ESAB PT-31XL User manual

PT-31XL and PT-31XLPC

Plasma Arc Cutting Torches

0558 005 698 GB

Instruction Manual (EN)

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

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

TABLE OF CONTENTS

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.

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

SECTION 2 DESCRIPTION

Figure 2-1. Dimensional Data for the PT-31XL and PT-31XLPC Torches

(70 mm)

2 3/4"

(178 mm)

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.

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.

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

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)

500

1000

1500

2000

2500

03691215

35A

100

0 0.125 0.25 0.375 0.5 0.625

35A

500

1000

1500

2000

2500

3000

0 3 6 9 12 15 18

40A

100

120

0 0.125 0.25 0.375 0.5 0.625 0.75

()

40A

508

1016

1524

2032

2540

3048

3556

4064

0 3 6 9 12 15 18

50A

100

120

140

160

0 0.125 0.25 0.375 0.5 0.625 0.75

50A

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