PT-38 - ESAB Welding & Cutting Products
Contents
1. ors suo 3 Tecnos neta sito cur cone 3 Tr UE Tesoro pos pow __ SECTION 2 DESCRIPTION 2 4 Consumables Breakdown PC 1300 1600 CUTTING COUPAGE 90A 0558007549 0558007680 0558005220 0558004870 P 38 O RING JOINT TORIQUE i 85W51 1 i I I 70A 0558007549 0558005219 0558005220 0558005217 I 1 40A 0558007549 0558007682 0558005220 0558005217 GREASE GRAISSE x ei 17672 STAND OFF GUIDE GOUGING O RING GUIDE DE HAUTEUR 2 GOUGEAGE JOINT TORIQUE 1 0558006613 0558006611 70558006601 0558006611 0558007681 0558004870 l Pod I I EE 1 l b m I 80 PSI FUSE 2 600V I 1 I 5 5 BAR WE i FUSIBLE 2 600V el weie Es s 0296901375 Note When Gouging use 90 amp Baffle 0558004870 CUTTING 90A 0558008094 0558007680 0558005220 0558004870 P 38 O RING 5 I2. 60A 0558007549 0558008417 0558005220 0558005217 P 1 38 JOINT TORIQUE 85W51 1 I 1 40A 0558007549 0558007682 0558005220 0558005217 co GREASE GRAISSE 9 js 17672 m STAND OFF GUIDE GOUGING i GUIDE DE HAUTEUR _____________ GOUGEAGE JOINT TORIQUE Se 1 0558008590 i 10558006602 0558006611 0558008588 0558005217 1 I SE I p 1 1 80 PSI EE FUSE 2A 600 E 1 1 FUSIBLE 2A 600V p 5 5 BAR Ka Z 0558001379 0558008592 0558008591 CUTTING 60A 0558008094 0558008417 0558005220 0558005217 PT 38 CE d 0558008592 0558008591 40A 0558008094 0558007682 0558005220 0558005217 m Y a 1 A GREASE le 17672 2 O RING Eee GOUGING 2064062 a ee 0558008590 0558006611 10558006602 0558006611 0558008588 0558005217 I ri bog UIN I E p 80 PSI FUSE 2A 600V 5 5 BAR BE 0558001379 1 L 1 39 SECTION 2 DESCRIPTION 40 SECTION 3 INSTALLATION ASSUREZ VOUS QUE L INTERRUPTEUR SUR LA CONSOLE EST EN POSITION MISE EN GARDE TEINTE OFF ET QUE L ALIMENTATION PRINCIPALE EST COUP E 3 0 Installation 3 1 Installation de la torche 1 Ouvrir la porte d acc s principale du panneau avant du Powercut 1300 1600 Porte
3. 1 1 i i 0558008094 0558005219 0558005220 0558005217 I 1 1 1 EE 40A 0558008094 0558007682 0558005220 0558005217 GREASE mue 17672 Y O RING EEE STAND OFF GUIDE GOUGING 2064062 al 1 0558006613 10558006601 0558006611 0558007681 0558004870 1 I ME E 80 PSI FUSE 2A 600V 5 5 BAR NE 0558001379 1 1 1 a 0558006614 0558008186 Note When Gouging use 90 amp Baffle 0558004870 14 SECTION 2 DESCRIPTION 2 5 Consumables Breakdown PC 900 CUTTING COUPAGE 60A 0558007549 0558008417 0558005220 0558005217 P 1 38 JOINT TORIQUE 85W51 l I I l 40A 0558007549 0558007682 0558005220 0558005217 STAND OFF GUIDE GOUGING O RIN i GUIDE DE HAUTEUR _____________ GOUGEAGE JOINT TORIQUE 1 0558008590 0558006611 0558006602 0558006611 0558008588 1 1 Qi CIT x Li li FUSE 2A 600V 93 BAR T Z FUSIBLE 2A 600V 0558006692 058800869 nz CUTTING 60A 0558008094 0558
4. 1 0 Pr cautions de s curit Les utilisateurs du mat riel de soudage et de coupage plasma ESAB ont la responsabilit ultime d assurer que toute personne qui op re ou qui se trouve dans l aire de travail observe les pr cautions de s curit pertinentes Les pr cautions de s curit doivent r pondre aux exigences applicables a ce type de mat riel de soudage ou de coupage plasma Les recommandations suivantes doivent tre observ es en plus des r gles standard qui s appliquent au lieu de travail Tous les travaux doivent tre effectu s par un personnel qualifi poss dant de bonnes connaissances par rapport au fonctionnement du mat riel de soudage et de coupage plasma Un fontionnement incorrect du mat riel peut produire des situations dangereuses qui peuvent causer des blessures l op rateur ou des dommages au mat riel 1 Toute personne travaillant avec le mat riel de soudage ou de coupage plasma doit conna tre son fonctionnement l emplacement des interrupteurs d arr t d urgence Sa fonction les pr cautions de s curit pertinentes les proc dures de soudage et ou de coupage plasma 2 L op rateur doit assurer que seules les personnes autoris es travailler sur l quipement se trouvent dans l aire de travail lors de la mise en marche de l quipement toutes les personnes dans l aire de travail sont prot g es lorsque l arc est amorc 3 Lelieu de travail doit tre am nag convenablem
5. Speed MM MIN 2667 1168 4 482 6 3556 60 Amperes Stainless Steel Material Initial Height 1883478 188 4 78 188 4 78 188 4 78 in mm Air Travel IPM 3 25 02 7 Speed MM MIN 20828 635 3048 177 8 25 SECTION 4 OPERATION PT 38 AA 2 Electrode 0558005220 ESAB Powercut 1300 1600 en 52 ME Plasma System Process Data en Retaining Shield Cup 0558007549 70 Amperes Carbon Steel Material Initial Height in mm Air Travel m 10 5 26 12 5 Speed MM MIN 3810 1270 660 4 35 127 70 Amperes Aluminum Material Initial Height 188 4 78 188 4 78 188 4 78 188 4 78 188 4 78 in mm Air Travel IM 6 2 Speed 3556 1676 4 7112 508 2794 70 Amperes Stainless Steel Material initial Height 188 4 78 188 4 78 188 4 78 188 4 78 188 4 78 in mm Air speed mmmn 2794 2794 1524 SECTION4 E PT 38 ESAB Powercut 1300 1600 Electrode 0558005220 N 0558007680 ME Plasma System Process Data Gas Baffle 0558004870 Retaining Shield Cup 0558007549 90 Amperes Carbon Steel Material Initial Height in mm Air Travel 1PM 10 Speed MM MIN 4064 1524 77 203 90 Amperes Aluminum Material Initial Height in mm Air Travel IPM 6 53 27 mn
6. MALAYSIA ESAB Malaysia Snd Bhd Shah Alam Selangor Tel 60 3 5511 3615 Fax 60 3 5512 3552 SINGAPORE ESAB Asia Pacific Pte Ltd Singapore Tel 65 6861 43 22 Fax 65 6861 31 95 SOUTH KOREA ESAB SeAH Corporation Kyungnam Tel 82 55 269 8170 Fax 82 55 289 8864 UNITED ARAB EMIRATES ESAB Middle East FZE Dubai Tel 971 4 887 21 11 Fax 971 4 887 22 63 Representative offices BULGARIA ESAB Representative Office Sofia Tel Fax 359 2 974 42 88 EGYPT ESAB Egypt Dokki Cairo Tel 20 2 390 96 69 Fax 20 2 393 32 13 ROMANIA ESAB Representative Office Bucharest Tel Fax 40 1 322 36 74 RUSSIA CIS ESAB Representative Office Moscow Tel 7 095 937 98 20 Fax 7 095 937 95 80 ESAB Representative Office St Petersburg Tel 7 812 325 43 62 Fax 7 812 325 66 85 Distributors For addresses and phone numbers to our distributors in other countries please visit our home page www esab com ESAB AB SE 695 81 LAXA SWEDEN Phone 46 584 81 000 www esab com
7. PT 38 Plasmarc Cutting Torches Instruction Manual EN Manuel d instructions FR P N 05580067886 PT 38 Torch 25 7 6 m P N 0558006787 PT 38 Torch 50 15 2 m 0558007599 09 2009 BE SURE THIS INFORMATION REACHES THE OPERATOR YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER 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 be fore installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa nying labels and or inserts when installed operated maintained and repaired in accordance with the instruc tions 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 imme diately Should such repair or replacemen
8. de coupe coupe 1 1 2 po 38 mm sectionne 1 3 4 po 45 mm Utilise l air de l atelier de l air de cylindre pour une versatilit sup rieure D marrage avec un arc pilote se met en marche m me a travers la peinture Choix de 25 pi 7 6 m ou 50 pi 15 2 m de longueur de branchement Excellente dur e de vie Conception pieces sur place Garantie d un an 35 SECTION 2 DESCRIPTION 2 1 Caract ristiques de la torche eoe 1 1 2 po 38 mm sectionne 1 3 4 po 45 mm INtensite p m 90 A cycle d utilisation de100 D bit nominal 400 cfh pied cube par heure 80 ppc 189 l min 5 5 bar Longueur des branchements nn 25 7 6 m ou 50 pi 15 2 m Dimensions Kette EL 8 2 po 208 mm Longueur de la t te 3 0 po 76 mm Torche IA dd 0558006786 Torche 8 152 WEE 0558006787 Les torches et les assemblages du corps de la torche sont fournis sans d flecteur de gaz d lectrode de tuy re et de buse Commandez des ensembles complets de pi ces de rechange ou des composants individuels dans la section Ensemble de pi ces de rechange PT 38 ou la section Consommables Compatible ESAB Consoles Consoles ESAB compatibles Powercut 1300 Console 208 230 460 0558007220 Console BL 208 230 460 V 0558007220 Console GE 400 0558007224 Console sentent 0558007634 Console 460 V L u a 0558008320 Console BL 575
9. PECTED HIGH VOLTAGE 2 0 Description The PT 38 is a manual torch with a 90 head designed for use with several plasma arc cutting packages using clean dry air asthe plasma gas The service line lengths available with the PT 38 torch are 25 feet 7 6 m and 50 feet 15 2 m The PT 38 torch is rated to operate at a maximum of 90 amperes at 100 duty cycle This manual is intended to provide the operator with all the information required to assemble operate and repair the PT 38 Plasma Arc Cutting Torch For additional safety precautions process instructions and system troubleshooting refer to the appropriate instruction manual for your Plasma Arc Cutting Package Designed for superior cutting performance and ease of handling the PT 38 produces clean exceptionally high quality cuts Most compact 90 amp torch on the market Excellent cutting capacity Cuts 1 1 2 in 38 mm severs 1 3 4 in 45 mm Uses shop air cylinder air for superior versatility Pilot arc starting even starts through paint Choice of 25 ft 7 6 m or 50 ft 15 2 m line length Excellent consumable life Parts in place design One year warranty SECTION 2 DESCRIPTION 2 1 Torch Specifications aU PRSE 1 1 2 in 38 mm severs 1 3 4 in 45 mm adderet 90 amps 100 duty cycle Nominal Flow Rate 400 cfh 80 psig 189 l min 5 5 bar Length of APP 25 ft 7 6 m or 50 ft 15 2 m Dimensions NE ai Cp Mise nro 8 2 in
10. 0 4 1 4 2 4 3 4 4 4 5 4 6 SECTION 5 5 0 5 1 5 2 5 3 5 4 SECTION 6 6 0 6 1 6 2 TABLE OF CONTENTS TITLE PAGE SAFETY AA O 9 Safety Preca utida tente tn en ner ein NAE 9 DESCRIPTION ME 11 le lo ME 11 Torch Specifications 12 Optional Accessories 13 Spare Parts Kits 1 Consumables Breakdown PC 1300 1600 rennes 14 Consumables Breakdown PC 900 rm 15 A A Installation Torch Installation A Cutting with hg ee avo aiii Drag C tting 40 P o aor Gouging with the PT 38 Installing Consumables Cut Operation of Power SOU cocinando bardas 23 M M sms General Ee ee eeben Dirt or Contamination nn Inspection Cleaning and Replacement of Consumables Disassembly Assembly of Torch Measuring Torch Gas FIO WS inicia REPLACEMENT PARTS Replacement Parts ii A na General Ordering Diagrams and Parts List TABLE OF CONTENTS 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 equi
11. 208 mm Length of Head E 3 0in 76 mm PI 38 Torch 25 7 6 0 iii acta til 0558006786 P 38 MOU iO 1572 TI eei rette ient ia 0558006787 Torches and torch body assemblies are supplied without gas baffle electrode nozzle and retaining shield cup Order com plete spare parts kits or individual components shown in PT 38 Spare Parts Kits or Consumables Breakdown section Compatible ESAB Consoles Powercut 1300 208 230 460 V Console 0558007220 208 230 460 V Console BL 0558007220 400 V CE Console EE 0558007224 400V CONSOLES een 0558007634 460 V Console 0558008320 575 V Console BL nn 0558007227 Powercut 1600 208 230 460 V Console 0558007230 208 230 460 V Console BL 0558007230 400 V CE CONSO 0558007234 400 V Console 0558007636 460 V Console 0558008323 575 Console BL 0558007237 Powercut 900 208 230 V Console 0558008120 208 230 V Console 0558008120F 230 V CE CONSOLE cronica 0558008123 400 V CE Console 0558008135 400 V Console 0558008133 460 V ConSole usesiereessanssusseassausssnseasssues sssussansssesensne 0558008127 575 V Console 0558008131 12 SECTION 2 DESCRIPTION 2 2 Optional Accessories Gas Flow Measuring Kit p n 19765 CE units
12. TITRE PAGE SECURIT RE 33 Pr cautions EE 33 DESCRIPTION 2 a222222222222002022000200022220020002000000000200020000000000000000000200020000 0000000 080 0000020 0000020 0000000 0000000000000020002 Nell e ME Caracteristiques de la torche Accessoires en OPTION Ensembles de pi ces de rechange Analyse des consommables 1300 1600 rennes 38 Analyse des consommables 900 rennes 39 LETRA sen EEN energie Installation Installation de la torche alle det II E el E ET de EE Coupe en glissement 40 EE Gougeage avec le PT 38 Installation des consommables Donn es de coupe Fonctionnement de la source d nergie u u u 47 ASA OT eri Ao enee eeben Dirt or Contamination ss Inspection Cleaning and Replacement of Consumables Disassembly Assembly of Torch Measuring Torch Gas 5 PIECES DE sem mi ei ii ie Gris EM E Replacement Parts reisir nenn en tra lan iia General Ordering ss Diagrammes et liste des pi ces 31 TABLE DES MATIERES 32 SECTION 1 PRECAUTIONS DE SECURITE
13. UNE SITUATION DANGEREUSE AVANT DE METTRE EN MARCHE LA TORCHE PT 38 REFEREZ VOUS AUX MESURES DE SECURITE VINS do ET AU MODE D EMPLOI DANS LE MANUEL D INSTRUCTIONS SUR LA SOURCE D ALIMENTATION APPROPRI E L UTILISATION DE LA TORCHE PT 38 SUR TOUTE UNIT NON QUIP E D UN CIRCUIT DE MATAGE BLOCAGE DE S CURIT RISQUE D EXPOSER L UTILISATEUR A UNE HAUTE TENSION INATTENDUE 2 0 Description Le PT 38 est une torche manuelle avec une t te de 90 con ue pour tre utilis e avec plusieurs ensembles de coupage l arc plasma utilisant de l air propre et sec comme gaz pour le plasma Les longueurs de branchement disponibles avec la torche PT 38 sont 25 pieds 7 6 m et 50 pieds 15 2 m La torche PT 38 est cot e pour fonctionner un maximum de 90 amp res avec un cycle d utilisation de 100 Ce manuel a pour but de fournir a l utilisateur tous les renseignements n cessaires pour assembler assurer le fonctionnement et r parer la la torche a coupage a l arc plasma PT 38 Pour des renseignements additionnels sur les mesures de s curit les instructions de processus et le systeme de d pannage r f rez vous au manuel d instructions appropri pour votre ensemble de coupage l arc plasma Concu pour une performance de coupe sup rieure et la facilit de manipulation le PT 38 produit des coupes propres d une qualit exceptionnelle La torche de 90 A est la torche la plus compacte sur le march Excellente capacit
14. done by unscrewing the electrode in a counter clockwise direction from the piston If the electrode is used beyond this recommended wear limit damage to the torch and power source may occur Nozzle life is also greatly reduced when using the electrode below the recommended limit WORN 4 Remove the gas baffle Inspect it and the piston for signs of damage such as arc tracking or crack ing and replace them if necessary Note Gas baffle and retaining shield cup need to be replaced only if cracked or significant signs of wear are noticeable Monthly replacement is generally a good practice 5 After installing the gas baffle onto the torch body assembly install electrode by screwing clockwise into place 6 Lastly replace the nozzle and retaining shield cup by screwing clockwise into place Note Firm tightening of the electrode by hand is suf ficient the use of tools such as wrenches or pli ers is not required or recommended 55 Torch Body Assembly Electrode Torch Body Seat a Piston Gas Baffle Gas Baffle 90A 30 70A Electrode Retaining Shield Cup Nozzle SECTION 5 MAINTENANCE BEFORE ANY MAINTENANCE IS ATTEMPTED ON THIS TORCH MAKE ZN SURE THE POWER SWITCH ON THE CONSOLE IS IN THE OFF POSITION AND THE PRIMARY INPUT IS DEENERGIZED 5 3 Disassembly Assembly of Torch Handle Assembly 1 Remove eight phillips head screws from handle Separate the two halves of the
15. handle assembly Be careful not to lose the trigger spring when removing torch body assembly 5 Torch Head Assembly SECTION 5 MAINTENANCE Note If only the trigger switch is to be replaced pull switch from handle assembly and disconnect wires 2 at the connections Connect new switch Either wire can go on either terminal Reposition switch in handle Replace the other half of the handle and tighten the screws Switch Spring 146 2 Carefully remove the torch body piston assembly from the handl cables and hose for reinstallation y Note position of switch If necessary remove old trigger switch by discon necting 2 lugs and replace with new assembly SECTION 5 MAINTENANCE Note If the torch cable is being replaced perform steps 3 and 4 Note If only the piston is being replaced skip to step 5 3 Pull the insulating sleeves back to expose the hose and pilot arc connections Disconnect the hose fit tings from the torch head assembly by using a 7 16 and 3 8 wrench to prevent twisting copper tube Insert 1 16 allen wrench here to loosen setscrew and remove power cable Use wrenches here to disconnect hose connection Power Cable Pilot Arc knife connection Insulating Sleeves 4 Disconnect the pilot arc wire from the torch head assembly by unattaching the lead at the knife splice connection 5 Carefully disconnect the power cable by using a wrench to secure the
16. le profil de rainure d sir e 900 Pour gouger ins rez le d flecteur de gaz l lectrode la tuyere de gougeage de 60 et l assemblage de l cran thermique de 60 A Les param tres de service sont 60 a 80 psi 4 1 5 5 bars et 40 a 60 A La pression d air et le courant peuvent varier l int rieur de ces limites pour produire le taux de d pose et le profil de rainure d sir e Tuy re de gaugeage 90 A PC 1300 1600 60 A PC 900 Deflecteur de gaz 90 A PC 1300 1600 Assemblage de l cran Electrode thermique de gaugeage de 90 A PC 1300 1600 de 60 A PC 900 D flecteur de gaz 60 A PC 900 4 4 Installation des consommables Des tests ont d montr que les cas d utilisation normale de la torche l int rieur des conditions assign es de fonctionnement tout particuli rement le courant d arc et le d bit gazeux les consommables de la torche ne se desserrent pas s ils sont fer mement install s Les pi ces l ches peuvent endommager et faire surchauffer la torche A Resserrez fond l lectrode et la buse lors de tout changement ou inspection d un consommable B V rifiez l tanch it des consommables au d but de chaque p riode de travail m me si tout semblait fonctionner normalement la fin de la p riode pr c dented Remarque Assurez vous que le si ge de l lectrode torche et le piston soient propres et d pourvus de poussi re ou de salet Des d bris risquent d emp
17. piston and a 1 16 allen wrench to loosen the set screw and pull the power cable free from the torch piston 6 Remove piston Wipe body cylinder inner walls and o ring seated at the bottom of the cylinder 7 To reinstall start set screw in piston two to three threads Install and grease piston o ring Place elec trode contact spring and cap with key toward front of torch on piston Pressing downward on cap and compressing spring insert power cable ferrule Make sure cable ferrule end is flush with surface of piston to ensure free movement Tighten set screw firmly Verify power cable ferrule is secure Carefully insert piston into torch body noting orientation of cap key toward front of body Place wrench here to prevent piston from turning during assembly disassembly of power cable Note that ferrule should be flush with pis ton to ensure no interference with handle Note placement of electrode contact spring and orientation of piston cap key Never clamp piston here 58 SECTION 5 MAINTENANCE 8 Iftorch cable was removed reconnect hose connection tighten with wrenches and pull insulating sleeve forward Reconnect pilot arc wire and pull insulating sleeve forward Again pressing downward on cap and compressing spring place the torch piston assembly into the handle cavity while observing the body and cap key guides Place the hose cable and pilot arc wire into the housing Fold the wiring into the handle assemb
18. 0 A rennes r f 0558007681 Assemblage d cran thermique de gougeage 90 A r f 0558008186 Remarque Doit utiliser un d flecteur de gaz de 90 100 A r f 0558004870 Powercut 900 Assemblage du guide de hauteur 60 A r f 0558008592 Utiliser pour maintenir une distance de s curit constante Gougeage 60 A Tuy re de ref 0558008588 Assemblage d cran thermique de gougeage 60 A ref 0558008591 2 3 Ensembles de pi ces de rechange Ensembles de pi ces de rechange PT 38 o Ensembles de pi ces de rechange PT38 O 0558007640 0558007639 0558007642 0558007641 0558008419 90 90 70A 70A 60A 60A de pi ce 1600 1600 1300 1300 PC 900 CE PC 900 Ea op po AA S M OS fon ETE eo AAA j sera Par ER EE ES ee 155 NN AAA Te O 4 0 22 er fan a dum ES OT E T j C IE I TT 37 SECTION 2 DESCRIPTION 2 4 Analyse des consommables PC 1300 1600 CUTTING COUPAGE 90A 0558007549 0558007680 0558005220 0558004870 P T 3 8 O RING JOINT TORIQUE 85W51 7
19. 008417 0558005220 0558005217 I i 40A 0558008094 0558007682 0558005220 0558005217 I GREASE 17672 GE O RING PT O GOUGING 2064062 T 027 1 0558008590 0558006611 10558006602 0558006611 0558008588 0558005217 E C O IM l Lcd o 80 PSI 2 B FUSE 2A 600V 5 5 BAR MB 0558001379 A nee p u ss SECTION 2 DESCRIPTION SECTION 3 INSTALLATION WARNING MAKE SURE POWER SWITCH ON CONSOLE IS IN OFF POSITION AND PRIMARY INPUT POWER IS DE ENERGIZED 3 0 Installation 3 1 Torch Installation 1 Open torch lead access door on the front panel of the Powercut 1300 1600 Torch Lead lt Access Door 2 Connect the torch cable male receptacle to the panel receptacle Check orientation of the sockets to ensure a correct fit Panel Receptacle Torch Cable Male Receptacle 3 Connect the air hose to the quick connect fitting Place the strain relief in the square cutout in the front of the console Line up the groove of the strain relief with the half square cutout area square cutout strain relief Air Hose quick connect fitting SECTION 3 INSTALLATION 4 Insert work cable into receptacle on the front ofthe console and turn clockwise until secure 5 Replace torch lead access door Wo
20. 0558000739 Valuable troubleshooting tool allows measurement ofthe actual air flow through EA the torch e C N Torch Guide Kit 1 io This complete kit in a rugged plastic carrying case includes attachments for circle and straight line cutting on ferrous and non ferrous metals Deluxe 1 3 4 42 44 5 mm 106 5 p n 0558003258 Basic 1 3 4 28 44 5 mm 71 cm Radius EE p n 0558002675 Powercut 1300 1600 Stand off Guide Assembly 90 p n 0558006614 Use to maintain constant stand off distance Gouging 90 Amp Gouging Nozzle 90 p n 0558007681 Gouging Heat Shield Assembly 90 Amp p n 0558008186 e Note Must use 90 100 Amp p n 0558004870 Stand off Guide Assembly 60 p n 0558008592 Use to maintain constant stand off distance Gouging 60 Amp GOUGING Nozzle 60 p n 0558008588 Gouging Heat Shield Assembly 60 Amp eere p n 0558008591 EU 2 3 Spare Parts Kits PT 38 Spare Parts Kits 0558007640 0558007639 0558007642 0558007641 0558008419 0558008418 Part Description 90 AMP 90 AMP 70 AMP 70 AMP 60 AMP 60 AMP Number PC 1600 CE PC 1600 PC 1300 CE PC 1300 PC 900 CE PC 900 A TA RTE 1 AA Tesco AA soon x a ossos Toro ora 3
21. 0A SECTION 4 OPERATION 4 5 Cut Data Use the following pages to adjust your torch settings to obtain optimum cutting performance DO NOT USE OXYGEN WITH THIS TORCH A HAZARDOUS FIRE MAY PY Cz ME RESULT 4 6 Operation of Power Source For operation of the power source refer to Powercut 1300 1600 power source instruction manual poWERCUT 1 600 23 SECTION 4 OPERATION Go PT 38 ESAB Powercut 1300 1600 Electrode 0558005220 Plasma System Process Data ee aen Retaining Shield Cup 0558007549 40 Amperes Carbon Steel Material Initial Height in mm Air sped mmmn oaa 1 40 Amperes Aluminum Material Initial Height in mm Air Travel 35 10 en 9525 406 40 Stainless Steel Material Initial Height in mm Air speed wus 3302 25 24 SECTION 4 OPERATION A 38 Electrode 0558005220 ESAB Powercut 900 Nozzle 0558008417 ME Plasma System Process Data ce or Retaining Shield Cup 0558007549 60 Amperes Carbon Steel Material ares venen Initial Height in mm Air Travel 8 Speed mmmn 2971 89 2032 60 Amperes Aluminum Material Thickness Initial Height 123478 188 4 78 188 4 78 188 4 78 in mm Air Travel 15 46
22. 0A 0558007549 0558005219 0558005220 0558005217 nem 40A 0558007549 0558007682 0558005220 0558005217 GREASE GRAISSE x s 17672 STAND OFF GUIDE GOUGING O RING GUIDE DE HAUTEUR 2 GOUGEAGE JOINT TORIQUE 1 0558006613 0558006611 70558006601 0558006611 0558007681 0558004870 E t I t 1 A de 1 lm EN 80 PSI ps FUSE 2 600V I I 1 1 5 5 WE i FUSIBLE 2 600V nn LE 0558001319 Remarque Lors du gougeage utiliser un d flecteur de 90 A 0558004870 CUTTING 90A 0558008094 0558007680 0558005220 0558004870 P 1 38 CE O RING 70A 0558008094 0558005219 0558005220 0558005217 Iu I I 40A 0558008094 0558007682 0558005220 0558005217 GREASE 17672 Y O RING EEE STAND OFF GOUGING 2064062 1 0558006613 10558006601 0558006611 0558007681 0558004870 I Fo U E Li i 80 PSI i FUSE 2A 600V 5 5 BAR A 7 0558001379 0558006644 1 055800810868 Remarque Lors du gougeage utiliser un d flecteur de 90 A 0558004870 38 SECTION 2 DESCRIPTION 2 5 Analyse des consommables PC 900 CUTTING COUPAGE
23. 1 Cet angle est tout particulierement utile pour cr er une coupe en glissement Lorsque le guide de hauteur n est pas utilis la tuy re doit tre maintenue environ PC 1300 1600 1 8 1 4 3 2 mm 6 4 mm PC 900 1 8 3 16 po 3 2 mm 4 8 mm de la pi ce travailler PC 900 1300 1600 PC 1300 1600 PC 900 IMPORTANT IMPORTANT Maintenez la bonne Maintenez la bonne distance de hauteur distance de hauteur La puissance de sortie La puissance de sortie augmente avec la distance augmente avec la distance de hauteur de hauteur 1 8 po 1 4 po 1 8 po 3 16 po Jr qe EIS mm 6 4 mm LE mm 4 8 mm DIRECTION DE LA COUPE Figure 4 1 Angle appropri Figure 4 2 Hauteur vs puissance de sortie de la torche 43 SECTION 4 FONCTIONNEMENT LES RAYONS DE L ARC RISQUENT DE BR LER LES YEUX ET LA PEAU LE BRUIT RISQUE D ENDOMMAGER L OUIE IL EST RECOMMAND DE PORTER UN MASQUE DE SOUDEUR AVEC UN CRAN NO 6 OU 7 IL EST RECOMMAND DE PORTER UNE PROTECTION DES YEUX DES OREILLES ET DU CORPS 2 LORSQUE L ARC PERCE LA PIECE METTEZ LA TORCHE EN POSITION DEBOUT ET PROC DEZ LA COUPE 1 POUR COMMENCER PERFORER UN TROU INCLINEZ LA TORCHE DE FACON A EMP CHER LA MATIERE EN FUSION DE REVENIR CONTRE LA TORCHE ET LENDOMMAGER IN Figure 4 3 Techniques de per age et de d coupage l aide du PT 38 44 SECTION 4 FONCTIONNEMENT LA COUPE EN GLISSE
24. 149 d placement MM MIN 4064 1524 77 483 203 Aluminium 90 A Epaisseur du 50 12 7 75 19 1 mat riel Hauteur initiale po mm Pression Vitesse de PPM 188 6 2 27 12 d placement MM MIN 4775 31930 1321 686 305 Acier inoxydable 90 A Epaisseur du 50 12 7 75 19 1 mat riel Hauteur initiale po mm ecean sous sos ws sssi Vitessede 16 15 d placement 29 23 SECTION 4 FONCTIONNEMENT 52 SECTION 5 MAINTENANCE BEFORE ANY MAINTENANCE IS ATTEMPTED ON THIS TORCH MAKE WARNING SURE THE POWER SWITCH ON THE CONSOLE IS IN THE OFF POSI TION AND THE PRIMARY INPUT IS DEENERGIZED 5 0 General A Periodically check torch head assembly Replace if worn or damaged B Torch cable should be inspected periodically If there are any cuts through the protective sheath or wire insulation replace the cable 5 1 Dirt or Contamination Dirt or other contamination in the torch and loose consumable parts can cause premature failure of the PT 38 Torch through internal arcing To avoid this users are instructed to do the following Ensure that clean dry and oil free air is being used Wipe the retaining cup clean with a cloth before installing each fresh set of consum ables The ability of the retaining cup to resist arc tracking over its surface is reduced when dirt or other contami nation is
25. 9 ID x 040 FKM 0558007460 0558009426 1 1 EE ETE Cp m ETA 3 63 SECTION 6 REPLACEMENT PARTS 64 NOTES 65 NOTES 66 REVISION HISTORY 1 Original release 10 2008 2 Revision 09 2009 Updated Replacement Parts section per ECN 093150 added o ring 67 ESAB subsidiaries and representative offices Europe AUSTRIA ESAB Ges m b H Vienna Liesing Tel 43 1 888 25 11 Fax 43 1 888 25 11 85 BELGIUM S A ESAB N V Brussels Tel 32 2 745 11 00 Fax 32 2 745 11 28 THE CZECH REPUBLIC ESAB VAMBERK s r o Prague Tel 420 2 819 40 885 Fax 420 2 819 40 120 DENMARK Aktieselskabet ESAB Copenhagen Valby Tel 45 36 30 01 11 Fax 45 36 30 40 03 FINLAND ESAB Oy Helsinki Tel 358 9 547 761 Fax 358 9 547 77 71 FRANCE ESAB France S A Cergy Pontoise Tel 33 1 30 75 55 00 Fax 33 1 30 75 55 24 GERMANY ESAB GmbH Solingen Tel 49 212 298 0 Fax 49 212 298 218 GREAT BRITAIN ESAB Group UK Ltd Waltham Cross Tel 44 1992 76 85 15 Fax 44 1992 71 58 03 ESAB Automation Ltd Andover Tel 44 1264 33 22 33 Fax 44 1264 33 20 74 HUNGARY ESAB Kft Budapest Tel 36 1 20 44 182 Fax 36 1 20 44 186 ITALY ESAB Saldatura S p A Mesero Mi Tel 39 02 97 96 81 Fax 39 02 97 28 91 81 THE NETHERLANDS ESAB Nederland B V Utrecht Tel 31 30 2485 377 Fax 31 30 2485 260 NORWAY AS ESAB Larv
26. CUTTING EVEN WITH LOWER CURRENT LEVELS MAY SIGNIFI LU CANTLY REDUCE THE LIFE OF TORCH CONSUMABLES ATTEMPTING TO DRAG CUT WITH HIGHER CURRENTS GREATER THAN 40 AMPS MAY CAUSE IMMEDIATE CATASTROPHIC CONSUMABLE DAMAGE 4 1 Stand off Guide Use to maintain a constant stand off distance Attach optional stand off guide assembly by removing the retaining shield cup and installing the stand off guide assembly Stand off guide assembly Guide against straight edge or free hand cut Figure 4 4 Installation and Operation of Stand off Guide 4 2 Drag Cutting 40 Amp For cutting thin material under 3 8 9 mm insert low current gas baffle electrode 40 amp drag nozzle and standard retaining shield cup Set current level to 40 amps and begin cutting Gas Baffle 30 70 Amp Electrode yo Amp Drag Nozzle z Retaining Shield Cup 21 SECTION 4 OPERATION 4 3 Gouging with the PT 38 PC 1300 1600 Insert high current gas baffle electrode 90 amp gouge nozzle and 90 amp gouging heatshield assembly Operating parameters are 60 80 psi 4 1 5 5 bar and 70 90 amps Air pressure and current can be varied within these ranges to produce desired metal removal rate and groove profile PC 900 Insert standard gas baffle electrode 60 amp gouge nozzle and 60 amp gouging heatshield assembly Operating parameters are 60 80 psi 4 1 5 5 bar and 40 60 amps Air pressure and current can be varied within these ranges
27. MENT MEME AVEC UN NIVEAU D INTENSITE DU COURANT LE PLUS BAS POSSIBLE PEUT REDUIRE DE FA ON SIGNIFICATIVE LA DUREE DE VIE DES CONSOMMABLES DE LA TORCHE TENTER DE FAIRE MISE EN GARDE DES COUPES EN GLISSEMENTS AVEC UN COURANT SUPERIEUR A 40 A RISQUE DE PRODUIRE DES DOMMAGES IMMEDIATS ET CATASTROPHIQUES AUX CONSOMMABLES 4 1 Guide de hauteur Utiliser pour maintenir une distance de hauteur constante Fixez l assemblage du guide de hauteur en retirant la buse et en installant l assemblage du guide de hauteur Assemblage du guide de hauteur Guide contre le Ba reglet d ajusteur ou coupe a main libre Figure 4 4 Installation et fonctionnement du guide de hauteur 4 2 Coupe en glissement 40 A Pour couper du mat riel mince moindre que 3 8 9 mm ins rez le d flecteur de gaz a faible intensit l lectrode la bouche d adduction de 40 A et la buse standard R glez le niveau d intensit 40 A et commencez couper D flecteur gaz 30 70 A Electrode Bouche d adduction de 40 A Al Th 45 SECTION 4 FONCTIONNEMENT 43 Gougeage avec le PT 38 PC 1300 1600 Pour gouger ins rez le d flecteur de gaz de haute intensit l lectrode la tuyere de gougeage de 90 A et l assemblage de l cran thermique de 90 Les param tres de service sont 60 a 80 psi 4 1 5 5 bars 70 90 A La pression d air et le courant peuvent varier a l int rieur de ces limites pour produire le taux de d pose et
28. Speed MM MIN 4775 19 0 1321 686 305 90 Amperes Stainless Steel Material Initial Height in mm Air Travel 1PM 1 48 15 MM MIN 320 129 762 331 203 SECTION 4 OPERATION 28 PT 38 Torches d oxycoupage Plasmarc Manuel d instructions FR P N 0558006786 PT 38 Torche 25 7 6 m P N 0558006787 PT 38 Torche 50 15 2 m 0558007599 29 ASSUREZ VOUS QUE CETTE INFORMATION EST DISTRIBU E A L OPERATEUR VOUS POUVEZ OBTENIR DES COPIES SUPPLEMENTAIRES CHEZ VOTRE FOURNISSEUR ATTENTION Les INSTRUCTIONS suivantes sont destin es aux op rateurs qualifi s seulement Si vous n avez pas une connaissance approfondie des principes de fonctionnement et des r gles de s curit pour le soudage l arc et l quipement de coupage nous vous sugg rons de lire notre brochure Precautions and Safe Practices for Arc Welding Cut ting and Gouging Formulaire 52 529 Ne permettez PAS aux personnes non qualifi es d installer d op rer ou de faire l entretien de cet quipement Ne tentez PAS d installer ou d op rer cet quipement avant de lire et de bien comprendre ces instructions Si vous ne comprenez pas bien les instructions communiquez avec votre fournisseur pour plus de renseignements Assurez vous de lire les R gles de S curit avant d installer ou d op rer cet quipement RESPONSABILIT S DE L UTILISATEUR Cet quipement op rera conform men
29. Vas caci n 0558007227 Powercut 1600 Console 208 230 460 0558007230 Console BL 208 230 460 0558007230 Console CE 400 V isis 0558007234 Console 400 Visites 0558007636 Console 460 pates el 0558008323 BL 575 cdi 0558007237 Powercut 900 Console 208 230 Voz as aquqa ushaq 0558008120 Console BL 208 230 V 0558008120F Console CE 230 V 0558008123 Console CE 400 V 0558008135 Console 400 V 0558008133 C nsole 460 0558008127 Console BL 575 u L 0558008131 36 SECTION 2 DESCRIPTION Guide dela torche ef Cet ensemble complet dans un amp tui en plastique solide comprend des accessoires pour des coupes rondes et en ligne droite pour les m taux ferreux et non ferreux 2 2 Accessoires en option Ensemble pour mesurer le d bit de gaz r f 19765 CE unit s 0558000739 Outil de d pannage de grande valeur permettant de mesurer le d bit d air r el circulant dans la torche Deluxe 1 3 4 42 44 5 mm 106 cm rayon r f 0558003258 De base 1 3 4 28 44 5 mm 71 cm rayon EE r f 0558002675 Powercut 1300 1600 Assemblage du guide de hauteur 90 r f 0558006614 Utiliser pour maintenir une distance de s curit constante Gougeage 90 A Tuy re gougeage 9
30. acement MM MIN 20828 635 3048 177 8 49 SECTION 4 FONCTIONNEMENT PT 38 ESAB Powercut 1300 1600 Electrode 0558005220 Be 2 EM Tuy re 0558005219 Donn es de proc d du systeme plasma Buse 0558007549 Acier au carbone 70A Epaisseur du 50 12 7 75 19 1 materiel Hauteur initiale po mm Pression Vitesse de PPM 1500 5 26 1 5 deplacement MM MIN 3810 1270 660 4 305 17 Aluminium 70 A paisseur du 50 12 7 75 19 1 materiel Hauteur initiale bo mm 188 4 78 1188 4 78 1188 4 78 188 4 78 1188 4 78 com ses men Vitesse de PPM 10 28 20 d placement MM MIN 3556 1676 4 711 2 _ 508 279 4 Acier inoxydable 70A Epaisseur du 50 12 7 75 19 1 materiel Hauteur initiale 188 4 78 188 4 78 188 4 78 188 4 78 188 4 78 po mm Pression d air en es soss soss soss 0055 Vitesse no 36 7 m 6 d placement MM MIN 294 9144 4318 2794 1524 SECTION 4 FONCTIONNEMENT By PT 38 ES AB a Powercut 1300 1600 Electrode 0558005220 Donn es de proc d du ei D flecteur de gaz 0558004870 systeme plasma Buse 0558007549 Acier au carbone 90A Epaisseur du 50 12 7 75 19 1 materiel Hauteur initiale po mm Pression Vitessede PPM 60
31. allowed to collect there 53 SECTION 5 MAINTENANCE 5 2 Inspection Cleaning and Replacement of Consumables Disassemble the front end of the PT 38 as follows Torch Body Assembly Piston Electrode Nozzle and Retaining Shield Cup Retaining Shield Cup Nozzle es 1 Position torch head in adownward direction and remove the retain ing shield cup by unscrewing in a counter clockwise direction The nozzle will drop from the torch head assembly and remain in the retaining shield cup Note The nozzle and electrode will generally wear at the same rate For best performance replace together Note When inspecting consumables visually check torch body assembly Replace torch body assembly if worn or damaged Remove the nozzle by tilting retaining shield cup upside down and pushing nozzle out Inspect nozzle for wear The nozzle orifice should be round at both the entrance and the exit If the nozzle orifice is worn in an oval shape or shows other signs of damage at either end it should be replaced The inside of the nozzle may have light gray deposits from the electrode These may be removed with steel wool but care must be taken to remove all traces of the steel wool after ward SECTION 5 MAINTENANCE CAUTION INCH 1 5 MM REPLACE ELECTRODE BEFORE WEAR BECOMES DEEPER THAN 060 3 If the electrode has a pit which is more than 06 1 5mm deep at its center it must be replaced This is
32. and these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions be fore installing or operating this equipment USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa nying labels and or inserts when installed operated maintained and repaired in accordance with the instruc tions 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 imme diately 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 ser vice facility designated by the manufacturer READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING PROTECT YOURSELF AND OTHERS SECTION SECTION 1 1 0 SECTION 2 2 0 2 1 2 2 2 3 2 4 2 5 SECTION 3 3 0 3 1 SECTION 4 4
33. arc should start The main arc should immediately fol low allowing the cut to begin If using the trigger LOCK mode torch switch may be released after establishing the cutting arc 6 After starting the cut the torch should be maintained at a 5 15 forward angle Figure 4 1 This angle is es pecially useful in helping to create a drop cut When not using the standoff guide the nozzle should be held approximately PC 1300 1600 1 8 1 4 in 3 2 mm 6 4 mm PC 900 1 8 3 16 in 3 2 mm 4 8 mm from the work PC 900 1300 1600 PC 1300 1600 PC 900 IMPORTANT IMPORTANT Maintain Proper Maintain Proper Stand Off Distance Stand Off Distance Power Output increases Power Output increases with Stand off Distance with Stand off Distance 1 8 to 1 4 in METUS 3 2 mm 6 4 mm 3 2 mm 4 8 CUT DIRECTION ii Figure 4 1 Proper Torch Angle Figure 4 2 Stand off vs Power Output 19 SECTION 4 OPERATION ARC RAYS CAN BURN EYES AND SKIN NOISE CAN DAMAGE HEARING e WEAR WELDING HELMET WITH NO 6 OR 7 LENS SHADE e WEAR EYE EAR AND BODY PROTECTION 2 WHEN THE ARC BREAKS THROUGH THE WORK BRING THE TORCH TO AN UPRIGHT POSITION AND PROCEED TO CUT 1 START A PIERCE TILT THE TORCH TO PREVENT MOLTEN MATERIAL FROM COMING BACK AGAINST AND DAMAGING THE TORCH IN Figure 4 3 Piercing amp Cutting Techniques using the PT 38 20 SECTION 4 OPERATION DRAG
34. ce inclin e autoris e de plus de 15 il y a danger de basculement et en cons quence des blessures personnelles et ou des dommages importants l quipement 15 33 SECTION 1 PRECAUTIONS DE SECURITE LESOUDAGE ET LE COUPAGE A L ARC PEUVENT CAUSER DES BLESSURES A L OP RATEUR OU LES AUTRES PERSONNES SE TROUVANT DANS L AIRE DE TRAVAIL ASSUREZ VOUS DE PRENDRE TOUTES LES PR CAUTIONS N CESSAIRES AVERTISSEMENT LORS D UNE OP RATION DE SOUDAGE OU DE COUPAGE DEMANDEZ VOTRE EMPLOYEUR UNE COPIE DES MESURES DE SECURITE QUI DOIVENT ETRE LABOR ES PARTIR DES DONN ES DES RISQUE DU FABRICANT CHOC LECTRIQUE peut tre mortel Assurez vous que l unit de soudage ou de coupage plasma est install e et mise la terre conform ment aux normes applicables Ne touchez pas aux pi ces lectriques sous tension ou les lectrodes si vos mains ne sont pas bien prot g es ou si vos gants ou vos v tements sont humides Assurez vous que votre corps est bien isol de la mise la terre et de la pi ce traiter Assurez vous que votre position de travail est s cure VAPEURS ET GAZ peuvent tre danereux pour la sant Gardez votre t te loign e des vapeurs Utilisez un syst me de ventilation et ou d extraction l arc pour vacuer les vapeurs et les gaz de votre zone respiratoire RAYONS DE L ARC peuvent endommager la vue ou br ler la peau Prot gez vos yeux et votre corps Utilisez un cran d
35. cher le plan de joint d obtenir un contact solide Assemblage du corps de la torche Si ge de Remarque l lectrode torche Resserrez fermement l lectrode la main est suffisant l utilisation d outils comme Piston une cl ou des pinces n est pas n cessaire Cr Le D flecteur ni recommand de gaz D flecteur de 30 70A Remarque gaz 90A Les pi ces laches peuvent endommager et faire surchauffer la torche Le chemi nement d arc est un signe que certaines pi ces sont l ches Assurez vous que la buse soit compl tement resserr e Les pi ces endommag es par l arc conduiront la destruction de la torche et se doivent d tre remplac es Buse lectrode Tuy re et buse 46 SECTION 4 FONCTIONNEMENT 45 Donn es de coupe Utilisez les pages suivantes pour ajuster les r glages de votre torche de fa on obtenir une performance de coupe optimale DAN G E R NE PAS UTILISER D OXYGENE AVEC CETTE TORCHE UN INCENDIE POURRAIT SURVENIR 4 6 Fonctionnement de la source d nergie En ce qui concerne le fonctionnement de la g n ratrice r f rez vous au manuel d instructions de la g n ratrice Powercut 1300 1600 po WERCUT 1 600 47 SECTION 4 FONCTIONNEMENT gt de PT 38 ESAB 1300 1600 lectrode 0558005220 z zur Tuyere 0558007682 Donn es de proc d du D flecteur de gaz 0558005217 systeme plasma Buse 0558007549 40 Amp res Acier au ca
36. d acc s principale de la torche 2 Brancher la prise m le du c ble de la torche la prise du panneau V ri fier l orientation des socles afin de s assurer que l ajustement est correct Prise du panneau Prise m le du c ble de la torche 3 Brancher le raccord d air au au raccord branchement rapide Placer le r ducteur de tension dans le coupe circuit carr l avant de la console Aligner la rayure du r ducteur de tension avec la partie du coupe circuit en forme d un demi carr Coupe circuit carr R ducteur de tension Fixation de prise de courant du raccord d air 41 SECTION 3 4 Ins rer le c ble de travail dans la prise de courant l avant de la console et tourner dans le sens horaire jusqu a ce qu il soit s curis 5 Replacer la porte d acc s principale C ble de travail Porte d acc s principale de la torche 42 INSTALLATION SECTION 4 FONCTIONNEMENT DAN G E R NE PAS UTILISER D OXYGENE AVEC CETTE TORCHE UN INCENDIE POURRAIT SURVENIR LES SECOUSSES ELECTRIQUES PEUVENT CAUSER LA MORT NE PAS UTILISER CETTE UNIT SI LE COUVERCLE A ETE RETIRE PAS ALIMENTER CETTE UNIT ALORS QU ELLE EST PORT E EE ECT 19 TRANSPORTEE NE TOUCHER AUCUNE PARTIE DE LA TORCHE DEVANT LE MACHE TUYERE CRAN THERMIQUE LECTRODE ETC LORSQUE L INTERRUPTEUR EST EN POSITION ON 4 0 Couper avec le PT 38 Utilisez les proc dures suivantes
37. e soudage coupage plasma convenable quip de lentilles teint es et portez des v tements de protection Prot gez les personnes se trouvant dans l aire de travail l aide d un cran ou d un rideau protecteur convenable RISQUE D INCENDIE Les tincelles projections peuvent causer un incendie Assurez vous qu il n y a pas de mat riel inflammable proximit de l appareil BRUIT un bruit excessif peut endommager la capacit auditive Prot gez vos oreilles Utilisez des protecteurs d oreilles ou un autre type de protection auditive Avertissez les personnes se trouvant dans l aire de travail de ce risque FONCTIONNEMENT D FECTUEUX Dans le cas d un fonctionnement d fectueux demandez l aide d une personne qualifi e ASSUREZ VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D UTILISATION AVANT D INSTALLER OU D OP RER L UNIT PROT GEZ VOUS ET LES AUTRES ATTE NTIO N Ce produit est uniquement destin la d coupe du plasma Toute autre utilisation peut entrainer des blessures ou endommager l quipement ATTENTION Pour viter toute blessure personnelle et ou en dommagement l quipement soulever l aide de la m thode et des points d attache indiqu s ici SECTION 2 DESCRIPTION LE PROC D DE COUPAGE L ARC PLASMA UTILISE DE LA HAUTE TENSION TOUT CONTACT AVEC DES PARTIES lt ACTIVES gt DE LA TORCHE ET DE LA MACHINE DOIT ETRE EVITE AUSSI LA MAUVAISE UTILISATION DE TOUT GAZ UTILISE PEUT PRESENTER
38. ent pour acqu rir le mat riel en toute s curit libre de courants d air 4 quipement de s curit personnelle Vous devez toujours utiliser un quipement de s curit convenable tels que les lunettes de protection les v tement ininflammables et des gants de protection Vous ne devez jamais porter de v tements amples tels que foulards bracelets bagues etc qui pourraient se prendre dans l appareil ou causer des br lures 5 Pr cautions g n rales Assurez vous que le c ble de retour est bien branch La r paration d un quipement de haute tension doit tre effectu e par un lectricien qualifi seulement Un quipement d extinction d incendie appropri doit tre proximit de l appareil et l emplacement doit tre clairement indiqu Vous ne devez jamais proc der la lubrification ou l entretien du mat riel lorsque l appareil est en marche Classe de boitier Le code IP indique la classe du boitier savoir le niveau de protection offert contre toute p n tration par des objets solides ou de l eau La protection est fournie contre le contact d un doigt la p n tration d objets solides d une taille sup rieure 12 mm et contre l eau pulv ris e jusqu 60 degr s de la verticale L quipement marqu IP23S peut tre stock mais ne doit pas tre utilis l ext rieur quand il pleut moins d tre sous abri ATTENTION Inclinaison maximum Si l quipement est plac sur une surfa
39. ik Tel 47 33 12 10 00 Fax 47 33 11 52 03 POLAND ESAB Sp zo o Katowice Tel 48 32 351 11 00 Fax 48 32 351 11 20 PORTUGAL ESAB Lda Lisbon Tel 351 8 310 960 Fax 351 1 859 1277 SLOVAKIA ESAB Slovakia s r o Bratislava Tel 421 7 44 88 24 26 Fax 421 7 44 88 87 41 SPAIN ESAB Ib rica S A Alcal de Henares MADRID Tel 34 91 878 3600 Fax 34 91 802 3461 SWEDEN ESAB Sverige AB Gothenburg Tel 46 31 50 95 00 Fax 46 31 50 92 22 ESAB International AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 2191 4333 Fax 55 31 2191 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 52 8 350 7554 USA ESAB Welding amp Cutting Products Florence SC Tel 1 843 669 44 11 Fax 1 843 664 57 48 Asia Pacific CHINA Shanghai ESAB A P Shanghai Tel 86 21 5308 9922 Fax 86 21 6566 6622 INDIA ESAB India Ltd Calcutta Tel 91 33 478 45 17 Fax 91 33 468 18 80 INDONESIA ESABindo Pratama Jakarta Tel 62 21 460 0188 Fax 62 21 461 2929 JAPAN ESAB Japan Tokyo Tel 81 3 5296 7371 Fax 81 3 5296 8080
40. ing 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 finger 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 in tended to be used outside during precipitation unless sheltered Tilt Allowed If equipment is placed on a surface that slopes more than 15 toppling over may occur Personal injury and or significant damage to equipment is possible SECTION 1 SAFETY PRECAUTIONS WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS TAKE PRECAUTIONS WHEN WELDING OR CUTTING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA 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 y
41. ly cavity being careful not to overlap any mating surfaces of the housing Install trigger switch spring and lever Ferrule not protruding Cap Cap guide PR Cap guide Spring O ring Cap key Body guide Piston 10 Replace the other half of the handle and tighten the screws Tighten screws until there is no gap be tween the two halves Note If halves do not seat flush remove one half and check for hoses and wires that are overlapping the handle surfaces Depress switch to ensure proper operation and clearance 5 4 Measuring Torch Gas Flows If low gas flow is suspected of causing poor cutting performance or short consumable life the flow can be checked by using the Gas Flow Measuring Kit The kit includes a hand held rotameter flowmeter which will indicate the gas flow rate exiting the torch The kit also includes a set of instruc tions which should be followed exactly to insure safe and accurate use of the rotameter See Optional Accessories section Total air flow rate in the PT 38 should be 375 cfh 10 6 cmh minimum with 90 amp consumables installed Flow Measuring Kit 59 SECTION 5 MAINTENANCE 60 SECTION 6 REPLACEMENT PARTS 6 0 Replacement Parts 6 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 2 Ordering To ensure proper operation it is recommended that only genuine ESAB parts and produc
42. our 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 filter lens and wear protective clothing Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make sure therefore that there are no inflammable materials nearby NOISE Excessive noise can damage hearing Protect your ears Use earmuffs 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 CAUTION This product is solely intended for plasma cutting Any other use may result in personal injury and or equipment damage To avoid personal injury and or equipment dam age lift using method and attachment points shown here SECTION 2 DESCRIPTION THE PLASMA ARC CUTTING PROCESS EMPLOYS HIGH VOLTAGES CONTACT WITH LIVE PARTS OF THE TORCH AND MACHINE MUST BE AVOIDED ALSO THE IMPROPER USE OF ANY OF THE GASES EM PLOYED CAN PRESENT A SAFETY HAZARD BEFORE BEGINNING OP ERATION WITH THE PT 38 TORCH REFER TO THE SAFETY PRECAU WAR N N G TIONS AND OPERATING INSTRUCTIONS IN THE APPROPRIATE POWER SOURCE INSTRUCTION MANUAL USING THE PT 38 TORCH ON ANY UNIT NOT EQUIPPED WITH A MAT ING SAFETY INTERLOCK CIRCUIT MAY EXPOSE OPERATOR TO UNEX
43. pment 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 Theoperator 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 flame proof clothing safety gloves Do not wear loose fitting 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 qualified electrician Appropriate fire extinquish
44. pour couper avec la torche PT 38 1 Assurez vous que sectionneur mural est en position ON Allumez l interrupteur du bloc d alimentation de la console R glez le r gulateur de pression 80 ppc 5 5 bars PC 1300 1600 Maintenez la tuy re de la torche entre 1 8 po et 1 4 po 3 2 mm 6 4 mm au dessus de la pi ce a travailler et inclin e entre 5 et 15 Cela r duit les risques que des claboussures entrent dans la tuyere Si le guide de hauteur du PT 38 90 A est utilis la distance entre la tuyere et la pi ce a travailler sera d environ 1 4 po 6 4 mm PC 900 Maintenez la tuy re de la torche entre 1 8 po et 3 16 po 3 2 mm 4 8 mm au dessus de la piece a travailler et inclin e entre 5 et 15 Cela r duit les risques que des claboussures entrent dans la tuyere Si le guide de hauteur du PT 38 60 A est utilis la distance entre la tuy re et la pi ce a travailler sera d environ 1 8 po 3 2 mm Appuyez sur l interrupteur de la torche De l air devrait s chapper de la tuy re de la torche Deux secondes apr s avoir appuy sur l interrupteur l arc pilote devrait se mettre en marche L arc principal devrait suivre imm diatement permettant de commencer a couper Si vous utilisez le mode de verrouillage de la gachette l interrupteur de la torche peut tre rel ch apr s avoir tabli l arc de coupe Apres avoir d but la coupe la torche doit tre maintenue avec un angle de 5 a 15 vers l avant Figure 4
45. rbone Epaisseur du 50 12 7 materiel hauteur initiale in mm PHA ses soss d placement aa iss 40 Amp res Aluminum Epaisseur du 50 12 7 mat riel i Hauteur initiale po mm d aire Vitesse de PPM 35 1590 6 d placement wM MIN 9525 3810 1219 406 40 Amp res Acier inoxydable paisseur du 50 12 7 mat riel i hauteur initiale po mm Pression d aire Be es wes ws we Vitesse de PPM 352 26 d placement 8941 3302 6604 203 48 SECTION 4 FONCTIONNEMENT PT 38 Electrode 0558005220 ESAB Powercut 900 Tuy re 0558008417 Donn es de proc d du D flecteur de gaz 0558005217 systeme plasma Buse 0558007549 60 Amp res Acier au carbone mat riel hauteur initiale in mm meng 2069 soss soss Vitesse de d placement MM MIN 2971 457 2 203 2 Pression d air 60 Amp res Aluminum Fparsseur du 50 12 7 75 19 1 materiel hauteur initiale gg 4 78 188 4 78 188 4 78 188 4 78 in mm Vitessede 15 19 deplacement MM MIN 2667 1168 4 4826 3556 60 Amp res Acier inoxydable Epaisseur du 50 12 7 75 19 1 mat riel hauteur initiale 188 4 78 188 4 78 188 4 78 188 4 78 in mm Vitesse de 1PM 8 2 2 7 depl
46. rk Cable Torch Lead Access Door POWERCUT 160 SECTION 4 OPERATION DANG ER DO NOT USE OXYGEN WITH THIS TORCH A HAZARDOUS FIRE MAY RESULT ELECTRIC SHOCK CAN KILL e DO NOT OPERATE THE UNIT WITH THE COVER REMOVED DO NOT APPLY POWER TO THE UNIT WHILE HOLDING OR CARRY ING THE UNIT DO NOT TOUCH ANY TORCH PARTS FORWARD OF THE TORCH HANDLE NOZZLE HEAT SHIELD ELECTRODE ETC WITH POWER SWITCH ON 4 0 Cutting with the PT 38 Use the following procedures to cut with the PT 38 torch 1 2 3 Make sure that the wall disconnect switch is on Turn on the Power Switch to the cutting power source console Set Pressure Regulator to 80 psig 5 5 bar PC 1300 1600 Hold the torch nozzle approximately 1 8 in to 1 4 in 3 2 mm 6 4 mm above the work and tilted at about 5 15 This reduces the chance of spatter entering the nozzle If the PT 38 s 90A stand off guide is being used the distance between nozzle and work piece will be approximately 1 4 in 6 4 mm PC 900 Hold the torch nozzle approximately 1 8 in to 3 16 in 3 2 mm 4 8 mm above the work and tilted at about 5 15 This reduces the chance of spatter entering the nozzle If the PT 38 s 60A standoff guide is being used the distance between nozzle and work piece will be approximately 1 8 in 3 2 mm 4 Depress the torch switch Air should flow from the torch nozzle 5 Two seconds after depressing the torch switch the pilot
47. t a la description contenue dans ce manuel les tiquettes d accompagnement et ou les feuillets d information si l quipement est install op r entretenu et r par selon les instructions fournies Vous devez faire une v rification p riodique de l quipement Ne jamais utiliser un quipement qui ne fonctionne pas bien ou n est pas bien entretenu Les pi ces qui sont bris es us es d form es ou contamin es doivent tre remplac es imm diatement Dans le cas o une r paration ou un remplacement est n cessaire il est recommand par le fabricant de faire une demande de conseil de service crite ou par t l phone chez le Distributeur Autoris de votre quipement Cet quipement ou ses pi ces ne doivent pas tre modifi s sans permission pr alable crite par le fabricant L utilisateur de l quipement sera le seul responsable de toute d faillance r sultant d une utilisation incorrecte un entretien fautif des dommages une r paration incorrecte ou une modification par une personne autre que le fabricant ou un centre de service d sign par le fabricant ASSUREZ VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D UTILISATION AVANT D INSTALLER OU D OP RER L UNIT PROT GEZ VOUS ET LES AUTRES 30 SECTION SECTION 1 1 0 SECTION 2 2 0 2 1 2 2 2 3 2 4 2 5 SECTION 3 3 0 3 1 SECTION 4 4 0 4 1 4 2 4 3 4 4 4 5 4 6 SECTION 5 5 0 5 1 5 2 53 54 SECTION 6 6 0 6 1 6 2 TABLE DES MATIERES
48. t 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 ser vice 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 English NN 5 e E E E T E E E E E T 29 PT 38 Plasmarc Cutting Torches Instruction Manual EN P N 05580067886 PT 38 Torch 25 7 6 m P N 0558006787 PT 38 Torch 50 15 2 m 0558007599 BE SURE THIS INFORMATION REACHES THE OPERATOR YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER 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 underst
49. to produce desired metal removal rate and groove profile Gouge Nozzle 90 Amp PC 1300 1600 60 Amp PC 900 Gas Baffle 90 Amp PC 1300 1600 Gouging Heatshield Assembly Electrode 90 Amp PC 1300 1600 60 Amp PC 900 Gas Baffle 60 Amp PC 900 4 4 Installing Consumables Tests have shown that with proper use of the torch within rated operating conditions especially arc current and gas flow rate the torch consumable parts do not become loose if they are firmly installed Torch damage and overheating can be caused by loose parts A Tighten electrode and retaining shield cup fully at each consumable change or inspection B Checkconsumable tightness at beginning of each work period even if everything was working normally at the end of the previous period Note Ensure that the electrode torch body seat Torch and piston are clean and free of dust Assembly dirt Debris may prevent mating surfaces from having solid contact Electrode Torch Note Body Seat Firm tightening of the electrode by hand is sufficient the use of tools such as wrench es or pliers is not required or recommended Gas Baffle 90A Note Torch damage and overheating can be caused by loose parts Arc tracking indi Electrode cates loose parts Make sure retaining cup is tightened fully Parts damaged by arcing will cause destruction of torch and must be replaced Retaining Shield Cup Nozzle 22 Piston Gas Baffle 30 7
50. ts 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 61 SECTION 6 REPLACEMENT PARTS H Es NS AA D GE DB UNS NS FS SECTION 62 SECTION 6 REPLACEMENT PARTS ITEM PART NUMBER QUANTITY DESCRIPTION PISTON PT 38 Includes Items 3 4 7 14 17 26 0558006791 CABLE AY TORCH 25 FT 7 6m PT 38 Includes Items 9 13 14 15 16 22 CABLE AY TORCH 50 FT 15 2m PT 38 Includes Items 9 13 14 15 16 22 0558006800 0558006801 0558006795 ee HANDLE SET PT 38 Includes Items 11 12 13 GREASE SILICON DOW DC 111 STRAIN RELIEF HALF O RING 0 23
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