ESAB Bubble Muffler System Instruction manual

BUBBLE MUFFLER SYSTEM

For use with m3 Plasma System
and the PT-36 Plasma Torch
ESAB Assembly Number: 37439

Instruction Manual

THE BUBBLE MUFFLER CAN NOT BE USED WHEN USING H35 OR CH
GAS MIXES. THE WATER LEVEL MUST BE LOWERED 4 TO 6 INCHES BE

WARNING

0558006722 08/2011

NEATH THE BOTTOM OF THE PLATE.

FAILURE TO COMPLY TO THIS WARNING CAN RESULT IN A HYDROGEN
DETONATION.

4

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!

TABLE OF CONTENTS

Section / Title Page

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

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

3.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

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, ame proof
clothing, safety gloves.

- Do not wear loose tting 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 qualied electrician.

- Appropriate re 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 nger, 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 signicant dam­age to equipment is possible.

Maximum

Tilt Allowed

15°

5

SECTION 1 SAFETY PRECAUTIONS

WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR

WARNING

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 lter lens and wear
protective clothing.

- Protect bystanders with suitable screens or curtains.

YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.

FIRE HAZARD

- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.

NOISE - Excessive noise can damage hearing.

- Protect your ears. Use earmus 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!

This product is solely intended for plasma cutting. Any other

CAUTION

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

DATE

RELEASED FOR

ENGLISH DWG

TITLE

REPRO MADE FROM

SIMILAR TO

SUP.

SUP. BY

APPROVED

BY

DATE

CHECKED

BY

DATE

DRAWN

BY

DATE

SCALE

FIRST MADE FOR

ESAB WELDING & CUTTING PRODUCTS

FLORENCE, SC 29501

UNLESS OTHERWISE

SPECIFIED, DIM ARE

IN INCHES.

TOL .XX

.XXX

ANGLES

CHAMFERS & C'SINKS 2

SURFACE ROUGHNESS IS IN

REMOVE ALL BURRS

BREAK SHARP EDGES

MICROINCHES

CHANGE

BY

DATE

CH'KD

TO EMPLOYEES OF THE PARTY TO WHOM THIS DRAWING IS LOANED ON A CONFIDENTIAL BASIS.

A-

.015

.005

PRO/ENGINEER DWG.

NOV.1994

A

A

19X19

ADAPT B-A/W*F B-A/W*M 90ASSY

BLP

10/23/08

63

2

1:1

FINISH:

BRIGHT DIP PER SPI 45.315.3 METHOD 6

P/N QTY DESCRIPTION

1. 836Z40 1 NUT HOSE B/A-W* .63-18F RH OLD

2. 03Z59 1 NPL B/SIZE .425ODX 0.81LG

3. 19Z48 1 BODY FOR 90 AIR WATER ADAPTOR

4. 6270869 1 RING SSBAG-1 0.438KDX.03D STD

"E" CN-083187 REVISED & RED BLP

WSS10/23/08

WSS

10/23/08

WSS

10/23/08

1

2

3

4

ELECTRIC SHOCK CAN KILL!

DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH-

WARNING

ING OR SERVICING THE BUBBLE MUFFLER AT THE TORCH.

DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.

The Bubble Muer System creates a bubble of air so that a Plasmarc
Cutting Torch can be used underwater with slight sacrice of cut
quality. This system also permits operation above water as the ow of
water through the muer reduces fume, noise, and arc U.V. radiation.

Compressed Air Supply

(Air Curtain)

Source: 80 psi @ 1200cfh

(5.5 bar @ 34 m3h)

Clean, dry & oil-free shop air

Bubble Muer System

Bubble Muer PT-19XLS P/N 37439 1

Strainer P/N 2133340 1

Water Pump P/N 2135445 1

Adaptor, 1.06-12F 3/4" Hose P/N 2135571 3

Adaptor, 3/4" NPTM, 3/4" Hose P/N 2135572 1

PIP, Pipe S.ST 2.357X2.00 CL P/N 43350490 1

Bushing Pipe 2X3/4 P/N 44056390 1

Optional Accessories

Control Box Assembly P/N 33383 1

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

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

Control Cable, 18 GA, 3-Cond

P/N 33255 75 ft.

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

Control Cable, 18 GA, 3-Cond P/N 33257 125 ft.

Fittings 3/8" Hose Control Box
B-Air/ Nut
3/8" ID Hose Nipple

Fittings 3/8" Hose to Bubble
Muer
R.H. Air Nut
3/8" ID Hose Nipple

Hose, 3/4" ID for Water P/N 2027202 Specify

Hose, 3/8" ID for Air P/N 23079995 Specify

Adapt B-A/W*F B-A/W*M 90 deg
assy

P/N 10N40 1

P/N 347995 1

P/N 36Z40 1

P/N 03Z74 1

Length

Length

P/N 19X19 1

7

SECTION 2 INSTALLATION

A. Installation of Bubble Muer Assembly on Plasma Torch (Figure 2)

1. Remove the Nozzle Retaining Cup from the torch.

2. Slide the chrome plated Bubble Muer Body on to the stainless steel body of the torch. Split Bushing P/N 21380 should
be in place.

NOTE:

It will ease assembly if all o-rings in the bubble muer body are lightly lubricated with silicone grease.

3. Install Nozzle Retaining Cup P/N 37431 and any front-end parts you may have removed from the torch including the
nozzle, shield, diuser and shield retainer.

4. Install Bubble Muer Sleeve over the completely assembled torch and snap it into the Bubble Muer Body. Secure
the sleeve by installing the Bubble Muer Retainer. The Retainer turns to engage or disengage with the locking pins.

5. Adjust the position of the Bubble Muer Assembly on the torch until the nozzle extends 0.06" from the end of the
bubble muer sleeve as illustrated in Figure 1. Lock the Bubble Muer in place by tightening the Allen screw on the
Bubble Muer.

NOTE:

The Bubble Muer Sleeve must remain completely bottomed in the Muer Body for the adjustment in

Step 5 to be correct.

8

SECTION 2 INSTALLATION

B. Installation of the Water Pump (P/N 2135445)

IF A BUBBLE MUFFLER IS BEING USED, TURN OFF WATER RECIRCU

WARNING

LATING PUMP.

0.75" ID
Hose

m3

Plumbing

Box

Torch

Bubble Muer

Pump

Water

Control Cable

Appropriate Amphenol

Connector On Back

Cutting Machine CNC

Figure 1. Installation of Water Pump

Bubble Muer Pump Input Voltage

50 Hz Operation of ESAB
60 Hz Motors

Water

Table

StrainerInlet

Pump

Power

To On
Use

60 50 Hertz
Hertz Operational Voltage
Motor Ratings +5%

230 V 190 V 200 V 208 V

460/575 V 380 V 400 V 415 V

Multiply
Nameplate .70 .75 .80
HP By

9

SECTION 2 INSTALLATION

25 Micron

Note:

For a complete listing of all available
lengths and part numbers for bubble
muer hose assemblies refer to m3

plasma system instruction manual.

Filter

See Detail "D"

Shield Gas Box

Bubble Muer Hose

Plasma Gas Box

Compressed Air Supply

(Air Curtain)

Source: 80 psi @ 1200cfh

(5.5 bar @ 34 m

Use clean, dry, oil free shop air

See Detail D for location of air
pressure regulator / gauge

See Detail "C"

See Detail "B"

3

h)

Earth

Ground

Torch

Lead

Plasma Torch

See Detail "A"

Bubble Muer Hose

Bubble Muer Assembly
37439

Workpiece

Work Table

10

SECTION 2 INSTALLATION

Detail "A"

Note:

For Bubble Muer hose assembly con­nector details refer to m3 plasma sys-

tem instruction manual.

Torch Leads

For torch lead connection details re­fer to m3 plasma system instruction

manual.

Bubble Muer Connection

(to air curtain assembly)

Plasma Gas Box 0560941491

Detail "B"

11

Bubble Muer

Connection

SECTION 2 INSTALLATION

Detail "C"

Note:

For Bubble Muer hose assembly con­nector details refer to m3 plasma sys-

tem instruction manual.

Bubble Muer Connection

Air Pressure

Gauge

Shield Gas Box 0560941536

Air Pressure Regulator

Remove outer enclosure and

adjust between 18-22 psi

(1.2-1.5 bar)

Bubble Muer Connection

(air supply)

12

Detail "D"

SECTION 3 REPLACEMENT PARTS

Replacement Parts for Bubble Muer - P/N 37439

Torch Body (Ref.)

1

10

2

5

6

7

3

8

4

9

0.06" Ref.

Figure 2 - Bubble Muer

Item Part Number Description

1 21380 BUSHING SPLIT BEVEL A/C

2 37438 BODY A/C

3 37433 RETAINER BUBBLE MUFFLER

4 37431 CUP NOZZLE RETAINING

5 519369 O-RING, 3" ID X 3-3/16" O.D. X 3/32"

6 443315 O-RING, 2.612 ID X .103W NEOPRENE

7 2221978 O-RING, 1.799 ID X .103W SILICONE RUBBER

8 2114581 O-RING, 2.114 ID X .070W NEOPRENE 70A

9 37436 SLEEVE PT-19XLS A/C

10 0558009395 SHIELD RETAINER, INSULATED

11 996528 O-RING, 1.984 ID X .139W NEOPRENE

NOTE: 4 each of the above o-rings are supplied.

13

NOTES

14

REVISION HISTORY

Revision 03/2010 - added 19X19 to optional accessories.
Revision 08/2011 - Updated BOM's, changed p/n 0558004616 to p/n 0558009395 per CCARES 110608095137.

15

ESAB Welding & Cutting Products, Florence, SC

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:
Telephone: [phone] / Fax: [phone] Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:
Telephone: [phone] / Fax : [phone] 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: [phone] Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations

D. LITERATURE REQUESTS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:
Telephone: [phone] / Fax: [phone] Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING
Telephone: [phone] / Fax: [phone] 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 : [phone] Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123

Fax: [phone]

Hours: 7:30 AM to 5:00 PM EST

or

visit us on the web at http://www.esabna.com

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