ESAB PT-27 User manual

PT-27
PLASMA ARC CUTTING TORCH
INSTRUCTION MANUAL
This manual provides installation and operation instructions for the following PT-27 torches:
P/N 21620 - 25 ft (7.6 m), PT-27, w/PLUG Pilot Arc Connection
P/N 21621 - 50 ft (15.2 m), PT-27, w/PLUG Pilot Arc Connection
P/N 21661 - 25 ft (7.6 m), PT-27, w/RING Pilot Arc Connection
P/N 21662 - 50 ft (15.2 m), PT-27, w RING Pilot Arc Connection
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and
safe practices for arc welding 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.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
F-15-203-C
January, 2002

2
USER RESPONSIBILITY
Thisequipmentwillperforminconformitywiththedescriptionthereofcontainedinthismanualandaccompanyinglabels
and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipmentmustbecheckedperiodically. Malfunctioningequipmentshouldnotbeused. Partsthatarebroken,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 purchased.
Thisequipmentoranyofitspartsshouldnotbealteredwithoutthepriorwrittenapprovalofthemanufacturer. Theuser
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.
TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH
SECTION 1 DESCRIPTION ................................................................................................. 4
1.1 General ............................................................................................................. 4
1.2 Scope................................................................................................................ 4
1.3 Specifications.................................................................................................... 4
1.4 OptionalEquipment........................................................................................... 6
SECTION 2 ASSEMBLY AND OPERATION ....................................................................... 7
2.1 General ............................................................................................................. 7
2.2 Assembly .......................................................................................................... 7
2.3 Steel Heat Shield Guards.................................................................................. 8
SECTION 3 MAINTENANCE ............................................................................................... 9
3.1 General ............................................................................................................. 9
3.2 Inspection and Cleaning of Consumables ......................................................... 9
3.3 Seat Maintenance, Removal, and Replacement................................................ 10
3.4 Removing/Replacing Torch Head and Switch from Service Line....................... 11
3.5 Pilot Arc Lead Connection and Strip Insulation ................................................. 12
3.6 Switch and Pilot Arc Plugs ................................................................................ 13
SECTION 4 REPLACEMENT PARTS ................................................................................. 14
4.1 General ............................................................................................................. 14

3
1.1 GENERAL
ThepatentedPT-27(Figure1-2)isamanualtorchwith
a 75° 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-27
torchare25feet(7.6m)and50 feet (15.2 m). ThePT-
27 torch is rated to operate at a maximum of 80
amperes at 100% duty cycle.
1.2 SCOPE
Thismanualisintendedtoprovidetheoperatorwithall
the information required to assemble, operate, and
repair the PT-27 Plasma Arc Cutting Torch. For addi-
tional safety precautions, process instructions, and
system troubleshooting; refer to the appropriate in-
structionmanualforyourPlasmaArcCuttingPackage.
1.3 SPECIFICATIONS
Refer to Figure 1-1, Figure 1-2, and Figure 1-3 for
specifications.
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 employed can present a safety hazard.
Before beginning operation with the PT-27 torch, refer to the Safety
Precautions and operating instructions in the appropriate power source
instruction manual.
Using the torch on any unit not equipped with a mating safety interlock
circuit may expose operator to unexpected high voltage.
Torch Assembly
(Part No.)
Service Line
Length Weight Pilot Arc Connection Type
Current
Capacity
(100% duty)
21620 25 ft (7.6 m) 5.2 lbs (2.4 kg)
PLUG
80 A DCSP
21621 50 ft (15.2 m) 9.6 lbs (4.4 kg)
(for service with older consoles
equipped with pilot arc
receptacles)
21661 25 ft (7.6 m) 5.2 lbs (2.4 kg)
RING
21662 50 ft (15.2 m) 9.6 lbs (4.4 kg)
(for service with current consoles
equipped with pilot arc terminal
studs)
Figure 1-1. PT-27 Specifications
SECTION 1 DESCRIPTION

4
SECTION 1 DESCRIPTION
Figure 1-2. PT-27 Dimensions
7.3" (185 mm)
1" (25.4 mm)
1"
(25.4 mm)
75°
3" (76 mm)
Figure 1-3. PT-27 Cutting Performance
50 A
80 A
30 A

5
SECTION 1 DESCRIPTION
PLASMA GUIDE KIT - P/N 604607
consists of:
circle guide adapter/bushing
roller guide radius bar
pivot pin suction pivot
magnetic pivot operator's manual
PLAIN TYPE
P/N 35443
GOUGING NOZZLE
P/N 35442
STAND OFF GUIDE TYPE
P/N 21420
1.4 OPTIONAL EQUIPMENT (NOT SUPPLIED WITH TORCH)
A. SparePartsKits-Thesparepartskitslistedinfigure1-4arerecommendedformaintainingthePT-27torch
with minimum downtime.
Figure 1-4. Contents of PT-27 Spare Parts Kits
B. Steel Guards (for extending the life of the heat shield) - Refer to Figure 3-2 for installation and operation.
C. Gouging Nozzle
D. Plasma Guide Kit
DESCRIPTION
PART NUMBER
(50/70 A Kit - P/N 21623)
PART NUMBER
(80 A Kit - P/N 21624)
Heat Shield 21616 (QTY 2) 21616 (QTY 2)
Stand Off Guide 21420 (QTY 1) 21420 (QTY 1)
Nozzle, 50-70 A 33369 (QTY 4) --
Nozzle, 80 A -- 33418 (QTY 4)
Swirl Baffle 33367 (QTY 1) 33367 (QTY 1)
Electrode 33366XL (QTY 3) 33366XL (QTY 3)
Fuse, 600 Vdc, 15 A, Fast Acting 952137 (QTY 1) 952137 (QTY 1)

6
2.1 GENERAL
Make sure power switch on console is in the
"OFF" position and primary input power is
deenergized.
2.2 ASSEMBLY
Install PT-27 front end parts as shown in Figure 2-1.
The torch head contains a gas flow check valve that acts in conjunction with circuitry within the power
source. This system prevents the torch from being energized with high voltage if the torch switch is acci-
dentally closed when the shield is removed. ALWAYS REPLACE TORCH WITH THE PROPER TORCH MANU-
FACTURED BY ESAB SINCE IT ALONE CONTAINS ESAB'S PATENTED SAFETY INTERLOCK.
!WARNING
ELECTRODE
SWIRL BAFFLE
NOZZLE
SHIELD
THREAD THIS ASSEMBLY TO THE
TORCH BODY AND HAND TIGHTEN.
2
3IMPORTANT!
MAKE SHIELD VERY TIGHT!
PLACE THE NOZZLE, SWIRL
BAFFLE, AND ELECTRODE INTO
THE SHIELD
1
Figure 2-1. Assembly of PT-27 Torch Front End Parts
SECTION 2 ASSEMBLY AND OPERATION

7
2.3 STEEL HEAT SHIELD GUARDS
(Refer to Figure 2-2)
THIN GAUGE MATERIALS
CAN BE CUT WITH 1/16" (1.6 mm)
TORCH-TO-WORK DISTANCE
ADJUST TO 3/16" (4.8 mm) FOR
MATERIALS OVER 1/4" (6.4 mm)
THICK
ADJUST GUIDE BY TURNING
IN A CLOCKWISE DIRECTION
ONLY. THIS WILL PREVENT
ACCIDENTAL LOOSENING
OF SHIELD.
STEEL GUARD
STAND OFF GUIDE
P/N 21420 IF GUIDE IS TOO
TIGHT ON SHIELD,
OPEN SLOT WITH
SCREWDRIVER.
IF TOO LOOSE, CLOSE
SLOT WITH VISE OR
LARGE PLIERS.
1/16" (1.6 mm) TO 1/4" (6.4 mm)
TORCH-TO-WORK
GUIDE AGAINST
STRAIGHT EDGE
OR FREE-HAND
CUT
STEEL GUARD (P/N 35443)
PROTECTS SHIELD WHEN
CUTTING OR GOUGING.
Figure 2-2. Installation and Operation of Steel Heat Shield Guards
SECTION 2 ASSEMBLY AND OPERATION

8
3.1 GENERAL
Before any maintenance is attempted on this
torch, make sure the power switch on the console
is in the "OFF" position and the primary input is
deenergized.
3.2 INSPECTION AND CLEANING OF
CONSUMABLES
A. Disassemble the front end of the PT-27 as
follows:
1. Position torch head in a downward direction
(refer to Figure 2-1) and remove the shield.
The nozzle, swirl baffle, and electrode will
drop from the head and remain in the shield.
Remove these components and inspect for
wear.Thenozzleandelectrodewillgenerally
wearatthesamerate.Forbestperformance,
replace together.
2. Nozzle:Replaceiftheorificeisclogged,nicked,
or out-of-round.
3. Electrode:SeeFigure3-1forelectrodemain-
tenance.
4. Shield: The face of the shield will gradually
erode from the heat and molten metal spray.
Replace the shield if more than 1/8 inch (3.2
mm)haserodedfromtheface.RefertoFigure
3-1.
5. Swirl Baffle: This is a ceramic part and may
crack or chip if dropped. Always replace if
cracks or chips are present.
6. O-ring: Lubricate as per Figure 3-1. Replace
if cut or worn. Air leaking past this seal will
reduce cutting performance.
B. To replace the above front end components,
refer to Figure 2-1.
HEAT SHIELD
Figure 3-1. O-ring, Electrode, and Shield Maintenance
LUBRICANT (P/N 17672) CAN BE
APPLIED TO O-RING OR HEAT SHIELD.
THE HEAT SHIELD FACE WILL
GRADUALLY ERODE WITH USE.
SEE PARAGRAPH 3.2.A.4.
19/32"
(15.1 mm)
REPLACE ELECTRODE BEFORE
LENGTH BECOMES SHORTER THAN 19/
32 INCH -
(15.1 mm).
O-RING
ELECTRODE
SECTION 3 MAINTENANCE

9
3.3 SEAT MAINTENANCE, REMOVAL, AND REPLACEMENT
The seat should be inspected when the electrode is replaced. Replace the seat whenever surfaces in contact with
the electrode show signs of arcing. Keeping the shield tight will prevent arc damage to the seat.
NOTE
It is not necessary to remove the seat in order to inspect.
Do not attempt to use any tool other than the ESAB
Seat Tool, P/N 0558003027 to remove or replace the
seat. If the seat is distorted or damaged, the elec-
trode will not fit properly.
REMOVE SEAT FROM THE
TORCH HEAD USING THE
NEW ESAB SEAT
INSTALLTION TOOL.
LOOSEN IN A COUNTER-
CLOCKWISE DIRECTION.
Figure 3-2. Seat Maintenance, Removal, and Replacement
ELECTRODE SEAT
P/N 0558003032
SECTION 3 MAINTENANCE
REPLACE SEAT USING THENEW
ESAB SEAT INSTALLATION TOOL.
TIGHTEN IN A CLOCKWISE DIREC-
TION.

10
SECTION 3 MAINTENANCE
3.4 REMOVING / REPLACING TORCH HEAD AND SWITCH FROM SERVICE LINE
(Refer to Figure 3-3)
1
VINYL TAPE
FLEX SUPPORT
SHEATH
SERVICE LINE ASSEMBLY
PUSH THE FLEX SUPPORT BACK FROM HANDLE.
REMOVE TAPE HOLDING SHEATH AND PULL THE
SHEATH BACK.
REMOVE TAPE HOLDING WIRES.
SWITCH
SWITCH BAND
HANDLE
SPLICE CONNECTIONS
PILOT ARC
CONNECTION
BLACK WIRE LEAD
SNAP SWITCH BAND FROM HANDLE
AND RELEASE THE SWITCH. IF THE
SWITCH IS TO BE REPLACED, TAG
AND SNIP LEADS (2) AT THE SPLICED
CONNECTIONS. (REPLACEMENT
SWITCHES ARE SUPPLIED WITH
NEW SPLICES AND EXTRA LONG
LEADS)
2
1
REMOVE TAPE FROM INSULATOR ON
BLACK WIRE. SLIDE INSULATOR BACK
AND SEPARATE THE KNIFE CONNEC-
TION. TO RE-CONNECT, SEE FIGURE
3-4 A.
3
BLACK
WIRE
LEAD
INSULATOR
KNIFE CONNECTION
UNSCREW HANDLE FROM TORCH
HEAD. REMOVE TAPE SECURING
INSULATOR. REMOVE HEAD FROM
POWER CABLE. (USE TWO
WRENCHES TO PREVENT TWIST-
ING COPPER TUBE)
HANDLE
POWER CABLE
TORCH HEAD
REFER TO FIGURE 3-4 B, FOR
SECURING THE STRIP INSULATOR
IN PLACE.
4
Figure 3-3. Removal of Torch Head and Switch from Service Line
Replace Torch Head in Reverse Order

11
SECTION 3 MAINTENANCE
3.5 PILOT ARC LEAD CONNECTION AND STRIP INSULATION
(Refer to Figure 3-4)
SLIDE INSULATOR ONTO LEAD.
ATTACH KNIFE CONNECTIONS INSULATOR
CENTER INSULATOR
OVER CONNECTION TAPE LEADS TO INSULATOR.
1
2
3FOLD BACK LEADS BY
TURNING THE INSULA-
TOR END FOR END.
4
A. PILOT ARC LEAD CONNECTION DETAIL
POWER CABLE CONNECTION
STRIP INSULATOR
P/N 21510
PLACE THE INSULATOR
BETWEEN THE POWER
CABLE CONNECTION AND
THE BLACK PILOT ARC
LEAD. TAPE IN PLACE AS
ILLUSTRATED.
VINYL TAPE EACH END
BLACK WIRE LEAD
B. STRIP INSULATION DETAIL
Figure 3-4. Assembling Pilot Arc Connection and Strip Insulator
PILOT ARC
WIRE LEAD

12
SECTION 3 MAINTENANCE
3.6 SWITCH AND PILOT ARC PLUGS
(Refer to Figure 3-5)
Figure3-5. Switch and Pilot Arc Removal/Replacement
STRAIN RELIEF
TUBING - 18226
SWITCH PLUG
P/N 2062336
WHITE SWITCH LEADS (2)
FROM TORCH SWITCH
STRAIN RELIEF
TUBING - P/N 18226
STRIP INSULATION 1/4" (6.4 mm)
BRASS TERMINAL
BLACK PILOT ARC LEAD
BLUE JUMPER
(SEE BELOW)
DO NOT STRIP INSULATION
FROM THESE THREE WIRES
*PILOT ARC PLUG
P/N 21427
BLACK PILOT ARC LEAD
(ATTACH TO CHROME PLATED TERMINAL)
PILOT ARC CONNECTION
(REFER TO FIGURE 3-4 A)
BLUE JUMPER
STRAIN RELIEF TUBING
P/N 21622
PILOT ARC PLUG
P/N 21427
BRASS TERMINAL
CHROME PLATED TERMINAL
A. SWITCH PLUG
CHROME PLATED TERMINAL
B. PILOT ARC LEAD AND PLUG
(ON TORCH ASSEMBLIES 21620 AND 21621 ONLY)
Do not interchange the torch switch plug and the pilot arc plug. If it becomes
necessary to remove these plugs, make sure the switch plug (P/N 2062336) is
attached to the two white switch leads and the pilot arc plug (P/N 21427) is attached
to the black lead with the blue jumper wire.
Interchanging these plugs may create an unsafe condition that could cause electric
shock and burns.
*TORCH ASSEMBLIES 21661 AND 21662 USE A RING CONNEC-
TOR IN PLACE OF THIS PLUG (REFERE TO FIGURE 4-2)

13
Replacement parts may be ordered from your ESAB
distributor or from:
ESAB Welding & Cutting Products
Attn.: Customer Service Dept.
PO Box 100545, Ebenezer Road
Florence, SC, 29501-0545
Refer to the Communication Guide located on the last
pageofthismanualforalistofcustomerservicephone
numbers.
4.1 General
Replacement parts are illustrated on the following fig-
ures. When ordering replacement parts, order by part
number and part name, as listed. Always provide the
seriesorserialnumberoftheunit on whichthepartswill
be used. The serial number is stamped on the unit
nameplate.
SECTION 4 REPLACEMENT PARTS

14
SECTION 4 REPLACEMENT PARTS
FLEX SUPPORT - 21218
SPLICES (2) (SUPPLIED WITH
SWITCH)
SWITCH - 18224
SWITCH BAND - 33400
INSULATOR - 21510
(SUPPLIED WITH
HEAD)
SHIELD -
21616
NOZZLE 30 AMP - 33368
*50-70 AMP - 33369
80 AMP - 33418
GOUGING - 35442
SWIRL BAFFLE - 33367
ELECTRODE - 33366XL
O-RING - 85W51
(SUPPLIED WITH HEAD)
SHEATH
25 FT (7.6 m) - 18320
50 FT (15.2 m) - 19026
INSULATOR-
33415
(SUPPLIED
WITH HEAD)
KNIFE CONNECTIONS -
98W40 (2 SUPPLIED
WITH HEAD)
BOOT - 49N83
GAS & POWER
5/8 - 18 L.H.
HANDLE -
33399
PT-27 TORCH
PILOT ARC PLUG-21427 (SUPPLIED
ON TORCH ASSEMBLIES 21620 AND
21621 - SEE FIGURE 3-5 B)
STRAIN RELIEF
- 18226
POWER CABLE
25 FT (7.6 m) - 19995
50 FT (15.2 m) - 19996
SWITCH PLUG
- 2062336 (SEE
FIGURE 3-5 A)
75° HEAD - 21610
INCLUDES:
INSULATOR - 21510
INSULATOR - 33415
KNIFE CONNECT - 98W40
O-RING - 85W51
SEAT - 0558003032
FOR SERVICE WITH CONSOLES WITH
PILOT ARC RECEPTACLES
Figure 4-1. PT-27 Torch Assembly Replacement Parts
*REPLACEMENT TORCHES ARE
SUPPLIED WITH 50 AMP NOZ-
ZLES.
REPLACEABLE
SEAT - 0558003032
THESEATISREMOVEDANDREPLACEDUSINGTHE
ESAB SEAT TOOL. (REFER TO FIGURE 3-2)
ALL TORCH ASSEMBLIES AND REPLACEMENT
HEADSARESUPPLIEDWITHTHESEATINSTALLED.
New Improved
Seat Design
No. 0558003032
Seat Installation Tool
No. 0558003027

15
SECTION 4 REPLACEMENT PARTS
FLEX SUPPORT - 21218
SPLICES (2) (SUPPLIED WITH
SWITCH)
SWITCH - 18224
SWITCH BAND - 33400
INSULATOR - 21510
(SUPPLIED WITH
HEAD)
SHIELD -
21616
NOZZLE 30 AMP - 33368
*50-70 AMP - 33369
80 AMP - 33418
GOUGING - 35442
SWIRL BAFFLE - 33367
ELECTRODE - 33366XL
O-RING - 85W51
(SUPPLIED WITH HEAD)
SHEATH
25 FT (7.6 m) - 18320
50 FT (15.2 m) - 19026
INSULATOR-
33415
(SUPPLIED
WITH HEAD)
KNIFE CONNECTIONS -
98W40 (2 SUPPLIED
WITH HEAD)
BOOT - 49N83
GAS & POWER
5/8 - 18 L.H.
HANDLE -
33399
POWER CABLE
25 FT (7.6 m) - 19995
50 FT (15.2 m) - 19996
SWITCH PLUG
- 2062336 (SEE
FIGURE 3-5 A)
PILOT ARC RING TERMINAL
(SUPPLIED ON TORCH
ASSEMBLIES 21661 AND
21662)
STRAIN RELIEF
- 18226
75° HEAD - 21610
INCLUDES:
INSULATOR - 21510
INSULATOR - 33415
KNIFE CONNECT - 98W40
O-RING - 85W51
SEAT - 0558003032
FOR SERVICE WITH CONSOLES WITH
PILOT ARC TERMINAL STUDS
Figure 4-2. PT-27 Torch Assembly Replacement Parts
*REPLACEMENT TORCHES ARE
SUPPLIED WITH 50 AMP NOZ-
ZLES.
PT-27 TORCH
REPLACEABLE
SEAT - 0558003032
THE SEAT IS REMOVED AND REPLACED USING THE
ESAB SEAT TOOL. (REFER TO FIGURE 3-2)
ALLTORCHASSEMBLIESANDREPLACEMENTHEADS
ARE SUPPLIED WITH THE SEAT INSTALLED.
New Improved
Seat Design
No. 0558003032
Seat Installation Tool
No. 0558003027

F-15-203-C 1/02 Printed in U.S.A.
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123/ Fax: [phone]/ Web:http://www.esab.com
Hours: 7:30 AM to 5:00 PM EST
A. CUSTOMER SERVICE QUESTIONS:
Order Entry Product Availability Pricing Delivery
OrderChanges Saleable Goods Returns ShippingInformation
Eastern Distribution Center
Telephone: [phone] / Fax: [phone]
Central Distribution Center
Telephone: [phone] / Fax: [phone]
Western Distribution Center
Telephone: [phone]/ Fax: [phone]
B. ENGINEERING SERVICE: Telephone: [phone] / Fax : [phone]
WeldingEquipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations
C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]
Part Numbers TechnicalApplications Hours: 8:00 AM to 5:00 PM EST
PerformanceFeatures Technical Specifications EquipmentRecommendations
D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]
Hours: 7:30 AM to 4:00 PM EST
E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]
Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
F. WELDING EQUIPMENT TRAINING:
Telephone: [phone] / Fax: [phone]
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES