Instructions for
F-15-189-B
March, 2010
TM
PLASMARC
Air Curtain Kits
P/N 22018 for PT-15XL Heavy Duty (H. D.)
P/N 34752 for PT-19XL and PT-15XL Beveling
21856 Air Curtain Assembly
WARNING
21549 Air Curtain Assembly
PT-15XL H.D.
THE AIR CURTAIN CAN NOT BE USED WHEN USING H35 OR CH4 GAS
MIXES. THE WATER LEVEL MUST BE LOWERED 4 TO 6 INCHES BE
NEATH THE BOTTOM OF THE PLATE.
FAILURE TO COMPLY TO THIS WARNING CAN RESULT IN A HYDRO
GEN DETONATION.
PT-19XL
BE SURE THIS INFORMATION REACHES THE OPERATOR.
YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc welding and cutting equipment, we urge
you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and
Gouging,” Form 52-529. Do NOT permit untrained persons to install, operate, or maintain
this equipment. Do NOT attempt to install or operate this equipment until you have read
and fully understand these instructions. If you do not fully understand these instructions,
contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
2
TABLE OF CONTENTS
Section / Title Page
1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3
TABLE OF CONTENTS
4
SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that
anyone who works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding or plasma cutting equipment. The following
recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, ame proof
clothing, safety gloves.
- Do not wear loose tting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions:
- Make sure the return cable is connected securely.
- Work on high voltage equipment may only be carried out by a qualied electrician.
- Appropriate re extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or
water. Protection is provided against touch with a nger, penetration of solid objects greater than 12mm and
against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered.
CAUTION
If equipment is placed on a surface that
slopes more than 15°, toppling over may occur. Personal injury and / or signicant damage to equipment is possible.
Maximum
Tilt Allowed
15°
5
SECTION 1 SAFETY PRECAUTIONS
WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDING OR CUTTING. ASK FOR
WARNING
ELECTRIC SHOCK - Can kill.
- Install and earth (ground) the welding or plasma cutting unit in accordance with applicable standards.
- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Insulate yourself from earth and the workpiece.
- Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health.
- Keep your head out of the fumes.
- Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and lter lens and wear
protective clothing.
- Protect bystanders with suitable screens or curtains.
YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE BASED ON
MANUFACTURERS’ HAZARD DATA.
FIRE HAZARD
- Sparks (spatter) can cause re. Make sure therefore that there are no inammable materials nearby.
NOISE - Excessive noise can damage hearing.
- Protect your ears. Use earmus or other hearing protection.
- Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
This product is solely intended for plasma cutting. Any other
CAUTION
use may result in personal injury and / or equipment damage.
CAUTION
To avoid personal injury and/or equipment
damage, lift using method and attachment
points shown here.
6
SECTION 2 INSTALLATION
DATE
RELEASED FOR
ENGLISH DWG
TITLE
REPRO MADE FROM
SIMILAR TO
SUP.
SUP. BY
APPROVED
BY
DATE
CHECKED
BY
DATE
DRAWN
BY
DATE
SCALE
FIRST MADE FOR
ESAB WELDING & CUTTING PRODUCTS
FLORENCE, SC 29501
UNLESS OTHERWISE
SPECIFIED, DIM ARE
IN INCHES.
TOL .XX
.XXX
ANGLES
CHAMFERS & C'SINKS 2
SURFACE ROUGHNESS IS IN
REMOVE ALL BURRS
BREAK SHARP EDGES
MICROINCHES
CHANGE
BY
DATE
CH'KD
TO EMPLOYEES OF THE PARTY TO WHOM THIS DRAWING IS LOANED ON A CONFIDENTIAL BASIS.
A-
.015
.005
PRO/ENGINEER DWG.
NOV.1994
A
A
19X19
ADAPT B-A/W*F B-A/W*M 90ASSY
BLP
10/23/08
63
2
1:1
FINISH:
BRIGHT DIP PER SPI 45.315.3 METHOD 6
P/N QTY DESCRIPTION
1. 836Z40 1 NUT HOSE B/A-W* .63-18F RH OLD
2. 03Z59 1 NPL B/SIZE .425ODX 0.81LG
3. 19Z48 1 BODY FOR 90 AIR WATER ADAPTOR
4. 6270869 1 RING SSBAG-1 0.438KDX.03D STD
"E" CN-083187 REVISED & RED BLP
WSS10/23/08
WSS
10/23/08
WSS
10/23/08
1
2
3
4
ELECTRIC SHOCK CAN KILL!
DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH-
WARNING
The Air Curtain is a device used to improve the performance of the PT-19XL and the PT-15XL Plasmarc Cutting Torches when
cutting underwater. Cut quality and speed are enhanced when using the Air Curtain with all the PT-19 cutting and with PT-15
oxygen/water injection cutting. Very minor improvements may be seen with nitrogen/water injection cutting.
The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone,
even though the torch has been submerged to reduce noise, fume, and are radiation.
ING OR SERVICING THE AIR CURTAIN AT THE TORCH.
DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING.
Compressed Air Supply
(Air Curtain)
Source: 80 psi @ 1200cfh
(5.5 bar @ 34 m3h)
Clean, dry & oil-free shop air
PT-15XL H.D. Air Curtain Kit, P/N 22018
Air Curtain Assy. P/N 21856 1 pc
Control Box Assy. P/N 33383 1 pc
Hose Assy., 50 ft. P/N 34033 1 pc
Optional Accessories
Cable, 18 GA 3-Cond. P/N 33253 25 ft.
Cable, 18 GA 3-Cond. P/N 33254 50 ft.
Cable, 18 GA 3-Cond. P/N 33255 75 ft.
Cable, 18 GA 3-Cond. P/N 33256 100 ft.
Cable, 18 GA 3-Cond. P/N 33257 125 ft.
PT-19XL Air Curtain Kit, P/N 34752
Air Curtain Assy. P/N 21549 1 pc
Control Box Assy. P/N 33383 1 pc
Hose Assy., 50 ft. P/N 34033 1 pc
Adapt B-A/W*F B-A/W*M
90 deg assy
P/N 19X19 1
7
SECTION 2 INSTALLATION
A. Installation of PT-15XL H. D. Air curtain As-
sembly on PT-15XL
1. Remove the brass Nozzle Retaining cup from the
torch.
2. Slide the chrome plated Air Curtain Body, P/N 21550
onto the stainless steel body of the torch.
NOTE: It will ease assembly if all o-rings in the air curtain
body are lightly lubricated with silicone grease
77500101 (5.3 oz.) or 17672 (1 oz.).
3. Replace Nozzle Retaining Cup, P/N 20758, and any
front-end parts you may have removed from the
torch.
4. Tighten the Nozzle Retaining Cup securely on the torch,
then mark the cup with a felt tip marker or pen. Loosen
the cup 3/4 to 1 full turn.
ALLEN
SCREW
5. Install the PT-15XL H. D. Air Curtain Sleeve (P/N 21859)
over the completely assembled torch and snap it into
the air curtain body. Secure the sleeve by installing the
Air Curtain Retainer, P/N 21553.
The Retainer turns to engage or disengage with the
locking pins.
6. Push the Air Curtain Assembly up on the torch until the
inside of the Air Curtain Sleeve, P/N 21859, bottoms
against the Nozzle Retaining Cup, P/N 29758. Lock the
Air Curtain Assembly in place by tightening the Allen
screw on the Air Curtain body.
7. Remove the Retaining Ring and Air Curtain Sleeve.
Tighten the Nozzle Retaining Cup, P/N 20758, securely.
Reinstall the Air Curtain Sleeve and the Nozzle Retaining Cup.
There should now be a gap of .040 to .062 inches be-
tween the Nozzle Retaining Cup, P/N 20758, and the
inside of the Air Curtain Sleeve, P/N 21859.
TORCH
RETAINING
CUP
.O40 - .062
Figure 1. Air Curtain Installation on PT-15XL
8
SECTION 2 INSTALLATION
B. Installation of Air Curtain Assembly on PT-15XL
with P/N 21378 Sleeve for Beveling with standard length nozzles.
1. Remove the brass nozzle Retaining Cup from the
torch.
2. Slide the chrome plated Air Curtain Body, P/N 21550,
onto the stainless steel body of the torch.
NOTE: It will ease assembly of all O-rings in the air
curtain body are lightly lubricated with silicone
grease; P/N 77500101 (5.3 oz.) or 176772 (1
oz.).
3. Replace Nozzle Retaining Cup, P/N 20758, and any
front-end parts you may have removed from the torch,
tightening securely, then mark the cup with a felt tip
marker or pen. Loosen the cup 3/4 to 1 full turn.
4. Install an Air Curtain Sleeve, P/N 21378, over the
complete assembled torch and snap it into the Air
Curtain Body. DO NOT use the Air Curtain Retainer, P/N
21553.
5. Push the Air Curtain Assembly up onto the torch until
the inside of the Air Curtain Sleeve, P/N 21378, bottoms
against the Nozzle Retaining cup, P/N 20758. Lock the
Air Curtain Assy. in place by tightening the Allen screw
on the Air Curtain Body.
NOTE: The Air Curtain Sleeve must remain completely
bottomed in the Air Curtain Body for the adjustment in step 5 to be correct.
6. Remove the Air Curtain Sleeve. Tighten the Nozzle
Retaining Cup 20758 securely. Reinstall the Air Curtain
Sleeve. There should be a gap of .040 to .062 inch between the inside of the Air Curtain Sleeve P/N 21378
and the Nozzle Retaining Cup, P/N 20758.
ALLEN
SCREW
SLEEVE
P/N 21378
.O40 - .062
Figure 2. Air Curtain Installation on PT-15XL
(For Beveling with standard length nozzles)
9
SECTION 2 INSTALLATION
C. Installation of Air Curtain Assembly on PT-19XL
or PT-15XL using Long Beveling Nozzles (Figure
3).
1. Remove the plastic nozzle Retaining Cup from the
torch.
PT-19XL or PT-15XL
Torch Body
Figure 3. Air Curtain Installation
On PT-19XL or PT-15XL Bevel
BUSHING
BODY
REMOVE HEAT SHIELD,
SET DIMENSION @
.10, SET PRESSURE @
20 PSIG
.10 INCH
AIR
INLET
RETAINING
NUT
2. Slide the chrome plated Air Curtain Body, P/N 29550,
onto the stainless steel body of the torch.
NOTE: It will ease assembly if all O-rings in the air
curtain body are lightly lubricated with silicone
grease.
3. Replace Nozzle Retaining Cup, P/N 34085, and any
front-end parts you may have removed from the torch.
Do not replace the heat shield, P/N 948186.
4. Install an Air Curtain Sleeve, P/N 12551, over the completely assembled torch and snap it into the Air Curtain
Body. Secure the sleeve by installing the air curtain
Retainer, P/N 21553. The Retainer turns to engage or
disengage with the locking pins.
5. Adjust the position of the Air Curtain Assembly on the
torch until the nozzle is recessed 0.10 inch from the end
of the air curtain sleeve as illustrated in Fig. 1. Lock the
Air Curtain in place by tightening the Allen screw on
the Air Curtain.
NOTE: The Air Curtain Sleeve must remain completely
bottomed in the Air Curtain Body for the adjustment in step 5 to be correct.
D. Installation of the Control Box Assembly (P/N 3383)
1. Mount the control box at a convenient location and use the hose supplied to connect the box with the unit mounted
on the torch.
2. Connect the control box to a source of oil free shop air capable of delivering at least 20 scfm at 80 psig. The hose used
should be at least 3/8" ID.
3. Use the SJO wire supplied to connect the control to the cutting machine control. If the ESP system is used, then the
connection may be made to the appropriate amphenol connector on the back of the ow control. The connection
of the control is made at the terminals marked F. C. An appropriate cable may be selected from the table of optional
accessories.
4. The user supplied 115 V ac may be connected to the terminals so marked. This will allow manual operation of the air
curtain control.
5. Connect a ground wire to the stud provided in the control box.
10
SECTION 3 OPERATION
E. Operation
1. Provide control box will oil free air at 80 psig minimum. Energize solenoid in control box and adjust regulator screw
on box to 20 psig delivery.
2. Place switch to AUTO. The system should turn on when the preow begins.
F. PT-19 Operation Notes
Cutting stando (Torch to Work Distance) must now be measured from the bottom of the Air Curtain Sleeve. This distance
is approximately 1/4".
NOTE: If piercing thick plate, increase stando to 0.400" for 1/2" thick plate, 0.650" for 3/4" thick plate. Then return to 1/4" stando
after completing the pierce and you are ready to cut.
Electric shock can kill. Disconnect power to power source before touching or servicing the air curtain at the torch.
Disconnect power to the control box before servicing.
11
SECTION 3 OPERATION
12
SECTION 4 REPLACEMENT PARTS
5
4
1
2
7
6
1
3
5
2
3
Figure 4. Air Curtain Assembly, P/N 21549 for use W/ PT-19XL
and PT-15XL With Long Beveling Nozzle
ITEM QTY PART
NO. REQ. NO. DESCRIPTION
1 1 21550 BODY, AIR CURTAIN
2 1 21551 SLEEVE, AIR CURTAIN
3 1 21553 RETAINER, AIR CURTAIN
4 1 21380 BUSHING, SPLIT
5 1 2221978 'O' RING, 1.799ID X .103 SILICON, 60A
6 2 21214 ‘O’ RING, 2.484ID X .139 NEOPR, 70A
7 1 85W87 ‘O’ RING, 1.984ID X .070 NEOPR, 70A
Note: Some spare o-rings are supplied with the Air Curtain assembly 21549
13
SECTION 4 REPLACEMENT PARTS
4
7
1
6
2
4
1
3
5
8
2
5
3
Figure 5. H.D. Air Curtain Assembly, P/N 21856 for use W/ PT-15XL
ITEM QTY PART
NO. REQ. NO. DESCRIPTION
1 1 21550 BODY, AIR CURTAIN
2 1 21859 SLEEVE ASSY, AIR CURTAIN
3 1 21553 RETAINER, AIR CURTAIN
4 1 21380 BUSHING, SPLIT
5 1 2221978 "O" RING, 1.799 ID X .103 SILC 60A
6 2 21214 "O" RING, 2.484 ID X .139 NEOPR, 70A
7 1 85W87 "O" RING, 1.984 ID X .139 NEOPR, 70A
8 1 952062 "O" RING. 1.989 ID X .070 NEOPR, 70A
NOT SHOWN, 1PC P/N 21378 SLEEVE BEVELING AIR CURTAIN
Note: Some spare o-rings are supplied with the Air Curtain assembly 21856
14
SECTION 4 REPLACEMENT PARTS
8*, 9
4
5
*AIR REGULATOR AND PRESSURE GAGE ARE SUPPLIED TOGETHER AS ITEM 8. REGULATOR W/GAGE P/N 522368.
6
7
3
Figure 6. Air Curtain Control Box Assembly
10
11
1
2
ITEM QTY PART
NO. REQ. NO. DESCRIPTION
1 2 8180W38 CONNECTOR, STRAIN RELIEF
2 1 951041 TERMINAL, BLOCK, 4 POSITIONS
3 1 636702 SWITCH, DPDT 3 POSITIONS
4 2 858775 ADAPT. BULKHD. B SIZE, 1/4 NPT
5 2 182W82 ELBOW, STREET 90 BRASS
6 1 636387 SOLENOID VALVE
7 1 67101075 NIPPLE, CLOSED, 1/4 NPT BR. M TO M
8 1 522368 REGULATOR W/GAGE
9 2 60101025 PLUG, 1/8" NPT ALLEN HEAD
10 1 67100081 NIPPLE, 2"LG. 1/4NPT BRASS M TO M
11 1 68161103 TEE, 1/4 NPT BRASS
15
SECTION 4 REPLACEMENT PARTS
CONTACT RING ASS'Y,
Includes: Setscrew, No. 6-32 X 3/16 lg. (Cup Point)
Screw, No. 6-32 X 1/2" lg.
O-RING - 996527
3
2
Note:
All Set Screws Are Stainless Steel & Should Only Be
Replaced With Stainless Steel or Brass Screws.
13
8
11
12
6
5
4
10
9
O-RING - 2064106
(1-5/16" I.D.)
Figure 7. PT-15XL Plasmarc Cutting Torch For Bevel Cut
ITEM QTY PART DESCRIPTION
NO. REQ. NO.
2 1 35570 CUP, NOZZLE RETAINING
3 1 21962 NOZZLE PT-15 O2 BEVEL - 21963 REVERSE
4 1 35886 ELECTRODE, HF
5 1 34084 ELECTRODE HOLDER ASSY
6 1 35660
8 X.047 HOLE BAFFLE, GAS SWIRL, CERAMIC - 35661 REVERSE
8 1 996341 CONTACT RING ASSY
9 1 20755 INSULATOR ASSY, FRONT BODY
10 2 996528 O-RING
11 1 996242 LOCATING PIN
12 1 20754 REAR MAIN BODY ASSY
13 1 19483 SLEEVE
OXYGEN - SET O2 FLOW AT 100 SCFH 100PSI SUPPLY
WATER - SET WATER FLOW AT 0.51 GPM
INLET TO TORCH PRESSURE - 35-42 PSI AT TORCH - CUTTING
15-20 PSI AT TORCH - STARTING
16
NOT SHOWN:
O-RING - 86W85 (1/2" I.D.)
(2) O-RING - 996526 (5/32" I.D.)
NOTES
17
NOTES
18
REVISION HISTORY
Revision 03/2010 - added 19X19 to optional accessories.
19
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
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
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F15-189-B 03/2010
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