ESAB PT-20AMX Plasmarc Cutting Torch and PT-21AMX Plasmarc Cutting Torch Installation manual / Instruction manual

December 2006

Installation, Operation and Maintenance

PT-20AMX Plasmarc Cutting Torch

and

PT-21AMX Plasmarc Cutting Torch

F15-778

The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.

Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total
customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.

This manual is ESAB Part Number

This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.

F15-778

Printed in U.S.A.

© ESAB Cutting Systems, 2002

Table of Contents

Page
Safety

Introduction ........................................................................................... 1

Safety Notations And Symbols ................................................................ 2

General Safety Information ...................................................................... 3

Installation Precautions............................................................................ 3

Electrical Grounding................................................................................ 5

Operating A Plasma Cutting Machine ...................................................... 5

Service Precautions ................................................................................ 9

Safety References................................................................................... 10, 11, 12

I. Description Introduction .....................................................................

II. Accessories.......................................................................................... 14

III. Installing Front End Parts.................................................................. 16

IV. Operation – Cutting Parameters....................................................... 20

V. Maintenance........................................................................................ 21

A. General.............................................................................................

B. Dirt or Contamination........................................................................

C. Loose Consumables.........................................................................

D. Damage Caused By Loose Parts and Torch Over Heating...............

E. Consumables – Removal and Replacement.....................................

F. Measuring Torch Gas Flows.............................................................

G. Removal and Replacement of Torch Body.......................................

PT-20AMX Torch...............................................................................

PT-21AMX Torch...............................................................................

H. Removal and Replacement of Torch Cables.....................................

13

21

22

22

23

23

25

26

26

27

28

VI. Replacement Parts............................................................................ 30

PT-20AMX 4ft, 17ft, and 25 ft.................................................................

PT-20AMX 50 ft. Wire Mesh Shielded....................................................

PT-21AMX Torches................................................................................

i

30,31

32,32

34,35

Table of Contents

ii

PT-20/21 AMX Plasmarc Torches

Safety Introduction

The process of cutting metals with plasma

equipment provides industry with a valuable and
versatile tool. ESAB cutting machines are
designed to provide both operation safety and
efficiency. However, as with any machine tool,
sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or
as an observer, compliance with established
precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious personnel injury
or severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the field
of cutting and welding apparatus, obtain and read
the publications listed in the Recommended
References.

1

PT-20/21 AMX Plasmarc Torches

Safety Notations And Symbols

!

DANGER

!

WARNING

!

The following words and symbols are used
throughout this manual. They indicate different
levels of required safety involvement.

ALERT or ATTENTION. Your safety is
involved or potential equipment failure exists.
Used with other symbols and information.

Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury o r lo ss o f life.

Used to call attention to potential hazards that
could result in personal injury or loss of life.

CAUTION

!

CAUTION

NOTICE

Used to call attention to hazards that could
result in minor personal injury or equipment
damage.

Used to call attention to minor hazards to
equipment.

Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.

2

PT-20/21 AMX Plasmarc Torches

General Safety Information

Machinery often starts automatically.

WARNING

!

WARNING

!

This equipment moves in various directions and
speeds.

· Moving machinery can crush.

· Only qualified personnel should operate or

service this power source.

· Keep all personnel, materials, and equipment
not involved in production process clear of
entire system area.

· Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.

· Post appropriate WARNING signs at every
work cell entrance.

· Follow lockout procedure before servicing any

equipment.

Failure to follow operating instructions
could result in death or serious injury.

Read and understand this operator’s manual
before using machine.

· Read entire procedure before operating or

performing any system maintenance.

· Special attention must be given to all hazard

warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.

· All safety precautions relevant to electrical

equipment and process operations must be
strictly observed by all having system
responsibility or access.

· Read all safety publications made available by

your company.

3

PT-20/21 AMX Plasmarc Torches

WARNING

!

Installation Precautions

Failure to follow safety warning label
instructions could result in death or
serious injury.

Read and understand all safety warning labels on
machine.

Refer to operator’s manual for additional safety
information.

DANGER

!

Improperly Installed Equipment Can
Cause Injury Or Death.

Follow these guidelines while installing machine:

· Contact your ESAB representative before

installation. He can suggest certain
precautions regarding piping installation and
machine lifting, etc. to ensure maximum
security.

· Never attempt any machine modifications or

apparatus additions without first consulting a
qualified ESAB representative.

· Observe machine clearance requirements for

proper operation and personnel safety.

· Always have qualified personnel perform

installation, troubleshooting and maintenance
of this equipment.

· Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

4

PT-20/21 AMX Plasmarc Torches

Electrical Grounding

Electrical grounding is imperative for proper
machine operation and SAFETY. Refer to this
manual’s Installation section for detailed grounding
instructions.

Electric shock hazard.

WARNING

!

Operating A Plasma Cutting Machine

Improper grounding can cause severe injury or
death.

Machine must be properly grounded before put
into service.

Flying debris and loud noise

WARNING

!

hazards.

· Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying
debris generated during operation.

· Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.

· Noise from plasma arc can damage hearing.

Wear correct ear protection when cutting
above water.

Burn hazard.

WARNING

!

Hot metal can burn.

· Do not touch metal plate or parts immediately
after cutting. Allow metal time to cool, or douse
with water.

· Do not touch plasma torch immediately after
cutting. Allow torch time to cool.

5

PT-20/21 AMX Plasmarc Torches

DANGER

!

Hazardous voltages. Electric shock
can kill.

· Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting process.

· Always turn power off to plasma power
supplies before touching or servicing plasma torch.

· Always turn power off to plasma power
supplies before servicing any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when

machine is connected to power source.

· Wear insulating gloves, shoes and clothing to
insulate yourself from workpiece and electrical
ground.

· Keep gloves, shoes, clothing, work area, and

equipment dry.

· Replace worn or damaged cables.

Fume hazard.

WARNING

!

Fumes and gases generated by the plasma cutting
process can be hazardous to your health.

· Do NOT breathe fumes.

· Do not operate plasma torch without fume

removal system operating properly.

· Use additional ventilation to remove fumes if
necessary.

· Use approved respirator if ventilation is not

adequate.

· Provide positive mechanical ventilation when

cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe these
fumes.

·

operations. Heat or arc rays can react with
chlorinated hydrocarbon vapors to form phosgene,
a highly toxic gas and other irritant gases.

Do not operate near degreasing and spraying

6

PT-20/21 AMX Plasmarc Torches

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn skin.

· Wear correct eye and body protection.

· Wear dark safety glasses or goggles with side

shields. Refer to following chart for recommended
lens shades for plasma cutting:

Arc Current Lens Shade

Up to 100 Amps Shade No. 8

100-200 Amps Shade No. 10

200-400 Amps Shade No. 12

Over 400 Amps Shade No. 14

· Replace glasses/goggles when lenses are

pitted or broken

· Warn others in area not to look directly at the

arc unless wearing appropriate safety glasses.

· Prepare cutting area to reduce reflection and

transmission of ultraviolet light.

§ Use special paint on walls to absorb UV
light.

§ Install protective screens or curtains to

reduce ultraviolet transmission.

7

PT-20/21 AMX Plasmarc Torches

WARNING

!

Burn Hazard.

Heat, spatter, and sparks cause fire and burns.

· Do not cut near combustible material.

· 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 flame-retardant clothing covering all

exposed areas.

· Wear cuffless trousers to prevent entry of
sparks and slag.

· Have fire extinguishing equipment available for
use.

Explosion hazard.

WARNING

!

· Certain molten aluminum-lithium (Al-Li) alloys

can cause explosions when plasma cut OVER
water.

§ These alloys should only be dry cut on a
dry table.

§ DO NOT dry cut over water.

§ Contact your aluminum supplier for

additional safety information regarding
hazards associated with these alloys

Do not cut in atmospheres containing

·

explosive dust or vapors.

·

Do not carry any combustibles on your person

(e.g. butane lighter)

· Do not cut containers that have held

combustibles.

.

8