ESAB PT-31XL User manual

PT-31XL and PT-31XLPC
Plasma Arc Cutting Torches
0558 005 698 GB
Instruction Manual (EN)

66
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.
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.
CAUTION
USER RESPONSIBILITY

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TABLE OF CONTENTS
1.0 SafetyPrecautions.................................................................................. 69
2.0 Description..........................................................................................71
2.1 Description.....................................................................................71
2.2 Scope..........................................................................................71
2.3 Accessories.................................................................................... 72
2.4 TechnicalData(requiredbyCE) ................................................................ 73
3.0 Installation/Operation...............................................................................75
3.1 Torch/ConsumablesInspection ................................................................75
3.2 DisassemblyofTorch-RemovingConsumables..................................................76
3.3 InstallingConsumables-AssemblyofTorch .....................................................76
4.0 Maintenance........................................................................................ 77
4.1 Maintenance.................................................................................. 77
5.0 ReplacementParts.................................................................................. 79
5.1 General ....................................................................................... 79
5.2 Ordering...................................................................................... 79
5.3 Definitions .................................................................................... 79
5.4 PT-31XLandPT-31XLPCReplacementParts ..................................................... 79
Section / Title Page

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TABLE OF CONTENTS

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SECTION 1 SAFETY PRECAUTIONS
1.0 Safety Precautions
Users of ESAB welding and plasma cutting equipment have the ultimate responsibility for ensuring that anyone
who works on or near the equipment observes all the relevant safety precautions. Safety precautions must meet
the requirements that apply to this type of welding or plasma cutting equipment. The following recommendations
should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well acquainted with the operation of the welding or plasma
cutting equipment. Incorrect operation of the equipment may lead to hazardous situations which can result in
injury to the operator and damage to the equipment.
1. Anyone who uses welding or plasma cutting equipment must be familiar with:
- its operation
- location of emergency stops
- its function
- relevant safety precautions
- welding and / or plasma cutting
2. The operator must ensure that:
- no unauthorized person stationed within the working area of the equipment when it is started up.
- no one is unprotected when the arc is struck.
3. The workplace must:
- be suitable for the purpose
- be free from drafts
4. Personal safety equipment:
- Always wear recommended personal safety equipment, such as safety glasses, 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 extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance must not be carried out on the equipment during operation.

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SECTION 1 SAFETY PRECAUTIONS
WELDINGAND PLASMA CUTTINGCAN BE INJURIOUS TO YOURSELF AND
OTHERS. TAKE PRECAUTIONS WHEN WELDINGOR 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 your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
- Protect your eyes and body. Use the correct welding / plasma cutting screen and 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 INSTALLINGOR OPERATING.
PROTECT YOURSELF AND OTHERS!
WARNING

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SECTION 2 DESCRIPTION
Figure 2-1. Dimensional Data for the PT-31XL and PT-31XLPC Torches
(70 mm)
2 3/4"
(178 mm)
7"
2.1 General
The patented PT-31XL and PT-31XLPC are manual torches with a 75°head designed for use with several plasma arc
cutting packages using clean, dry air as the plasma gas. The service lines are 3.8, 7.6 or 15.2 meters (12 1/2, 25 or
50 feet) long and the torch is rated to operate up to 50 amperes at 100% duty cycle for cutting most metals.
2.2 Scope
This manual is intended to provide the operator with all the information required to assemble, operate, and repair
the PT-31XL and PT-31XLPC Plasma Arc Cutting Torches. For additional safety precautions, process instructions,
and system troubleshooting; refer to the appropriate instruction manual for your Plasma Arc Cutting Package.
WARNING
ELECTRIC SHOCK CAN KILL.PLASMA CUTTINGUSES HIGH VOLTAGE.
SKIN CONTACT WITH THE TORCH, THE POWER SOURCE, THE WORK
PIECE OR ANY GROUNDED OBJECT MUST BE AVOIDED WHENEVER
THE POWER SOURCE IS ON.
USINGTHE TORCH ON ANY POWER SOURCE NOT EQUIPPED WITH A
FLOW SWITCH SAFETY INTERLOCK MAY EXPOSE OPERATOR TO UN
EXPECTED HIGH VOLTAGE.
BEFORE BEGINNINGOPERATION OF THE TORCH, REFER TO THE SAFE
TY PRECAUTIONS AND OPERATINGINSTRUCTIONS.

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SECTION 2 DESCRIPTION
* Also see Tables 5-2 and 5-3.
Table 2-1 Contents of Spare Parts Kits:
* PT-31XL and PT-31XLPC Spare Parts Kits P/Ns
Description Part Number
P/N 0558003464
50A / HP-50
(Europe only)
P/N 0558003462
35A / Caddycut
(Europe only)
P/N 0558005392
40A / PC-650
(Europe only)
Heat Shield, long "CE“ 0558000509 1 1 1
30/40 amp High Performance Nozzle 0558000512 3
35/40 amp Extended Life Nozzle 0558000508 3
Nozzle, 50 amp 0558000513 3
Swirl Baffle 0558000506 1 1 1
Electrode 0558000507 3 2 2
O-ring 0558000514 1
Lubricant (0.25 ounce) 0558000443 1
Torch Guide Kit
Permits cutting accurate circles from 45mm (1.7") to 1050mm (41.3") in diameter with the PT-31XL or PT-31XLPC. The attach-
ment includes a head and radius bar assembly, center-point / adaptor, and dual swivel castor assembly. Cuts can be made
inside or outside the circle. The torch head is always held vertical during the cutting operation. The attachment is also handy
for maintaining a constant standoff in other types of cutting. ..............................................................................................0558003258
2.3 Accessories
A spare parts kit is recommended for maintaining the torch with minimum downtime. A spare parts kit is supplied with
each plasma cutting package.

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a. Process:
Manual torch used for plasma arc cutting
b. Method of guidance:
Manual
c. Voltage class:
M (113v peak to 400v peak)
Striking voltage: 8000 VAC
Stabilizing voltage: 200 VDC
d. Maximum rated current: 50 amps
Maximum current at 100% duty cycle: 50 amps
Type gas: Air 120 I/min. at 5.5 bar (254 cfh at 80 psi)
e. Max. and min. gas pressure at inlet: 4.8 to 5.9 bar (70 to 86 psi)
f. Type of cooling:
Air
g. Rating of auxiliary electrical control in torch:
N/A
h. Requirements for connection of torch:
Wrenches and screwdriver
i. Essential information about safe operation of torch:
Refer to all safety precautions in manual
j. Essential information about safe operation of the plasma cutting torch and the functioning of interlocking and safety
devices:
Meets requirements by means of pneumatic interlock safety system. The interlocking device deenergizes the torch
when parts, particularly protective cone, are removed to expose electrode connection. For the interlocking device
to function properly, the torch electrode must remain in the protective cone. Do not attempt to install the electrode
into the torch without first placing it in proper position (with the other parts) within the protective cone.
2.4 Technical Data (required by CE)
k. Type of plasma cutting power source that can form a safe system with the plasma cutting torch:
PCM-500i, PowerCut 650, HandyPlasma 550, HandyPlasma 380, HandyPlasma 250, HandyPlasma 50 and Caddycut.
I. Plasma cutting ability:
See Graphs 2-1a, 2-1b and 2-1c on following page:
SECTION 2 DESCRIPTION

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SECTION 2 DESCRIPTION
Steel Thickness (inches)
Speed (ipm)
Graph 2-1c 50 Amp Cutting Parameters
Graph 2-1a 35 Amp Cutting Parameters
Graph 2-1b 40 Amp Cutting Parameters
Steel Thickness (mm)
Speed mm/min)
Steel Thickness (inches)
Speed (ipm)
Steel Thickness (mm)
Speed (mm/min)
Steel Thickness (inches)
Speed (ipm)
Steel Thickness (mm)
Speed (mm/min)
0
500
1000
1500
2000
2500
03691215
35A
0
10
20
30
40
50
60
70
80
90
100
0 0.125 0.25 0.375 0.5 0.625
35A
0
500
1000
1500
2000
2500
3000
0 3 6 9 12 15 18
40A
0
20
40
60
80
100
120
0 0.125 0.25 0.375 0.5 0.625 0.75
()
40A
0
508
1016
1524
2032
2540
3048
3556
4064
0 3 6 9 12 15 18
50A
0
20
40
60
80
100
120
140
160
0 0.125 0.25 0.375 0.5 0.625 0.75
50A