ESAB Air Curtain Kit Troubleshooting instruction

INSTRUCTIONS for

F-15-128

October, 2006

Air Curtain Kit

Standard, P/N 21385

Beveling, P/N 21404

The Air Curtain is a device used to improve the performance
of the PT-15XL Plasma Arc Torch when cutting underwater.
Cut quality and speed are enhanced when using the Air
Curtain with oxygen/water-injection cutting. Very minor im­provements may be seen with N2/water-injection cutting.

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 arc radiation.

Air Curtain Kit

Air Curtain Assy, Standard or
Air Curtain Assy, Beveling

Control Box Assy P/N 33383 1

Hose Assy, 50 ft. P/N 33133 1

Optional Accessories

Cable, 18 GA 3-Cond P/N 33253 25 ft.

Cable, 18 GA 3-Cond P/N 33254 50 ft.

Cable, 18 GA 3-Cond P/N 33255 75 ft.

Cable, 18 GA 3-Cond P/N 33256 100 ft.

Cable, 18 GA 3-Cond P/N 33256 125 ft.

P/N 21212
P/N 21377

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 BE

WARNING

NEATH THE BOTTOM OF THE PLATE.

Compressed Air Supply

(Air Curtain)

1
1

Source: 80 psi @ 1200cfh

(5.5 bar @ 34 m3h)

Clean, dry & oil-free shop air

FAILURE TO COMPLY TO THIS WARNING CAN RESULT IN A HYDRO
GEN 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.

2

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

3

TABLE OF CONTENTS

4

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety 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.

5

SECTION 1 SAFETY PRECAUTIONS

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!

6

SECTION 2 INSTALLATION

A. Installation of Air Curtain Assembly on PT-15XL

(Figure 1).

1. Remove the brass nozzle Retaining Cup from the

ALLEN
SCREW

torch.

2. Slide the chrome plated Air Curtain Body, P/N 21213,
onto the PT-15XL and about 1/2 inch up the torch sleeve
(handle). The Beveling Air Curtain body mounts 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.

.040 - .060

Figure 1. Air Curtain Installation

TORCH
RETAINING
CUP

3. Replace beveling nozzle Retaining Cup, P/N 21377, and
any front-end parts you may have removed from the
torch.

4. Install an Air Curtain Sleeve, P/N 21211, over the com­plete assembled torch and snap it into the Air Curtain
body.

5. Adjust the position of the Air Curtain Assembly on
the torch until a gap of between .040 and .060 inch
is obtained between the Air Curtain sleeve and the
Nozzle Retaining Cup. Lock the Air Curtain in place by
tightening the Allen screw on the Air Curtain Body.

NOTE

The Air Curtain Sleeve must remain completely bottomed
in the Air Curtain Body for the adjustment in step 5 to be
correct.

After tightening the Allen screw in the Air Curtain Body, the
gap between the sleeve and torch cup should be nearly
uniform all the way around.

7

SECTION 2 INSTALLATION

B. Installation of the Control Box Assembly (P/N 33383).

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.

8

SECTION 3 OPERATION

C. Operation.

1. Provide control box with oil free air at 80 psig minimum. Energize solenoid in control box and adjust regulator screw
on box to 30 psig delivery.

2. Place switch to AUTO. The system should turn on when the preflow begins.

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.

D. Servicing.

Refer to Figure 2 for air curtain O-ring part numbers and Figure 3 for air curtain box assembly component part numbers.

9

SECTION 3 OPERATION

10

SECTION 4 REPLACEMENT PARTS

5

3

2

Figure 2. Air Curtain Assembly, P/N 21212

ITEM QTY. PART
NO. REQ. NO. DESCRIPTION

1

4

1 1 21213 AIR CURTAIN BODY (INCLUDES 2, 3, 5)
2 2 21214 O-RING, PARKER 2-230, 2.484 ID X .139 WALL
3 1 85W87 O-RING, 1.98 ID X .139 WALL
4 1 21211 SLEEVE
5 1 #10-32 X 3/4" SCKT HD CAPSCREW, S. STL

11

SECTION 4 REPLACEMENT PARTS

3

Figure 3. Beveling Air Curtain Assembly, P/N 21377

ITEM QTY. PART
NO. REQ. NO. DESCRIPTION

1 1 21379 AIR CURTAIN BODY, BEVELING
2 1 21378 SLEEVE
3 1 21380 BUSHING, SPLIT FOR BEVELING AIR CURTAIN

1

2

12

SECTION 4 REPLACEMENT PARTS

8*, 9

4

5

* Air regulator and pressure gauge are supplied together as item 8. Regulator w/gauge P/N 522368

6

7

3

Figure 4. Air Curtain Control Box Assembly

10

11

1

2

ITEM QTY. PART
NO. REQ. NO. DESCRIPTION

1 2 180W38 CONNECTOR, STRAIN RELIEF
2 1 951041 TERMINAL, BLOCK, 4 POSITIONS
3 1 636702 SWITCH, DPDT 3 POSITIONS
4 2 58V75 ADAPT. BULKHD. B SIZE, 1/4 NPT
5 2 182W82 ELBOW, STREET 90° BRASS
6 1 636387 SOLENOID VALVE
7 1 67101075 NIPPLE, CLOSED, 1/4 NPT BR. M TO M
8 1 522368 REGULATOR W/GAUGE
9 2 60101025 PLUG, 1/8" NPT ALLEN HEAD
10 1 67100081 NIPPLE, 2" LG. 1/4 NPT BRASS M TO M
11 1 68161103 TEE, 1/4 NPT BRASS

13

SECTION 4 REPLACEMENT PARTS

NOTES

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

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or

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F15-128 10/2006