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

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
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.

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 

          
        

 - 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


 

81
1. Periodically check the heat shield, electrode, nozzle, and swirl baffle. Replace if worn or damaged.
2. The power cable assembly should be inspected periodically. If there are any cuts through the protective sheath or if gas
leaks are noted, replace the damaged assembly.
3. Do not continue to use torch if the electrode erodes to a length shorter than 16mm (0.63 inch) as shown in Figure 3-1.
4. The gas flow check valve is part of the safety interlock and is permanently assembled in the torch head. The head must
be replaced if this valve malfunctions. The light spring force used to close the ball check can be felt by pushing on the
electrode when assembling the front end components.

The electrode seat comes assembled in the front end of the torch. When using the XT consumables, make
sure the plunger, P/N 0558000511 (20324), is installed under the seat. If missing, remove seat and install
plunger. Make sure seat is tightened firmly with a wrench but do NOT overtighten.
 
1. To disassemble the front end, hold the torch with the shield in an upright position as shown in Figure 3-2. This will prevent
the nozzle, electrode, and swirl baffle from falling free when the shield is removed.
2. If the torch is fixed and cannot be rotated upward, the alternate method of disassembly is to disassemble the electrode,
swirl baffle and nozzle as above being careful not to damage them by letting them fall.
 


For detailed installation and operation follow all torch instructions in the plasma system manual packed with your cutting
package. DO NOT install or attempt to operate this torch without following those instructions first.







 


 




          




82


16mm (0.63")
Heat Shield
Nozzle
Swirl Baffle
Electrode
*Plunger
Torch
Seat
Minimum
"XT" Electrode
Replace electrode when end
wears to 16mm (0.63") long.
Lubricant can be applied to O-ring or Heat Shield
 
*Note: Plunger, P/N 0558000511 (20324), used only with "XT" consumables.
 

Apply a small amount of lubricant - 0558000443 (17672), supplied in spare parts kit, to the heat shield or to
the o-ring as shown in Figure 3-1. Check o-ring for damage whenever the shield is removed. Replace if
necessary. O-ring part number is 0558000514 (950790).
1. To assemble with the torch front end facing up, assemble electrode, swirl baffle, tip and heat shield in that order as shown
in Figure 3-2. The swirl baffle is symmetrical and it can be positioned either way. Tighten heat shield snugly to hold the
parts in firm contact with each other and the torch head. Do not overtighten the heat shield.
2. If the torch is fixed and cannot be rotated upward, the alternate method of assembly is to assemble the electrode, swirl
baffle and nozzle as above and drop them into the heat shield. Then thread the heat shield upward into the torch body.

83
 
Lay the line out straight.
Pull flex support back and remove the tape from around the switch lead splices.
Free the switch by cutting the leads close to the splices.
Replacement switches have extra long leads to make up for any loss due to cutting.
Remove the rubber boot from the inlet end of the cable.
Remove the tape that secures the sheath at each end.
Pull the sheath off the cable (over small fitting at torch end).

The switch leads wrapped around the power cable are secured with tape several places along the cable.
8. The leads, switch cord plug, and strain relief can now be removed. See Figure 4-1, Step 3.






9. Reassemble in reverse order.
 
In some applications it is more convenient for the troch switch to be positioned 180 degrees from current configuration.
To reposition the switch on the torch, slide the flex support back, remove the tape securing the spliced leads to the power
cable, reposition switch, retape the leads, and pull the flex support back in place. See Figure 4-1.

A thin film of silicone lubricant P/N 0558000443 (17672), supplied with the spare parts kit, applied inside of
the flex support will ease the assembly of this part.
1.
2.
3.
4.
5.
6.
7.
 

              




The power cable and switch leads in the service line should be inspected periodically. If there are any cuts through the pro-
tective sheath or if gas leaks are noted, replace the damaged component.




84




Pull flex support back. Remove
tape holding splices.



Slide switch and band from handle.
Snip leads at splice to replace
switch.
Unscrew handle and
power cable from head

 

85
 
To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this equipment.
The use of non-ESAB parts may void your warranty.
Have the plasma power source model number and serial number handy if there are any questions concerning required
parts.
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.
 
 
The PT-31 torch is used on several different cutting packages which require different torch trigger connection configura-
tions as shown in Figure 5-1 and Table 5-1.
The PT-31 torch is adaptable to standard, heavy duty or XT consumables to meet specific cutting applications. See
Subsections 5.3.1, 5.3.2 and 5.3.3.
Individual consumable parts can be ordered as needed if spare parts kits do not fit current needs.
In most cases, it is recommended that you order the same consumable parts that were shipped with your plasma cutting
system.
1.
2.
3.
 - Used with currently produced product (HandyPlasma 380, HandyPlasma 550, PCM-500i, PowerCut
650, Caddycut and HandyPlasma-50), and older products dating back to 1990.
  - Available for support of pre-1990 year machines (PCM-32i,
PCM-50 and PCM-31) and consumables configurations. These are the original consumables designed for the torch.
 - Gives maximum cutting thickness and speed capability.
 - Gives extended nozzle life at the expense of top end cutting thickness and speed capability.
 

86
PLUNGER- 0558000511 (20324)
(used only with "XT" consumables)
SEAT - 0558000510 (19679)
(Included with Head)
750 HEAD - 0558000790 (20072)
(Includes O-ring and Seat)
POWER CABLE
HANDLE - 0558000796 (18208)
SWITCH BAND
0558000699 (18207)
SWITCH - 0558000818 (18224)
(2) SPLICES (Supplied with Switch)
FLEX SUPPORT - 0558000710 (18225)
SHEATH
5/8 X 18 L.H.
BOOT - 0558000793 (49N83)
PLUG - 2062336
0558000583 (19675) - 4.6m (15')
0558000791 (18320) - 7.6m (25')
0558000792 (19026) - 15.2m (50')
0558005148 (19672) - 4.6m (15')
0558000795 (18221) - 7.6m (25')
0558005146 (19028) - 15.2m (50')
O-ring - 0558000514 (950790)
(included with head)
 


STRAIN RELIEF
0558000794 (18226)


87
 


NOZZLE 30-40 AMP - 0558000512 (20860)
PLUNGER - 0558000511 (20324)
O-RING - 0558000514 (950790)
BAFFLE SWIRL - 0558000506 (20463)
ELECTRODE - 0558000507 (20862)
HEAT SHIELD - 20282
BODY ASSEMBLY 75° - 0558000790 (20072)
BAND SWITCH - 0558000699 (18207)
SWITCH - 0558000818 (18224)
FLEX SUPPORT - 0558000710 (18225)
HANDLE - 0558000796 (18208)
SPLICE - 0558004020 (674520)
POWER CABLE 0558003323
3/8-24UNF-2A


88
 
 
  

1
20084 - 4.6m (15') lines
20080 - 7.6m (25') lines
20082 - 15.2m (50') lines
Seat and o-ring. Consumables and plunger not
included.
21985 - 7.6m (25') lines
30A / 40A high performance "XT" consumables,
standard heat shield P/N 20282, seat, o-ring and
plunger.
PCM 500i, Handy
Plasma-550 (Asia)
20558005393
7.6m (25') lines
30A / 40A high performance "XT" consumables,
standard heat shield P/N 20282, seat, o-ring and
plunger.
Powercut-650
3
0558004482
4.6m (15') lines
30A / 40A high performance "XT" consumables,
standard heat shield P/N 20282, seat, o-ring and
plunger.
 When ordering the PT-31XL torch
assembly for use on the HandyPlasma-380,
Female Torch Connector P/N 0558004947 shown
below  also be ordered.
HandyPlasma-380
0558001466
4.6m (15') lines
30A / 40A high performance "XT" consumables,
long heat shield P/N 0558000509 (36284), seat,
o-ring and plunger.
CaddyCut
(Europe)
0558004498
7.6m (25') lines
30A / 40A high performance "XT"
consumables,standard heat shield P/N 20282,
seat, o-ring and plunger.
HandyPlasma-550
(North America)
0558003467
7.6m (25') lines
30A / 40A high performance "XT" consumables,
long heat shield P/N 0558000509 (36284), seat,
o-ring and plunger.
HandyPlasma-50
(Europe)


89

 
 
These consumable parts will give good cut quality on light to medium thick metals when used within the recom-
mended cutting range of the plasma power source. The reversible electrode design gives extra electrode life and
enables the safety interlock for operator safety.
P/N 18844
Ceramic
(White)
1-21/64"
(33.7mm)
P/N 18820
50 Amp
(Original Style )
P/N 18785
"White”
4 Holes
1-1/8"
(28.6mm)
0.155"
(3.9mm)
5 Stakes
BAFFLE
NOZZLE
(TIP)
HEAT SHIELD

4 Stakes
P/N 18205
ELECTRODE
P/N 18866
30 Amp
P/N 19667
15 Amp
P/N 20282 Standard
(Lite Blue)









90
 
 
The larger electrode diameter increases the electrode mass to provide improved cooling and reduced wear on
medium to heavy cutting applications when correctly used within the recommended cutting range of the plasma
power source. The reversible electrode design gives extra electrode life and enables the safety interlock for op-
erator safety.

6 Stakes
No
Cross
Hatch
1-1/32"
(26.2mm)
0.200"
(5.1mm)
P/N 19683
P/N 0558000506 (20463)
"Pink”
6 Holes
P/N 19682
30 Amp
P/N 20079
50 Amp
P/N 20282 Standard
(Lite Blue)

BAFFLE
NOZZLE
(TIP)
HEAT SHIELD
ELECTRODE







