ESAB PT-31XL User manual

PT-31XL and PT-31XLPC
Plasma Arc Cutting Torches



72
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.




             








73

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.0 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.1 Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.2 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.3 Technical Data (required by CE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.0 Installation / Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.1 Torch / Consumables Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.2 Disassembly of Torch - Removing Consumables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
3.3 Installing Consumables - Assembly of Torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.0 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.2 Repositioning Torch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
5.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.2 Ordering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
5.3 PT-31XL and PT-31XLPC Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
         

74


75
 
 
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 .
- Appropriate fire extinquishing equipment must be clearly marked and close at hand.
- Lubrication and maintenance  be carried out on the equipment during operation.

76
 

          
        

 - 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.
 - 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.
 - 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.

- Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
 - Excessive noise can damage hearing.
- Protect your ears. Use earmuffs or other hearing protection.
- Warn bystanders of the risk.
 - Call for expert assistance in the event of malfunction.




77
 
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 4.5, 7.6 or 15.2 meters (15, 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 1/4"
(57mm)

5 1/4"
(133mm)


5 1/4"
(133mm)
2 7/8"
(73mm)
PT-31XLPC, 7.6m ................................................................................................................................................................................... 0558005393

78

A spare parts kit is recommended for maintaining the torch with minimum downtime. A spare parts kit is supplied with each
plasma cutting package.


35/40A XT Spare Parts Kit (Extended Life) ................................................................................................................................................ 21980

30/40A Standard Spare Parts Kit (High Performance) .............................................................................................................0558003301

The high performance kit (0558003301) is the preferred kit and is included with all of the above
referenced plasma cutting systems.
 



 
    
      
   
Heat Shield 20282 1 1
Heat Shield, Long "CE" 0558000509 (36284) 1 1 1
30/40 amp High
Performance Nozzle 0558000512 (20860) 3 3
35/40 amp Extended
Life Nozzle 0558000508 (21008) 3 3
Nozzle, 50 amp 0558000513 (20861) 3
Swirl Baffle 0558000506 (20463) 1 1 1 1 1
Electrode 0558000507 (20862) 2 2 3 2 2
O-ring 0558000514 (950790) 1
Lubricant (0.25 ounce) 0558000443 (17672) 1 1 1

This valuable troubleshooting tool allows measurement of
the actual plasma gas flow through the torch 0558000739

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" (44.5mm-1060mm) Radius ..............................................................................................................................................................................0558003258
Basic, 1-3/4” - 28” (44.5mm-710mm) Radius ....................................................................................................................................................................................0558002675

79
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: 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.

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 50 and Caddycut.
I. Plasma cutting ability:
See Graphs 2-1a and 2-1b on following page:
 

80

80
60
40
20
10
00

.750
160
140
120
100

2032
1524
1016
508
254
003 6 10 13 16

19
4064
3556
3048
2540
 

100
80
60
40
20
0
0.125 .250 .375 .500 .625



.125 .250 .375 .500 .625


 