ESAB PT-38 User manual

GB
0463 334 001 GB 20120618
PT-38
Instruction manual

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TOCe
Rights reserved to alter specifications without notice.
1 SAFETY 4...........................................................
2 INTRODUCTION 5...................................................
3 TECHNICAL DATA 6.................................................
4 OPERATION 6.......................................................
4.1 Cutting with the PT-38 6.....................................................
4.2 Stand-off guide 8............................................................
4.3 Drag cutting 40 Amp 8.......................................................
4.4 Gouging with the PT-38 9....................................................
4.5 Installing consumables 9.....................................................
4.6 Cut data 10..................................................................
4.7 Operation of power source 10..................................................
5 MAINTENANCE 10....................................................
6 ORDERING NUMBER 10...............................................
WIRE DIMENSION 12....................................................
ORDER NUMBER 15.....................................................
WEAR PARTS 16........................................................
ACCESSORIES 18.......................................................

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1 SAFETY
Users of ESAB 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 equipment. The following recommendations should be ob
served 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 equip
ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in
jury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
Sits operation
Slocation of emergency stops
Sits function
Srelevant safety precautions
Swelding and cutting
2. The operator must ensure that:
Sno unauthorised person is stationed within the working area of the equipment when it is
started up.
Sno-one is unprotected when the arc is struck
3. The workplace must:
Sbe suitable for the purpose
Sbe free from drafts
4. Personal safety equipment
SAlways wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
SDo not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
SMake sure the return cable is connected securely.
SWork on high voltage equipment may only be carried out by a qualified electrician.
SAppropriate fire extinquishing equipment must be clearly marked and close at hand.
SLubrication and maintenance must not be carried out on the equipment during operation.
WARNING
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.
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
SInstall and earth the unit in accordance with applicable standards.
SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
SInsulate yourself from earth and the workpiece.
SEnsure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
SKeep your head out of the fumes.
SUse 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.
SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
SProtect bystanders with suitable screens or curtains.
FIRE HAZARD
SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
SProtect your ears. Use earmuffs or other hearing protection.
SWarn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for plasma cutting.
ESAB can provide you with all necessary welding protection and accessories.
2 INTRODUCTION
The PT-38 is a manual torch with a 90° head designed for use with several plasma
arc cutting packages using clean, dry air as the plasma gas. The service line lengths
available with the PT-38 torch are 7.6 m and 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.
ESAB's accessories for the product can be found on page 18.
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SExcellent cutting capacity - Cuts 38 mm; severs 45 mm
SUses work air or cylinder air for superior versatility
SPilot arc starting - even starts through paint
SChoice of 7.6 m. or 15.2 m line length
3 TECHNICAL DATA
PT-38
Cuts 38 mm; severs 45 mm
Current capacity 90 amps at 100% duty cycle
Nominal flow rate 189 l/min at 5.5 bar
Length of service lines 7.6 m or 15.2 m
Dimensions
Overall length
Length of head
208 mm
76 mm
Duty cycle
The duty cycle refers to the time as a percentage of a ten-minute period that you can weld or cut at
a certain load without overloading. The duty cycle is valid for 40°C.
Torches and torch body assemblies are supplied without gas baffle, electrode,
nozzle, and retaining/shield cup. Order complete spare parts kits or individual
components see spare parts list.
4 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
4.1 Cutting with the PT-38
Use the following procedures to cut with the PT-38 torch.
1. Make sure that the wall power supply switch is on. Turn on the Power to the
cutting power source console.
2. Set Pressure Regulator to 5.5 bar.
3. Powercut 1600: Hold the torch nozzle approximately 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 standoff guide is being used, the distance between
nozzle and work piece will be approximately 6.4 mm.
Powercut 900: Hold the torch nozzle approximately 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 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 arc should start. The
main arc should immediately follow, allowing the cut to begin. If using the trigger
LOCK mode, torch switch may be released after establishing the cutting arc.
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6. After starting the cut, the torch should be held at a 5 - 15° forward angle. This
angle is especially useful in helping to create a "drop" cut. When not using the
standoff guide, the nozzle should be held approximately, PC-1300/1600: 3.2 mm
- 6.4 mm, PC-900: 3.2 mm - 4.8 mm from the work.
PC 900, PC 1600 PC 1600 PC 900
Proper torch angle Stand-off vs. Power output
WARNING
Arc rays can burn eyes and skin; noise can damage hearing.
-Wear a welding helmet with no. 6 or 7 lens shade.
-Wear eye, ear, and body protection.
Piercing and cutting techniques using the PT-38.
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4.2 Stand-off guide
A: Guide against straight edge or free-hand cut.
Use to maintain a constant stand-off distance. Attach optional stand-off guide
assembly by removing the retaining/shield cup (B) and installing the stand-off guide
assembly (C).
Installation and operation of stand-off guide
4.3 Drag cutting 40 Amp
For cutting thin material, under 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.
A: Gas baffle (30-70 Amp) C: 40 Amp Drag nozzle
B: Electrode D: Retaining/ shield cup.
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4.4 Gouging with the PT-38
Powercut 1600: Insert high current gas baffle, electrode, 90 amp gouge nozzle, and
90 amp gouging heatshield assembly. Operating parameters are 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.
Powercut 900: Insert standard gas baffle, electrode, 60 amp gouge nozzle, and 60
amp gouging heatshield assembly. Operating parameters are 4.1 - 5.5 bar and
40 - 60 amps. Air pressure and current can be varied within these ranges to produce
desired metal removal rate and groove profile.
A: Gas baffle 90 Amp- PC 1600 D: Gouging heatshield assembly
90 Amp- PC 1600, 60 Amp- PC 900
B: Electrode E: Gas baffle 60 Amp- PC 900.
C: Gouge nozzle 90 Amp- PC 1600,
60 Amp- PC 900
4.5 Installing consumables
Tests have shown that with proper use of the torch, within the rated operating
conditions (especially arc current and gas flow rate), consumable parts do not
become loose if they are firmly installed. Torch damage and overheating can be
caused by loose parts.
1. Tighten the electrode and retaining/shield cup fully at each consumable change
or inspection.
2. Check consumable 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 and piston are clean and free of
dust or dirt. Debris may prevent mating surfaces from having solid contact.
Note: Firm tightening of the electrode by hand is sufficient; the use of tools such as
wrenches or pliers is not required or recommended.
Note: Torch damage and overheating can be caused by loose parts. Arc tracking
indicates loose parts. Make sure the retaining cup is tightened fully. Parts damaged
by arcing will cause greater damage to the torch and must be replaced.
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A: Nozzle E: Piston
B: Retaining/ shield cup F: Electrode/ torch body seat
C: Electrode G: Torch body assembly
D: Gas baffle (90A) H: Gas baffle (30-70A).
Information regarding wear parts, see page 16.
4.6 Cut data
Information regarding cut data, see “wire dimensions” on page 12.
4.7 Operation of power source
For operation of the power source, refer to Powercut 900, Powercut 1600 power
source instruction manual.
5 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
IMPORTANT! Switch off the power source when cleaning the torch.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee period.
6 ORDERING NUMBER
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
PT-38 is designed and tested in accordance with the international and European stan
dards EN 60974-7, . It is the obligation of the service unit which has carried out the
service or repair work to make sure that the product still conforms to the said stan
dard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
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