
2
3
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