System Interconnection
m3 G2 Plasma System
System Manual
0558008527 01/2012
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions ....................................................................................5
1.1 Safety - English .................................................................................5
1.2 Safety - Spanish.................................................................................9
1.3 Safety - French.................................................................................13
m3 G2 System Interconnect Diagram, Introduction and Installation..........................................17
2.0 Shield Gas Box (0558008251) .........................................................................19
2.1 Functions and Features ....................................................................... 22
2.2 Plumbing Schematic ...........................................................................24
2.3 Electrical Schematic........................................................................... 25
2.4 Connections.................................................................................. 26
2.5 Troubleshooting .............................................................................. 26
2.6 Replacement Parts.............................................................................27
3.0 Plasma Gas Box (0558008252) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.1 Functions and Features ........................................................................31
3.2 Plumbing Schematic ...........................................................................33
3.3 Electrical Schematic........................................................................... 34
3.4 Connections...................................................................................35
3.5 Troubleshooting ...............................................................................35
4.0 Remote Arc Starter Box (0558008150).................................................................37
4.1 Power Source Connections .................................................................... 39
4.2 Torch Connections.............................................................................41
4.3 Remote Arc Starter Box Mounting ............................................................. 43
4.4 Typical / Recommended E-stop Connection.................................................... 44
5.0 Hoses and Cables..................................................................................... 45
6.0 PT-36 Plasma Torch...................................................................................53
6.1 General........................................................................................53
6.2 Scope .........................................................................................53
6.3 Package Options Available .....................................................................53
6.4 Optional Accessories: ..........................................................................53
6.5 PT-36 Technical Specications ................................................................. 57
6.6 Connection of Torch To Plasma System .........................................................59
6.7 Mounting Torch to Machine ..................................................................60
6.8 Set Up........................................................................................ 63
6.9 Cut Quality ................................................................................... 63
6.10 Torch Flow Passages ......................................................................... 68
6.11 Introduction .................................................................................. 69
6.12 Torch Front End Disassembly .................................................................. 69
6.13 Assembly of Torch Front End .................................................................. 72
6.14 Torch Front End Disassembly (for Production Thick Plate)........................................74
6.15 Assembly of Torch Front End (for Production Thick Plate) ....................................... 77
6.16 Torch Body Maintenance .................................................................... 79
6.17 Removal and Replacement of the Torch Body .................................................. 80
6.18 Reduced Consumable Life ................................................................... 82
6.19 Replacement Parts ............................................................................ 85
TABLE OF CONTENTS
4
SECTION 1 SAFETY PRECAUTIONS
1.0 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 safet y 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, e mits
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, cuess 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 cus, 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.
1.1 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
workpiece has been completely cleaned so that there
are no substances on the workpiece 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, Batterymarch 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 conned, or if there is
danger of falling.
5
SECTION 1 SAFETY PRECAUTIONS
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical
ground.
3. Connect the work cable to the workpiece. 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 workpiece 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 conned 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 specic 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 eects 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 specic ventilation recommendations.
6
SECTION 1 SAFETY PRECAUTIONS
5. WA RNING: 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 qualied personnel perform the installation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied 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 G ases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson 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 S ociety, 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
SECTION 1 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
SECCION 1 SEGURIDAD
1.2 Safety - Spanish
ADVERTENCIA: Estas Precauciones de Se-
guridad 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 inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.
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 corri-
ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.
9
SECCION 1 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 especícas 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. M antenga 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 especícas en la ventilación.
10
SECCION 1 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 cualicado para efectuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado 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 modique 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
SECCION 1 SEGURIDAD
SIGNIFICADO DE LOS SIMBOLOS
-- Según usted avanza en la lectura
de este folleto: Los Símbolos Signican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.
Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.
Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.
Signica el posible riesgo que
puede resultar en menores daños
a la persona.
12
SECTION 1 SÉCURITÉ
1.3 Safety - French
AVERTISSEMENT : Ces règles de sécurité
ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution
provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurezvous de lire et de suivre les précautions de sécurité cidessous, 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 an 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 an 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 ininammable an 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 ininammable.
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 susamment tous les matériaux combustibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. 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 inammables 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'extinction
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 surchauer 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 mor-
telles. 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
SECTION 1 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 an 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 eectuer 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
spéciques 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 eets 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 ecaces. Ne
respirez pas les vapeurs de ces matériaux.
2. N'eectuez 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 an
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 spéciques
concernant la ventilation.
14
SECTION 1 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
Jeerson 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 qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.
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'eectuez aucune modication.
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
SECTION 1 SÉCURITÉ
SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.
DANGER
Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.
ATTENTION
Signie un danger qui peut entraîner des blessures
corporelles mineures.
16
Arc Starter Assembly
Air Curtain
( Optional )
Shield Gas Hose
Air Curtain Hose
AHC / Lift
CAN
Power
( Optional )
Shield Gas Control
Air Curtain Hose
Shield Gas Hose
Power, Pilot Arc, Coolant
VDR Cable
CAN
E-Stop
Plasma Gas Control
Power
Plasma Gas Hose
PG1
PG2
PG1 (Air/N2/O2)
PG2 (Air/N2/O2)
H35
Ar
CAN
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Return Hose
Coolant Supply Hose
Air
N2
O2
CH4
Air Curtain
Hose
Gas Filters Assembly
Air
N2
O2
CH4
CAN (3)
CAN (4)
Gas Controls Power Cable
AHC/Lift Power Cable
CAN (5)
CAN (2)
Control Interface
the AHC)
Ext. E-Stop
Digital Inputs
& Outputs to
External CNC
Ext. 120/230V
(Must be 230V if using
H35
Ar
Vision 50P
CAN (1)
m3 G2 System Interconnect Diagram, Introduction and Installation
Power Supply
CC Control Cable
PN 055 8007515
17
CC-11 Coolant Circulator
18
SECTION 2 SHIELD GAS BOX
2.0 Shield Gas Box (0558008251)
PT-36
m3 G2
Plasma Torch
Air Curtain
Vision 50P
Control
Interface
Gas Controls Power Cable
CAN
Gas Filters Assembly
Air
N2
O2
CH4
A
B K
L
C
D
E
F
Control
Shield Gas
(See following component illustrations)
Air Curtain Hose
J
I
H
G
Shield Gas Hose
Power
PG1 (Air/N2/O2)
PG2 (Air/N2/O2)
Component Locator Designation
Shield Gas Box Component Locator Designations
Note:
Refer to enclosed tables for all available hoses and cables.
Plasma
Gas Control
19
SECTION 2 SHIELD GAS BOX
I
B
A
L
E
C
D
F
K
J
20
H
G
SECTION 2 SHIELD GAS BOX
Voltage Select Switch MUST be set to the proper input voltage
(115 or 230 volts - default setting is 230 volts) before energiz-
CAUTION
Voltage Select Switch
(cover must be re-
moved to access
switch)
ing system. Failure to do so could result in personal injury or
equipment damage.
21
SECTION 2 SHIELD GAS BOX
2.1 Functions and Features
The Shield Gas Box selects dierent gases (Air, N2, O2, CH4) to mix shield gas (SG), plasma gas 1 (PG1), and plasma
gas 2 (PG2). The selections are done through a group of solenoids integrated on a manifold. The CNC sends
commands through CAN-bus to operate all these solenoids. The gas output of the Shield Gas Box is monitored
and fed back through the CAN-bus to CNC for self-diagnosis. Also, the Shield Gas Box controls the solenoid for
operation of the Air Curtain.
The default power input to Shield Gas Box is 230VAC. However, the Shield Gas Box input power is customer
selectable, between 115 VAC and 230 VAC. This is accomplished by changing the input power switch inside the
Shield Gas Box. The Shield Gas Box provides 24VDC and 24VAC power for the Plasma Gas Box.
* 8.12”
Note:
Pressure Regulator is factory set
for carbon steel at 40 psi (2.8 bar).
If cutting stainless steel or alumi-
num set at 20 psi (1.4 bar).
(206.4 mm)
Weight:
25.0 lbs. (11.3 kg)
* 11.63” (295.3 mm) including ttings on front and back
7.88 ”
(200.0 mm)
8.25”
(209.6 mm)
Note:
For required gas specications see
manual 0558008682, Subsection 7.1
22
SECTION 2 SHIELD GAS BOX
5.00”
Shield Gas Box Mounting Hole Locations
(Bottom View)
1.75”
(44.5mm)
4.25”
(108.0mm)
2.25”
(57. 2m m)
(127. 0 mm)
Shield Gas Box Mounting
Plate Hole Locations
(0558008794)
0.281
(7.1mm)
0.313”
(8.0mm)
M6-1
5.75”
(146.0mm)
0.50”
(12.7mm)
23
9.50”
(241.3mm)
SECTION 2 SHIELD GAS BOX
2.2 Plumbing Schematic
∆P
P
P
1
2
SG1
PT
SG
∆P
P
P
1
2
SG2
Air
N2
O2
S2,2
S2,1
S3,2
PV1
Air
N2
PV2
O2
CH4
S3,1
S0,1
S0,2
S0,3
S1,1
S1,2
S1,3
CH4
O2
N2
Air
O2
N2
Air
PT = Pressure Transducer
PV = Proportional Valve
PG1
PG2
Air
S4,1
24
Air Curtain
Air
SECTION 2 SHIELD GAS BOX
2.3 Electrical Schematic
2
1
3
4
Con 6
Solenoid
Air Curtain
Transformer
115VAC
24VDC
AC2
AC1
DC Com
Regulator
+24VDC
24VAC
CO 11
4
2
Fan
6
3
1
5
12
10
8
7
14
16
LED 2
9
13
11
15
LED 1
230VAC
Switch
Fuse
Con 3
∧∧
NC
2
1
3
4
115 / 230VAC
25
Con 1
CAN H In
CAN L In
CAN Gnd
CAN H Out
CAN L Out
NCNCNC
1
2
3
4
5
6
7
8
SECTION 2 SHIELD GAS BOX
2.4 Connections
There are three cables connected to the Shield Gas Box. They are 115/230VAC power input, 24V power output,
and CAN. There are ve gas inputs (Air, N2, O2, CH4 and Air Curtain) and four gas outputs (SG, PG1, PG2 and Air
Curtain). The gas ttings are listed below.
Note:
Chassis must be connected to the machine ground.
ESAB
P/N
Inputs
Outputs
Gas Fitting
Air 1/4” NPT x “B” Inert Gas RH Male 10Z30
N2 1/4” NPT x “B” Inert Gas RH Female 74S76
O2 1/4” NPT x “B” Oxygen RH Male 3389
CH4 1/4” NPT x “B” Fuel LH Male 3390
Air
Curtain
SG 1/4” NPT x “B” Inert Gas RH Male 10Z30
PG1 1/4” NPT x “B” Inert Gas RH Female 74S76
PG2 1/4” NPT x “B” Oxygen RH Male 3389
Air
Curtain
1/4” NPT x “B” Inert Gas RH Male 10Z30
1/4” NPT x “B” Inert Gas LH Female 11N16
2.5 Troubleshooting
On the Shield Gas Box, there are two LEDs displaying the status of the CAN-bus module. The states of these lights
are shown in the table below.
LED Status Meaning
OFF Power OFF
Green
Yellow ON Station is selected
10% ON, 90% OFF Boot loader is running
50% ON, 50% OFF Application is running
90% ON, 10% OFF Application is running, CAN is available
In normal operation, the green LED indicating the power must be ON. When the station is selected, the yellow
LED should be ON all the time; and green LED will ash 90% ON and 10% OFF. Otherwise, there is a problem.
1. If the green light is not on, check the power input (cale connection) and fuse.
2. If the yellow light is not on and the green light is on, check can-bus connection. Make sure the station is selected.
26
SECTION 2 SHIELD GAS BOX
2.6 Replacement Parts
The Shield Gas Box is highly integrated and only a few parts can be replaced by a qualied service engineer or
by the customer. These parts are listed below. Otherwise, the entire Shield Gas Box needs to return for repair. It
is recommended that customers contact Technical Support before attempting repairs on these units.
Item No. Description ESAB PN
1 Transformer 0558008612
2 Fan 0558008614
3 Fuse - T630mA 250V, 5 x 20mm 0558008613
4 Solenoid 6240 for Air Curtain 0558008615
5 Pressure Gauge 0558008616
6 Pressure Regulator 0558008617
1
4
3
2
6
5
27
SECTION 2 SHIELD GAS BOX
28
SECTION 3 PLASMA GAS BOX
3.0 Plasma Gas Box (0558008252)
NOTE:
The PT-36 Torch is shipped with hose lengths that will not allow the Plasma Gas Box to be mounted more than
two meters (6.6 feet) away from the torch. Please make sure the routing of the standard hoses will allow them to
bend and connect properly before permanently mounting the Plasma Gas Box.
If additional distance between the torch and box is required the standard torch hose assembly will need extension hoses to create longer lengths. Extension hoses can be ordered to connect to the existing hose assembly.
BOTH HOSES MUST BE ORDERED
Extension Hose, Plasma Gas, 1M (3.3 ft.) ESAB P/N 0558008996
Extension Hose, Shield Gas, 1M (3.3 ft.) ESAB P/N 0558008997
The longer hose lengths will require that the pierce time be increased and a longer lead-in time must be specied. This is due to the additional time required to purge the N2 start gas from the hose before the O2 cut gas
becomes aective. This condition occurs when cutting carbon steel with oxygen.
PT-36
m3 G2
Plasma
Torch
Vision 50P
Control
Interface
Shield Gas Hose
Shield Gas
Control
Gas Filters Assembly
Component Locator Designation
(See following component illustrations)
H35
Argon
CAN
Power
PG1 (Air/N2/O2)
PG2 (Air/N2/O2)
B
C
D
E
F
G
Plasma Gas Box Component Locator Designations
Note:
Refer to enclosed tables for all available hoses and cables.
29
AHI
Plasma
Shield Gas Hose
Plasma Gas Hose
Gas Control
SECTION 3 PLASMA GAS BOX
G
B
A
C
E
F
D
30
H
I
SECTION 3 PLASMA GAS BOX
3.1 Functions and Features
The Plasma Gas Box regulates the output of the plasma gas (PG) selected from the four gas inlets (Argon, H35,
PG1 and PG2). It is powered by 24 Volts (AC and DC) from the Shield Gas Box and receives commands via the
CAN-bus directly from the CNC.
Like the Shield gas box, the gas output of the Plasma Gas Box is monitored and fed back through the CAN-bus
to CNC for self-diagnosis.
Note: For required gas specications see manual 0558008682, Subsection 7.1
NOTE:
* 6.25”
(158. 8 mm)
CAN cable must be routed separate
from torch leads.
* 8.50” (215.9 mm) including ttings on front and back
Weight:
9.3 lbs. (4.2 kg)
Shield Gas Bracket Assembly
( 0558008459 )
4.50”
(114. 3 m m)
31
4.75”
(120.7 mm)
6.50”
(165.1 mm)
SECTION 3 PLASMA GAS BOX
Plasma Gas Box Mounting Hole Locations
(Bottom View)
M6-1
2.52”
(64.0mm)
0.90”
(22.9mm)
(9.5mm)
Plasma Gas Box Mounting
Plate Hole Locations
(0558008793)
0.281
(7.1mm)
0.313”
(8.0mm)
0.37”
4.72”
(120. 0mm)
4.00”
(101.6mm)
0.37”
(9.5mm)
32
7.50”
(190.5mm)
SECTION 3 PLASMA GAS BOX
3.2 Plumbing Schematic
Ar
H35
N2/O2/Air
V1
V2
V3
PT1
PT2
PV1
V4
Exhaust Port
PT3
Plasma Gas
N2/O2/Air
0.5mm
Purge Orice
∆P
P
P
1
2
PV2
PT = Pressure Transducer
PV = Proportional Valve
33
SECTION 3 PLASMA GAS BOX
3.3 Electrical Schematic
Con 1
1
2
3
4
CAN
5
6
7
8
Con 2
1
2
3
POWER
4
CAN H Out
CAN L Out
CAN Gnd
CAN H In
CAN L In
NC
NC
NC
24VAC In
24VAC In
-24VDC In
+24VDC In
CO 1
1
2
3
4
5
6
7
8
9
10
12
11
14
13
15 16
LED 1
34
LED 2
SECTION 3 PLASMA GAS BOX
3.4 Connections
There are two cables connected to the Plasmas Gas Box: one is 24V power, the other is CAN. There are four gas
inputs (Argon, H35, PG1 and PG2) and one gas output (PG). The gas ttings are listed below.
Note:
Chassis must be connected to the machine ground.
Gas Fitting
Argon 1/8” NPT x “A” Inert Gas RH Female 631475
H-35 1/4” NPT x “B” Fuel LH Male 83390
Inputs
PG1 1/4” NPT x “B” Inert Gas RH Female 74S76
PG2 1/4” NPT x “B” Oxygen RH Male 83389
Output PG
Connection, Male
0.125NPT to "A" Size
ESAB
P/N
206 4113
3.5 Troubleshooting
The Plasma Gas Box has two visible LEDs that indicate its’ status. When the GREEN LED is on, this indicates power
is applied to the unit and the rate at which it is ashing shows the operational status of the unit (refer to the chart
below). If the Green LED is not ON, check the power cable, which should carry 24VDC and 24VAC from the Shield
Gas Box.
If the Yellow LED is not ON, either there is no power to the unit or the station is not selected.
The Plasma Gas Box is highly integrated and is treated as a “Black Box”. If one or more functions of the unit stop
working, the unit must be returned for repair. Contact technical support for troubleshooting and RMA assistance.
LED Status Meaning
OFF Power OFF
Green
Yellow ON Station is selected
10% ON, 90% OFF Boot loader is running
50% ON, 50% OFF Application is running
90% ON, 10% OFF Application is running, CAN is available
35
SECTION 3 PLASMA GAS BOX
36
SECTION 4 REMOTE ARC STARTER BOX
4.0 Remote Arc Starter Box (0558008150)
Component Locator Designation
(See following component illustrations)
Power
Supply
CC-11
Coolant
Circulator
PS & CC Control Cable
Power Cable
Pilot Arc Cable
Coolant Supply Hose
Coolant Return Hose
E-Stop
Vision 50P
Control Interface
Cutting Machine
Relay Box
or
CAN
A
B
C
D
E
F
G
Arc
Starter
Assembly
Power, Pilot Arc, Coolant
I
VDR Cable
H
AHC / Lift
( Optional )
PT-36
m3 G2
Plasma
Torch
Cutting Machine
Relay Box
Remote Arc Starter Box Component Locator Designations
NOTE: Refer to enclosed tables for all available hoses and cables.
37
SECTION 4 REMOTE ARC STARTER BOX
The Remote Arc Starter Box is more commonly referred to as the RAS Box. The RAS Box serves as an interface
between the Vision 50P CNC and the EPP family of Plasma Power Supplies, helping to deliver the plasma arc.
The RAS Box also provides a voltage feedback to the plasma torch lift. This voltage is used to regulate the torch
height while cutting, maintaining the proper height of the torch above the work piece.
Within the RAS box there is an ACON module for communicating with the CNC, a High Frequency/Voltage Divider circuit board which functions to provide pilot arc ionization and voltage divider functions to regulate torch
height.
Coolant connections and torch power connections are made within the RAS box and provide an interface between the power supply, coolant circulator and the torch.
GND
H
B, C
G
A
F
D
E
Letter Description
A 24 Pin Amphenol Power Supply Connection
B
C
D Coolant Inlet - Flowing To The Torch
E
F E-Stop
G 8 Pin Can Bus Connection To The Cnc Or Interface
H 3 Pin Voltage Divider Connection To The Lift
I Torch Shroud Connection
GND Machine Ground Connection
Coolant Return - Flowing Back To The Coolant
Strain Relief Fittings
Circulator From The Torch
I
Note:
Chassis must be connected to
the machine ground.
38
SECTION 4 REMOTE ARC STARTER BOX
4.1 Power Source Connections
1. To make the power supply connection to the RAS box, you must rst open the unit: remove or unlock the
cover screws and lift the box cover o to expose internal components.
The cover is grounded to the Remote Arc Starter Box inter-
CAUTION
2. To attach the Pilot Arc and Power cables to the RAS box, you must pass them through the strain relief t-
tings.
nally with a short ground wire. Remove cover carefully to
avoid damage to the wire or loosening of the ground wire.
Strain Relief Fittings
Pilot Arc Cable
Power Source Cables
39
SECTION 4 REMOTE ARC STARTER BOX
4.1 Power Source Connections (con’t.)
Nomex Insulation
Connection for Pilot Arc Cable
Buss Bar / Block
Locking Screw
1. Strip back the insulation of the 4/0 (95 mm2) cable, approximately 38 mm.
2. Insert the 4/0 (95 mm2) cable in the buss bar / block hole until copper extends to the edge of the
buss bar / block.
3. Tighten the locking screw(s) down on the cable.
Refer to the following table to determine the number of 4/0 (95 mm2) conductors required for
your application.
Amperage Required # of 1/0 Cables
Up to 200 amps 1
Amperage Required # of 4/0 Cables
Up to 400 amps 1
Up to 800 amps 2
Up to 1000 amps 3
Careful attention while stripping the insulation of the 4/0 (95 mm2)
NOTICE
cable will make installation in the buss clamp easier. Do not spread
or are the copper conductors.
Note:
Chassis must be connected to the machine ground.
40
SECTION 4 REMOTE ARC STARTER BOX
4.2 Torch Connections
Torch hook-up requires the connection of power cables / coolant hoses, pilot arc cable and chassis ground. On
the PT36 torch, the coolant hoses from the RAS box to the torch also carry electrode power.
Power Cable /
Pilot Arc
Connection
Ground
Lug
Coolant Connections
Pilot
Arc Cable
Power Cable /
Coolant
Chassis
Ground
Wire
41
SECTION 4 REMOTE ARC STARTER BOX
* 8.75”
(222.3 mm)
* 9.75” (247.7 mm) including handle on top
Weight:
7.50”
(190.5 mm)
28.5 lbs. (12.9 kg)
17.0 0 ”
(431.8 mm)
42
SECTION 4 REMOTE ARC STARTER BOX
4.3 Remote Arc Starter Box Mounting
The box has four M6 x 1 threaded mounting holes shown in pattern below.
If fasteners are threaded into the box from below, the length of the fasteners
must not allow them to extend more than 0.25” beyond the edge of the internal
CAUTION
5.00
(127. 0 0)
female threads. If fasteners are too long they can interfere with the components
inside the box.
7.50 "
(190 .5 mm)
(165.1 mm)
6.50"
1.00
(2.54)
3.25"
(82.6 mm)
2.75
(69.85)
13.75
(349.25)
Remote Arc Starter Box Mounting Hole Locations (Bottom View)
18. 50"
(469.9 mm)
17. 50"
(444.5 mm)
8.75"
(222.3 mm)
Remote Arc Starter Box Optional Mounting Plate (0558008461) Hole Locations
43
SECTION 4 REMOTE ARC STARTER BOX
4.4 Typical / Recommended E-stop Connection
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Items listed in the assembly drawing Bill of Materials (included in the back
of this publication) that do not have a part number shown are not avail-
able from ESAB as a replaceable item and cannot be ordered. Descriptions
are shown for reference only. Please use local retail hardware outlets as a
source for these items.
44
SECTION 5 HOSES AND CABLES
5.0 Hoses and Cables
NOTE:
This cable is only used
with a Vision 50P to connect the second Interface
Box.
For multiple CAN hubs on
ESAB cutting machines
use cable 0558008824.
Cable / Hose
Description
CAN Bus Cable
CAN Bus Crossover Cable 0.5m (1.7’) 0558008524
115 / 230 VAC Input Power Cable
Plasma Gas Control Power Cable
Basic Flex Cable
Available
Lengths
m ( ft. )
1m (3.3’ ) 0558008464
2m (6.5’) 0558008465
3m (10’) 0558008466
4m (13’) 0558008467
5m (16’) 0558008468
6m (19’) 0558008469
7m (23’) 0558008470
8m (26’) 0558008471
9m (30’) 0558008472
10m (33’) 0558008473
11m (36’) 0558008474
12m (39’) 0558008475
13m (43’ ) 0558008476
14m (46’) 0558008477
15m (49’ ) 0558008478
20m (66’) 0558008479
25m (82') 0558008809
36m (118') 0558008480
5m (16’) 0558008261
10m (33’) 0558008262
15m (49' ) 0558008810
20m (66’) 0558008811
25m (82') 0558008812
1.5m (5’) 0560947079
3m (10’) 0560947080
4m (13’) 0560947061
5m (16’) 0560947081
6m (19’) 0560947062
7m (23’) 0560947063
8m (26’) 0560947064
9m (30’) 0560947065
10m (33’) 0560947082
12.8m (42') 0560946780
15m (49’ ) 0560947066
20m (66’) 0560947083
4.6m (15’) 0560936665
7.6m (25’) 0560936666
15m (50’) 0560936667
22.8m (75’) 0560936668
25m (82’) 056094 8159
Part Number
45
ESAB
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
E-Stop Cable
Gas Controls Power Cable
Cable / Hose
Description
VDR Cable
Available
Lengths
m ( ft. )
5m (16’) 0558008329
10m (33’) 0558008330
15m (49’) 0558008331
20m (66') 0558008807
25m (82') 0558008808
1m (3. 3’) 0560947962
2m (6.4’) 0560946776
3m (10’) 0560947964
4m (13’) 0560947087
5m (16’) 0560947088
6m (19’) 0560947089
7m (23’) 0560947090
Available
Lengths
m ( ft. )
0.5m (1.7’) 0560947067
1.5m (5’) 0560947075
3m (10’) 0560947076
4m (13’) 0560947068
5m (16’) 0560947077
6m (19’) 0560947069
6.1m (20') 0560946782
7m (23’) 0560947070
8m (26’) 0560947071
9m (30’) 0560947072
10m (33’) 0560947078
15m (49’) 0560947073
20m (66’) 0560947074
25m (82') 0560946758
ESAB
Part Number
ESAB
Part Number
46
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
Pilot Arc Cable
Torch
Description
PT-36 m3 G2
Plasma Torch
Available
Lengths
m ( ft. )
1.4m (4.5’) 0558008310
1.8m (6’) 0 5580 08 311
3.6m (12’) 05580 08312
4.6m (15’) 0558008313
5.2m (17 ’ ) 0558008314
6.1m (20’) 0558008315
7.6m (25’) 0558008316
4.5m (14.5’) 0558 0 08317
Available
Lengths
m ( ft. )
1.4m (4.5’) 0558008301
1.8m (6’) 0558008302
3.6m (12’) 0558008303
4. 3m (14’) 0558008308
4.6m (15’) 0558008304
5.2m (17 ’ ) 0558008305
6.1m (20’) 0558008306
7.6m (25’) 0558008307
ESAB
Part Number
ESAB
Part Number
Torch
Description
P2 Control Cable
47
Available
Lengths
m ( ft. )
7.6m (25’) 0558004651
10m (33’) 0558008360
15m (50’) 0558004652
22.8m (75’) 0558004653
30.5m (100’) 0558004654
40m (131’) 0558003978
45.7m (150’) 0558004655
50m (164’) 0558008355
60m (200’) 0558008356
ESAB
Part Number
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
O2 / PG-2 Hose
Available
Lengths
m ( ft. )
1.5m (5’) 0558006106
5m (16’) 0558006107
6m (19’) 0558006108
7m (23’) 0558006109
8m (26’) 0 558 0 06110
9m (30’) 0 5580 0 6111
10m (33’) 055800 6112
11m (36’) 055800 6113
12m (39’) 0558006114
13m (43’) 055 8 0 06115
14m (46’ ) 055 80 06116
15m (49’) 0558 0 06117
16m (52’) 0 5580 0 6118
17m (56’) 05580 0 6119
18m (59’) 0558006120
19m (62’) 05580 06121
20m (66’) 0558006122
30m (98') 0558008815
2. 3m (7. 5’) 0558007314
4m (13’) 0558008358
0.5m (1.7’) 0558008444
1m (3. 3’) 0558008445
3m (10’) 0558008446
ESAB
Part Number
48
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
H35 / CH4 Hose
Available
Lengths
m ( ft. )
0.5m (1.7’) 0558008371
1m (3. 3’) 0558008372
2. 3m (7. 5’) 0558008373
3m (10’) 05580 08374
4m (13’) 0558008375
5m (16’) 0558008376
6m (19’) 0558008377
7m (23’) 0558008378
8m (26’) 0558008379
9m (30’) 0558008380
10m (33’) 0558008381
11m (36’) 0558008382
12m (39’) 0558008383
13m (43’) 0558008384
14m (46’ ) 0558008385
15m (49’) 0558008386
16m (52’) 0558008387
17m (56’) 0558008388
ESAB
Part Number
Hose
Description
Coolant Hose
49
Available
Lengths
m ( ft. )
5m (16') 0558005246
10m (33') 0558005563
15m (49') 0558005564
20m (66') 0558005565
30m (98') 0558005247
40m (131') 0558005248
50m (164') 0558005567
60m (196') 0558005249
ESAB
Part Number
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
Argon Hose
Cable / Hose
Description
Air Curtain Hose
Available
Lengths
m ( ft. )
5m (16’) 0558008390
6m (19’) 0558008391
7m (23’) 0558008392
8m (26’) 0558008393
9m (30’) 0558008394
10m (33’) 0558008395
11m (36’) 0558008396
12m (39’) 0558008397
13m (43’) 0558008398
14m (46’ ) 0558008399
15m (49’) 0558008400
16m (52’) 0558008401
17m (56’) 0558008402
40m (132’) 0558008816
Available
Lengths
m ( ft. )
1.4m (4.5’) 0558004841
1.8m (6’) 0558004842
3.6m (12’) 0558004843
4.6m (15’) 0558004844
5.2m (17 ’ ) 0558004845
7.6m (25’) 0558004846
6m (20’) 0558006865
7m (23’) 0558008502
8m (26’) 0558008503
9m (30’) 0558008504
10m (33’) 0558008505
11m (36’) 0558008506
12m (40’ ) 0558008507
ESAB
Part Number
ESAB
Part Number
50
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
N2 / PG-1 Hose
Available
Lengths
m ( ft. )
1.5m (5’) 0558006089
5m (16’) 0558006090
6m (19’) 0558006091
7m (23’) 0558006092
8m (26’) 0558006093
9m (30’) 0558006094
10m (33’) 0558006095
11m (36’) 0558006096
12m (39’) 0558006097
13m (43’) 0558006098
14m (46’ ) 0558006099
15m (49’) 0558006100
16m (52’) 0558006101
17m (56’) 0558006102
18m (59’) 0558006103
19m (62’) 0558006104
20m (66’) 0558006105
30m (98') 0558008814
2. 3m (7. 5’) 0558007313
4m (13’) 0558008357
0.5m (1.7’) 0558008441
1m (3. 3’) 0558008442
3m (10’) 0558008443
ESAB
Part Number
51
SECTION 5 HOSES AND CABLES
Cable / Hose
Description
Air / Shield Gas Hose
Available
Lengths
m ( ft. )
1.5m (5’) 0558006200
5m (16’) 0558006201
6m (19’) 0558006202
7m (23’) 0558006203
8m (26’) 0558006204
9m (30’) 0558006205
10m (33’) 0558006206
11m (36’) 0558006207
12m (39’) 0558006208
13m (43’) 0558006209
14m (46’ ) 0558006210
15m (49’) 0 5580 0 6211
16m (52’) 055800 6212
17m (56’) 0558006213
18m (59’) 0558006214
19m (62’) 0558006215
20m (66’) 0558006216
30m (98') 0558008813
2. 3m (7. 5’) 0558007315
4m (13’) 0558008359
0.5m (1.7’) 0558008447
1m (3. 3’) 0558008448
3m (10’) 0558008449
ESAB
Part Number
52
SECTION 6 PT36 PLASMA TORCH
6.0 PT-36 Plasma Torch
6.1 General
The PT-36 Mechanized Plasmarc Cutting Torch is a plasma arc torch factory assembled to provide torch component concentricity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the eld.
Only the torch front-end has replaceable parts.
6.2 Scope
The purpose of this manual is to provide the operator with all the information required to install and service
the PT-36 Mechanized Plasmarc Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package.
6.3 Package Options Available
PT-36 package options available through your ESAB dealer. See Replacement Parts section for component part
numbers.
DESCRIPTIONS FOR PT-36 TORCH ASSEMBLY'S PART NUMBER
PT-36 Torch Assembly 4.5 ft (1,4m) 0558008301
PT-36 Torch Assembly 6 ft (1,8m) 0558008302
PT-36 Torch Assembly 12 ft (3,6m) 0558008303
PT-36 Torch Assembly 14 ft Mini-Bevel (4,3m) 0558008308
PT-36 Torch Assembly 15 ft (4,6m) 0558008304
PT-36 Torch Assembly 17 ft (5,2m) 0558008305
PT-36 Torch Assembly 20 ft (6,1m) 0558008306
PT-36 Torch Assembly 25 ft (7,6m) 0558008307
6.4 Optional Accessories:
Bubble Muer - When used in conjunction with a water pump recirculating water
from the table and by using compressed air, this device creates a bubble of air which
enables a PT-36 Plasmarc Cutting Torch to be used underwater with less sacrice of cut
quality. This system also permits operation above water as the ow of water through
the muer reduces fume, noise, and arc U.V. Radiation.
(for installation/operation instructions see manual 0558006722).............................. 37439
Air Curtain - This device when supplied with compressed air is used to improve the
performance of the PT-36 Plasmarc Cutting Torch when cutting underwater. The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to
operate in a relatively dry zone, even though the torch has been submerged to reduce
noise, fume, and arc radiation. To be used in underwater applications only.
(for installation/operation instructions see manual 0558006404) .............................37440
53
SECTION 6 PT36 PLASMA TORCH
Speedloader assembly, handheld ...............................................................0558006164
NOTE:
Cannot be used with vent hole nozzles.
Speedloader assembly, 5 xtures ................................................................0558006165
6.4.1 PT-36 Torch Consumable Kits
PT-36 Repair & Accessories Kit ...................................................................................0558005221
Part Number Quantity Description
0558003804 1 PT-36 TORCH BODY ASSY (w/ Contact Ring)
0558003858 2 CONTACT RING (w/ SCREW)
0004470044 6 CONTACT RING SCREW
0558003924 3 ELECTRODE HOLDER PT-36
0558005457 5 BAFFLE 4 HOLE x .022
0558002533 5 BAFFLE 4 HOLE x .032
0558002534 1 BAFFLE 4 HOLE x .032 - REVERSE
0558001625 5 BAFFLE 8 HOLE x .047
0558002530 1 BAFFLE 8 HOLE x .047 - REVERSE
0004470045 2 NOZZLE RETAINING CUP
0004470030 5 DIFFUSER 16-HOLE
0004470031 5 DIFFUSER 24-SLOT
0004470115 1 DIFFUSER 24-SLOT - REVERSE (Blk)
0004470046 2 SHIELD RETAINER PT-36
0004485648 10 O-RING 1.614 ID .070 Nitrile
0004485671 10 O-RING 0.364 ID x .070 FKM
0004470869 1 GREASE SILICONE DOW DC-111 (5.3 Oz)
0558003918 1 TOOL ELECTRODE HOLDER PT-36
0558007105 1 NUT DRIVER 7/16" (Electrode Tool)
0004470049 2 WRENCH HEX KEY 0.109"
54
SECTION 6 PT36 PLASMA TORCH
PT-36 Start-Up Kits ..............................................................................................................................
0558005224
600 amp
10 10 10 0558003914 Electrode O2 UltraLife, Standard
5 5 5 0558003928 Electrode N2/H35, Standard
5 5 5 0558005459 Electrode O2/N2, Low Current
5 5 5 0558006908 Nozzle PT-36 0.8mm (.030")
5 5 5 0558006010 Nozzle PT-36 1.0mm (.040")
5 5 5 0558008010 Nozzle PT-36 1.0mm (.040") PR
5 5 5 0558006014 Nozzle PT-36 1.4mm (.055")
5 5 5 0558006018 Nozzle PT-36 1.8mm (.070")
5 5 5 0558006020 Nozzle PT-36 2.0mm (.080")
5 5 5 0558006023 Nozzle PT-36 2.3mm (.090")
5 5 - 0558006025 Nozzle PT-36 2.5mm (.099")
5 5 - 0558006030 Nozzle PT-36 3.0mm (.120")
5 5 - 0558006036 Nozzle PT-36 3.6mm (.141")
5 - - 0558006041 Shield PT-36 4.1mm (.161")
5 5 5 0558007624 Shield PT-36 2.4mm (.095")
5 5 5 0558006130 Shield PT-36 3.0mm (.120")
5 5 5 0558006141 Shield PT-36 4.1mm (.160")
5 5 5 0558006166 Shield PT-36 6.6mm (.259")
5 - - 0558006199 Shield PT-36 9.9mm (.390")
0558005223
360-450 amp
0558005222
200 amp
Part Number Description
55
SECTION 6 PT36 PLASMA TORCH
PT-36 H35 Heavy Plate Start-up Kit ............................................................................0558005225
Part Number Quantity Description
0558003963 5 Electrode, Tungsten 3/16"D
0558003965 5 Nozzle H35 .198" Divergent
0558003964 2 Collet 3/16"D Electrode
0558005689 2 Electrode/Collet Holder PT-36
0558003967 2 Collet Body
0558002532 2 Bae, 32 Hole x .023
0558006688 5 Shield High Current
0558003918 1 Electrode Holder Tool PT-36
0558003962 1 Tungsten Electrode Tool
0558006690 2 Nozzle Retaining Cup Assy High Current
56
SECTION 6 PT36 PLASMA TORCH
6.5 PT-36 Technical Specications
7.54"
(191. 5mm)
6.17"
(156.7mm)
Clamp only on insulated torch sleeve not less than
1.25" (31.7mm) from the torch end of sleeve.
(231.9mm)
10.50" (266.7mm)
Length of Sleeve
NOTE:
2.00"
(50.8mm)
9.13"
6.5.1 Recommended Regulators
Liquid Cylinder Service:
O2 : R-76-150-540LC ................................................................................................................P/N 19777
N2 : R-76-150-580LC ................................................................................................................P/N 19977
High Pressure Cylinder Service:
O2 : R-77-150-540 .........................................................................................................P/N 0558010676
Ar & N2 : R-77-150-580 .................................................................................................P/N 0558010682
H2 & CH4 : R-77-150-350 ............................................................................................P/N 0558010680
Industrial Air : R-77-150-590 ...................................................................................P/N 0558010684
Station/Pipeline Service:
O2 : R-76-150-024 .........................................................................................................P/N 0558010654
Ar & N2 : R-76-150-034 .................................................................................................P/N 0558010658
Air, H2, & CH4 : R-6703 .............................................................................................................P/N 22236
57
SECTION 6 PT36 PLASMA TORCH
6.5.2 PT-36 Torch Technical Specications
Type: Water cooled, Dual gas, mechanized plasmarc cutting torch
Current Rating: 1000 Amps @ 100% duty cycle
Mounting Diameter: 2 inches (50.8 mm)
Length of Torch without leads: 16.7 inches (42 cm)
IEC 60974-7 Voltage Rating: 500 volts peak
Striking Voltage (maximum value of HI-FREQUENCY voltage): 8000 VAC
Minimum Coolant Flowrate: 1.3 GPM (5.9 l/min)
Minimum Coolant Pressure at Inlet: 175 psig (12.1 bars)
Maximum Coolant Pressure at Inlet: 200 psig (13.8 bars)
Minimum Acceptable Rating of Coolant Recirculator:
16,830 BTU/HR (4.9 kW) at High Coolant Temperature - Ambient = 45°F (25°C) and 1.6 USGPM (6 L/min)
Maximum Safe Gas Pressures at Inlets to Torch: 125 psig (8.6 bars)
Safety Interlocks: This torch is intended for use with ESAB plasmarc cutting systems and controls employing a water ow
switch on the coolant return line from the torch. Removal of the nozzle retaining cup to service the torch breaks the
coolant return path.
58
SECTION 6 PT36 PLASMA TORCH
6.6 Connection of Torch To Plasma System
Refer to system manual.
DANGER
Electric Shock Can Kill!
• Disconnect primary power source before making any adjustments.
• Disconnect primary source before doing maintenance on system
components.
• Do not touch front-end torch parts (nozzle, retaining cup, etc.) without turning primary power o.
Power Cables
6.6.1 Connection to the Remote Arc Starter Box
The PT-36 has two water cooled power cables which must be connected to the negative output from the power
supply. The right handed 7/16-20 tting is on the cable supplying coolant to the torch. The left handed 7/16-20
tting is on the cable returning coolant from the torch. Both of these cables have a green/yellow wire to be connected to the ground stud shown below.
The pilot arc cable is connected to the arc stater box (see Plasma/Shield Gas Box manual). The pilot arc cable also
has a green/yellow wire that is connected to a grounding stud.
59
SECTION 6 PT36 PLASMA TORCH
6.7 Mounting Torch to Machine
Refer to machine manual.
CLAMPIN G ON TORCH BODY MAY C AUSE DANGEROUS CURRE NT TO
DANGER
Mount torch on insulated sleeve here
DO NOT mount
on steel torch
body here
FLOW THROUGH MACHINE CHASSIS.
• Do not mount on stainless steel torch body.
• Torch body is electrically insulated, however high frequency start
current may arc through to nd a ground.
• Clamping near torch body may result in arcing between body and
machine.
• When this arcing occurs, torch body may require non-warranty
replacement.
• Damage to machine components may result.
• Clamp only on insulated torch sleeve (directly above label) not less
than 1.25" (31.75mm) from the torch end of the sleeve.
60
SECTION 6 PT36 PLASMA TORCH
Hydrogen explosion hazard! Read the following before attempting
DANGER
A hazard exists whenever a water table is used with plasma arc cutting. Severe explosions have resulted from the accumulation of hydrogen beneath the plate being cut. Thousands of dollars in property damage have 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 ox-
ides. This reaction explains why reactive metals with greater anity 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.
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.
to cut when using a water table.
3. Plasma & Shield Gas
Hydrogen or other fuel gases, such as Methane (CH4), may come from the plasma or shield gas. H-35 is a commonly
used plasma gas. This gas is 35% hydrogen by volume. When using H-35 at high currents, as much as 125 cfh of
hydrogen will be released.
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:
A. Clean the slag (especially ne particles) from the bottom of the table frequently. Rell 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 conned 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.
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.
61
SECTION 6 PT36 PLASMA TORCH
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.
WARNING
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.
WARNING
WARNING
WARNING
Oil And Grease Can Burn Violently!
• Never use oil or grease on this torch.
• Handle torch clean hands only on clean surface.
• Use silicone lubricant only where directed.
• Oil and grease are easily ignited and burn violently in the presence of
oxygen under pressure.
Hydrogen explosion hazard.
Do Not Cut Underwater With H-35! Dangerous buildup of hydrogen gas is possible in
the water table. Hydrogen gas is extremely explosive. Reduce the water level to 4 inches minimum below the workpiece. Vibrate plate, stir air and water frequently to prevent
hydrogen gas buildup.
Spark hazard.
Heat, spatter, and sparks cause re and burns.
• Do not cut near combustible material.
• Do not cut containers that have held combustibles.
• Do not have on your person any combustibles (e.g. butane lighter).
• Pilot arc can cause burns. Keep torch nozzle away from yourself and
others when activating plasma process.
• Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and hat.
• Wear ame-retardant clothing that covers all exposed areas.
• Wear cuess trousers to prevent entry of sparks and slag.
62
SECTION 6 PT36 PLASMA TORCH
6.8 Set Up
• Select an appropriate condition from the process data (SDP File) and install recommended torch
front-end parts (nozzle, electrode, etc.) See process data to identify parts and settings.
• Position torch over material at desired start location.
• See Power Source Manual for proper settings.
• See Flow Control Manual for gas control procedures.
• See Control and Machine Manuals for startup procedures.
6.8.1 Mirror Cutting
When mirror cutting, a reverse swirl gas bae and reverse diuser are required. These reverse parts will “spin” the
gas in the opposite direction, reversing the “good” side of the cut.
Reverse 4 x .032 Bae P/N 0558002534
Reverse 8 x .047 Bae P/N 0558002530
Reverse Diuser P/N 0004470115
6.9 Cut Quality
6.9.1 Introduction
Causes aecting cut quality are interdependent. Changing one variable aects all others. Determining a solution may be dicult. The following guide oers possible solutions to dierent undesirable cutting results. To
begin select the most prominent condition:
6.9.2 Cut Angle, negative or positive
6.9.3 Cut Flatness
6.9.4 Surface nish
6.9.5 Dross
6.9.6 Dimensional Accuracy
Usually the recommended cutting parameters will give optimal cut quality, occasionally conditions may vary
enough that slight adjustments will be required. If so:
• Make small incremental adjustments when making corrections.
• Adjust Arc Voltage in 5 volt increments, up or down as required.
• Adjust cutting speed 5% or less as required until conditions improve.
63
SECTION 6 PT36 PLASMA TORCH
Before attempting ANY corrections, check cutting variables with the
CAUTION
6.9.2 Cut Angle
Negative Cut Angle
Top dimension is greater than the bottom.
• Misaligned torch
• Bent or warped material
• Worn or damaged consumables
• Stando low (arc voltage)
• Cutting speed slow (machine travel rate)
factory recommended settings/consumable part numbers listed in
Process Data.
Part
Positive Cut Angle
Top dimension is less than the bottom dimension.
• Misaligned torch
• Bent or warped material
• Worn or damaged consumables
• High stando High (arc voltage)
• Cutting speed fast
• Current high or low. (See Process Data for rec-
ommended current level for specic nozzles).
Drop
Drop
Part
Part
Part
64
SECTION 6 PT36 PLASMA TORCH
6.9.3 Cut Flatness
Top And Bottom Rounded. Condition usually occurs when
material is .25" thick (6,4mm) or less.
• High current for given material thickness (See Process Data for proper settings).
Top Edge Undercut
• Stando low (Arc Voltage)
Drop
Drop
Part
Part
65
SECTION 6 PT36 PLASMA TORCH
6.9.4 Surface Finish
Process Induced Roughness
Cut face is consistently rough. May or may not be conned
to one axis.
•IncorrectShieldGasmixture(SeeProcessData).
•Wornordamagedconsumables.
Machine Induced Roughness
Can be dicult to distinguish from Process Induced
Roughness. Often conned to only one axis. Roughness is
inconsistent.
•Dirtyrails,wheelsand/ordriverack/pinion.
(Refer to Maintenance Section in machine operation
manual).
•Carriagewheeladjustment.
Top View
Process
Induced
Roughness
or
Cut Face
Machine
Induced
Roughness
6.9.5 Dross
Dross is a by-product of the cutting process. It is the undesirable
material that remains attached to the part. In most cases, dross
can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.
High Speed Dross
Material weld or rollover on bottom surface along kerf. Dicult to
remove. May require grinding or chipping. “S” shaped lag lines.
•Standohigh(arcvoltage)
•Cuttingspeedfast
Slow Speed Dross
Forms as globules on bottom along kerf. Removes easily.
•Cuttingspeedslow
Cut Face
Lag Lines
Rollover
Side View
Cut Face
Lag Lines
Globules
66
Side View
SECTION 6 PT36 PLASMA TORCH
Recommended cutting speed and arc voltage will give optimal cutting performance in most cases. Small incremental adjustments may
CAUTION
Top Dross
Appears as splatter on top of material. Usually removes easily.
•Cuttingspeedfast
•Standohigh(arcvoltage)
Intermittent Dross
Appears on top or bottom along kerf. Non-continuous. Can appear as
any kind of dross.
•Possiblewornconsumables
Other Factors Aecting Dross;
•Materialtemperature
•Heavymillscaleorrust
•Highcarbonalloys
be needed due to material quality, material temperature and specic
alloy. The operator should remember that all cutting variables are interdependent. Changing one setting aects all others and cut quality could deteriorate. Always start at the recommended settings.
Side View
Splatter
Cut Face
Before attempting ANY corrections, check cutting variables with the
CAUTION
factory recommended settings/consumable part numbers listed in
the Process Data.
6.9.6 Dimensional Accuracy
Generally using the slowest possible speed (within approved levels) will optimize part accuracy. Select consumables to allow
a lower arc voltage and slower cutting speed.
NOTICE
Recommended cutting speed and arc voltage will give optimal cutting performance.
Small incremental adjustments may be needed due to material quality, material temperature and specic alloy. The
operator should remember that all cutting variables are interdependent. Changing one setting aects all others and cut
quality could deteriorate. Always start at the recommended settings. Before attempting ANY corrections, check cutting
variables with the factory recommended settings/ consumable part numbers listed in the process data.
67
SECTION 6 PT36 PLASMA TORCH
6.10 Torch Flow Passages
Pilot Arc
Shield Gas In
Plasma Gas In
Pilot Arc
68
Water In
Water Out
SECTION 6 PT36 PLASMA TORCH
6.11 Introduction
Wear on torch parts is a normal occurrence to plasma cutting. Starting a plasma arc is an erosive process to both
the electrode and nozzle. Regularly scheduled inspection and replacement of PT-36 parts must take place to
maintain cut quality and consistent part size.
6.12 Torch Front End Disassembly
DANGER
1. Remove the Shield Cup Retainer.
If the shield cup retainer is dicult to remove, try to screw the nozzle retaining cup tighter to
2. Inspect mating metal surface of shield cup and shield cup retainer for nicks or dirt that might prevent these
two parts from forming a metal to metal seal. Look for pitting or signs of arcing inside the shield cup. Look
for melting of the shield tip. Replace if damaged.
3. Inspect diuser for debris and clean as necessary. Wear on the top notches does occur, eecting gas volume.
Replace this part every other shield replacement. Heat from cutting many small parts in a concentrated area
or when cutting material greater than 0.75" (19.1mm) may require more frequent replacement.
CAUTION
HOT TORCH WILL BURN SKIN!
ALLOW TORCH TO COOL BEFORE SERVICING.
NOTE:
relieve pressure on the shield cup retainer.
Incorrect assembly of the diuser in the shield will prevent the torch
from working properly. Diuser notches must be mounted away
from the shield as illustrated.
Shield Cup
Shield Cup Retainer
Diuser
Torch Body
Electrode
Nozzle
Nozzle Retaining Cup
69
SECTION 6 PT36 PLASMA TORCH
4. Unscrew nozzle retainer and pull nozzle straight out of torch body. Inspect insulator portion of the nozzle
retainer for cracks or chipping. Replace if damaged.
Inspect nozzle for:
• melting or excessive current transfer.
• gouges from internal arcing.
• nicks or deep scratches on the O-ring seating surfaces .
• O-ring cuts, nicks, or wear.
• Remove hafnium particles (from the nozzle) with steel wool.
Replace if any damage is found.
NOTE:
Discoloration of internal surfaces and small black starting marks are normal and do not eect
cutting performance.
If the holder was tightened suciently, the electrode may unscrew without being attached to the electrode
holder. When installing the electrode, use only sucient force to adequately secure the electrode.
5. Remove electrode using electrode removal tool.
6. Disassemble electrode from electrode holder. Insert ats on the holder into a 5/16" wrench. Using the electrode tool, rotate electrode counter-clockwise to remove. Replace electrode if center insert is pitted more
than 0.09" (3/32").
Torch Body
Electrode Removal Tool
Electrode
Replace electrode if center insert is
pitted more than 0.09" (3/32")
70
SECTION 6 PT36 PLASMA TORCH
7. Remove electrode holder from torch body. Hex on the end of the electrode holder removal tool will engage
in a hex in the holder.
Removal
Tool
Electrode
Gas Bae
Electrode Holder Assembly
NOTE:
The electrode holder is manufactured in two pieces. Do not disassemble. If the holder is dam-
aged, replace the electrode holder assembly.
8. Disassemble electrode holder and gas bae. Carefully remove O-ring from electrode holder and slide bae
from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not
attempt to clear holes. Replace bae if damaged.
NOTE:
Check all O-rings for nicks or other damage that might prevent O-ring from forming a gas/water
tight seal.
Gas Bae
Electrode Holder Assembly
O-ring
NOTE:
Discoloration of these surfaces with use is
normal. It is caused by galvanic corrosion.
71
SECTION 6 PT36 PLASMA TORCH
6.13 Assembly of Torch Front End
Over tightened Parts Will Be Dicult To Disassemble And May Damage Torch. Do not over tighten parts during reassembly. Threaded
CAUTION
• Reverse order of disassembly.
• Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates
easy future assembly and disassembly for service.
• Installing the electrode requires only moderate tightening. If the electrode holder is made tighter
than the electrode, it is possible to change worn electrodes without removing the electrode holder.
When assembling, place the nozzle inside the nozzle retaining cup and thread the nozzle retaining cup/nozzle combination on the torch body. This will help align the nozzle with the assembly.
The shield cup and shield cup retainer should be installed only after installing the nozzle retain-
parts are designed to work properly when hand tightened, approximately 40 to 60 inch/pounds.
NOTE:
ing cup and nozzle.
Otherwise the parts will not seat properly and leaks may occur.
Diuser
Shield Cup Retainer
Shield
Cup
Nozzle
Nozzle Retaining
Cup
Electrode
Torch
body
72
SECTION 6 PT36 PLASMA TORCH
6.13.1 Assembly of Torch Front End using the Speedloader
Use of a speedloader, p/n 0558006164, will ease assembly
of the torch front end parts.
step 1. To use the speedloader, rst insert the nozzle into the
nozzle retaining cup.
Nozzle
Nozzle Retaining Cup
step 2. Screw the speedloader into the nozzle retaining cup
to secure the nozzle.
step 3. Secure retaining nut on nozzle with preassembly tool,
p/n 0558005917 included with the speedloader.
step 4. Remove the speedloader. It is very important to
remove the speedloader to ensure proper seating of
the remaining parts.
step 5. Insert the diuser into the shield cup.
Diuser
step 6. Insert the nozzle retaining cup assembly into the
shield cup retainer.
Nozzle retaining cup assembly
Shield cup retainer assembly
Preassembly tool
Retaining nut
p/n 0558005916
Shield Cup
Shield cup retainer
step 7. Screw shield cup retainer assembly onto nozzle re-
taining cup assembly.
73
SECTION 6 PT36 PLASMA TORCH
6.14 Torch Front End Disassembly (for Production Thick Plate)
DANGER
CAUTION
1. Remove the High Current Nozzle Retaining Cup assembly. Unless one of these components requires replacement, they can remain assembled to each other. Inspect for signs of melting on the shield cup and check the
insulator portion of the nozzle retaining cup for wear or damage.
HOT TORCH WILL BURN SKIN!
ALLOW TORCH TO COOL BEFORE SERVICING.
Incorrect assembly of the diuser in the shield will prevent the torch
from working properly. Diuser notches must be mounted away
from the shield as illustrated.
High Current Shield
Torch Body
Nozzle
High Current Nozzle Retaining Cup Assembly
74
SECTION 6 PT36 PLASMA TORCH
2. Pull nozzle straight out of torch body.
Inspect nozzle for:
• melting or excessive current transfer.
• gouges from internal arcing.
• nicks or deep scratches on the O-ring
seating surfaces.
• O-ring cuts, nicks, or wear.
• Remove tungsten particles (from the
nozzle) with steel wool.
Nozzle Retaining Cup
Replace if any damage is found.
Torch Body
Nozzle
NOTE:
Discoloration of internal surfaces and small black starting marks are normal and do not eect
cutting performance.
3. Remove electrode using electrode removal tool.
4. Disassemble electrode from electrode holder. Insert ats on the holder into a 5/16" wrench. Using the electrode tool, rotate the collet body counter-clockwise to remove. Replace electrode if center is pitted more
than 0.06" (1/16") or if the at has become irregular in shape or is worn to a larger diameter. Use only sucient
force to adequately secure the electrode.
Torch Body
Note:
The electrode has two usable ends.
When one end is worn, ip electrode to
other end for continued use.
Electrode
Electrode Removal Tool
Collet
Collet Body
Electrode, Tungsten
75
SECTION 6 PT36 PLASMA TORCH
5. If the electrode holder did not come out in step 3, remove the electrode holder from torch body using the
Electrode Holder Removal Tool. The hex on the end of the electrode holder removal tool will engage in a hex
in the holder.
Torch Body
Electrode Holder
Electrode Holder Removal Tool
8. Disassemble electrode holder and gas bae. Carefully remove O-ring from electrode holder and slide bae
from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not
attempt to clear holes. Replace bae if damaged.
NOTE:
Check all O-rings for nicks or other damage that might prevent O-ring from forming a gas/water
tight seal.
Electrode Holder
O-ring (located behind bae)
Gas Bae
76
SECTION 6 PT36 PLASMA TORCH
6.15 Assembly of Torch Front End (for Production Thick Plate)
Over tightened parts will be dicult to disassemble and may damage torch. Do not over tighten parts during reassembly. Threaded
CAUTION
• Reverse order of disassembly.
• Apply a very thin coat of silicone grease to O-rings before assembling mating parts. This facilitates
easy future assembly and disassembly for service.
• Installing the electrode requires only moderate tightening.
parts are designed to work properly when hand tightened, approximately 40 to 60 inch/pounds.
Torch Body
1. Replace electrode holder in torch body. Hex on the
end of the electrode holder removal tool will engage
in a hex in the holder.
Collet
Collet Body
Electrode, Tungsten
2. To replace the electrode, assemble collet, collet body
and electrode. Insert electrode assembly into the electrode removal tool and ensure electrode makes contact with bottom of tool hole (electrode will fall into
place).
77
SECTION 6 PT36 PLASMA TORCH
3. Screw electrode assembly in a clockwise direction to torch body. Electrode will
tighten in the correct position when collet closes. When using the high current
nozzle retaining cup remove o-ring indicated and replace it with o-ring, p/n
488158 as shown.
remove this o-ring
place o-ring, p/n 488158 here
Nozzle Retaining Cup
Torch Body
Nozzle
NOTE:
When assembling, place the nozzle inside the high current nozzle retaining cup and thread the
high current nozzle retaining cup/nozzle combination on the torch body. This will help align the
nozzle with the assembly. The high current shield cup can be assembled onto the high current
nozzle retaining cup at any time.
78
SECTION 6 PT36 PLASMA TORCH
6.16 Torch Body Maintenance
• Inspect O-rings daily and replace if damaged or worn.
• Apply a thin coat of silicone grease to O-rings before assembling torch. This facilitates easy future
assembly and disassembly for service.
• O-ring (1.61" (41mm) I.D. x .07" (1.8mm) BUNA-70A) p/n 996528.
ELECTRIC SHOCK CAN KILL!
BEFORE PERFORMING TORCH MAINTENANCE:
WARNING
• Turn power switch of the power source console to the OFF position
• Disconnect primary input power.
O-Ring locations
• Keep electrical contract ring contact points free of grease and dirt.
• Inspect ring when changing nozzle.
• Clean with cotton swab dipped in isopropyl alcohol.
Contact Ring Points
Contact Ring Screw
Contact Ring Points
79
Contact Ring
SECTION 6 PT36 PLASMA TORCH
6.17 Removal and Replacement of the Torch Body
ELECTRIC SHOCK CAN KILL!
BEFORE PERFORMING TORCH MAINTENANCE:
WARNING
• Turn power switch of the power source console to the OFF position
• Disconnect primary input power.
1. Loosen the worm gear hose clamp so that the torch sleeving can be freed and pulled back up the cable
bundle. Approximately 7 inches should be far enough. Unscrew the torch sleeve and slide it back until the
pilot arc connection is exposed.
Handle
Torch Body
2. Disconnect the power cables which are threaded onto the shorter stems at the back of the torch. Note that
one of these connections is left-handed. Unscrew the gas hoses from the torch head assembly by using a
7/16" (11.1mm) and a 1/2" (12.7mm) wrench. Removal of the gas hoses is easier if the power cables are removed rst.
1/2" power cable
connections
1/2" shield gas
connection
7/16" plasma gas
connection
80
SECTION 6 PT36 PLASMA TORCH
3. Unwrap the electrical tape at the back of the gray plastic insulator over the pilot arc connection. Slide the
insulator back and undo the knife connectors.
Pilot Arc Cable
Wire splice
Electrical Tape
(shown removed)
Knife-splice connection
4. To install the new torch head assembly - Connect the pilot arc cable and the main power cable by reversing
the steps taken to disconnect them. Be sure the gas and water ttings are tight enough to prevent leaks, but
do not use any kind of sealant on them. If the knife connection seems loose, tighten the connection by pressing on the parts with needle-nosed pliers after they are assembled. Secure the gray pilot arc insulator with 10
turns of electrical tape.
New Torch Head Assembly
5. Slide the handle forward and thread it rmly onto the torch body.
81
SECTION 6 PT36 PLASMA TORCH
6.18 Reduced Consumable Life
1. Cutting Up Skeletons
Cutting skeletons (discarded material left after all pieces have been removed from a plate). Their removal from
the table can adversely aect electrode life by:
• Causing the torch to run o the work.
• Greatly increasing the start frequency. This is mainly a problem for O2 cutting and can be alleviated by
choosing a path with a minimum number of starts.
• Increasing 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 stando and reducing cutting speeds.
If possible, use an OXWELD torch for skeleton cutting or operate the PT-36 at a high stando.
2. Height Control Problems
• Torch diving is usually caused by a change in arc voltage when an automatic height control is used.
The voltage change is usually the result of plate falling away from the arc. Disabling the height
control and extinguishing the arc earlier when nishing the cut on a falling plate can eectively
eliminate these problems.
• Diving can also occur at the start if travel delay is excessive. This is more likely to occur with thin
material. Reduce delay or disable the height control.
• Diving can also be caused by a faulty height control.
3. Piercing Stando Too Low Increase pierce stando
4. Starting on edges with
continuous pilot arc Position torch more carefully or start on adjacent scrap material.
5. Work Flipping The nozzle may be damaged if the torch hits a ipped up part.
6. Catching on Pierce Spatter Increase stando or start with longer lead-in.
7. Pierce not complete before
starting Increase initial delay time.
8. Coolant ow rate low, Correct settings
Plasma gas ow rate high,
Current set too high
9. Coolant leaks in torch Repair leaks
82
SECTION 6 PT36 PLASMA TORCH
Checking for Coolant Leaks:
Coolant leaks can originate from seals on the electrode, electrode holder, nozzle, and torch body. Leaks could
also originate from a crack in the insulating material of the torch or nozzle retaining cup or from a power cable.
To check for leaks from any source remove the shield cup, clean o the torch, purge it, and place it over a clean
dry plate. With the gases o, run the watercooler for several minutes and watch for leaks. Turn on the plasma gas
and watch for any mist from the nozzle exit. If there isn’t any, turn o the plasma gas, turn on the shield gas, and
watch for any mist from the shield gas passages in the nozzle retaining cup.
If a leak appears to be coming from the nozzle orice, remove and inspect the o-rings on the nozzle, electrode,
and electrode holder. Check the sealing surfaces on the electrode holder and stainless steel torch liner.
If you suspect that a leak is coming from the electrode itself, you can install a PT-19XL 100 to 200 amp 2-piece
nozzle base without a nozzle tip. After purging, run the water cooler with the gas o and observe the end of the
electrode. If water is seen to collect there, make sure it is not running down the side of the electrode from a leak
at an o-ring seal.
If it is necessary to supply power to the power source to run the water cooler, it is possible to have high voltages at the torch with no arc
WARNING
present. Never touch the torch with the power source energized.
83
SECTION 6 PT36 PLASMA TORCH
84
SECTION 6 PT36 PLASMA TORCH
6.19 Replacement Parts
6.19.1 General
Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.
6.19.2 Ordering
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.
Replacement parts may be ordered from your ESAB Distributor.
Be sure to indicate any special shipping instructions when ordering replacement parts.
Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.
Note
Bill of material items that have blank part numbers are provided for customer information only.
Hardware items should be available through local sources.
85
SECTION 6 PT36 PLASMA TORCH
PT-36
Mechanized Plasmarc Cutting Torch
for Production Thick Plate
Use:
PT-36 H35 Heavy Plate Start-up Kit ................................. 0558005225
Item No. Part Number Quantity Description
1 0558003963 1 Electrode, Tungsten 0.19" (4.8mm)D
2 0558003965 1 Nozzle H35 .198" (5.0mm) Divergent
3 0558003964 1 Collet 0.19" (4.8mm)D Electrode
4 0558005689 1 Electrode/Collet Holder PT-36
5 0558003967 1 Collet Body
6 0558002532 1 Bae, 32 Hole x .023" (0.6mm)
7 0558006688 1 Shield High Current
8 0558003918 1 Electrode Holder Tool PT-36
9 0558003962 1 Tungsten Electrode Tool
10 0558006690 1 Nozzle Retaining Cup Assy
High Current
11 4 88158 1
12 181W89 1
4
6
9
3
5
NOTE:
These are the only items
that are dierent for Pro-
1
8
181W89
duction Thick Plate. Refer
to the Cut Data manual
(0558008434/0558008435) for
complete setup and param-
eters.
2
10
7
488158
NOTE:
P/N 0558003965 is supplied with (2) p/n
181W89 installed & (1) p/n 488158 loose in
the box. When using the high current noz-
zle retaining cup and high current shield,
as recommended, remove and discard the
o-ring nearest the orice and install p/n
488158 on the step originally intended for
the diuser.
86
SECTION 6 PT36 PLASMA TORCH
* bill of materials listed on 11 x 17 fold-out pages (0558008300)
10
O-rings supplied with
Torch Body,
P/N 996528
17
O-ring supplied with
Electrode Holder assembly, P/N 86W99
33
O-ring supplied with
Electrode
O-rings, p/n 181W89
supplied with Nozzle
3
6
21
9
11
16
18
8
19
15
87
NOTE:
Items 8, 15, 18 & 33 are supplied in a
bag with the torch.
SECTION 6 PT36 PLASMA TORCH
88
NOTES
89
NOTES
90
REVISION HISTORY
1. Initial release - 04/2009
2. Revision 02/2010 - added coolant hose info.
3. Revision 05/2010 - CN-103051 M6-1 change.
4. Revision 10/2010 - updated p/n's per PD 6900-10-02 & PA 6900-10-09 Rev 1.
5. Revision 08/2011 - updated start up kits.
6. Revision 10/2011 - removed CGC section.
7. Revision 01/2012 - removed Torch Lead sets per N. Dortman.
91
ESAB Welding & Cutting Products, Florence, SC
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
B. ENGINEERING SERVICE:
Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specications Equipment Recommendations
D. LITERATURE REQUESTS:
Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
F. WELDING EQUIPMENT TRAINING
Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site oers
Comprehensive Product Information
Material Safety Data Sheets
Warranty Registration
Instruction Literature Download Library
Distributor Locator
Global Company Information
Press Releases
Customer Feedback & Support
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