ESAB ESP-1000 Plasmarc System Instruction manual

INSTRUCTION MANUAL

ESP - 1000 PLASMARC SYSTEM

MECHANIZED CUTTING WITH PT-15XL OR PT-19XLS

F15-116-D 07/2007

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
PARAGRAPH

SAFETY PRECAUTIONS .....................................................................................................................................5

SECTION 1 INTRODUCTION ...................................................................................................................17

1.1 General ................................................................................................................................................................... 17

1.2 Features .................................................................................................................................................................. 17

1.3 Component Description ..................................................................................................................................18

SECTION 2 INSTALLATION ......................................................................................................................23

2.1 General ................................................................................................................................................................... 23

2.2 System Component Location ......................................................................................................................... 23

2.3 System Connections ..........................................................................................................................................24

2.4 Torch Components ............................................................................................................................................. 30

2.5 Installing Air Curtain ..........................................................................................................................................31

2.6 Bubble Muer Installation .............................................................................................................................. 32

2.7 WATER MUFFLER SYSTEM FOR THE PT-19XLS .......................................................................................... 33

2.8 AIR CURTAIN/BUBBLE MUFFLER CONTROL BOX INSTALLATION ........................................................ 33

2.9 WATER INJECTION PUMP .................................................................................................................................33

2.10 INSTALLATION OF THE SECONDARY GAS METERING BOX ...................................................................34

SECTION 3 OPERATION.......................................................................................................................................................... 39

3.1 General ................................................................................................................................................................... 39

3.2 Controls and Indicators .................................................................................................................................... 39

3.3 Pre-Operation Test and Checkout ................................................................................................................41

3.4 Oxygen Cutting with PT-15XL ........................................................................................................................ 44

3.5 Nitrogen Cutting with PT-15XL ......................................................................................................................49

3.6 H-35 Cutting with PT-15XL .............................................................................................................................. 51

3.7 CUTTING WITH THE PT-19XLS and PT-600 TORCHES ............................................................................ 52

3.8 High Current Cutting with PT-19XLS ...........................................................................................................55

PT-19XLS Cutting Tables ................................................................................................................................... 56

3.9 Operating Techniques ....................................................................................................................................... 70

SECTION 4 TROUBLESHOOTING ....................................................................................................................................... 75

4.1 Programmable Logic Controller ....................................................................................................................75

4.2 Sequence Description ....................................................................................................................................... 75

4.3 Operating Information......................................................................................................................................77

4.4 Troubleshooting Guide .................................................................................................................................... 78

3

TABLE OF CONTENTS

4

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 tted with the correct lter 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 ameproof gauntlet type gloves, heavy

long-sleeve shirt, cuess 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 protection against radiated
heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, 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.

Safety - English

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 pro­tective 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
hidden 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 work piece has been completely cleaned so
that there are no substances on the work piece
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
example, 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 Protection Association, Battery march 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 conned, or if there is danger
of falling.

5

SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con­nected to the ground system of the input power.

2. Connect the work piece to a good electrical
ground.

3. Connect the work cable to the work piece. 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.

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 work piece 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 conned spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda­tions. Do not mistake the work lead for a ground
cable.

ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur­rent owing 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 eects which

are unknown.

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 specic ventilation recommendations.

6

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 ttings in good
condition. Follow manufacturer's operating instruc­tions for mounting regulator to a compressed gas
cylinder.

1. Always have qualied personnel perform the instal­lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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 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 con­nected. 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 Jeerson Davis Highway,
Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

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.

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

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

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 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 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 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 totalmente
limpia y libre de substancias que puedan producir
gases inamables o vapores tóxicos. No trabaje den­tro o fuera de contenedores o tanques cerrados. Estos
pueden explotar si contienen vapores inamables.

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
connado en lugares estrechos o si hay

posibilidad de caer al suelo.

9

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 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 especícas 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 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 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 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 per­siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen­daciones especícas en la ventilación.

10

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

1. Siempre tenga personal cualicado para efec­tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado 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 modique 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"

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

11

SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig­nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Signica el posible riesgo que
puede resultar en menores daños
a la persona.

12

SÉCURITÉ

Safety - French

AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection.
Ils récapitulent les informations de pré-

caution 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
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 an 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 an 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 ininammable an 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 ininammable.

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.

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 susamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. 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 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 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 inammables 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'ex tinction
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 surchauer 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

SÉCURITÉ

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 an 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 eectuer 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
spéciques 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 conduc-

teur 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 magné-

tiques peut avoir des eets néfastes inconnus pour
la santé.

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 ecaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'eectuez 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 an
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 spéciques
concernant la ventilation.

14

SÉCURITÉ

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 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 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
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 dis­position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.

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 qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.

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
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 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'eectuez aucune modication.

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

SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures
corporelles mineures.

Additional Safety Information for Mechanized Plasmarc Cutting Systems:

Electrical Shock can kill or cause severe burns. Plasmarc cutting uses DC currents at dangerously high voltages.

• DonottouchthetorchorchangetheconsumablesifinputpowertothePlasmarcpowersourcehasnotbeendiscon­nected.

• Donotstandon,touch,orinanywaycontacttheplatewhilecuttingvoltagesarepresent.

• Theworkpiecemustbeelectricallyconnectedtothepowersourceworkterminalforsafeoperationofthesystem.

• Donotperform maintenanceonanypart of the Plasmarc systemunlessall powerinputshavebeendisconnected

and locked out. This includes 115vac inputs as well as high voltage inputs.

• Troubleshootingrequiringpowertobeonshouldonlybedonebyqualiedpersonnel.

Hydrogen Explosions can cause injury or death.

• Seepage?????.

Fumes and Gases can cause discomfort or death. Do not breath fumes or gases.

• Donotcutcontainersoftoxicmaterialsorcontainersthathaveheldtoxicmaterials.Cleansuchcontainersthorough­ly before cutting.

• Beforecuttingacoatedmaterial,consultwithitsmanufacturerforpropersafetyprecautions.

Noise and Ultraviolet Light

• Thenoiselevelofplasmarccutting can be greater than110dbatadistanceof6feetfromthetorch.Wearproper

hearing protection.

• Reectionofultravioletlightfromareaswallsclosetothecuttingarccanbeminimizedbyselectingpaintshavinga

high percentage of ZnO and TiO2 pigments. Do not use paints containing metallic akes. Refer to “Ultraviolet Reec­tance of Paint” from the American Welding Society.

• Underwatercuttingisawellacceptedtechniqueforreducingthenoise,fumes,andUVradiationofthePlasmarccut­ting process. Often an air curtain or bubble muer is required for underwater cutting. Above water cutting with a
water muer can also achieve much of the benets of underwater cutting.

16

SECTION 1 DESCRIPTION

1.1 GENERAL

The ESP-1000 is a full capability plasmarc cutting system
that oers a wide variety of plasma cutting processes
and applications. The system is designed specically for
computer controlled mechanized cutting applications
with expanded interfacing, exible conguration from a
selection of packages and versatile ease of operation. By
selecting the components that best suit your needs the
ESP system can fully automate your cutting process.

1.2 FEATURES

• Thesystemiscapableofwaterinjectioncutting

with the PT-15XL torch and gas shielded un­derwater cutting can be accomplished at most
current levels with appropriate accessories with
the PT-19XLS torch.

• TheESP-1000canaccommodateallmajorcutting

gases including; oxygen, air, nitrogen or argon/
hydrogen mixture.

• The separatecomponent design,ow control,

plumbing box, power source provides maximum
flexibility for system layout tailored to your
needs.

• Selection from a varietyof power sources and

the paralleling capability allows a wide range
of available cutting power to meet virtually any
cutting condition.

• Patented ESAB technology allows underwater

cutting and beveling with excellent results.

• TheESP-1000usessimpleswitchsettingstosetup

process parameters for ow control and cutting
power eliminating the diculty of adjustment
associated with needle valves.

• Theshieldedconstructionoftheplasmatorches

and versatility of component location minimizes
electrical interference with surrounding equip­ment.

• The ESP system uses advanced technologyfor

high quality cutting for a variety of common
metals while keeping the operating costs at a
minimum.

COOLANT

CIRCULATOR

TORCH

(PT-15XL or PT-19XLS)

FLOW

CONTROL

CUT WATER

PUMP

PLUMBING

BOX

SECONDARY

GAS METERING

BOX

POWER SOURCE

(ULTRA LIFE 300, ESP-

400 or ESP-600C)

Figure 1-1. ESP-1000 Major Components

17

SECTION 1 DESCRIPTION

VOLTS

AMPS

OUTPUT

ACTUAL AMPS

PRESET AMPS

LOW

HIGH

PILOT
ARC

50
MIN

100

200

300

400

500

600
MAX

0

MAIN

POWER

CURRENT

PANEL

REMOTE

OVER
TEMP

CONTACTOR

ON

FAULT

POWER

RESET
FAULT

400C

1.3 COMPONENT DESCRIPTION

The components that make up an ESP-1000 are designed
specically to interface into a system for use in automated
plasma cutting applications.

Refer tothe specic equipment manual for detailed
information.

Ultra Life 300 Power Source

Designed for high speed plasma cutting, the Ultra Life 300
is basically a silicon controlled rectier (SCR) DC unit with
solid state circuitry. The unit can be operated from 50 to
300 amperes output (cutting) current.

Figure 1-3 ESP-400C Power Source

Figure 1-2. Ultra Life 300 Power Source

The solid state circuitry of the Ultra Life 300 produces
stable cutting current and eliminates changes in output
current as components heat up to operating tempera­ture. Fluctuations in line voltage within +/- 10% of normal
and/are extremely low ripple output current is produced,
which results in longer consumable life.

Refer to Instruction Manual F-15-141 for specic details
for the Ultra Life 300.

ESP-400C Power Source

The ESP-400C Power Source is a solid state DC pwoer source
capable of producing up tp 400 amperes.

The design of the solid state circuitry produces stable
cutting current and eliminates changes in output current
as components heat up to operating temperature and/or
uctuations in line voltages within + or - 10% of nominal.
If cutting currents above the rating is required, two ESP­400C units can be paralleled.

Refer to the power source manual for installation instruc­tions.

ESP-600C Power Source

The ESP-600C is normally used in mechanized cutting ap­plications for high speed cutting. The ESP-600C is a solid
state DC power source capable of producing 100 to 600
amperes of cutting current at 100% duty cycle (no cool
down requirements). The extremely low ripple current is
produced by a ripple cancellation technique and results
in increased life of plasma consumables. "Current slope
up" is also featured with the ESP-600C.

18

SECTION 1 DESCRIPTION

L

O

W

H

I

G

H

L

O

W

H

I

G

H

C

U
T

G

A

S

C

U

T

A

W

T

E

R

T

E

S

T

R

U

N

Connections to the ow control are Oxygen In, Nitrogen
In, Start Gas Out, Cut Gas Out, Cut Water In and Cut Water
Out.

Plumbing Box

The ESP Plumbing Box is an interconnecting device
between the torch and other system components. It
also contains the arc starting high frequency genera­tor. Connection of functions through the plumbing box
include; cut gas, start gas, cut water, torch coolant, pilot
arc, cutting current and height control.

Figure 1-4. ESP-600C Power Source

For currents beyond the ESP-600C capability 2 units can be
connected in a parallel conguration. Refer to Instruction
Manual for specic details of the ESP-600C.

Flow Control

The Flow Control is a programmable Logic Control (PLC)
based unit. This device provides all the necessary control
functions for various uids and signals to and from other
components of the system. Control Inputs/Outputs are
connected to the power source, cut water pump, plumb­ing box, coolant circulator, air curtain and the cutting
machine control.

Figure 1-6. Plumbing Box Assembly

Coolant Circulator

The WC-7C circulator is a radiator type cooler for circulat­ing a coolant uid through the plasma torch providing
heat exchanger action for the internal parts of the torch.
Though the system refers to water, it is not recommended
that water be used. For the protection of internal parts
and lines a specially formulated coolant liquid is avail­able that prevents production of corrosion and mineral
buildup. Refer to Instruction Manual F-15-138 for detailed
information on the WC-7C unit.

Figure 1-5. Flow Control Assembly

19

SECTION 1 DESCRIPTION

10

9
8
7
6
5
4
3
2
1
0

PRESSURE

FLOW

OFF

ON

AUTO

PRESSURE

ADJUSTMENT

INLET

FLOW

ADJUSTMENT

OUTLET

READ TOP

OF BALL

0

50

100

PLASMARC

SECONDARY SHIELD

GAS FLOW CONTROL

Secondary Gas Metering Box

Figure 1-7A

The secondary shield/PT-19XLS improves the cut square­ness. The secondary gas metering box measures the ow
rate of shield gas (nitrogen or air).

Adaptor: PT-19XLS to Plumbing Box for shield gas con­nection to torch.

PT-15XL Plasma Torch

The PT-15XL is designed for high current plasma cut­ting with water injection. Cutting is accomplished with
nitrogen cut gas up to 750 amps, oxygen cut gas up to
360 amps. Use of H-35 mixture for cut gas extends cur­rent capability up to 1000 amps. Each condition requires
specic torch components for the type of cut gas and
current level.

Figure 1-8. PT-15XL Plasma Torch

The PT-15XL is designed to eliminate double arcing, high
frequency leakage, and electrolytic corrosion of parts.
The electrode cooling and nozzle concentricity makes arc
ignition more reliable, longer life of the nozzle, electrode
and other consumable parts. Operating details for specic
cutting conditions are presented in later sections of this
manual. Refer to Form F-15-031 for detailed information
of the PT-15XL torch.

PT-19XLS Plasma Torch

The PT-19XLS Torch is designed with all the quality stan­dards and feature characteristics of the PT-15XL. The
dierences are primarily in applications and conditions
for which the PT-19XLS is to be used. The PT-19XLS is a
mechanized torch designed for high speed, high current
cutting using gas shielding instead ofwater injection.

Figure 1-7A

Figure 1-9. PT-19XLS Plasma Torch

PT-600 Plasma Torch

The PT-600 torch is a PT-19XLS with reduced manu­facturing tolerances. The result is improved torch
component concentricity and cut accuracy. Connec­tions, mounting and process data are identical.

20

SECTION 1 DESCRIPTION

The PT-19XLS is intended for applications of dry cutting
using air (clean & dry) for the cut gas at current levels up
to 200 amps. Oxygen (to 360A) or H-35 (to 600A) can be
used with the PT-19XLS, however these gases are not
recommended for some materials. Use of an air curtain
kit permits the PT-19XLS to be used for underwater cut­ting. Further details of the PT-19XLS are contained in
Form F-15-430.

Water Pump

The Water Pump is used to supply de-ionized cut water
to the PT-15XL torch for water injected cutting.

Air Curtain

Figure 1-11. Bubble Muer Assembly

The Air Curtain assembly provides improved cutting
performance of the PT-15XL and PT-19XLS plasma torches
when cutting underwater. A source of oil free air at 80
psig is required to the air curtain control box. A curtain
(wall) of air is created around the plasma arc area allowing
operation in a relatively dry zone, even with the end of
the torch submerged 2 - 3 inches.

PT15XL H.D.
AIR CURTAIN

Figure 1-10. Air Curtain Assembly

PT-19XLS
AIR CURTAIN

PT-19XLS Water Muer

The PT-19XLS water muer works much as the bubble
muer described above.

Underwater Cut quality and speed are enhanced when
using the air curtain for all PT-19XLS cutting applications
and PT-15XL O2/water injection cutting.

Bubble Muer

The Bubble Muer system creates a bubble of air sur­rounded by water that allows the PT-15XL torch to be
used underwater with oxygen cut gas and water injection
cutting without signicant loss of cut quality.

This device also allows above water cutting with reduced
fume, noise and UV radiation from the arc by the ow
of water through the bubble muer. A separate water
pump recycles ltered water from the water cutting table
through the bubble muer.

Figure 1-12. PT-19XLS Water Muer Assembly

21

SECTION 1 DESCRIPTION

TABLE 1-1. ESP 1000 COMPONENTS

DESCRIPTION PART NUMBER INSTRUCTION MANUAL

Power Sources

Ultra Life 300 460/575 V, 3-Phase, 60 Hz 33520 F-15-141

ESP-400C 460 V, 3-Phase, 60 Hz 0558001729 F-15-657
400 V, 3-Phase, 50 Hz CE 0558001730 F-15-681
575 V, 3-Phase, 50 Hz 0558001731 F-15-657

ESP-600C 460 V, 3-Phase, 60 Hz 35609 F-15-656
400 V, 3-Phase, 50 Hz CE 35610 F-15-682
575 V, 3-Phase, 60 Hz 35611 F-15-656

Plasma Torches: The basic torch body can be supplied in seven lead lengths between the plumbing box and torch. The replaceable

PT-15XL - 4.5 ft. 21307 F-15-031
PT-15XL - 6 ft. 21304
PT-15XL - 12 ft. 21305
PT-15XL - 15 ft. 21301
PT-15XL - 17 ft. 21306
PT-15XL - 20 ft. 21302
PT-15XL - 25 ft. 21303

PT-19XLS - 4.5 ft. 37086 F-15-430
PT-19XLS - 6 ft. 37087
PT-19XLS - 12 ft. 37088
PT-19XLS - 15 ft. 37089
PT-19XLS - 17 ft. 37090
PT-19XLS - 20 ft. 37091
PT-19XLS - 25 ft. 37092

PT-600 - 4.5 ft. 0558001827 F-15-646
PT-600 - 6 ft. 0558001828
PT-600 - 12 ft. 0558001829
PT-600 - 15 ft. 0558001830
PT-600 - 17 ft. 0558001831
PT-600 - 20 ft. 0558001832
PT-600 - 25 ft 0558001833

Flow Control: Provides interface for uids, gases and 21294 F-15-106
power.

torch components are selected for the type of cut gas and current level used.

Plumbing Box: Provides interconnection between torch 21295 F-15-107
and rest of system includes adaptor for
shield gas connection.

WC-7C Water Recirculator: Circulates coolant for the torch 33859 F-15-138

Cut Water Pump:

Supplies cut water to torch for water injection cutting 33772 F-15-131

Air Curtain:

PT-19XLS and PT-600 37440 F-15-475
Heavy Duty PT-15XL 21856 F-15-189
PT-15XL Beveling (PT-19XL and PT-600) 34752 F-15-189

Bubble Muer System 2232615 F-15-127

PT-19XLS (and PT-600) Water Muer 37439 F-15-474

Secondary Gas Metering Box (for PT-19XLS) 22178 See pages 28 - 32 of this manual.

22

SECTION 2 INSTALLATION

ing. In relationship to a cutting machine, the power
source can be positioned virtually anywhere that will

WARNING

READ THIS MANUAL COMPLETELY PRIOR TO
INSTALLING AND OPERATING THE ESAB SMART
PLASMA (ESP) 1000 SYSTEM.

not interfere with machine travel. Accessories on the
cutting machine are available to carry hoses and cables
without interference with machine travel.

Flow Control

2.1 General

Proper installation substantially contributes to the
satisfactory and trouble-free operation of the ESP-1000
System components. Each step in this section should
be studied carefully and followed as closely as possible.
Immediately upon receipt of the ESP components,
each should be inspected closely for damage which
may have occurred in transit. Notify the carrier of any
damage or defects immediately. Instruction manuals for
each component of the system are included in the pack­age. It is recommended that these manuals be collected
and compiled in a common location.

NOTE

If the components are not to be immediately
installed, store them in a clean, dry, and well ventilated
area.

2.2 System Component Locations

Power Source

WARNING

When lifting the Power Source using the lifting
lugs, ensure the lifting means is securely connected
to BOTH lifting lugs to prevent damage to the unit or
injury to personnel. DO NOT USE ANY LEVER DEVICE
WHICH COULD DAMAGE THE UNIT.

The location of the Power Source should be care­fully selected to ensure satisfactory and dependable
service. The Power Source components are maintained
at the proper operating temperatures by forced air that
is drawn through the cabinet by the fan units. For this
reason, it is important that the Power Source be located
in an indoor-open area where air can circulate freely at
the front, bottom, and rear openings of the cabinet. If
space is a premium, leave at least two feet of clearance
at the rear of the cabinet.

The Flow Control can be placed on the Power
Source or mounted onto the cutting machine. It con­nects to the Power Source by a control cable from 6' to
125' long. The Flow Control needs to be accessible for
setting various cutting parameters. After setting the
cutting conditions, access to the Flow Control is not
required during the cutting operation.

Plumbing Box

The Plumbing Box is normally located on the
cutting machine in close proximity to the torch station.
Since the torch can be equipped with various standard
lengths of cable and hose, the exact location is deter­mined by the conguration and station load capacity of
the machine.

Access to the Plumbing Box is not required during
the standard operating procedures, location near the
operator is not required. Two important considerations
pertain to the location of the plumbing box:

1. There should be space for the box door to be
opened fully .

2. Sucient space should be provided on all
sides to permit easy connection of gas/water
hoses and electrical cables to the box.

Secondary Gas Metering Box

The gas metering box can be mounted on the cut­ting machine or a convenient wall with the owmeter
vertical. The hose supplied is used to connect metering
box to torch shield gas using the adaptor supplied with
the plumbing box. The gas metering box must be con­nected to a source of dry oil free shop air or N2 capable

The location should be such that a minimum of
dirt, dust, or moisture will be drawn into the air stream.
It is desirable to locate the unit so that the top and side
panels can be removed for cleaning and troubleshoot-

23

SECTION 2 INSTALLATION

2.3. SYSTEM CONNECTIONS

Power Source

WARNING

Before making any connections to the output bus bars,
make sure the power source is de-energized by opening
the line (wall) disconnect switch. To be doubly safe, have a
qualied person check the output bus bars with a voltmeter
to be sure all power is o.

Input Power Connections

The power sources (ESP-600C, ESP-400 or Ultra Life 300) used
with the ESP-1000 system are 3-phase units and must be con­nected to a 3-phase power line. Although designed with line
voltage compensation, it is suggested that the unit be operated
on a separate line to ensure the performance of the power
source is not impaired due to an overloaded circuit.

A line (wall) disconnect switch, with fuses or circuit breakers,
shall be used at the main power panel. The primary power input
must have four insulated power leads (three power leads and
one ground wire). The wires may be a heavy rubber covered
cable or may run in a solid or exible conduit.

NOTE

The ground wire must be approximately six inches longer than
the power leads. This is a safety measure to ensure that in the
event the power lines are accidently pulled out the ground wire
will remain connected.

Input conductors must be terminated with ring terminals sized
for 1/2 inch hardware before being connected.

NOTE: Refer to the specic equipment manual for

detailed installation instructions.

Flow Control Connections

The Flow Control serves as a form of interface between the
various process utilities to enable a central location for setup
adjustments. Connections are made to receptacles on the rear
panel and are grouped into two sections, the bottom row is for
gas and water connections while the top row is for electrical
connections. The uid connections should be made rst.

Fluid Hookups (See Table 2-1 for hose assemblies)

1. OXYGEN (O
tting. Connect the supply hose from the oxygen
regulator to this point.

2. NITROGEN (N2) IN - This is a "B" size IAA tting.
Connect the supply hose from the nitrogen
regulator to this point.

3. START GAS OUT - This is a "B" size IAA tting. From
this point connect the hose to Start Gas INPUT on
the Plumbing Box.

4. CUT GAS OUT - This is a "B" size oxygen tting.
The hose is connected from this point to the Cut
Gas INPUT on the Plumbing Box.

Electrical Hookups (See Table 2-2 for cables)

1. PARALLELED POWER SOURCE - A cable from a
second power source connects to this receptacle
whenever two power sources are used in paral­lel. It parallels all control connections between
the power source and ow control.

2. AIR CURTAIN - This is used to connect the coil of
a solenoid valve in the air curtain control (when
used) or to control a relay coil in the water muer
pump unit.

3. CUT WATER PUMP - Provides connection to a relay
coil in the cut water pump unit

4. WATER COOLER - This point is used to connect to
the relay coil in the water cooler.

5. PLUMBING BOX - This cable connection goes to
the gas solenoid valves, ow switch, interlock
switch and provides power to the primary of
the high frequency transformer in the plumbing
box.

6. CUTTING MACHINE NUMERICAL CONTROL (CNC)

- This connection provides a current reference
signal to the plasma power source and provides
control signals to and from the ow control cir­cuits, Start Process Command, Arc On, Process
Fault, and E-Stop Interlock.

7. 115 VAC AUXILIARY POWER - This optional con­nection allows the Flow Control to be energized
without powering up the system. Disconnect
after test function is completed.

) IN - This is a "B" size CGA oxygen

2

24

SECTION 2 INSTALLATION

Oxygen

Nitrogen

Gas Regulators

Cut
Water

Pump

On-O

Flow Control

Wall Box

Input
Power

Cooler and
Pump

Start Gas Solenoid
Cut Gas Solenoid

High Freq. On-O

Interlocks

Injection Water

Start Gas

Cut Gas

Voltage Feedback

Power Source

Coolant Return

Coolant Output

(+) Work

(-) Electrode

Pilot Arc

Plumbing Box

Process OK

Interlocks

Current Ref.

E-Stop

Process
O

Cutting Machine Control

Height
Reference

Legend

Electrical Connections
Fluid Lines

*For use on the PT-19XLS and PT-600 only. For
dry cutting the cut water switch on the ow
control must be in the "OFF" position.

Figure 2-2. ESP-1000 Interface Block Diagram

Workpiece
Voltage

Height
Control

25

Torch
PT-15XL or
PT-19XLS or
PT-600

Work Piece

Gas
Metering
Box

Shield

Air Supply

Gas*

Secondary
Shield Gas

Cut Gas

Pilot Arc High Freq.

Water Injection

Coolant To
(-) Current To
Coolant From
(-) Current To

SECTION 2 INSTALLATION

TO PARALLEL

115 VAC

AUXILIARY POWER

FOR TESTING

(DISCONNECT FOR

CUTTING OPERATION)

POWER SOURCE

TO AIR
CURTAIN

TO CUT WATER
PUMP

O2 IN
FROM
REGULATOR

N2 IN
FROM
REGULATOR

START GAS
OUT TO
PLUMBING
BOX

CUT GAS
OUT TO
PLUMBING
BOX

POWER
SOURCE

CUT WATER
IN FROM CUT
WATER PUMP

Figure 2-4. Flow Control Connections

TO WATER
COOLER

TO PLUMBING
BOX

TO CUTTING
MACHINE CNC

CUT WATER
OUT TO PLUMBING
BOX

26

SECTION 2 INSTALLATION

TABLE 2-1. HOSE ASSEMBLIES

CABLE LENGTH CUT WATER HOSE COOLING WATER START GAS HOSE CUT GAS HOSE

25 FT. 33127 21588 33122 33117
50 FT. 33128 21574 33123 33118
75 FT. 33129 1575 33124 33119
100 FT. 33130 21576 33125 33120
125 FT. 33131 21577 33126 33121

TABLE 2-2. COOLING WATER HOSE ASSEMBLIES

CUT GAS HOSE Hose Assembly

25 FT. 33132
50 FT. 33133
75 FT. 33134
100 FT. 33135
125 FT. 33136

TABLE 2-3. INTERCONNECTION CABLES

CABLE

LENGTH

25 FT. 33219 33224 33253 33303 33253
50 FT. 33220 33225 33254 33304 33254
75 FT. 33221 33226 33255 33305 33255
100 FT. 33222 33227 33256 33306 33256
125 FT. 33223 33228 33257 33307 33257

Flow Control Remote Location- Flow Control to Power Source cable: 30 Ft. - 34378

FLOW CONTROL -

PLUMBING BOX

(Cable, 18 AWG,

8 conductor)

FLOW CONTROL

- CNC

(Cable, 16 AWG

12 conductor)

FLOW CONTROL

- WATER COOLER

(Cable, 18 AWG

3 conductor)

POWER SOURCE -

PLUMBING BOX

(Cable, Pilot Arc)

60 Ft. - 34377

CURTAIN

(Cable, 18 AWG

3 conductor)

AIR

27

SECTION 2 INSTALLATION

TABLE 2-3. RECOMMENDED REGULATORS

DESCRIPTION PART NUMBER

Station Regulator, O2, R-76-150-024* 19151

Station Regulator, N2, R-6703 22236
Two Stage Cylinder Regulator, O2, R-77-150-540** 998337
Two Stage Cylinder Regulator, N2, R-77-150-580** 998344

Two Stage Cylinder Regulator, H-35, R-77-150-350 998342

Liquid Cylinder Regulator, O2, R-76-150-540LC 19777

Liquid Cylinder Regulator, N2, R-76-150-580LC 19977

Water to Injection pump use Regulator R-6702 22235

* Station (line) regulators connect to station outlets of piping systems that transport gas to welding or cutting stations. These regulators are
intended for inlet pressures of less than 200 psig. When used with plasma cutting systems, minimum inlet pressure should be 120 psig.

** Two stage cylinder regulators provide a more constant delivery pressure than single stage cylinder regulators. The delivery pressure of a
single stage varies about 1 psig per 10 psi of change in the inlet pressure as the cylinder empties.

28

SECTION 2 INSTALLATION

Plumbing Box Connections

B. Connect the Pilot Arc cable from the torch bundle

WARNING

Make sure that all connections are properly made to
prevent any leaks. Any leakage during actual opera­tion could lead to a hazardous situation because of
the high voltages involved.

C. Connect the Cut Water hose to the CUT WATER

to the stud marked PILOT ARC TORCH (TB1) lo­cated inside the Plumbing Box.

TO TORCH connector on the top section of the
Plumbing Box.

NOTE

To make the following connections, the door must be
opened and the cover removed.

Cut Gas to Torch

Cut Water
To Torch

D. Connect the Cut Gas hose to the GAS TO

TORCH connector on top section of Plumbing
Box.

Start Gas

Cut Gas

Coolant Out

Coolant In
Control Cable
(from Flow
Control)

Pilot Arc
from Power
Source

4/0 Power
Cables
from Power
Source

To Height Control

Figure 2-5. Plumbing Box Connections

To Torch

1. Connect the torch bundle to the plumbing box. Check
that the box location permits torch movement as
required.

A. Connect the cooling water (coolant) in and out

(with the internal power cable) to the connec­tors on the main power junction bus bar inside
the plumbing box. Refer to Figure 2-6. One con­nection has right-hand threads and the other
has left-hand threads. Left-hand threads are
indicated by a groove or notch on the hex of the
tting.

To Power Source

2. Connect the 4/0 power cable(s) to the studs on the
main power bus bar TB3 (see Figure 2-6). The number
of cables depends on the maximum cutting thickness
capacity for the installation. Three cables must b e
connected to carry the full 1000 amperes.

Select plasma cutting output cables on the basis of

one 4/0 AWG, 600 volt insulated copper cable for each
400 amperes of output current. Do not use ordinary
100 volt insulated welding cable.

Each 4/0 cable must be terminated with the correct

lug prior to attempting connection to the bus bar.

29

SECTION 2 INSTALLATION

Each cable goes through one of three strain reliefs on
the box. Ensure neither lugs nor bare wires touch
the sheet metal of the box.

3. Connect the Pilot Arc cable from the power source
through its strain relief (PILOT CURRENT) to the stud

TORCH PILOT
ARC
CABLE STUD

PILOT
CURRENT STUD
(FROM POWER
SOURCE)

COOLANT
IN AND OUT
CONNECTORS

4/0 POWER CABLE
CONNECTING STUDS

Figure 2-6. Plumbing Box Internal Connections

FRONT BODY
INSULATOR
ASSEMBLY

BODY
ASSEMBLY

NOZZLE
RETAINING
CUP

ELECTRODE

)

TIP (N

2

NOZZLE
ASSEMBLY

GAS SWIRL
BAFFLE

ELECTRODE
HOLDER

Figure 2-7. PT-15XL Plasma Torch Components

WARNING

Electric shock can kill! Before touching the torch, be
sure the power source is shut o by turning o the
3-phase power input to the power source.

WARNING

Never use oil or grease on this torch. Handle parts only
with clean hands and lay parts only on a clean surface.
Oil and grease are easily ignited and burn violently in
the presence of oxygen under pressure. Use silicone
lubricate only where indicated.

(TB2) on the side of the high frequency box inside the
Plumbing Box. This cable runs uninterrupted from the
power source to the termination in the plumbing box,
so it is essential that it be the proper length. Use # 6
AWG 600 volt wire with ring terminals to t the 1/4­inch stud.

2.4 TORCH COMPONENTS

Refer to your torch manual for detailed
installation instructions.

PT-15XL

The PT-15XL torch is supplied with front end parts for water
injection cutting using nitrogen cutting gas at currents
up to 400 amps DCSP. Nozzles for other applications are
available and are referenced in the Cutting Data Tables
in Section 3.

PT-19XLS

The PT-19XLS is a water-cooled plasma arc torch designed
for mechanized cutting at currents up to 350 Amps with
oxygen and up to 600 Amps with nitrogen or H-35.

ELECTRODE HOLDER -

ELECTRODE

NOZZLE BASE

NOZZLE TIP

NOZZLE RETAINING CUP

DIFFUSER

SHIELD

SHIELD RETAINER

NOZZLE RETAINING CUP, AIR CURTAIN

Figure 2-8. PT-19XLS Components

30

GAS BAFFLE

SECTION 2 INSTALLATION

WARNING

Make sure that the heat shield, shield retainer,

and other front end parts are cool before handling.

2.5. INSTALLING AIR CURTAIN

The Air Curtain is a device used to improve performance
of the PT-15XL and PT-19XLS when cutting underwater.
Cut quality and cutting speed are enhanced when us­ing the air curtain with all PT-19XLS cutting and PT-15XL
oxygen/water injection cutting. The device mounts onto
the torch and produces a curtain of air around the cutting
area producing a relatively dry area.

Installation procedures of the air curtain for the PT-15XL
and PT-19XLS are very similar with slight dierences in the
nozzle clearance positioning.

1. Remove the torch nozzle retaining cup.

2. Slide the chrome plated Air Curtain Body.

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.).

3. Replace the nozzle retaining cup and any front-end
parts that may have removed from the torch.

4. Install the air curtain sleeve over the assembled torch
and snap it into place.

5. Secure the air curtain sleeve by installing the air cur­tain retainer. The Retainer rotates to lock in place with
the locking pins.

6. Adjust the position of the air curtain on the torch
until:

A. PT-15XL - a gap from 0.040 to 0.060 inch is ob-

tained between the air curtain sleeve and the
nozzle retaining cup.

B. PT-15XL - the nozzle is recessed 0.10 inch from

the end of the air curtain sleeve.

C. PT-19XLS - the nozzle extends 0.06 inch from the

end of the air curtain sleeve.

7. Lock the air curtain into place by tightening the al-

len screw on the air curtain body. Refer to Figure
2-9.

NOTE: The air curtain sleeve must remain completely bot-

tomed in the air curtain body for the adjustment in
step 6 to be correct.

After tightening the allen screw, the gap between

the sleeve and torch cup should be uniform all the
way around.

With PT-15XL torches, verify that the Bubble Muer/Air
Curtain air does not excessively interfere with the injection
spray pattern. A small interference is normal, as long as it
is uniform. If not uniform, try turning the sleeve. This will
at times correct the problem. Turn o muer water when
checking for this interference.

BUSHING

ALLEN
SCREW

.040 - .062

PT-15XL

TORCH
BODY

ALLEN
SCREW

AIR
CURTAIN
BODY

RETAINER

AIR
INLET

PT-15XL BEVEL

Figure 2-9. Air Curtain Installation

31

0.10"

BUSHING

AIR CURTAIN
BODY

AIR
INLET

RETAINER

TORCH
BODY

PT-19XLS

0.06"

AIR
INLET

SECTION 2 INSTALLATION

2.6. BUBBLE MUFFLER INSTALLATION

The bubble Muer creates a bubble of air surrounded
by water so that a PT-15XL plasma torch can be used
underwater with oxygen/water injection cutting without
signicant sacrice of cut quality. This system also permits
operation above water as the ow through the muer
reduces fumes, noise and arc UV radiation.

Installation and Adjustment

1. Remove the brass nozzle retaining cup from the
torch.

NOTE: Lubrication of O-rings in the bubble muer is rec-

ommended for ease of installation.

2. Slide the chrome plated bubble muer clamp onto
the torch about 1/2 inch up the torch sleeve (body).

3. Replace the nozzle retaining cup and any front-end
torch parts that may have removed from the torch.

4. Install the bubble muer sleeve in the bubble muer
main body. Maker sure it bottoms completely.

5. Install the bubble muer main body (with sleeve)
over the assembled torch and snap it into place on
the bubble muer clamp.

6. Adjust the position of the bubble muer on the torch
until a gap of .040 to .060 (use 1/16 inch allen wrench
for gapping) is obtained between the inside wall of
the muer sleeve and the torch retaining cup.

7. Lock the bubble muer into position by tightening
the allen screw on the bubble muer clamp.

A helpful hint for adjusting the Air Curtain or bubble Muf­er for proper location on the PT-15XL:

1. Mark the nozzle retaining cup and back it up 3/4 to 1
turn from fully tight.

2. Install the Air Curtain or Bubble Muer sleeve and
push the assembly up the torch until the sleeve bot­toms out against the nozzle retaining cup.

3. Lock into position with the allen screw.

4. Retighten the nozzle retaining cup.

ALLEN
SCREW

MAIN
BODY

SLEEVE

.040 - .060

Figure 2-10. Bubble Muer Assembly

The sleeve must remain completely bottomed in
the Bubble Muer body for the adjustment in step 6 to
be correct.

After tightening the allen screw, the gap between
the sleeve and torch cup should be uniform all the way
around.

With PT-15XL torches, verify that the Bubble Muf­er air does not excessively interfere with the injection
spray pattern. A small interference is normal, as long as
it is uniform. IF not uniform, try turning the sleeve. This
will at times correct the problem. Turn o muer water
when checking for this interference.

Better centering of the bubble muer sleeve can
be obtained by putting 3 evenly spaced (120" interval)
pads of tape of electrical tape on the nozzle retaining
cup.

NOZZLE
RETAINING
CUP

CLAMP

TORCH
RETAINING
CUP

32

2-3 LAYERS ELECTRICAL
TAPE AT 3 PLACES
SPACED 120

Figure 2-11. Centering Tape on Retaining Cup

o

SECTION 2 INSTALLATION

2.7 WATER MUFFLER SYSTEM FOR THE PT­19XLS

This system is similar to the PT-15XL

Bubble Muer.

2.8. AIR CURTAIN/BUBBLE MUFFLER

CONTROL BOX INSTALLATION

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 inch inside diameter. Refer to
Figure 2-12 for plumbing hookup.

3. Use SJO wire to connect the control to the cutting machine
control. If the ESP system is used, 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 terminals marked FC. An appropriate cable may
be selected from the table of optional accessories.

2.9. WATER INJECTION PUMP

The Water Injection Pump is intended to supply cut water
to the PT-15XL water injection torch. It may be used in
other applications where water requirements do not ex­ceed the pump capacity of 0.5 gpm @ 200 psig. See Figure
2-13 for Installation Diagram.

CONTROL CABLE

PUMP

APPROPRIATE AMPHENOL
CONNECTOR ON FLOW
CONTROL OR CNC

POWER

AIR CURTAIN

CONTROL BOX

Figure 2-12. Electrical Connections for Water Pump

CONTROL CABLE

115VAC
OPTIONAL

4. The user supplied 115 volt 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.

6. Provide air to the control box. Energize solenoid in control
box and adjust regulator screw from 15 - 30 psig delivery.
Adjust within range for best cut quality.

7. Place switch in AUTO. The system should turn on when the
preow begins. The pump will recirculate approximately
20 gpm from the water table.

Further details and replacements parts for the air curtain and
bubble muer are depicted in instruction manuals, F-15-189
& F-15-127, 15-474 & 15-475.

3/8" ID
HOSE

3/8" ID
HOSE

3/4" ID
HOSE

PUMP

WATER

INLET

AIR CURTAIN
CONTROL BOX

TORCH

BUBBLE MUFFLER

WATER
TABLE

STRAINER

AIR

Figure 2-13. Plumbing Connections for Water Pump

To prevent damage to pump, do not operate water injec­tion pump with delivery pressure above 220 psig. Do not
operate for more than 2 minutes without ow (with the
pump deadheaded). Do not operate for extended periods
of time with less than 0.2 gpm ow.

33

SECTION 2 INSTALLATION

INTERMEDIATE

WATER QUALITY INDICATOR
FILTER TO
PROTECT
TANKS

LIGHT (50,000 OHM RATING)

TAP

WATER

IN

R-5702 REGULATOR
(PN 639629) SET TO
DELIVER 25-30 PSIG

CATION
TANK

TO

CUT WATER

PUMP

ANION
TANK

Figure 2-14. Deionizer System for Plasma Cut Water

The PT-19XLS incorporates arrangements for sec­ondary gas shielding to improve cut squareness. A sec­ondary gas metering box and accessories are required.
The adaptor for torch to gas metering box is supplied
with the plumbing box.

The installation, operation and replacement parts
for the secondary gas metering box will be covered in
this section.

Required Accessories

Item Part No. Length

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 33257 125 ft.

ITEM Part No. Quantity

Secondary Gas Metering

22178 1

Box

Hose Assy., 50 ft. w/

34033 1

5/8" 18f Fittings

30 MICRON FILTER
TO PROTECT SYSTEM
WHEN TANKS ARE
CHANGED

2.10 INSTALLATION OF THE SECONDARY GAS
METERING BOX

1. Mount the gas metering box at a convenient location

with the owmeter vertical and use the hose supplied
to connect the box with the unit mounted on the
torch.

2. Connect the gas metering box to a source of dry oil

free shop air capable of delivering at least 11 scfm at
80 psig. The hose used should be at least 3/8" ID.

3. Use SJO wire to connect the gas metering box to the

cutting machine control. If the ESP system is used,
then the connection may be made to the "Air Curtain"
amphenol connector on the back of the ow control.
See Figure 2-16 if Air Curtain is already installed. The
connection of the gas metering box is made at the
terminals marked F. C. An appropriate cable may be
selected from the table of required accessories.

4. User supplied 115 V ac may be connected to the ter-

minals so marked. This will allow manual operation
of the gas metering box assembly.

5. Connect a ground wire to the stud provided in the

control box.

Note: For dry cutting, turn o the "cut water switch" on ow

control.

MIXED
BED
TANK

FINAL WATER
QUALITY INDICATOR
LIGHT
(200,000 OHM RATING)

34

SECTION 2 INSTALLATION

Plumbing Box Connections

Remove the hose nut from adaptor assembly. Place the
adaptor over the "cut water" tting as shown in gure 2-15
and screw the hose nut previously removed onto the "cut
water" tting and assemble as shown.

Operation

1. Provide gas metering box with oil free air at 80 psig
minimum. Energize solenoid in control box and adjust
regulator screw to the desired pressure and throttle
valve to set the desired ow. Refer to the appropriate
cutting parameter charts starting on page 49.

2. Place switch to AUTO. The system should turn on when
the preow begins.

3. Cutting stando (Torch to Work Distance) must now
be measured from the bottom of the Secondary Shield
Assembly. Refer to appropriate tables for proper
standos.

Note: Set piercing stando as specied in the appropri-

ate parameter chart.

WARNING

Electric shock can kill. Disconnect power from power
source before touching or servicing the Secondary
Shield at the torch. Disconnect power to the Control
Box before servicing.

Figure 2-15 Plumbing Box Connections

AIR CURTAIN

AMPHENOL

Terminal

Strip

Figure 2-16. Air Curtain, Secondary Gas Metering Box and Pump Motor

35

SECTION 2 INSTALLATION

1

14

16

15

12

13

2

8

6

7

11

ITEM NO. QTY REQ. PART NO. DESCRIPTION

1 1 22174 FLOWMETER ASSEMBLY (See Fig.4)
2 3 10Z30 ADAPTOR B-A/W X 1/4 NPTM
3 1 19Z99 ADAPTOR 1/4 NPTM X .69 - 24F
4 1 82Z46 WASHER FLAT .61 X .32 X .06 NYLATRON
5 1 19906 VALVE RELIEF ASSEMBLY
6 1 22220 GAUGE 2.50, 100PSI
7 1 22181 HOSE ASSEMBLY FOR PRESSURE GAUGE
8 2 22182 HOSE ASSEMBLY FOR GAS IN & OUT

9 1 632904 VALVE NEEDLE 1/4PF X 1/4PF 3000PSI
10 2 11N16 ADAPTOR B/A-WF X 1/4 NPTM
11 1 522368 AIR REGULATOR (Discard Gauge)
12 3 639501 ADAPTOR 1/4-18NPT x 1/4 NPTM
13 1 636387 VALVE SOL. 1/4P
14 1 96W85 STRAIN RELIEF
15 1 951041 TERM BLOCK 4 POS.
16 1 636702 SWITCH TOGGLE DPDT 3 POS 15A

10

2,12,3,4,5

9

Figure 2-15. Secondary Gas Metering Box. P/N 22178

36

SECTION 2 INSTALLATION

6

10

8

9

11

12

13

7

5

4

1

3

2

ITEM NO. QTY REQ. PART NO. DESCRIPTION

1 1 22168 FLOWMETER BODY
2 2 86W62 O-RING 1.239ID X .070W NEOPR 70A
3 1 85W10 O-RING .239ID X .070W NEOPR 70A
4 1 639571 TUBE METER 1.4-33-G-5 GLS
5 1 53A61 BALL 0.250 DIA STAINLESS STEEL
6 1 22169 FLOAT STOP FLOWMETER
7 1 12N29 SPRING 0.75 X 0.63D
8 1 22170 CAP

9 8 61340006 SCREW STLZPC 0.190-32 X 0.50 (#10-32 X .5)
10 1 22171 SPIDER
11 8 64302920 WSR 52002 STLZPC 0.190 (WASHER #10)
12 2 22172 FRAME
13 1 22173 OUTER TUBE

Figure 2-16. Flowmeter Assembly, Secondary Gas, P/N 22174

37

SECTION 2 INSTALLATION

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

100 PSIG

80 PSIG

Pressures Shown Are Measured At Flowmeter Outlet

2

60 PSIG

SCFH N

Figure 5. Flowmeter Calibration Curves

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

38

2.0

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700

1.0

Flowmeter Reading (Measured At Top Of Ball)

SECTION 3 OPERATION

3.1. GENERAL

Operating with a plasma system such as the ESP-1000
contains a great number of variables to achieve quality
cutting over a wide range of applications. The setup and
operating characteristics for specic applications depend
on, type of material, thickness of material, type of cut gas,
dry cutting, water injection cutting or underwater cutting.
The information in this section will provide standard pro­cedures and general guidelines for application.

WARNING

Electric shock can kill! Do not operate this equipment
with any covers removed. Take all precautions to re­move power before attempting any service or main­tenance inside cabinets or torch.

Arc rays can burn eyes and skin, noise can damage
hearing! Wear welding helmet with appropriate lter.
Wear ear and body protection.

3.2. CONTROLS AND INDICATORS

A. TEST/RUN

This area includes a 5-position switch, the CUT

WATER FLOW meter and the CUT WATER
PRESSURE SET regulator. The functions are:

1. CUT GAS position permits testing the cut gas ow
or purging the system without actually cutting.

2. START GAS permits testing the start gas ow or
purging the system without cutting.

3. RUN 1 position is used when cutting is to start with
the start gas, and after arc transfer occurs to switch
automatically to cut gas. This is one of two posi­tions for actual cutting to occur. (Oxygen cutting is
normally performed in this position.)

4. RUN 2 position is used when the start of the process
is done with the same gas and ow as the cutting
process. (This position is normally used when Nitro­gen and Argon-Hydrogen cutting is performed.

5. HF position permits testing of the high frequency
without cutting.

FLOW CONTROL

All controls are located on the front of the Flow Control.
The control panel is laid out in three sections, TEST/RUN,
CUT WATER, CUT GAS, plus, the Power Switch.

B. CUT WATER

This area pertains to control of the cut water ow for PT-

15XL only. The approximate ow rates for each position
are given in Table 3-1.

Figure 3-1. Flow Control Front Panel

39

SECTION 3 OPERATION

1. The ON/OFF switch is used to select whether or
not cut water is to be used. If ON, the ow rate is
determined by the setting of the ow rate switches.
This switch should always be ON for cutting with
the PT-15XL torch and o with the PT-19XLS (PT-

600).

2. FLOWRATE switches. The 8-position rotary switch
and two position toggle switch are used to set the
cut water ow rate. The 8-position switch (0-7) is
used for inputs within the ow control that deter­mines the water ow rates. The switch operates
a combination of three of four solenoid valves in
parallel. The fourth valve is operated by the HIGH/
LOW switch. The cut water ows through measur­ing orices in each line of the four solenoid valves.
The orices vary in size so that each is capable of
doubling the ow, the largest orice delivers eight
times the ow as the smallest.

In the 0/ LOW setting no solenoid is energized. Posi-

tion 1 energizes the solenoid valve in the smallest
orice line. Position 2 energizes the valve next in
line of ow rate. Position 3 energizes both of these
valves. The progression continues to provide more
ow at each higher numbered position in equal
increments. In combination the four valves are
capable of providing dierent ows but the switch
limit is eight settings. The HIGH/LOW switch is used
to energize the solenoid with the largest orice that
allows using the remainder of the ows.

C. CUT GAS

This area includes the O
8-position switch and HI/LOW toggle switch. Refer to Table
3-2 for approximate ow rate for specic settings.

1. The O2/N2 switch selects the type of cut gas being
used for cutting.

2. FLOWRATE switches. The 8-position rotary switch and
two position toggle switch are used to set the cut
gas ow rate. The 8-position switch (0-7) is used for
inputs within the ow control that determines the
gas ow rates. The switch operates a combination of
three of four solenoid valves in parallel. The fourth
valve is operated by the HIGH/LOW switch. The cut
gas ows through measuring orices in each line of
the four solenoid valves. The orices vary in size so
that each is capable of doubling the ow, the largest
orice delivers eight times the ow as the smallest.

In the 0/ LOW setting no solenoid is energized. Posi-

tion 1 energizes the solenoid valve in the smallest
orice line. Position 2 energizes the valve next in
line of ow rate. Position 3 energizes both of these
valves. The progression continues to provide more
ow at each higher numbered position in equal
increments. In combination the four valves are
capable of providing dierent ows but the switch
limit is eight settings. The HIGH/LOW switch is used
to energize the solenoid with the largest orice that
allows using the remainder of the ows.

switch, Flow Rate that is an

2/N2

TABLE 3-1. CUT WATER FLOW RATES

SWITCH SETTING/

FLOW RATE

0/LOW 0
1/LOW 0.03
2/LOW 0.07
3/LOW 0.10
4/LOW 0.14
5/LOW 0.17
6/LOW 0.21

7/LOW 0.24
0/HIGH 0.28
1/HIGH 0.31
2/HIGH 0.35
3/HIGH 0.38
4/HIGH 0.41
5/HIGH 0.45
6/HIGH 0.48
7/HIGH 0.51

CUT WATER GPM

TABLE 3-2. CUT GAS FLOW RATES

SWITCH SETTING/

FLOW RATE

0/LOW 0
1/LOW 20
2/LOW 40
3/LOW 60
4/LOW 80
5/LOW 100
6/LOW 120

7/LOW 140
0/HIGH 160
1/HIGH 180
2/HIGH 200
3/HIGH 220
4/HIGH 240
5/HIGH 260
6/HIGH 280
7/HIGH 300

CUT GAS (O2/N2)

SCFH

40

SECTION 3 OPERATION

POWER SOURCE (ESP-600C)

All control functions are provided through one receptacle
located on the front panel of the power source. A 19-pin re­ceptacle allows plugging in the cable from the ow control.
All control signals are routed through this connection.

A. The current control mode for the power source is set

using the PANEL/REMOTE switch.

1. With the switch in the PANEL position, output current
is controlled by setting the power source current
control potentiometer (CCP).

2. With the switch in the REMOTE position, output
current is controlled from a remote device such as
a cutting machine CNC.

B. When using an ESP-600C power source, the LED indica-

tor lights on the front panel are used to help check for
proper operation of the unit.

1. OVER TEMP - illuminates should the power source
become over heated.

2. CONTACTOR ON - This light indicates that the main
power contactor has been energized and voltage is
being applied to the cutting circuit.

3. FAULT INDICATOR - illuminates should abnormalities
occur in the cutting process or if the input line volt­age falls outside of the nominal value by +/- 10%.

F. AMMETER displays the arc current level when cut-

ting.

For control descriptions pertaining to the ESP-400
and Ultra Life 300 refer to the appropriate instruction
manual.

3.3. PRE-OPERATION TEST/CHECKOUT

The pre-operation testing and checking oers the ad­vantage of having the parameters set and established in
proper order before starting to cut actual material.

A. TEST FUNCTIONS

The TEST/RUN portion of the Flow Control front panel

allows the user to test parts of the system, purge gas,
water lines and to select between two dierent RUN
modes.

B. RUN MODES

The rst run mode (RUN 1) starts with start gas (at start

gas ow) and switches over to cut gas when the arc
transfers.

The start gas is taken from the N2 gas input on the back

of the ow control box. The cut gas is taken either from
the N2 or the O2 input on the back of the ow control
box. The selection of the cut gas is accomplished with
the O2/N2 selector switch on the front panel.

4. POWER RESET FAULT - illuminates when a serious
fault is detected. Input power must be disconnected
far at least 5 seconds and then reapplied.

C. MAIN POWER indicator illuminates when input power is

applied to the Power Source.

D. PILOT ARC HIGH/LOW switch allows selection of the

pilot arc range HIGH or LOW.

E. VOLTMETER displays the arc voltage value when cut-

ting.

TABLE 3-3. TEST/RUN SELECTION DESCRIPTION

TEST POSITIONS ACTIVATED FUNCTION

START GAS CUT GAS CUT WATER HF

CUT GAS NO YES YES (if on) NO
START GAS YES NO YES (if on) NO
HF YES NO NO YES

The second run mode (RUN 2) starts directly with cut

gas ow. In this case the gas used for cutting must
be connected to the N2 input on the back of the ow
control.

NOTE

Purging of gas leads should be possible even if insucient
gas pressure exists on incoming gas pressure switches.

41

SECTION 3 OPERATION

C. TEST FUNCTIONS

The tests are used to test and purge gas and water. The

test of the HF unit is made without activating the main
contactor of the power source. Since water is tested
at the same time, some of the tests are combined to
reduce the number of positions on the switch.

WARNING

Never operate the power source with the cover re­moved. In addition to the safety hazard, improper
cooling may cause damage to internal components.
Keep side panels closed when unit is energized. Also,
make sure you are adequately protected before you
start to cut.

Ensure that the power cable connections are properly
made to prevent water leaks. Any leakage during op­eration could be hazardous because of high voltage
and current.

CUT GASES

A. Set the delivery pressure of the gas supply regula-

tors according to the Table 3-4 (with gas owing).
For example, the recommended delivery pressure
for nitrogen cut gas and 50 feet of 1/4 inch ID hose is
104 psig. Delivery gauge mounted on regulator must
not read greater than 200 psig. Refer to Table 2-3 for
recommended gas regulators.

NOTE

Do not use hoses less than 1/4 inch ID in
the system.

CUT WATER

A. Basic Requirements

The PT-15XL requires a supply of clean cut water with

high electrical resistance.

1. To adjust the delivery pressure of the water injection
pump, remove the
pump and turn screw "in" to increase pressure or "out"
to reduce pressure. After adjusting replace the
nut.

2. The water injection pump must be supplied with
water from a source capable of delivering at least 1/2
gpm @ 25 psig minimum. The water injection pump
boosts this pressure to 190 to 200 psig for delivery to
the ow control.

3. Cut water must have a high electrical resistance (at
least 200,000 ohm-cm is recommended) and low
hardness (0.5 grains per gallon maximum). Conduc­tive water can cause problems with starting reliabil­ity, high frequency noise problems with the cutting
machine or height control, and can cause corrosion of
torch parts such as; cups, nozzles. These deposits will
reduce cooling, lower cut quality by disrupting ow
through the nozzle, and can clog the ow control.

Tribed deionizer systems have generally proved to be the
best solution to supplying good quality cut water. Some
sources of deionizer systems are:

Culligan Water Treatment 708-205-6000
ECO Water Systems 513-423-9421
Master Chemical Corporation 419-874-7902

Local distributors can be found in the phone book or by
calling one of the above numbers.

acorn

nut located on top of the

acorn

TABLE 3-4. RECOMMENDED REGULATOR PRESSURE SETTINGS (PSIG)

CUT
GAS

TYPE

O

2

N

2

H-35 For PT-15XL 138 139 141 144 135 135 137 138 135 135 135 135

1/4-IN. ID HOSE

LENGTH IN FEET

12.5 25 50 100 12.5 25 50 100 12.5 25 50 100
100 100 100 100 100 100 100 100 100 100 100 100
100 103 104 105 100 100 100 102 100 100 100 100

5/16-IN. ID HOSE

LENGTH IN FEET

42

3/8-IN. ID HOSE

LENGTH IN FEET

SECTION 3 OPERATION

CUT WATER BLOWDOWN

After deionizing, water should pass through a 30-micron lter
before going to the cut water pump. Refer to Figure 2-13 for
further details of installation.

B. Cut Water Flow System Calibration

If the equipment is to be exposed to freezing temperatures
(while during non-operative time), water lines should be
blown out to prevent freeze damage to torch and equip­ment.

This is done to calibrate the cut water system when used

with the PT-15XL torch. Once it is completed, the cut
water ow is set with the ow rate switches for each case
according to the dierent cutting cable sizes.

1. Make sure that the Flow Control is turned on, the ON/
OFF switch is in the ON position and the indicator
light is lighted.

2. Set TEST/RUN selection switch to either CUT GAS or
START GAS position.

3. Set CUT WATER ON/OFF switch to ON.

4. Set CUT WATER HIGH/LOW switch to HIGH.

5. Set FLOW RATE switch to position 5.

6. Adjust CUT WATER pressure adjusting screw until the
CUT WATER FLOW gauge reads 0.45 gpm at the top
of the ball. Ensure that cut water pump gauge reads
no more than 220 psig. The preferred reading is 190
to 200 psig.

7. Toggle the CUT WATER ON/OFF switch a few times to
ensure any creep is out of the regulator adjustment.
Readjust if necessary.

The cut water system is now calibrated. This calibration

should be checked occasionally.

NOTE

Blowdown of the coolant system is not required if Plasma
Torch Coolant is used.

To blowdown the water injection system, disconnect water
supply to the Water Injection Pump and connect a supply
of nitrogen or clean air at 130 to 150 psig. Set the system
in test and set cut water ow to HIGH 7. Let the gas ow
until water stops coming out the front of the torch. It is
important that the Start Gas or Cutting Gas continues to
be supplied (at the same time as the purging air/nitrogen),
to prevent water feedback into the gas lines.

To blowdown the cooling system, disconnect the hose
from the cooler or pump and connect it to nitrogen or
clean air at 20 psig. The return hose should be connected
to drain. Blow gas through the system until coolant no
longer comes out the drain line. Do Not operate the cool­ant circulator without using plasma coolant 156F05 . The
coolant provides lubrication of the internal pump parts.
Algae growth and damage to the pump may occur if plain
water is substituted.

NOTE

Contact the supplier of the deionizer to discuss freezing
of the deionizing system.

POWER SOURCE

COOLANT

Cooling of the plasma torch is usually accomplished with a
coolant circulator. This circulator should be lled with plasma
torch coolant. Always use torch coolant, it lubricates the in­ternal parts of the pump.

WARNING

Settings over 150 psig will cause premature failure of the
pump and/or motor-to-pump coupling.

Check out the coolant ow with the power source ON, by
observing the return water at the cooler. Coolant ow with N2
consumables should be 1.4 to 1.6 gpm. Coolant ow with O2
consumables should be 1.25 gpm. Coolant can be conveniently
checked at the return line by using a suitable container.

WARNING

Never operate the power source with the cover re­moved, in addition to the safety hazard, improper
cooling can cause damage to internal components.
Keep side panels closed when unit is energized. Also,
make sure you are adequately protected before you
start to cut.

The Power Source controls and their functions are de­scribed in the following sequence.

A. Check the secondary output connections to the posi-

tive and negative output bus bar terminals.

B. Verify that the control connections have been prop-

erly made.

43

SECTION 3 OPERATION

C. Determine the current control mode the power source is

to be operated in and set the Control Switch in the desired
position. With this switch in the PANEL position, output
current is controlled by setting the power source current
potentiometer. When the power source output current
is controlled by a cutting machine control system, place
this switch in the REMOTE position.

D. If the primary electrical input connections to the power

source have been installed correctly, close the main line
(wall) disconnect switch. Power will be applied and the
Pilot Light on the front panel will be on. The cooling fans
will come on when cutting starts.

E. Adjust the desired output current level at the power

source or at the remote control location.

F. Operate the starting switches on the cutting control to

energize the power source main contactor. Power will
appear at the power source output bus bar terminals.

G. After cutting has started, observe the ammeter, voltmeter

and/or the cutting operation. If necessary readjust the
current control as required.

H. The cutting arc will extinguish and the power source will

shut o automatically when the torch travels beyond the
edge of the work piece. The nozzle and electrode will
experience excessive wear (especially with O2). Therefore,
extinguishing the arc with an Arc Stop Signal before run­ning o the work piece is recommended.

A properly installed and operating power source should func­tion as follows:

A. After energizing the power source (at the disconnect

switch), the Main Power light (on the front panel) will il­luminate and the Fault Indicator light will ash and then
go out.

B. When the contactor signal is received ( the "Contactor

On" indicator will light) and power is applied to the main
transformer, Open Circuit Voltage is available at the power
source output terminals as indicated on the voltmeter.

C. Upon transfer of the main arc to the work, a current de-

tector circuit senses the current and sends an "ARC ON"
signal to the Flow Control.

3.4. OXYGEN CUTTING WITH PT-15XL

The procedures presented in this section pertain to use of
Oxygen as the cutting gas in conjunction with the PT-15XL
plasma cutting torch. The information is relative to setting
parameters for various types and thicknesses of materials.
Refer to the torch instruction manual F-15-031 for details
of the torch assembly.

WARNING

Electric shock can kill! Before touching the torch, be
sure the power source is shut o by removing the
3-phase power input to the power source.

A. Ensure that the torch is assembled correctly for oxy-

gen cutting. Internal parts of torch must be clean and
dry.

B. If using an air curtain or bubble muer, be sure instal-

lation and setup are correct.

C. Set Flow Control O2/N2 switch to O2 position.

D. Set the Flow Control CUT WATER ON/OFF switch to

ON.

E. Set the Cut Water and Cut Gas ow as indicated in

Table 3-6.

NOTE

Cut Water must be calibrated as described on Page 27.

F. Set Flow Control TEST/RUN switch to CUT GAS TEST

position.

1. Ensure that O2 regulator is set to 100 psig.

2. Observe torch spray pattern. It should be rela­ tively even, regular and steady.

G. Set Flow Control TEST/RUN switch to START GAS TEST

position.

H. Set start gas regulator on Plumbing Box to 26 psig.

Check N2 regulator setting per Table 3-4.

I. After changing consumables or a substantial break in

cutting operations, purge the torch in CUT GAS TEST
position for at least 60 seconds before cutting.

J. Set the TEST/RUN switch in the RUN 1 position. The

system is ready to cut.

44

SECTION 3 OPERATION

GAS

BAFFLE

OXYGEN
ELECTRODE

BODY
ASSEMBLY

NOZZLE

NOZZLE RETAINING
CUP

Figure 3-2. PT-15XL Torch Components for Oxygen Cutting

TABLE 3-5. COMPONENTS FOR OXYGEN CUTTING WITH PT-15XL

OXYGEN
ELECTRODE
HOLDER

ELECTRODE

HOLDER

20398 20763XL 0.099 260A 20751 8-HOLE

ELECTRODE NOZZLE ASSEMBLY SWIRL BAFFLE

Diameter RATING P/N standard optional

35666XL

(FLAT)

0.099
REV.

0.116

0.120

0.116
REV.

0.120
REV.

260A 20920 8-HOLE

300A
340A

300A 35663 8-HOLE

340A 35665

35662
35664

FRONT BODY
INSULATOR
ASSEMBLY

NOTE: Refer to F-15-031 for part
numbers and options.

4-HOLE

CERAMIC

2075586

CERAMIC

REVERSE

20918

8-HOLE

CERAMIC

35660

CERAMIC

REVERSE

35661

CERAMIC

948142

4-HOLE
CERAMIC
REVERSE

948143

N/A

45

SECTION 3 OPERATION

TABLE 3-6. OXYGEN CUTTING CONTROL SETTINGS WITH PT-15XL

MATERIAL

THICKNESS

(CARBON

STEEL)

1/8 200 120-125 LOW 5 HIGH 7 175-200 1/2" FOR
1/4 260 120-125 LOW 5 HIGH 7 150-170 PIERCING
1/2 260 125-130 LOW 5 HIGH 7 90-100 1/8-5/32"
3/4 260 130-135 LOW 5 HIGH 7 60-70 FOR

*1 260 135-140 LOW 5 HIGH 7 40-50 CUTTING

Higher speed is sometimes obtained on thicker plate by increasing gas setting to LOW 6.
* Dross free conditions on 1" are more easily obtained at 300 to 340 amps.

CURRENT

AMPS

VOLTAGE

SETTING

OXYGEN

CUT GAS

FLOW

NOTES

CUT

WATER

FLOW

CUT

SPEED

(Inches

per min-

ute)

STANDOFF
(TORCH TO

WORK - inches)

• Cuttingspeedsgivenareaverage.Theymayvarywithmaterialcompositionandsurfacecondition.

• Onlyceramicbaesmaybeusedwithoxygencutting.

• Useofmorethan260ampswhencuttingwithoxygenwillreduceelectrodeandnozzlelife.

• Thenozzlesforoxygenservice,PN20751and20920,arefactoryassembledandshouldnotbetakenapart.Itmust

be replaced as a complete unit.

• Thenozzlesforoxygenservice,PN21206Band21207B,haveareplaceableinsulator,PN21193.

• Replaceelectrode,PN20763XL,whenthecavityinthehafniuminsertreaches0.09"indepthor0.12"indiameter.

• Removingthenozzlefromthetorchtocheckelectrodeweargreatlyreduceselectrodelife.Removenozzleonlywhen

changing electrode or cut quality has deteriorated.

• Reversenozzleandswirlbaesareusefulinapplicationswheretwoplasmatorchesarecuttingwith onecutting

mirror images.

• 8-HolebaesarerecommendedforESPsystems.Consumablelifeisextended.

• Cuttingconditionshavebeendevelopedupto360amps.

46

SECTION 3 OPERATION

TABLE 3-7. HIGH CURRENT OXYGEN CUTTING WITH PT15XL

MATERIAL

THICKNESS

(CARBON

STEEL)

1/4 300 126 HIGH 1 HIGH 7 225-250 5/32
3/8 300 128 HIGH 1 HIGH 7 165-180 5/32
1/2 300 130 HIGH 1 HIGH 7 135-145 5/32
3/4 300 144 HIGH 1 HIGH 7 75-85 1/4

1 300 148 HIGH 1 HIGH 7 50-60 1/4

3/4 340 130-132 LOW 6 HIGH 7 85-100 5/32-3/16

1 340 128-135 LOW 6 HIGH 7 59-65 5/32-1/4
1-1/4 340 140 LOW 6 HIGH 7 40-45 1/4
1-1/4 360 140 LOW 6 HIGH 7 45-50 1/4

MATERIAL

THICKNESS

(CARBON

STEEL)

1/4 300 126 HIGH 1 225-250 5/32 20
3/8 300 127 HIGH 1 165-180 5/32 20
1/2 300 132 HIGH 1 135-145 5/32 30
3/4 300 144 HIGH 1 75-85 1/4 30

1 300 148 HIGH 1 50-60 1/4 30

3/4 340 131 LOW 6 75-95 5/32 20

1 340 130 LOW 6 59-65 5/32 20
1-1/4 340 140 LOW 6 40-45 1/4 30
1-1/4 360 140 LOW 6 45-50 1/4 30

CURRENT

AMPS

TABLE 3-8. OXYGEN UNDERWATER CUTTING WITH PT-15XL

CURRENT

AMPS

VOLTAGE

SETTING

Cut water ow setting should be HIGH 7

VOLTAGE

SETTING

OXYGEN

CUT GAS

FLOW

OXYGEN

CUT GAS

FLOW

CUT

WATER

FLOW

CUT

SPEED

(Inches per

minute)

CUT

SPEED

(Inches

per min-

ute)

STANDOFF

(TORCH

TO

WORK -

inches)

STANDOFF
(TORCH TO

WORK - inches)

AIR CURTAIN

PRESSURE

(PSIG)

Cut water ow setting should be at HIGH 7.

NOTES

Nitrogen Start Gas setting should be at 26 psig for both above and under water cutting.

Torch components for both above and underwater oxygen cutting with a PT-15XL are:

Nozzle - PN 35662 or 35663 reverse up to 300 amps
PN 35664 or 35665 reverse for over 340 to 360 amps

Swirl Bae - PN 35660 or 35661 reverse

Electrode - PN 35666XL

47

SECTION 3 OPERATION

TABLE 39. LOW CURRENT CUTTING CONDITIONS WITH PT15 ABOVE WATER

MATERIAL
TYPE/
THICKNESS

CS/ 0.078 70 125 OXY  LOW 5 LOW 5 240 0.156
CS/0.125 70 129 OXY  LOW 5 LOW 5 165 0.156
CS/0.188 90 129 OXY  LOW 5 LOW 5 140 0.156
CS/0.250 90 134 OXY  LOW 5 LOW 5 120 0.156
CS/0.312 125 134 OXY  LOW 5 LOW 5 120 0.156

SS/0.062 60 128 OXY  LOW 5 LOW 5 150 0.156
SS/0.125 65 130 OXY  LOW 5 LOW 5 100 0.156
SS/0.188 75 132 OXY  LOW 5 LOW 5 125 0.156
SS/0.250 90 136 OXY  LOW 5 LOW 5 100 0.156
SS/0.312 125 137 OXY  LOW 5 LOW 5 90 0.156

AL/0.062 100 136 OXY  LOW 5 LOW 5 175 0.156
AL/0.125 100 128 OXY  LOW 5 LOW 5 125 0.156
AL/0.250 100 135 OXY  LOW 5 LOW 5 75 0.156
AL/0.312 125 136 OXY  LOW 5 LOW 5 75 0.156
AL/0.375 125 149 OXY  LOW 5 LOW 5 50 0.156

CURRENT
AMPS

VOLTAGE
SETTING

CUT GAS
FLOW

CUT WATER
FLOW

CUT SPEED
IPM

STANDOFF
TORCH TO
WORK  IN.

SS/0.062 80 155 NIT  LOW 5 LOW 4 275 0.156
SS/0.125 100 150 NIT  LOW 5 LOW 4 150 0.156
SS/0.188 125 155 NIT  LOW 5 LOW 5 100 0.156
SS/0.250 125 156 NIT  LOW 5 LOW 5 90 0.156
SS/0.312 125 162 NIT  LOW 5 LOW 5 75 0.156

AL/0.062 65 160 NIT  LOW 5 LOW 5 150 0.156
AL/0.125 65 160 NIT  LOW 5 LOW 5 100 0.156
AL/0.250 125 160 NIT  LOW 5 LOW 5 100 0.156
AL/0.312 125 167 NIT  LOW 5 LOW 5 50 0.156
AL/0.375 125 179 NIT  LOW 5 LOW 5 45 0.156

NOTES: 1. N

2. When using the ESP-300 power supply, low range must be used for current under 80 amps. High range

3. Gas Bae: 948142 "4x030"
948143 "4x30 Rev."
Electrode: 35666XL
Nozzle: 37317 "Nozzle low current PT-15XL"
37318 "Nozzle low current PT-15 Rev."

itrogen generally produces smoother cut surfaces on stainless steel and aluminum, but with

somewhat more bevel and top edge rounding than oxygen. Oxygen generally has a wider
dross free speed range.

will produce less ripple on the cut face and can usually be user at current over 80 amps. The cut face
ripple is most noticeable on stainless steel cut with nitrogen.

48

SECTION 3 OPERATION

3.5. NITROGEN CUTTING WITH PT-15XL

WARNING

Electric shock can kill! Before touching the torch, be
sure the power source is shut o by turning o the
3-phase power input to power source.

The procedures presented in this section pertain to use
of Nitrogen as the cutting gas in conjunction with the
PT-15XL plasma cutting torch. The information is relative
to setting parameters for various types and thicknesses of
materials. Refer to the torch instruction manual F-15-031
for details of the torch assembly.

A. Ensure that the torch is correctly assembled for nitro-

gen cutting. (Refer to Table 3-9 for components.)

TABLE 3-10. COMPONENTS FOR NITROGEN CUTTING WITH PT-15XL

B. Set Flow Control switch O2/N2 in the N2 position.

C. Set Flow Control CUT WATER ON/OFF switch to ON

position.

D. Set CUT WATER and CUT GAS ow per Table 3-10.

NOTE

Cut water must be calibrated as described on page 26.

E. Set Flow Control TEST/RUN switch in CUT GAS TEST

position.

1. Ensure that N2 regulator is set per Table 3-4.

2. Observe spray pattern. It should be relatively
even, regular and steady.

ELECTRODE

HOLDER

2075343 600236 .125 250A 2075691 2075341 948142

ELECTRODE NOZZLE ASSEMBLY SWIRL BAFFLE

Diameter RATING P/N standard optional

.156 400A 2075611 4-HOLE 4-HOLE
.200 600A 2075612 PLASTIC CERAMIC
.230 750A 2075613

REVERSE

.125 250A 2075692 2075360 948143
.156 400A 2075614 4-HOLE 4-HOLE
.200 600A 2075615 PLASTIC CERAMIC
.230 750A 2075690

NOZZLE RETAINING

CUP

NOZZLE
ASSEMBLY

Figure 3-3. Nitrogen Components for PT-15XL

ELECTRODE
HOLDER

BODY
ASSEMBLY

FRONT BODY

INSULATOR
SWIRL
BAFFLE

ELECTRODE

49

SECTION 3 OPERATION

TABLE 3-11. PARAMETERS FOR NITROGEN CUTTING WITH PT-15XL

MATERIAL

THICKNESS

1/32 250 NA LOW 6 LOW 6 1/4
1/16 NA 350 385 400
1/8 150-155 265 290 340
3/16 155-160 200 220 270
1/4 160-165 140 155 200
3/8 165-1170 ----- ----- 180
1/16 400 NA LOW 7 HIGH 0 3/8
1/8 NA 330 360 400
3/16 NA 250 280 320
1/4 145-150 160 180 240
3/8 150-155 135 145 210
1/2 155-165 110 120 170
3/4 165-175 60 70 110
1 175-180 45 50 60
1/2 600 140-150 HIGH 1 HIGH 3 3/8
3/4 155-160 75 80 130
1 160-170 65 75 100
1-1/2 175-185 1/2 33 36 50
2 180-190 22 24 38
3/4 750 160 HIGH 4 HIGH 7 5/8
1 170 75 80 ----­1-1/2 185 40 44 ----­2 190 28 30 45
3 210 13 14 30

CUR-

RENT

AMPS

VOLTAGE

SETTING

NITROGEN

CUT GAS

CUT WATER

FLOW

STANDOFF

(INCH)

CUT SPEED (IPM)

carbon

steel

500 550 600

450 490 500

130 140 190

90 98 -----

stainless

steel

alumi-

num

NOTE

When changing consumables always wipe any water

or coolant from new parts before restarting a torch.
The electrode removal nut driver must be clean. It
must not leave any contamination on the electrode.

F. After changing consumables or any substantial break

in cutting operations, purge the torch in START GAS
TEST for at least 60 seconds before cutting.

CAUTION

Purge the gas line with the Flow Control TEST/RUN
switch in the CUT GAS position for three minutes when
switching from O2 to ArH2 or N2 cutting. This will ensure
that no O2 exists in the cut gas lines. Small amounts of
O2 will cause rapid erosion of the tungsten electrode
that is used for cutting with N2 or ArH2.

G. Set Flow Control TEST/RUN switch in the RUN 2 posi-

tion.

The system is now ready to cut.

Underwater Nitrogen Cutting

When cutting plates up to 1 inch thick using N2 underwa­ter, cutting speeds and cut surface appearance are not
appreciably aected. Therefore, the data in Table 3-10 are
suitable for both above and underwater cutting.

Cut quality and cutting speed diminish when cutting
1-to-3 inch thick materials underwater, particularly alumi­num. The 0.230 inch nozzle is not recommended for cut­ting under water; however, the 0.200 inch nozzle assembly
may be used for cutting up to 3 inch thick aluminum at
600 amps and still give a reasonable appearing cut. The
approximate cutting speeds for underwater cutting of ma­terials 1-to-3 inches are given in Table 3-12. Flow settings
for each nozzle are the same as given in Table 3-11.

DANGER

Hydrogen explosion hazard! Read the precautions on
page 42 before starting under water cutting.

50

SECTION 3 OPERATION

TABLE 3-12. UNDERWATER CUTTING SPEEDS

MATERIAL

THICKNESS

(inches)

1 0.200
1-1/2 175-185 1/2 30 33 50
2 0.200
2-1/2 190 5/8 ---- ---- 28
3 210 5/8 ---- ---- 20

1-1/2 0.230
2 190 5/8 20 20 ---­3 0.230

2075612

REVERSE
2075615

2075613

REVERSE
2075690

NOZZLE

ASSEMBLY

DIA./ PN

CUR-

RENT

AMPS

600 160-170 1/2 50 65 80

750 185 5/8 35 35 ----

VOLTAGE

SETTING

180-190 1/2 15 18 35

210 5/8 8 8 ----

STANDOFF

(INCH)

3.6. H-35 CUTTING WITH THE PT-15XL

H-35 is a mixture of hydrogen and argon that is used
for cutting material thicknesses of 3 to 6 inches. The
hydrogen component of the gas is ammable, requiring
certain precautions. Underwater cutting with H-35 is not
recommended. Table 3-14 provides the control settings
for cutting conditions.

When changing consumables, always wipe any water or
coolant from parts before installing and restarting torch.
The electrode removal nut driver must be clean. It must
not leave any contamination on the electrode.

B. Set Flow Control O2/N2 switch to N2.

CUT SPEED (IPM)

carbon

steel

stainless

NOTE

steel

alumi-

num

A. Install high current parts in torch per Table 3-13.

RETAINING
CUP

Figure 3-4. PT-15XL Front End Assembly for H-35 Cutting

TABLE 3-13. COMPONENTS FOR H-35 CUTTING WITH PT-15XL

NOZZLE

ELECTRODE

HOLDER

2075343 600236 .250

ELECTRODE NOZZLE ASSEMBLY SWIRL BAFFLE

Diameter RATING P/N standard optional

ELECTRODE
HOLDER

ELECTRODE

875A to

1000A

C. Set Control CUT WATER ON/OFF to ON.

BAFFLE

2075586

2075587

8-HOLE

CERAMIC

NONE

51

SECTION 3 OPERATION

TABLE 3-14. CONTROL SETTINGS FOR H-35 CUTTING

MATERIAL

THICKNESS

(inches)

CUR-

RENT

AMPS

VOLTAGE

SETTING

H-35

CUT GAS

CUT WATER

FLOW

STANDOFF

(INCH)

CUT SPEED (IPM)

carbon

steel

stainless

steel

3 875 215 HIGH 7 HIGH 7 3/4 13 13 27
4 220 10 10 15
5 1000 230 HIGH 7 HIGH 7 3/4 5 6 10
5-1/2 235 4 5 9
6 240 3 4 8

D. Purge cut gas lines.

1. Disconnect O

. Place the Flow Control TEST/RUN

2

switch in the CUT GAS TEST position. Purge with
N2 for three minutes.

2. Connect H-35 to the Flow Control N2 IN connector
and purge N2 from the lines for 60 seconds.

E. Set H-35 regulator in accordance with Table 3-4.

3.7. CUTTING WITH THE PT-19XLS and
PT-600 TORCHES

The PT-19XLS and PT-600 are mechanized plasma cutting
torches designed for cutting without water injection. Cut­ting can be performed using air, oxygen, nitrogen or H-35
as the cut gas at currents ranging from 50 to 360 amperes.
Underwater cutting can be performed with the PT-19XLS
by using an Air Curtain at 150 amps or higher. Refer to
your torch manual.

F. Set Flow Control TEST/RUN switch to RUN 2 posi­ tion. The system is now ready for cutting.

alumi-

num

Shield Retainer ­37081

Shield
50A - 21795
100-250A - 21802
250-600A - 21945

Nozzle Retainer Cup ­37082

Diuser
50A - 21796
100-600A - 21944
100-600A Rev - 22496

Nozzle Assembly
250A - 21822
360A - 35885
400A - 22195
600A - 22401

Nozzle Tip

50A - 22026
100A - 22029
150A - 22030
200A - 22031

Electrode

/Air - 34086XL

O

2/N2

H-35 - 34557
400A, O2, N2, Air, H-35 - 22196
600A, N2, H-35 - 22403

Electrode Holder -

Nozzle Base
50A - 22027
100-200A - 22028

37068

Gas Bae
50-200A - 948142
250-600A - 35660
400A, O

- 22194

2

Figure 3-5. PT-19XLS Components

Reference only. Refer to your torch manual for specic or updated instructions

52

SECTION 3 OPERATION

Table 3-15 COMPONENT SELECTION FOR PT-19XLS

Application

Current & Thickness Shield Diuser Nozzle Electrode Gas Bae
Plasma Gas & Material

50-65A 1.16 to 6mm 50A 50A Tip-22026 34086XL 948142
Air & N2 CS, SS, AL 21795 21796 Base-22027 4 Hole STD

100A 4 to 19mm 100A-250A 100-360A Tip 22029 34086XL 948142

, O2 CS, SS, AL 21802 21944 Base 22028 4-Hole STD

Air, N

2

948143
22496Rev. 4 Hole Rev

150A 6 to 25mm 100A-250A 100 -360A Tip 22030 34086XL 948142
Air, N2, O2 CS, SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.

150A 6 to 25mm 100A-250A 100-360A Tip 22030 22403 948142
N2, H35 SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.

200A 6 to 50mm 100A - 250A 100 - 360A Tip 22031 34086XL 948142
Air, N2, O2 CS, SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.

200A 6 to 38mm 100A-250A 100-360A Tip 22031 22403 948142
N2, H35 SS, AL 21802 21944 Base 22028 4 Hole STD
948143
22496Rev. 4 Hole Rev.

250A 6 to 50mm 100A-250A 100-360A 21822 34086XL 35660
Air, O2 CS, SS, AL 21802 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.

250A 6 to 50mm 100A-250A 100-360A 21822 22403 35660
N2, H35 SS, AL 21802 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.

325-360A 13 to 50mm 360A 100-360A 35885 35886XL 35660
Air, N2, O2 CS, SS, AL 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.

325-360A 13 to 50mm 360A 100A-360A 35885 22403 35660
N2,H35 CS, SS, AL 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047 Rev.

400-450A 19 to 50mm 360A 100A-360A 22195 22196 22194
O2 CS, SS, AL 21945 21944 (1-Piece 32 x .023

400-450A 19 to 50mm 360A 100A-360A 22195 22403 35660
N2, H35 AL, SS 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047Rev.

600A 25 to 75mm 360A 100-360A 22401 22403 35660
N2, H35 CS, SS, AL 21945 21944 (1-Piece) 8 x .047
35661
22496Rev. 8 x .047Rev.

Recommended Replacement Parts

53

SECTION 3 OPERATION

NOTE
For expanded details of the PT-19XLS (PT-600) refer to the
your torch manual.

LOW CURRENT CUTTING WITH AIR AND PT-19XLS (50
to 100 Amps)

1. Ensure that the correct components are assembled

in the PT-19XLS (PT-600) for the cutting conditions.
Refer to Table 3-15.

ADAPTOR
999304

1/4 NPTM*

B-OXY -F*

CHECK VALVE
ASSEMBLY - 21124

HEX. NIPPLE
639501

4. Set the O2/N2 switch to N2 position.

5. Place CUT WATER switch to OFF.

6. Set CUT GAS Flow Rate as shown in Table 3-14.

7. Position TEST/RUN switch to RUN 1.

AIR REGULATOR
ASSEMBLY -522368

CONNECTOR
3389

1/4 NPTM*

1/4 NPTF*

* Use Locktite pipe sealant on threads, DO NOT use

Teon tape.

Figure 3-5. PT-19XLS (PT-600) Regulator Assembly

2. To cut with air, disconnect N2 supply from the Flow

Control. Connect a supply of clean, ltered air (ap­proximately 100 psig to the N2 inlet on the Flow
Control.

3. For low current cutting with the PT-19XLS (PT-600)

and ESP-1000 a cut gas regulator system is required
for air. See gure 3-5 for assembly details.

(2) 1/8" NPT
PIPE PLUGS
643792

8. Set start gas pressure as follows:

A. TEST/RUN switch to START GAS TEST.

B. Adjust start gas regulator to 30 psig.

C. Return TEST/RUN switch to RUN 1.

9. Set cut gas pressure as follows:

A. TEST/RUN switch to CUT GAS TEST

B. Adjust cut gas regulator to 60 psig.

1/4 NPTF*

1/4 NPTM*

B-OXY-M*

C. Return TEST/RUN switch to RUN 1 position.

54

SECTION 3 OPERATION

PT-19XLS (PT-600) H-35 CUTTING AT 150 TO 300

WARNING

AMPS

Electric shock can kill! Before touching torch, be sure
power source is shut o by turning o the 3-phase
power input to the power source.

OXYGEN AND AIR CUTTING WITH PT-19XLS (PT-600)
(100 - 360 AMPS)

1. Ensure that the torch is assembled correctly for oxy­gen or air cutting at the selected current level. See
Table 3-15 for parts and setup information.

2. If using PT-19XLS air curtain, see Form 15-475 for cor­rect installation and setup.

3. Set Flow Control O2/N2 switch to O2 position.

4. Set Flow Control Cut Water ON/OFF switch to OFF.

5. Set CUT GAS Flow per Cutting Tables starting on page

50.

6. Set Flow Control TEST/RUN switch to CUT GAS TEST.
Check that O2 regulator is set at 100 psig.

7. Set Flow Control TEST/RUN switch to START GAS TEST
switch. Adjust Start Gas regulator, on Plumbing Box, to
25 psig. Check that N2 regulator is set to 100 psig.

8. Purge torch in START GAS TEST position for at least
60 seconds before cutting after changing consum­ables.

9. Set Flow Control TEST/RUN switch in the RUN 1 posi­tion. The system is ready for cutting.

H-35 is a mixture of hydrogen and argon that can be
used with the PT-19XLS (PT-600) for cutting stainless and
aluminum. This mixture is ammable requiring certain
precautions. Underwater cutting with H-35 is not recom­mended.

1. Install H-35 torch parts for the chosen current level
per Table 3-15.

2. Set the Flow Control O2/N2 switch in the N2 position.

3. Set Flow Control CUT WATER ON/OFF switch to OFF.

4. Purge gas lines:

A. Disconnect O2, with the Flow Control in the CUT

GAS TEST position, purge with N2 for three min­utes.

B. Connect H-35 to the Flow Control N2 Inlet con-

nection and purge N2 from the lines for 60 sec­onds.

5. Check H-35 regulator for setting of 100 psig.

6. Adjust gas setting per Cutting Tables. The system is
now ready to cut.

3.8. HIGH CURRENT CUTTING CONDITIONS
PT-19XLS (PT-600)

PT-19XLS (PT-600) NITROGEN CUTTING AT 150 AND
250 AMPS

1. Ensure that the torch is assembled correctly for nitro­gen cutting at the selected current level. See Table
3-15 for parts and setup information.

2. If using a PT19XLS air curtain, see Form F-15-475 for
correct installation and setup.

3. Set Flow Control O2/N2 switch to N2 position.

4. Set Flow Control CUT WATER ON/OFF switch to OFF
position.

5. Set CUT GAS ow per Cutting Tables starting on page

50.

6. Set Flow Control TEST/RUN switch to START GAS TEST.
Adjust Start Gas Regulator, on Plumbing Box, to 26
psig. Check that N2 regulator is set to 100 psig

7. Purge torch in CUT GAS TEST position for at least 60
seconds after changing consumables before cutting.

8. Set Flow Control TEST/RUN switch to RUN 1. The sys­tem is now ready to cut.

By using special components in the front end assembly
of the PT-19XLS (PT-600) cutting can be accomplished at
higher current and faster speeds. Cutting carbon steel
can be performed either above water of underwater,
cutting stainless steel and aluminum underwater is not
recommended.
The cutting speeds listed in the following tables are aver­age values. Variations may occur depending on material
composition, surface conditions, etc. Practice cuts in a
scrap area of new material are recommended before
starting production cuts.

TORCH COMPONENTS FOR HIGH CURRENT
CUTTING

NOZZLE 360A P/N 35885
ELECTRODE 360A P/N35886XL
HEAT SHIELD 360A P/N 21945
DIFFUSER 360A P/N 21944
BAFFLE 8-HOLE P/N 35660
START GAS N

@ 25 PSIG

2

55

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

A.

To use the 50A or 100A nozzles with the ESP-1000 System, you must install a regulator at the Cut Gas conn

the Plumbing Box. See Figure 3-5.
B. Cut Gas & Start Gas input pressures to the ow control should be 100 psig (6.9 Bar) for all Nozzles and Gases.
c. Refer to torch manual for recommended torch parts for these cutting conditions.

ection on

Cutting Data:

NOZZLE

50-65 AMP

MATERIAL THICK­NESS

IN MM START

.063 1.6 30/2.1 60/4 2.2 .250 6 .125 3 115 50 180 4572
.125 3 30/2.1 60/4 2.2 .250 6 .125 3 115 50 110 2294
.250 6 30/2.1 60/4 3.5 .250 6 .156 4 128 65 65 165

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

50
ALUMINUM

VOLTAGE

Cutting Data:

50-65 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

50
ALUMINUM

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

AIR
AIR
AIR

MIN

MIN

N

2

N

2

N

2

.063 1.6 30/2.1 60/4 2.2 .250 6 .125 3 118 50 180 4572
.125 3 30/2.1 60/4 2.2 .250 6 .125 3 117 50 120 3048
.250 6 30/2.1 60/4 3.5 .250 6 .125 3 125 65 70 1778

Cutting Data:

50-65 AMP

MATERIAL THICK­NESS

IN MM START

.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 111 50 180 4572
.125 3 30/2.1 60/4 2.2 .250 6 .156 4 119 65 80 2032
.250 6 30/2.1 60/4 3.5 .250 6 .156 4 118 65 60 1524

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

50
STAINLESS STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

56

AIR
AIR
AIR

MIN

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

START GAS

50-65 AMP

MATERIAL THICK­NESS

IN MM START

.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 119 50 180 4572

.125 3 30/2.1 60/4 2.2 .250 6 .156 4 125 65 80 2032
.250 6 30/2.1 60/4 3.5 .250 6 .156 4 127 65 55 1397

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

50
ALUMINUM

VOLTAGE

Cutting Data:

50-65 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

50
CARBON STEEL

VOLTAGE

CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

N
N
N

MIN

AIR
AIR
AIR

MIN

2

2

2

.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 115 50 220 5588

.125 3 30/2.1 60/4 2.2 .250 6 .125 3 112 50 120 3048
.125 3 30/2.1 60/4 2.2 .250 6 .125 3 110 65 120 3048
.187 5 30/2.1 60/4 2.2 .250 6 .156 4 118 65 95 2413
.250 6 30/2.1 60/4 3.5 .250 6 .156 4 120 65 80 2032

Cutting Data:

100 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 45/3.1 3.5 .375 10 .187 5 154 100 100 2540

.375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 174 100 70 1778
.500 13 25/1.7 45/3.1 4.4 .375 10 .312 8 183 100 50 1270
.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 30 762

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

NOZZLE

100
ALUMINUM

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

AIR
AIR
AIR

MIN

57

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

100 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 45/3.1 4.4 .375 10 .125 3 154 100 55 1397
.375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 165 100 35 889
.500 13 25/1.7 45/3.1 3.5 .375 10 .312 8 180 100 25 635
.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 10 254

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

100
STAINLESS STEEL

VOLTAGE

Cutting Data:

100 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

100
STAINLESS STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

AIR
AIR
AIR

MIN

N
N
N

MIN

2

2

2

.250 6 25/1.7 35/2.4 4.4 .375 10 .125 3 153 100 55 1397
.375 10 25/1.7 35/2.4 4.4 .375 10 .187 5 157 100 45 1143
.500 13 25/1.7 35/2.4 4.4 .375 10 .187 5 162 100 35 889
.750 19 25/1.7 35/2.4 3.5 .500 13 .312 8 185 100 13 330

Cutting Data:

100 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 35/2.4 4.4 .375 10 .125 3 153 100 55 1397
.375 10 25/1.7 35/2.4 4.4 .375 10 .187 5 157 100 45 1143
.500 13 25/1.7 35/2.4 4.4 .375 10 .187 5 162 100 35 889
.750 19 25/1.7 35/2.4 3.5 .500 13 .312 8 185 100 13 330

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

NOZZLE

100
STAINLESS STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

N
N
AIR

MIN

2

2

58

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

100 AMP

MATERIAL THICK­NESS

IN MM START

.188 4 25/1.7 45/3.1 5.2 .375 10 .125 3 148 100 150 3810

.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 154 100 120 3048
.375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 159 100 65 1651
.500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 162 100 50 1270
.625 16 25/1.7 45/3.1 3.5 .500 13 .281 7 175 100 35 889
.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 184 100 20 508

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

100
CARBON STEEL

VOLTAGE

Cutting Data:

100 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

100
CARBON STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

TRAVEL
SPEED

AIR
AIR
AIR

MIN

N
O
AIR

MIN

2

2

.188 4 25/1.7 45/3.1 4.4 .375 10 .156 4 135 100 150 3810

.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 133 100 120 3048
.375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 149 100 80 2032
.500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 141 100 60 1524
.625 16 25/1.7 45/3.1 3.5 .500 13 .312 8 159 100 37 940
.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 162 100 20 508

Cutting Data:

150 AMP

MATERIAL THICK­NESS

IN MM START

.188 4 20/1.4 LOW 3 4.4 .375 10 .187 5 148 150 200 5080

.250 6 20/1.4 LOW 3 4.4 .375 10 .187 5 149 150 140 3556
.375 10 20/1.4 LOW 3 3.5 .375 10 .250 6 159 150 105 2667
.500 13 20/1.4 LOW 3 4.4 .375 10 .312 8 174 150 80 2032
.750 19 20/1.4 LOW 3 3.5 .500 13 .312 8 180 150 45 1143
1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 184 150 30 762

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

NOZZLE

150
ALUMINUM

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

AIR
AIR
AIR

MIN

59

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

150 AMP

MATERIAL THICK­NESS

IN MM START

.188 4 20/1.4 LOW 4 3.5 .375 10 .187 5 136 150 200 5080
.250 6 20/1.4 LOW 4 3.5 .375 10 .250 6 141 150 150 3810
.375 10 20/1.4 LOW 4 3.5 .375 10 .250 6 145 150 110 2794
.500 13 20/1.4 LOW 4 3.5 .375 10 .312 8 155 150 90 2286
.750 19 20/1.4 LOW 4 3.5 .500 13 .375 10 166 150 50 1270
1 25 20/1.4 LOW 4 3.5 .500 13 .375 10 171 150 30 762

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PSI/BAR

CUT
PSI/BAR

MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

NOZZLE

150
ALUMINUM

Cutting Data:

150 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

150
STAINLESS STEEL

START GAS
CUT GAS
SHIELD GAS

ARC

VOLTAGE

CUR­RENT

START GAS
CUT GAS
SHIELD GAS

ARC

VOLTAGE

CUR­RENT

N2 OR H-35
H-35
N

2

TRAVEL
SPEED

TRAVEL
SPEED

MIN

AIR
AIR
AIR

MIN

.188 4 20/1.4 LOW 3 4.4 .375 10 .187 5 138 150 200 5080
.250 6 20/1.4 LOW 3 3.5 .375 10 .187 5 146 150 165 4191
.375 10 20/1.4 LOW 3 3.5 .375 10 .250 6 155 150 95 2413
.500 13 20/1.4 LOW 3 3.5 .375 10 .312 8 163 150 60 1524
.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 175 150 25 635
1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 185 150 15 381

Cutting Data:

NOZZLE

150 AMP

MATERIAL THICK­NESS

IN MM START

.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 132 150 200 5080
.250 6 20/1.4 LOW 3 4.4 .375 10 .187 5 140 150 130 3302
.375 10 20/1.4 LOW 3 4.4 .375 10 .187 5 143 150 85 2159
.500 13 20/1.4 LOW 3 4.4 .375 10 .250 6 154 150 60 1524
.750 19 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 18 457
1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 179 150 10 254

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

150
STAINLESS STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

MIN

N
N
AIR

2

2

60

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

150 AMP

MATERIAL THICK­NESS

IN MM START

.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 127 150 160 4064

.250 6 20/1.4 LOW 3 2.6 .375 10 .187 5 130 150 150 3810
.375 10 20/1.4 LOW 3 3.5 .375 10 .187 5 134 150 90 2286
.500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 142 150 75 1905
.625 16 20/1.4 LOW 3 4.4 .500 13 .312 8 151 150 55 1397
.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 157 150 45 1143
1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 160 150 25 635

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

150
CARBON STEEL

VOLTAGE

Cutting Data:

150 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

150
CARBON STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

MIN

AIR
AIR
AIR

MIN

N
O
AIR

2

2

.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 143 150 160 4064

.250 6 20/1.4 LOW 3 3.1 .375 10 .125 3 145 150 140 3556
.375 10 20/1.4 LOW 3 3.1 .375 10 .187 5 156 150 90 2286
.500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 160 150 75 1905
.625 16 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 50 1270
.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 179 150 45 1143
1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 184 150 25 635

Cutting Data:

200 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 4 3.5 .375 10 .312 8 146 200 155 3937

.375 10 25/1.7 LOW 4 2.6 .375 10 .250 6 148 200 120 3048
.500 13 25/1.7 LOW 4 2.6 .375 10 .312 8 155 200 110 2794
.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 166 200 60 1524
1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 40 1016

1.25 32 25/1.7 LOW 4 4.4 NR NR .375 10 175 200 26 660

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

200
ALUMINUM

START GAS
CUT GAS
SHIELD GAS

VOLTAGE

ARC
CUR-

RENT

N2 or H-35
H-35
N

2

TRAVEL
SPEED

MIN

61

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

200 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 4 4.4 .375 10 .187 5 155 200 125 3175
.375 10 25/1.7 LOW 4 4.4 .375 10 .250 6 165 200 110 2794
.500 13 25/1.7 LOW 4 4.4 .375 10 .250 6 167 200 85 2159
.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 182 200 60 1524
1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 189 200 40 1016

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

200
ALUMINUM

VOLTAGE

Cutting Data:

200 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

200
ALUMINUM

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

MIN

N
N
AIR

MIN

AIR
AIR
AIR

2

2

.250 6 25/1.7 LOW 4 3.5 .375 10 .187 5 151 200 180 4572
.375 10 25/1.7 LOW 4 3.5 .375 10 .187 5 155 200 110 2794
.500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 159 200 70 1778
.750 19 25/1.7 LOW 4 3.5 .500 13 .250 6 170 200 55 1397
1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 177 200 30 762

Cutting Data:

200 AMP

MATERIAL THICK­NESS

IN MM START

.500 13 25/1.7 LOW 4 4.4 .500 13 .375 10 163 200 50 1270
.625 19 25/1.7 LOW 4 4.4 .500 13 .312 8 162 200 47 1194
.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 32 813
1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 175 200 17 432

1.25 32 25/1.7 LOW 4 3.5 NR NR .500 13 191 200 10 254

1.50 38 25/1.7 LOW 4 3.5 NR NR .625 16 203 200 8 203

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

200
STAINLESS STEEL

START GAS
CUT GAS
SHIELD GAS

VOLTAGE

ARC
CUR-

RENT

N2 OR H-35
H-35
N

2

TRAVEL
SPEED

MIN

62

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

200 AMP

NOZZLE
MATERIAL

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 4 4.4 .375 10 .125 3 142 200 140 3556

.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 150 200 125 2667
.500 13 25/1.7 LOW 4 4.4 .375 10 .187 5 154 200 85 2159
.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 174 200 55 1397
1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 180 200 20 508

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

200
STAINLESS STEEL

VOLTAGE

Cutting Data:

200 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

200
STAINLESS STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

AIR
AIR
AIR

MIN

N
N
AIR

MIN

2

2

.250 6 25/1.7 LOW 4 4.4 .375 10 .250 6 158 200 165 4191

.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 149 200 105 2667
.500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 150 200 90 2286
.750 19 25/1.7 LOW 4 2.6 .500 13 .250 6 159 200 45 1143
1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 169 200 20 508

Cutting Data:

NOZZLE

200 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 143 200 150 3810

.375 10 25/1.7 LOW 4 3.5 .375 10 .125 3 146 200 100 2540
.500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 158 200 95 2413
.625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 160 200 75 1905
.750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 165 200 65 1651
1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 180 200 35 889

1.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 182 200 25 635

1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 189 200 15 380

1.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 201 200 10 255
2 50 25/1.7 LOW 4 2.2 NR NR .375 10 211 200 6 152

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

200
CARBON STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

63

AIR
AIR
AIR

MIN

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

NOZZLE

200 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 129 200 170 4318
.375 10 25/1.7 LOW 4 3.5 .375 10 .187 4 133 200 110 2794
.500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 136 200 95 2413
.625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 139 200 75 1905
.750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 142 200 55 1397
1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 155 200 40 1016

1.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 164 200 25 635

1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 166 200 20 508

1.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 185 200 10 255
2 50 25/1.7 LOW 4 2.2 NR NR .500 13 205 200 5 127

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

MATERIAL

200
CARBON STEEL

VOLTAGE

Cutting Data:

250
CARBON STEEL

250 AMP

NOZZLE
MATERIAL

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

N
O
AIR

MIN

N
O
AIR

2

2

2

2

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 5 4.0 .375 10 .125 3 130 250 170 4318
.375 10 25/1.7 LOW 5 4.0 .375 10 .187 5 135 250 125 3175
.500 13 25/1.7 LOW 5 4.0 .500 13 .219 5.6 138 250 100 2540
.750 19 25/1.7 LOW 5 4.0 .500 13 .250 13 142 250 65 1650
1 25 25/1.7 LOW 5 4.0 .500 13 .375 10 155 250 50 1270

325 AMP

MATERIAL THICK­NESS

IN MM START

.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 130 325 130 4572
.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 132 325 90 2286
1 25 25/1.7 LOW 5 7.5 .625 16 .250 6 141 325 55-65

1.25 32 25/1.7 LOW 5 7.5 .625 16 .250 6 146 325 35-40

GAS SET UP STANDOFF ARC

VOLTAGE

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

Cutting Data:

NOZZLE
MATERIAL

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

360
CARBON STEEL

VOLTAGE

ARC
CUR-

RENT

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

TRAVEL
SPEED

MIN

N
O
AIR

MIN

2

2

64

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

360 AMP

MATERIAL THICK­NESS

IN MM START

.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 132 360 140 3556

.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 135 360 90-100
1 25 25/1.7 LOW 5 8.7 .625 16 .250 6 141 360 65-70

1.25 32 25/1.7 LOW 5 8.7 .625 16 .250 6 146 360 45 1143

1.50 38 25/1.7 LOW 5 8.7 .625 16 .312 8 153 360 30-35

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

360 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 HIGH 5 8.7 .500 13 .250 6 160 360 230 5842

.500 13 25/1.7 HIGH 5 7.5 .625 16 .250 6 163 360 110 2794
.750 19 25/1.7 HIGH 5 8.7 .625 16 .375 10 176 360 80 2032
1 25 25/1.7 HIGH 5 8.7 .625 16 .500 13 192 360 45 1143

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

Cutting Data:

NOZZLE
MATERIAL

360
CARBON STEEL

VOLTAGE

360
STAINLESS STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

N
O
AIR

MIN

N
N
AIR

MIN

2

2

2

2

360 AMP

MATERIAL THICK­NESS

IN MM START

1 25 25/1.7 HIGH 5 8.7 .625 16 .625 16 190 360 30 762

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PSI/BAR

CUT
PSI/BAR

Cutting Data:

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

360
STAINLESS STEEL

START GAS
CUT GAS
SHIELD GAS

VOLTAGE

ARC
CUR-

RENT

H-35 or N
H-35
N

2

TRAVEL
SPEED

65

2

MIN

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

360 AMP

MATERIAL THICK­NESS

IN MM START

.250 6 25/1.7 LOW 7 9.5 .500 13 .375 10 158 360 250 6350
.500 13 25/1.7 LOW 7 9.5 .625 16 .375 10 160 360 160 4064
.750 19 25/1.7 LOW 7 9.5 .625 16 .375 10 164 360 90 3386
1 25 25/1.7 LOW 7 9.5 .625 16 .375 10 171 360 60 1524

360 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

Cutting Data:

NOZZLE
MATERIAL

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

360
ALUMINUM

360
ALUMINUM

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

H-35 or N
H-35
N

ARC
CUR-

RENT

TRAVEL
SPEED

2

N
N
N

MIN

MIN

2

2

2

2

.500 13 25/1.7 HIGH 1 9.5 .625 16 .375 10 157 360 150 3810
.750 19 25/1.7 HIGH 1 9.5 .625 16 .375 10 176 360 90 2286
1 25 25/1.7 HIGH 1 9.5 .625 16 .375 10 180 360 60 1524

Cutting Data:

400 AMP

MATERIAL THICK­NESS

IN MM START

.750 19 25/1.7 LOW 7 7 .625 16 .188 4 134 400 110 2794
1 25 25/1.7 LOW 7 7 .625 16 .250 6 140 400 80 2032

1.25 32 25/1.7 LOW 7 4.5 .625 16 .438 11 150 400 60 1524

1.50 38 25/1.7 LOW 7 3 .625 16 .438 11 155 400 42 1067

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

400
CARBON STEEL

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

N
O
AIR

MIN

2

2

66

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

VOLTAGE

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

Cutting Data:

410 AMP

NOZZLE
MATERIAL

MATERIAL THICK­NESS

IN MM START

.750 19 25/1.7 HIGH 0 6.5 .625 16 .312 8 132 410 140 3556

1 25 25/1.7 HIGH 0 6.5 .625 16 .438 11 135 410 110 2794

1.25 32 25/1.7 HIGH 0 6.5 .625 16 .500 13 141 410 85 2159

1.50 38 25/1.7 HIGH 0 6.5 .625 16 .500 13 146 410 65 1651
2 50 25/1.7 HIGH 0 6.5 .625 16 .500 13 153 410 45 1143

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

400
ALUMINUM

Cutting Data:

450 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

450
STAINLESS STEEL

H-35
H-35
N

TRAVEL
SPEED

TRAVEL
SPEED

2

MIN

MIN

N
N
AIR

2

2

.750 19 25/1.7 LOW 7 7 .625 16 .375 10 160 450 100 2540

1 25 25/1.7 LOW 7 7 .625 16 .250 6 163 450 70 1778

1.25 32 25/1.7 LOW 7 4.5 .625 16 .375 10 176 450 52 1321

1.50 38 25/1.7 LOW 7 3 .625 16 .500 13 192 450 33 838

Cutting Data:

600 AMP

MATERIAL THICK­NESS

IN MM START

1 25 RUN 2 HIGH 4 8* .750 19 .625 16 172 600 80* 2032*

1.50 38 RUN 2 HIGH 4 8* .750 19 .625 16 177 600 65* 1651*
2 50 RUN 2 HIGH 4 8* moving .750 19 192 600 30* 762*
3 75 RUN 2 HIGH 4 8 moving .750 19 212 600 15 381

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

600
ALUMINUM

VOLTAGE

ARC
CUR-

RENT

H-35
H-35
N

2

TRAVEL
SPEED

MIN

67

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

NOZZLE

600 AMP

MATERIAL THICK­NESS

IN MM START

1.50 38 RUN 2 HIGH 4 8 .750 19 .625 16 172 600 75 1905
2 50 RUN 2 HIGH 4 6 mov-

3 75 RUN 2 HIGH 4 8 mov-

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

ing

ing

PSI/BAR

CUT
PSI/BAR

MATERIAL

Cutting Data:

600
ALUMINUM

600 AMP

MATERIAL THICK­NESS

IN MM START

GAS SET UP STANDOFF ARC

PSI/BAR

CUT
PSI/BAR

SHIELD
@ 60 PSI / 4

BAR

NOZZLE
MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

600
ALUMINUM

VOLTAGE

.750 19 192 600 40 1016

.750 19 205 600 20 508

START GAS
CUT GAS
SHIELD GAS

VOLTAGE

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

N
N
AIR

ARC
CUR-

RENT

TRAVEL
SPEED

2

2

H-35
H-35
Air

MIN

MIN

1 25 RUN 2 HIGH 0 8 .625 16 .375 10 158 600 100 2540

1.50 38 RUN 2 HIGH 0 7 .625 16 .375 10 168 600 60 1524

Cutting Data:

600 AMP

MATERIAL THICK­NESS

IN MM START

1 25 RUN 2 HIGH 4 8 .750 19 .500 13 163 600 40 1016

1.50 38 RUN 2 HIGH 4 8 .750 19 .625 16 186 600 18 457
2 50 RUN 2 HIGH 4 6 mov-

3 75 RUN 2 HIGH 4 8 mov-

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PIERCE CUT IPM MM/
IN MM IN MM

ing

ing

PSI/BAR

CUT
PSI/BAR

NOZZLE
MATERIAL

600
STAINLESS STEEL

VOLTAGE

.750 19 204 600 12 305

.750 19 206 600 9 229

START GAS
CUT GAS
SHIELD GAS

ARC
CUR-

RENT

TRAVEL
SPEED

H-35
H-35
N

2

MIN

68

SECTION 3 OPERATION

CUTTING TABLES FOR PT19XLS AND PT600

Cutting Data:

NOZZLE

600 AMP

MATERIAL THICK­NESS

IN MM START

1 25 RUN 2 HIGH 0 8 .625 16 .500 13 160 600 70 1778

1.5 38 RUN 2 HIGH 0 8 .625 16 .500 13 163 600 40 1016

GAS SET UP STANDOFF ARC

SHIELD
@ 60 PSI / 4

BAR

PSI/BAR

CUT
PSI/BAR

MATERIAL

PIERCE CUT IPM MM/
IN MM IN MM

600
STAINLESS STEEL

START GAS
CUT GAS
SHIELD GAS

VOLTAGE

ARC
CUR-

RENT

N

2

N

2

AIR

TRAVEL
SPEED

MIN

Notes on 600A Cutting

H-35 plasma gas/nitrogen shield produces good to excellent cut quality on 1" to 3" aluminum. H -35 plasma gas/air shield
produces cut quality nearly as good on 1-1/2" to 3" aluminum. Nitrogen plasma gas/air shield produces fair quality cuts on
1“ to 1-1/2 “ aluminum.

H-35 plasma gas/nitrogen shield yields the best quality on 1“ to 3“ stainless steel, with smooth surfaces and moderate
quantities of dross. Nitrogen plasma gas/air shield may be used to achieve good cuts on 1“ and fair cuts on 1-1/2“ stainless
steels at higher speeds than H-35.

Piercing of plate 2" to 3" thick is best accomplished with the moving pierce technique: Start the arc at 3/4" stando, 250
amps, and 35 to 40 ipm. Immediately upon arc transfer, raise the stando to a cutting voltage of 225 to 240 volts. After the
arc has been on about one second, ramp the current up to 600 amps over a two second interval. After another two second
delay, reduce the speed to about half the recommended cutting speed until the arc burns through the plate.

69

SECTION 3 OPERATION

3.9. OPERATING TECHNIQUES

Mirror Image Cutting

If desiring to cut with two torches simultaneously, with one
moving in the mirror image of the other, the standard gas
bae can be replaced by their reverse swirl counterparts
so that the right-edge remains square.

Bevel Cutting with Standard Parts

Bevel cutting requires the same setup considerations
as standard straight cutting with a few exceptions. The
thickness of the cut is longer than the material thickness
therefore the nozzle assembly and cutting speed must
be selected accordingly. Illustrated in Figure 3-5 are the
maximum bevel angles that can provide good quality cuts
with each nozzle based on 1/8 inch clearance (not stand­o) between torch and work piece. Large bevel angles can
be made by reducing the clearance and increasing the arc
length if cut quality can be sacriced.

PT-15XL Bevel Angles

PLATE

THICKNESS

(IN.)

1/4 2075691 (0.125) 35
3/4 2075611 (0.156) 40

1-1/2 2075612 (0.200) 45

2 2075613 (0.230) 40-45

XR NOZZLE

ASSEMBLY

PART NO.

MAXIMUM

BEVEL ANGLE

(A)

o

o

o

o

The resulting bevel angle setting, particularly on thin ma­terials, may be 5 degrees greater than the torch angle. The
bevel retaining cup has smaller feet and steeper sloped
sides required to angle the torch without hitting the work
piece. The bevel retaining cup is also usable for straight
cutting required with an air curtain or bubble muer
although there is less protection than with the standard
cup. Normally used with oxygen.

Special nozzles for oxygen beveling are available. See Form
F-15-031 Instructions or PT-15XL Plasmarc torch.

A

ARC LENGTH

1/8"

Figure 3-6. Bevel Cutting Characteristics

Piercing

Piercing can be accomplished on plates up to about 1-1/2
inches thick by delaying carriage movement until the arc
penetrates through the plate. The following are typical
delay timer settings:

PLATE

THICKNESS

1/2 IN. 1/4 SEC.

1 IN. 3/4 SEC.

1-1/2 IN. 1-1/2 SEC.

SET CARRIAGE

DELAY TO

When piercing plate 1-1/2 to 3 inches thick, allow the
carriage to move (no delay) at about 1/2 the normal cut­ting speed. Permit the arc to slice through the plate and
produce a rooster-tail eect of molten spray. As soon as
the arc penetrates through the plate, adjust the carriage
travel to the normal cutting speed. Piercing requires prac­tice and skill. Piercing is made at a higher stando than
actual cutting. This helps prevent spatter from destroying
the nozzle.

70

a b

c

d

SECTION 3 OPERATION

1/4 SPEED

2/3 OF
THICKNESS

Figure 3-7. High Current Cutting Thick Plate

PT-15XL Cutting with High Current Nozzles (4 to 6
inch Plates)

Normally, only a slight carriage delay (1/2 to 2 seconds de­pending on plate thickness) is required to allow cutting arc
to penetrate through a plate, then cutting can continue at
the recommended speed. However, when cutting plate 4
inches or more thick, a little more consideration is required
for starting and ending a cut. The following procedures are
recommended (refer to Figure 3-6).

a. Start at edge of plate as normal.

b. Delay carriage movement until arc penetrates

about two-thirds of the plate thickness. (2-1/2 to
3 seconds.)

c. Start carriage movement about 1/4 of the recom-

mended speed until arc cuts through the lower
corner of the plate edge and then cut at the
recommended speed. The molten spray from the
bottom of the plate should be lagging slightly
behind the arc cutting at the top of plate.

d. When about 1 inch from end of cut, reduce the

speed slowly, allowing the molten spray to catch
up to the arc cutting at the top.

FULL
SPEED

LAG

1"

REDUCE
SPEED

1. Underwater Cutting: PT-15XL & N2 Plasma Gas

It has been found that an eective means of reducing

the cutting noise level to 85 db or lower is by cutting
under 2 to 3 inches of water. Fumes and UV radiation
are substantially reduced. No plasma arc equipment
change or accessory is required for underwater cut­ting. However, an automatic cutting system requires
controlling the initial stando when starting the cut.
In cutting materials up to 1-inch thick underwater,
neither cutting speed nor cut surface appearance is
appreciably aected. Cutting speed and cut surface
quality diminishes when cutting plates between 1 and
3 inches thick. Underwater cutting of plates 3-inches
or thicker is not recommended. Underwater cutting
with oxygen requires the use of an air curtain or bubble
muer.

NOTE

When cutting underwater, care must be taken when

a rust inhibitor is used in the water. Some inhibitors
contain enough conductive materials to prevent
arc starting. CM-1000S (manufactured by Chemicals
Methods, Inc.) is one satisfactory inhibitor.

2. Water Muer (Option) PT-15XL & N2 Plasma Gas

Noise, Fume and UV Radiation Considerations

The noise level of plasma cutting is greater than 110 db 6
ft. or 1.8 m from torch and depending on location of torch
with respect to sound reecting surfaces and the power
level used for cutting. OSHA allows exposure to 95 db on
a 50% duty cycle (4 hours out of an 8 hour shift) and to
90 db on a 100% duty cycle.

There are currently several methods of attenuating noise,
fumes and UV radiation of the plasma arc process; under­water cutting, underwater cutting with bubble muer,
underwater cutting with air curtain or cutting with a
water muer.

Another method of fume control is to use the water

muer, above or underwater. For maximum eec­tiveness, the water muer is recommended for use
in conjunction with a water table to eliminate 99.5%
of noxious gases and particulate emissions from the
plasma arc cutting operation. The water muer is less
eective in controlling noise and UV radiation than
underwater cutting. The water muer is not recom­mended for use with oxygen cutting.

3. Air Curtain (Option) PT-15XL & PT-19XLS

The air curtain uses air to provide a "dry" area around

the arc during underwater cutting. The air curtain is
recommended for use with oxygen cutting as the most
economical approach to fume and noise control.

71

SECTION 3 OPERATION

4. Bubble Muer (Option) PT-15XL & Water Muer

(Option) PT-19XLS

The bubble muer can be viewed as a combination air

curtain and water muer. It is recommended for use
with oxygen when both underwater and above water
cutting are to be used.

WARNING

Regardless of the source, the hydrogen gas can collect

in pockets formed by the plate being cut and slats on
the table, or pockets from warped plate. There can also
be accumulation of hydrogen under the slag tray or
even in the air reservoir, if these are part of the table
design. The hydrogen, in the presence of oxygen or
air, can then be ignited by the plasma arc or a spark
from any source.

4. Follow these practices to reduce hydrogen genera­tion and accumulation:

Hydrogen explosion hazard! Read the following before
attempting to cut with a water table.

A hazard exists whenever a water table is used for plasma
arc cutting. Severe explosions have resulted from the
accumulation of hydrogen beneath the plate being cut.
Thousands of dollars in property damage has been caused
by these explosions. Personal injury or death could result
from such an explosion.

The best available information indicates that three pos­sible sources of hydrogen exists in water tables:

1. Molten Metal Reaction

Most of the hydrogen is liberated by a fast reaction of

molten metal from the kerf in the water to form metal­lic oxides. This reaction explains why reactive metals
with greater anity for oxygen, such as aluminum
and magnesium, release greater volumes of hydrogen
during the cut than does iron or steel. Most of this
hydrogen will come to the surface immediately, but
some will cling to small metallic particles. These par­ticles will settle to the bottom of the water table and
the hydrogen will gradually bubble to the surface.

A. Clean the slag (especially ne particles) from the

bottom of the table frequently. Rell the table
with clean water.

B. Do not leave plates on the table overnight or a

weekend.

C. If a water table has been unused for several hours,

vibrate it in some way before the rst plate is laid
in position. This will allow accumulated hydrogen
in the refuse to break loose and dissipate before
it is conned by a plate on the table. This might
be accomplished by laying the rst plate onto
the table with a slight jolt, then raising the plate
to permit hydrogen to escape before it is nally
set down for cutting.

D. If cutting above water, install fans to circulate air

between the plate and the water surface.

E. If cutting underwater, agitate the water under

the plate to prevent accumulation of hydrogen.
This can be done by aerating the water using
compressed air.

2. Slow Chemical Reaction

Hydrogen may also result from the slower chemical

reactions of cold metal particles with the water, dis­similar metals, or chemicals in the water. The hydrogen
gradually bubbles to the surface.

3. Plasma Gas

Hydrogen may come from the plasma gas. At currents

over 750 amps, H-35 is used as cut gas. This gas is 35%
hydrogen by volume and a total of about 125 cfh of
hydrogen will be released.

F. If possible, change the level of the water between

cuts to dissipate accumulated hydrogen.

G. Maintain pH level of the water near 7 (neutral).

This reduces the rate of chemical reaction be­tween water and metals.

H. Programmed part spacing should be a minimum

of twice the kerf width to ensure material is alu­minum under the arc.

72

SECTION 3 OPERATION

DANGER

Possible explosion hazard from plasma cutting alumi­num-lithium alloys!

Aluminum-Lithium (Al-Li) alloys are used in the aerospace
industry because of 10% weight savings over conventional
aluminum alloys. It has been reported that molten Al-Li
alloys can cause explosions when they come into con­tact with water. Therefore, plasma cutting of these alloys
should not be attempted in the presence of water. These
alloys should only be dry cut on a dry table. Alcoa has
determined that "dry" cutting on a dry table is safe and
gives good cutting results. DO NOT dry cut over water. DO
NOT water injection cut.

The following are some of the Al-Li alloys currently avail­able:
Alithlite (Alcoa) X8192 (Alcoa)
Alithally (Alcoa) Navalite (U. S. Navy)
2090 Alloy (Alcoa) Lockalite (Lockhead)
X8090A (Alcoa) Kalite (Kaiser)
X8092 (Alcoa) 8091 (Alcan)

For additional details and information on the safe use
from the hazards associated with these alloys, contact
your aluminum supplier.

73

SECTION 3 OPERATION

74

SECTION 4 MAINTENANCE

4.1. PROGRAMMABLE LOGIC CONTROLLER (PLC)

The PLC is located in the top section of the Flow Control and
is a device capable of providing predened outputs depend­ing on the state of the inputs. The precise conditions are
programmed and permanently stored in the PLC. Because
it is a solid state device the PLC is inherently very reliable. It
is also relatively compact.

The PLC will provide predened outputs in response to in­puts from external devices. This exchange of signals can be
conrmed by observing the LEDs on the top of the PLC while
troubleshooting. These indications are useful in isolating a
system failure to the most likely device. They can be seen
through window in the Flow Control top cover.

The LEDs are divided into two groups; Input (0-15) and Out­put (0-11). Input LEDs light when the corresponding signal is
detected by the PLC. Output LEDs light when the PLC issues a
signal to an external device. The fault LED (output 1) indicates
the PLC has detected an error within the ESP and has caused
the system to enter the not ready (fault) state.

LEDs are highly reliable indicators. It is not likely that one will
burn out. However, if the technician is not condent that the
LEDs are working the presence of a signal can be conrmed
by using a meter to measure the appropriate pin. Refer to
the schematic and wiring diagrams.

The signal exchange between the PLC and external devices
are both time dependent and condition dependent. If a
required signal is not received in the proper sequence, the
PLC will discontinue the process and generate a fault signal
to the CNC.

TABLE 4-1 PLC INPUT/OUTPUT LEDs

INPUT OUTPUT

LED FUNCTION LED FUNCTION

0 Start/Stop 0 Process Running

1 Current Detector 1 Fault Signal
2 Nitrogen Pressure 2 Power Source On/O
3 Oxygen Pressure 3 Cut Water On/O
4 Interlock Plumb.Box 4
5 Cooling Water Flow 5
6 Cut Water Flow 6 Air Curtain
7 Cut Gas Pressure 7 Cut Gas Metering
8 Run 1 8 Cut Gas On/O
9 O2/N2 Select 9 Start Gas On/O
10 Emergency Stop 10 HF On/O
11 Cut Water On/O 11
12 Test Cut Gas
13 Test Start Gas
14 Run 2

15 Test HF

4.2 Sequence Description

The program controlling the plasma system sequence
is made with the help of a group of conditional states.
Inputs from sensors, and the cutting machine are continu­ously evaluated by the PLC to determine whether the
program stays in its present state or makes a transition to
another state.

The dierent states are shown as rectangles in gure 4-2.
The function of the seven states are described in the fol­lowing paragraphs.

0 - Ready state

The "Ready" state is the normal state for the system to be
in when not executing the cutting process. In this state,
the system awaits the start signal from the cutting ma­chine and monitors the selection keys and safety switches.
While in this state it is possible to activate the gas ows
and cut water ow for testing and purging the system.

Figure 4-1. PLC LED Panel (Partial View)

1 - Preow state

The "Preow" state is a xed duration and is reached only
from state "0". Nitrogen is always the preow gas in RUN 1
position. Selected cut gas type and ow is the preow gas
in RUN 2 position. Cut water ow during preow whenev­er a water injection torch is used and cut water is switched
on at the front panel. The air curtain output is energized
at this time also.

2 - Open Circuit Voltage State

The main contactor of the power source is activated after
the preow, and a short time is allowed for the open cir­cuit voltage to be reached.

75

SECTION 4 MAINTENANCE

3 - PILOT ARC STATE

The Pilot Arc State is started by activating the high fre­quency unit. The time allowed between this and the re­quirement of a current ow signal from the power source
is a xed time. If the signal from the power source is not
received during this time, the state is transferred to the
not ready state 7.

4 - CUTTING STATE

In the Cutting State, the cut gas is turned on and the start
gas o if using RUN 1. A signal is sent to the cutting ma­chine control indicating that the process is running. This
is the normal state to be in during cutting.

5 - PRIORITY POSTFLOW STATE

The Priority Postow State provides the minimum post­ow of nitrogen gas and cut water ow necessary before
a restart is possible. The time is dierent depending upon
whether cutting with nitrogen or oxygen. This state is
reached when the START/STOP goes low or current ow
through the arc is lost.

6 - FINAL POSTFLOW STATE

The Final Postow State provides the time during which
nitrogen gas and cut water ow cools the torch. This state
immediately follows the Priority Postow state, a restart is
possible during postow.

When the time for postow has elapsed, the program
transfers to the 0 Ready state. If a new start signal has been
given from the cutting machine control after it stopped
the process, a fast restart will be executed directly from the
Postow state to state 2 that turns on the main contactor
in the power source.

7 - NOT READY STATE

During the Not Ready State (fault state) the Programmable
Logic Controller (PLC) is sending a fault signal to the cut­ting machine.

It is possible to test gas/water ows in this state. The HF
unit can be run for test purposes in this state.

Figure 4-2. Plasma Sequence Flow Diagram

76

SECTION 4 MAINTENANCE

4.3. OPERATING INFORMATION

MAXIMIZING CONSUMABLE LIFE

Plasma torch electrode and nozzle life is a function of many
factors, some of which are under control of the opera­tor. When using oxygen as the plasma gas in a properly
operating system, electrode wear and life is a function of
the number of arc starts, the total duration of the cutting
time and the current level. The longer the cut time for a
part being cut, the fewer the number of arc starts on an
oxygen electrode before it must be replaced. The graph
below shows the relationship between the two.

ELECTRODE LIFE
LINE

# OF STARTS

CLEANING OXYGEN NOZZLES

As the electrode wears considerable deposits of hafnium
oxide and silver can build up in the nozzle. Calcium car­bonate can also build up at he nozzle exit if the cut water
is not adequately treated. These deposits can sometimes
cause substantial reductions in cut quality, speed and
consumable life.

Nozzle performance can be restored by removing these
deposits from the inside of the nozzle and the nozzle exit. A
twisted piece of very ne sandpaper or crocus cloth usually
cleans the nozzle well enough. Care must be taken not to
damage the thin copper edge at the nozzle exit. The 340
amp nozzles have a heavier less easily damaged exit as
compared to the 260 and 300 amp nozzles.

Nozzle performance is also degraded by nicks and elonga­tion of the orice due to double arcs or mechanical dam­age. Cleaning will not restore a damaged nozzle.

Whenever a nozzle is removed for cleaning the electrode
should be inspected. If the wear is greater than 0.090 inch
or very irregular, the electrode should be replaced.

DURATION OF CUT

Figure 4-3. Oxygen Electrode Life Graph

Oxygen electrode and nozzle life are also aected by the
current setting. If parts are operated above their recom­mended current level, life deteriorates quickly. Improper
cutting and parts programming can adversely eect oxy­gen consumable life, so it is important that proper tech­niques be used. Oxygen plasma nozzles and electrodes
are less forgiving of improper operation than nitrogen
nozzles and electrodes. When using nitrogen or argon/
hydrogen as a plasma gas, nozzle and electrode life are
primarily a function of current level. The higher the current
the shorter the life.

CUT QUALITY

Maximum attainable cut quality is highly dependent on
the material being cut. With the wide variety of commercial
metals and alloys being cut with plasma, optimum cut
quality can vary widely from situation to situation. Sug­gested cut parameters given in this manual are starting
points only for general cases. Fine tuning of the various
parameters may be required to get the best possible cut of
a specic material. Some materials, including certain steels,
are dicult, if not impossible to cut dross free. Likewise, in
carbon steels, variations in plate composition, treatment
while rolling, contaminants and other factors can cause the
dross generated to vary from heat to heat, plate to plate
and area to area on a plate. As a general rule, using oxygen
as a plasma gas produces less dross variation on carbon
steel as a result of these factors, but is not a guarantee that
"dross free" cuts will be produced.

77

SECTION 4 MAINTENANCE

4.4. TROUBLESHOOTING

The following troubleshooting guide is primarily an operationally oriented guide. If a problem exists in one of the system
components, the guide will direct you to that manual. When directed to another manual, be sure a qualied mainte­nance technician is contacted.

TROUBLESHOOTING GUIDE

Problem Probable Cause Remedy

1. Reduced consumable
(electrode) life (O2 and N2
cutting)

Excessive current. Check Power Source ammeter (Refer to

Power Source Manual).

Gas settings - inlet pressure. Check that settings are in accordance with

charts. Use gas ow check kit.
Gas or water leak. Check for leaks.
Inadequate cooling. Check water cooler for proper operation.
Single phasing of Power Source. Refer to Power Source manual.
Wrong gas bae (O2). Install correct gas bae (O2).
Moisture in system. Purge system of moisture for a minimum of

30 seconds after long idle time.
Cut water setting. If set to high, it can cause water to reach the

electrode.
Process factors:
Running o work. Extinguish arc with Arc Stop Signal prior to

running o work or use a waste plate to run

o on. This is most important with O2 cut-

ting.
Flipping or twisted parts hitting

torch.
Skeleton cutting. Cutting skeletons to facilitate their removal

Change program or x table.

from the table can adversely aect electrode

life by:

A. Causing the torch to run o the work. (see

above)

78

B. Causing multipop edge starts. (see below)

C. Greatly increasing the frequency of starts.

This is mainly a problem for O2 cutting and

can be alleviated by choosing a path with a

minimum number of starts or by bridging

gaps in the skeleton with water plates.

D. Increased likelihood that the plate will

spring up against the nozzle causing a

double arc. This can be mitigated by careful

operator attention and by increasing stand-

o and reducing cutting speeds.

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem Probable Cause Remedy

1. Reduced consum­able (electrode) life
(O2 and N2 cutting) ­(cont)

Height control problems.

Piercing stando too low.

Starting on edges with multipop
starts.

Drawn arc from falling part.

Purity and dryness of gas.

Gas switching is not activating.

Since many of these problems are most se­vere with O
when it may be practical to cut skeletons
with N2 consumables:

A. When you will be changing to N2
consumables for the next plate anyway.

B. When one plasma station on the
machine is not being used for part
cutting and could be used for cutting
skeletons with N2.

On machine with Oxweld or Purox torch,
it may be practical to use the gas torch for
skeleton cutting.

See crashing/diving in item 2 below.

Increase piercing stando.

Position torch more carefully or use a waster
plate to start on. This is most important for
O2 cutting.

Change program.

Verify purity to be 99.55% O2 . Verify dew
point. Verify purity of N2 to be 99.995%.

This pertains to O2 cutting only. Check to
make sure that switch is in Run 1 mode so
that the arc begins in N2 and switches to O2.
This may be checked by installing the gas
test ow-meter rst on the N2 line into the
ow control to see that N2 is owing during
preow and postow only. Then install it
on the O2 line into the ow control to check
that O2 is owing only during the cut. O2
should never ow when cutting with N2.

cutting consumables, consider

2

79

SECTION 4 MAINTENANCE

Problem Probable Cause Remedy

1.Reduced consumable
(electrode) life (O

and

2

N2 cutting) - (cont)

2.Reduced nozzle life
(N2, O2 and ArH2)

O2 present at start.

Using non-genuine consumables.

Incorrect cut water sequence.

When O

cutting, check above for gas switch-

2

ing.

When N2 cutting, any presence of O2 will
result in rapid electrode wear. Make sure
system has been purged in cut gas test.

Check for gas or water leaks in torch or hoses.
Check gas quality. Ensure that O2 OSV in ow
control is not leaking by disconnecting O2
from the ow control purging system.

N2 cutting is done with a tungsten electrode.
Tungsten will turn blue or yellow in the pres­ence of oxygen from any source.

Replace with genuine consumables.

Correct cut water sequence. Cut water must
be on when arc starts. PT-15XL only.

Cut water quality.

Cut water settings.

Improper pierce height.

Contacting work:

Diving

See section 3.

Review and set proper cut water settings per
instructions in Section 3.

Refer to appropriate application Table for
correct setting.

Diving is usually caused by a change in arc
voltage when an automatic height control is
in use. Diving can result in loss of cut dam­age to the nozzle. Usually the voltage change
is as the result of a change of direction or
speed to negotiate a corner or as a result
of plate falling away from the arc. These
problems can be dealt with by disabling the
height control in such situations and by extin­guishing the arc earlier when nishing the cut
on falling plate.

Diving may also be caused by a problem with
the height control or the signals fed to it.

Work ipping

The nozzle may sometimes be damaged if the
torch hits a ipped up part. This is dicult to
avoid entirely but careful part programming
can minimize the problem.

80

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem Probable Cause Remedy

2. Reduced nozzle life
(N2, O2 and ArH2) ­(cont)

catching on piece

Air curtain/bubble muer
alignment

Excessive speed

Excessive pilot arc on
time.

Process factors:

Cut water not at torch when arc
starts.

Inadequate initial delay.
Pierce not complete before
starting.

This refers to crashes or nozzle damaged
caused by the front end of the torch catching
on top spatter after a pierce. Hold the torch
at a high stando for a longer lead-in to avoid
this problem.

Refer to paragraphs 3.3.7 and 3.3.8 to make
necessary adjustments.

Reduce speed to prevent rooster tailing
during cut. Reduce speed corners if rooster
tailing occurs only coming out of corners.

Same as for electrode above.

Check cut water system.

Increase delay time.

Excessive initial delay.

Improper torch assembly.

Improper piercing
technique.

Running pilot arc without
transfer.

Using non-genuine
consumables.

Improper connection or in­advertent grounding of pilot
arc cable running from Power
Source to Plumbing Box.

Worn feet on retaining

Decrease initial delay.

Reassemble torch properly. Check for gas
and water leaks.

Refer to paragraph 3.3.6.

Running pilot arcs without transfer is very
damaging to nozzles. Check stando and
work connections.

Replace with genuine consumables.

Connect wire properly in the Power Source.
Make sure there are no breaks in the insula­tion.

Replace retaining cup.

81

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem Probable Cause Remedy

3. Poor cut quality.

Dross and cut surface:

Varying characteristics of material
being cut.

Incorrect speed

Incorrect stando

Incorrect gas or cut water ow.

Incorrect alignment or improper
operation of air curtain or bubble
muer.

Damaged or worn consumables.

Using non-genuine consumable
part.

Gas selection.

No remedy.

Adjust to correct speed.

Refer to paragraph for applicable cutting
technique.

Refer to paragraph 3.1.1.

Refer to paragraph 3.3.7 or 3.3.8.

Replace.

Replace with genuine consumable part.

N2 produces smoother surfaces on Al and SS
than O2. O2 sometimes produces less dross on
C.S. than N2.

Torch alignment to work.

Incorrect current.

Cutting over slats.

Cutting machine or torch
vibrates.

Mixing standard and
reverse swirl parts.

Bevel Angle:

Verify and correct torch alignment.

Verify correct current. Refer to appropriate table
in section 3.

Cutting over slats will cause some bottom dross.
If the cut runs along the slat, it can produce other
cut quality problems. The only solution is to try
to avoid running along the slats.

Make sure brackets and height control are rigid
and properly adjusted.

Check to be sure swirl is in the same direction.
Remove swirl parts that are marked with an "R".

Same as Dross and Cut surface above
except varying characteristics of material being
cut and cutting machine or torch vibrations.
Stando and speed have considerable eect
on bevel angle.

82

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem Probable Cause Remedy

3. Poor cut quality ­(cont)

4. No pilot arc.

Damaged nozzle

Wrong travel direction
(good angle on scrap side)

Plate shifting while being
cut.

Slag buildup on cut table.

Contaminated electrode.

Excessively conductive
cut water (injection water).

Insucient spark gap
setting (in plumbing box).

Pilot Arc Contactor (PAC)
malfunctioning.

Plate not level - ensure work is level. Torch
not perpendicular to work - ensure torch is
plumb (perpendicular) to work.

With standard swirl parts the most square
side of the cut is on the right side of the
direction of travel.

Small, thin, or light weight plates can shift
while cutting. Clamp them down.

Clean slag from cut table.

Clean or replace electrode.

Check injection water instructions in Sec­tion 3. PT-15XL only.

Set spark gap to 0.040+.004".

Refer to Power Source manual.

Blown fuse in P.A. or starting
circuit.

Improperly assembled torch
or broken torch pilot xar
cable.

Broken or improperly con­nected P.A. cable between
Plumbing Box and Power
Source.

Insucient Open Circuit
Voltage (OCV).

Gas ow improperly set.

Improper clamping of stain­less steel torch body.

Conductive water muer
hoses.

Water leak in torch.

Refer to Power Source manual.

Reassemble torch properly or replace torch
pilot arc cable.

Replace or verify connections between
Plumbing Box and Power Source.

Refer to Power Source manual.

Refer to paragraph 3.1.1.

Clamp onto nonconductive sleeve above
indicated mark.

Replace with nonconductive hoses.

Determine cause of leak.

83

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem

4. No pilot arc - (cont)

5. No arc transfer.

Probable Cause Remedy

Cut Water Flow Switch (CWFS)
not activated (water injection
only).

Blown fuse in P.A. or starting
circuits.

Insucient Open Circuit Volt­age (OCV).

Gas ow improperly set.

Stando too high or torch
centered o edge of work.

Poor connection to work­piece.

Heavy mill scale or noncon­ductive surface on work.

Power Source current setting
too low.

Check for adequate cut water ow. Check
CWFS.

Refer to Power Source manual.

Refer to Power Source manual.

Refer to Section 3.

Check cutting technique or position torch to be
over work.

Check connection.

Clean mill scale or ensure conductive surface
on work.

Refer to Power Source manual.

6. No preow.

Defective power source.

No start signal.

Emergency stop signal open.

Door opened on Plumbing
Box allowing interlock to
open.

Shorted, closed or jumpered
out CWFS.

No cooling water.

N2 pressure switch not acti­vated.

O2 pressure switch not acti­vated when N2/O2 switch is set
to O2.

See Power Source manual.

Check input 0 on PLC in Flow Control. Should
be lit when receiving start signal. Ensure
qualied technician performs this check.

Check input 10 on PLC in Flow Control. Should
be lit to enable operation. Ensure qualied
technician performs this check.

Close door.

Check input 6 on PLC. Should be o before
start signal applied. Should be on when in
test. Ensure qualied technician performs
this check.

Check Flow Switch.

100 psig N
the ow control.

100 psig O2 (gas owing) should be supplied to
the ow control.

(gas owing) should be supplied to

2

84

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem

7. No cut water ow when in
Test Position.

8. Arc extinguishes during a
cut or shuts down immedi­ately after transfer.

Probable Cause

No power to pump.

Relay in pump not activated.

Failed pump and/or motor.

Insucient or no water
supply.

Back pressure regulator set
above 115 psig.

Cut water regulator on Flow
Control set too low.

Loss of start signal.

Interlock not satised - loss
of gas pressure or water
ow.

Remedy

Apply power.

Check for 110 V ac from ow control.

Replace.

Make sure pressure is set to 190 to 200
psig. Correct or provide water supply. 20
psig should be supplied to pump.

Reset to 90 to 115 psig.

Adjust as necessary.

Check signal from cutting machine.

Check PLC inputs.

9. Bubble muer air supply
does not come on.

10. Bubble muer under
pump does not come on.

Water hose kinked.

Running across very large
kerf or o plate.

Speed too low.

Switch on air curtain control
box in the OFF position.

Air curtain control box is not
receiving signal from ow
control.

Starting relay on bubble
muer is not receiving sig­nal from ow control.

Pump is not connected to
main power.

Pump is running backwards.

Straighten water hose.

Check part program.

Increase speed as necessary.

Switch to AUTO.

Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of ow control. Check wiring.

Check for presence of 115 V ac signal at
Amphenol connector labeled AIR CURTAIN
on back of ow control. Check wiring.

Check wiring and fuses.

Check wiring.

85

SECTION 4 MAINTENANCE

TROUBLESHOOTING GUIDE - (Cont)

Problem Probable Cause Remedy

11. Poor cut quality with
Bubble Muer or Air
Curtain installed. (Cuts
are good above water
with Bubble Muer or
Air Curtain turned o.
Cuts are bad under-wa­ter with device operat­ing.)

12. Cut water ow inad­equate. Cannot reach
proper ow setting.

Sleeve not bottomed out on the
Main Body.

O-rings missing or broken.

Air Pressure set too high, or air shut
o.

Sleeve spacing between Air Cur­tain or Bubble Muer and Torch
Retaining Cup incorrect.

Sleeve not centered in reference to
the Torch Retaining Cup.

Dirt in Sleeve holes.

Holes in Sleeve align with air input
port.

Internal cut water lter (in Flow
Control) is clogged.

Reseat Sleeve.

Replace O-rings in Main Body.

Set air pressure between 15-30 psi. Some
trails should be made on scrap plate to nd
the optimum pressure for your conditions.

Adjust spacing. See Section 3.

Center Sleeve. Clamp may be cocked on
torch handle or O-rings may be damaged.

Remove sleeve and clean.

Rotate Sleeve 5°.

Replace internal lter of ow control. Check
all external water lters.

86

SECTION 4 MAINTENANCE

87

NOTES

88

REVISION HISTORY

Revision 07/2007 - RE-Formatted manual for German translation per R. Chico.1.

89

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

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