PT-26 Plasma Arc Cutting Torch Instruction Manual F15-345-H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. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompa- ying 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. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS!TABLE OF CONTENTS Section / Title Page 1.0 Safety Precautions .......++.++ cbs I 11 Safety - English .. 1.2. Safety Spanish . 13 Safety French 20. Description . 3.0 Installation. .........+ ‘ — 3.1 Torch to Power Source Connections ... 3.2. Retrofits to Older Power Sources 3.3. GasSelection 34 Gas Connections . 3.5. Assembling Front End Parts 3.6 Stand-off Guide .. ivats 37 Loose Consumables ......s+erseree4 3.8 Installation of Swirl Baffle . 40 Operation ....seseverseeerere 41 Operating Parameters. 42 Cut Data... 5.0 Maintenance. 5.1 Disassembly of Front End 52 General ......+ 5.3 Dirt or Contamination .... : 5.4 Removal and Replacement of Torch Head 5.5 Removal and Replacement of Torch Cables . 5.6 Replacement of Flex Support, Switch Band or Handle . 5.7 Replacement of Torch Switch, oa 5.8 Measuring Torch Gas Flows ... 60 Replacement Parts 61 General 6.2. Ordering .TABLE OF CONTENTSSECTION 1 1.0 Safety Precautions WARNING: These Safety Precautions are for your protection. They summarize pre- cautionaryinformation from thereferences listed in Additional Safety Information sec- tion. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels,etc.Failuretoobserve Safety Precautions can result in injury or death PROTECT YOURSELF AND OTHERS -- a Some welding, cutting, and gouging processes are noisy and require ear aZ protection. Thearc, likethesun,emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore: 1. Always wear safety glasses with side shields in any workarea,even if welding helmets, face shields,and goggles are also required. 2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operat ing or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electricarc or hot metal. 3. Wear flameproof gauntlet type gloves, heavy long- sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks orhot metal. A flameproof apron may also be desirable as protec- tion against radiated heat and sparks. 4, Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, andopen pocketseliminatedfrom the front of clothing. 5, Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains. 6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses. SAFETY PRECAUTIONS 1.1 Safety-English Q= FIRES AND EXPLOSIONS -- Heat from @, flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protec- tivenon-flammablecovering, Combustiblematerials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc. 2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hid- den smoldering fire or fires on the loorbelow.Make certain that such openings are protected from hot sparks and metal 3. Donotweld, cutor perform otherhotworkuntilthe workpiecehas been completely cleanedsothatthere are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode. 4, Have fireextinguishing equipmenthandyforinstant use, such as garden hose, water pail, sand bucket, or portable freextinguisher. Besure youare trained inits use. 5, Do not use equipment beyond its ratings. For ex- ample, overloaded welding cable can overheatand create a fire hazard. 6, After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal which could causea later fire. Use fire watchers when necessary. 7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes’, available from the National Fire Protec- tion Association, Batterymarch Park, Quincy, MA 022689. ELECTRICAL SHOCK ~ Contact with © live electrical parts and ground can cause severe injury or death.DO NOT use ACwelding currentin dampareas, if movementis confined, or if there is danger of falling.SECTION 1 1. Be sure the power source frame (chassis) is con- ected to the ground system of the input power. 2. Connect the workpiece to a good electrical ground. 3. Connect the work cable to the workpiece. A poor ‘or missing connection can expose you or others toa fatal shock. 4, Use well-maintained equipment. Replace worn or damaged cables. 5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source. 6. Make sure that all parts of your body are insulated from work and from ground. 7, Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand ‘on dry boards or an insulating platform and wear rubber soled shoes. 8, Put on dry, hole-free gloves before turning on the power. 9. Tum off the power before removing your gloves. 10. Refer to ANSI/ASC Standard 249.1 (listed on next page) for specific grounding recommenda- tions. Do not mistake the work lead for a ground cable. @ _TECTAIC AND MaGNeTiC FieLDs — May be dangerous. Electric cur- rent flowing through any conduc- =i tor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore: 1. Welders having pacemakers should consult their Physician before welding. EMF may interfere with some pacemakers. 2. ExposuretoEMF mayhaveotherhealtheffects which are unknown, SAFETY PRECAUTIONS 3. Welders should use the following procedures to minimize exposure to EMF: A. Route the electrode and work cables together. Secure them with tape when possible, B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and Work cables. Route cables on the same side of your body. D. Connectthe workcabletothe workpieceasclose as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible. FUMES AND GASES -- Fumes and gases, cancausediscomfortorharm, particularly in confined spaces. Do notbreathe fumes and gases. Shield- ing gases can cause asphyxiation. 1. Always provideadequate ventilationintheworkarea bynaturalormechanical means. Donotweld,cut,or gouge on materials such as galvanized steel, stain- less steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials. 2. Donotoperateneardegreasingandsprayingopera- tions.The heat or arcrays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases. 3. IF you develop momentary eye, nose, or throat ir- ritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Donot continue to operate if physical discom- fort persists. 4, RefertoANSV/ASC Standard 749.1 (see listing below) for specific ventilation recommendations.SECTION1 5. WARNING: Thisproduct,whenusedforwelding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code §25249.5 et seq.) CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and vio- F; lently release gas. Sudden rupture of cylinder, valve, or relief devicecan injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not Use adaptors, Maintain hoses and fittings in good condition. Follow manufacturer's operating instruc- tions for mounting regulator to a compressed gas olinder. 2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercar- riages, benches, walls, post, or racks. Never secure oylinders to work tables or fixtures where they may become part of an electrical circuit. 3. When not in use, keep cylinder valves closed, Have valve protection cap in place if regulator isnot con- nected.Secureand movecylindersbyusing suitable hand trucks. Avoid rough handling of cylinders. 4. Locatecylindersaway from heat, sparks,and flames. Never strike an arc on a cylinder. 5. Foradditionalinformation, refertoCGA Standard P-1, Precautions forSafe Handling of Compressed Gases, in Cylinders’, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202, A EQUIPMENT MAINTENANCE — Faulty or improperly maintained equipment can cause injury or death. Therefore: SAFETY PRECAUTIONS 1. Always have qualified personnel performtheinstal- lation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work. 2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power. 3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do ot operate any equipment in faulty condition. 4. Do not abuse any equipment or accessories, Keep equipmentaway fromheatsources suchasfurnaces, wet conditions such as water puddles, oll or grease, corrosive atmospheres and inclement weather. 5. Keepallsafetydevicesand cabinet coversin position and in good repair. 6. Use equipment only for its intended purpose. Do not modify it in any manner. ADDITIONALSAFETY INFORMATION--For more information on safe practices for electric arc welding and cutting equip- ment, ask your supplier for a copy of "Precautions and Safe Practices for Arc Welding, Cutting and Gouging’, Form 52-529, The following publications, which are available from the American Welding Society, 5S0N.W. LeJuene Road, Miami, FL 33126, are recommended to you: 1, ANSV/ASC 249.1 - "Safety in Welding and Cutting” 2. AWSC5.1- "Recommended Practices for Plasma Arc Welding* 3. AWS C5.2-"Recommended Practices for Plasma Arc Cutting” 4. AWS C5.3-"Recommended Practices for Air Carbon ‘Arc Gouging and Cutting"SECTION 1 5. AWS C5.5 - "Recommended Practices for Gas Tung- sten Arc Welding” 6. AWS C5.6- "Recommended Practices for Gas Metal ‘Arc Welding" 7. AWS SP - "Safe Practices" - Reprint, Welding Hand- book. 8, ANSV/AWS F4.1, "Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances" MEANING OF SYMBOLS - As used A throughout this manual: Means Atten- tion! Be Alert! Your safety is involved. Meansimmediatehazards which, if not avoided, will result in im- AXBENEEN mediate, serious personal injury or loss of life. Means potential hazards which AMMEN «could result in personal injury or loss of life. Meanshazards which couldresult AXEMGIE in minor personal injury. SAFETY PRECAUTIONSSECTION 1 1.2 Safety-Spanish ADVERTENCIA: Estas Precauciones de Se- A {guridad son para su proteccién. Ellas hacen resumen de informacién proveniente de las referencias listadas en la seccién "Informacion Adi- clonal Sobre La Seguridad Antes de hacer cualquier instalacién 0 procedimiento de operacién, asegtirese de leery seguirlas precauciones de seguridad lstadas a continuaci6n asi como también todo manual, hoja de datos de seguridad del material, calcomanias, etc. Elno observar las Precauciones de Seguridad puede resultar en dafio ala persona o muerte, PROTEJASE USTED Y A LOS DEMAS- Algunos procesosdesoldadura,corte aZ yranurado son ruidosos y requiren proteccién para los ofdos. El arco, como el sol, emite rayos ultravioleta (Uv)yotras radiaciones que pueden dafiarla piel y los ojos. El metal caliente causa quemaduras. EL entrenamiento en el uso propio de los equipos y sus procesos es esencial para prevenir accidentes, Porlo tan 1. Utilice gafasde seguridad con protecciénaloslados siempre que esté en el rea de trabajo, atin cuando esté usando careta de soldar, protector para su cara Uotto tipo de proteccién. 2. Use una careta que tenga el filtro correcto y lente ara proteger sus ojos, cara, cuello, y ofdos de las chispas y rayos del arco cuando se esté operando y observando las operaciones. Alerte a todas las per- sonas cercanas de no mirarel arco yno exponerse allos rayos del arco eléctrico 0 el metal fundido. 3. Use guantes de cuero a prueba de fuego, camisa esada de mangas largas, pantalén de ruedo liso, Zapatoaltoaltobillo,y careta de soldar con capucha Para el pelo, para proteger el cuerpo de los rayos y chispas calientes provenientes del metal fundido. En ocaciones un delantal a prueba de fuego es Necesario para protegerse del calor radiado y las chispas. 4. Chispasyparticulasdemetal caliente puede alojarse en las mangas enrolladas de la camisa, el ruedo del Pantalén o los bolsillos, Mangas y cuellos deberén Mantenerse abotonados, bolsillos al frente de la ‘camisa deberan ser cerrados 0 eliminados. 5. Proteja a otras personas de los rayos del arco y chis- ascalientes con una cortina adecuadano-flamable como divisién. 6. Use careta protectora ademds de sus gafas de segu- Tidad cuando esté removiendo escoria o puliendo. SEGURIDAD Laescoria puede estar caliente y desprenderse con velocidad. Personas cercanas deberdn usar gafas de seguridad y careta protectora. G= FUEGO Y EXPLOSIONES ~ El calor de lasflamas yel arco pueden ocacionar fuegos. Escoria caliente y las chispas pueden causar fuegos y explosiones. Por lo tanto: 1, Remueva todo material combustible lejos del érea de trabajo o cubra los materiales con una cobija a prueba defuego. Materiales combustibles incluyen madera, ropa, liquidos y gases flamables, solventes, pinturas, papel, etc. 2. Chispasyparticulasdemetal puedenintroducirseen las grietas y agujeros de pisos y paredes causando fuegos escondidos en otros niveles o espacios. Asegdresedequetodagrietayagujeroesté cubierto para proteger lugares adyacentes contra fuegos, 3. No corte, suelde o haga cualquier otro trabajo relacionado hasta que la pieza de trabajo esté to- talmente limpia y libre de substancias que puedan producir gases inflamables o vapores téxicos. No trabaje dentro o fuera de contenedores o tanques cerrados. Estos pueden explotar sicontienen vapores inflamables. 4, Tenga siempre a la mano equipo extintor de fuego para uso instanténeo, como por ejemplo una manguera con agua, cubeta con agua, cubeta con arena, oextintor portétil, Aseguirese que usted esta entrenado para su uso. 5. Nouseelequipofueradesu rangodeoperacion.Por ejemplo, el calor causado por cable sobrecarga en los cables de soldar pueden ocasionar un fuego. 6. Después determirarlaoperacién delequipo, inspec- cione el drea de trabajo para cerciorarse de que las chispas 0 metal caliente ocasionen un fuego mas tarde. Tenga personal asignado para vigilar si es necesario. 7. Para informacién adicional , haga referencia a la publicacién NFPA Standard 518, ‘Fire Prevention in Use of Cutting and Welding Processes’, disponible a través de la National Fite Protection Association, Batterymarch Park, Quincy, MA 02269. @ CHOQUE ELECTRICO ~- El contacto conlasparteseléctricas energizadas y tierra puede causar dafio severo 0 muerte, NO use soldadura de cor entealterna (AC) en dreas htimedas, de movimiento confinado en lugares estrechos 0 si hay posibilidad de caer al suelo.SECTION 1 1. Aseguirese de que el chasis de la fuente de poder esté conectado a tierra através del sistema de electricidad primario. 2. Conecte la pieza de trabajo a un buen sistema de tierra fisica. 3. Conecte el cable de retorno a la pieza de trabajo, Cables y conductores expuestos 0 con malas conexiones pueden exponer al operador u otras personas a un choque eléctrico fatal. |. Use el equipo solamente siesta en buenas condi- ciones, Reemplaze cables rotos, dafiados 0 con conductores expuestos. 5. Mantengatodo seco, incluyendo suropa,elareade trabajo, los cables, antorchas, pinza del electrodo, yla fuente de poder. Asegurese que todas las partes de su cuerpoestén insuladas de ambos, la pieza de trabajo y tierra. 7. Nose paredirectamente sobremetalotierramien- tas trabaja en lugares estrechoso éreas humedas; trabaje sobre un pedazo de madera seco o una plataforma insulada y use zapatos con suela de goma 8. Useguantes secosy sinagujerosantesdeenergizar el equipo. 9. Apage el equipo antes de quitarse sus guantes. . Use como referencia la publicacién ANSI/ASC Standard 249.1 (istado.en la préxima pagina) para recomendacionesespecificasde comoconectarel ‘equipo a tierra. No confunda el cable de soldar a la pieza de trabajo con el cable a tierra, CAMPOS ELECTRICOS Y MAGNETI- COS - Son peligrosos, La corriente eléctrica fluye através de cualquier =e conductor causando a nivel local Campos Eléctricos y Magnéticos (EMF). Lascorrienteseneléreadecorteysoldadura, crean EMF alrededor de los cables de soldar y las maquinas. Por lo tanto: 1. Soldadores u Operadores que use marca-pasos para el corazén deberén consultar a su médico antes de soldar. El Campo Electromagnético (EMF) puede interferir con algunos marca-pasos. 2.Exponerseacamposelectromagnéticos (EMF) puede causar otros efectos de salud atin desconocidos. 10 SEGURIDAD 3.Los soldadores deberén usar los siguientes proced- imientos para minimizar exponerse al EMF: ‘A. Mantenga el electrodo y el cable a la pieza de trabajo juntos, hasta llegar a la pieza que usted quiere soldar. Aseguirelos uno junto al otro con cinta adhesiva cuando sea posible. B. Nunca envuelva los cables de soldar alrededor desu cuerpo. C. Nunca ubique su cuerpo entre la antorcha y el cable, a la pieza de trabajo. Mantega los cables a un sélo lado de su cuerpo. D. Conecte el cable de trabajo a la pieza de trabajo Jo mas cercano posible al drea de la soldadura. E, Mantengalafuentedepoderyloscablesdesoldar lo mas lejos posible de su cuerpo. HUMO_Y GASES -- EI humo y los gases, pueden causar malestar 0 dafio, particularmente en espacios sin ventilacién. No inhale el humo o gases. El gas de proteccién puede causar falta de oxigeno. Por lo tanto: 1. Siempre provea ventilacién adecuada en el drea de trabajo por medio natural omecénico. No solde, corte,o ranure materiales con hierro galvanizado, acero inoxidable, cobre,zinc, plomo, berilio,o cad- mio a menos que provea ventilacién mecénica Positiva . No respire los gases producidos por estos materiales. 2. No opere cerca de lugares donde se aplique sub- stancias quimicas en aerosol. El calor de los rayos del arco pueden reaccionar con los vapores de hidrocarburo clorinado para formarun fosfégeno, © gastéxico, y otros irritant es. 3, Si momenténeamente desarrolla inrritacién de oj0s,nariz ogarganta mientras est 4 operando, es indicacién de que la ventilacién no es apropiada. Pare de trabajar y tome las medidas necesarias para mejorar la ventilacion enel area de trabajo. No contintie operando si el malestar fisico per- siste. Hagareferenciaa la publicaci6n ANSV/ASC Standard 749.1 (Vea la lista a continuacién) para recomen- daciones especificas en la ventilacion.SECTION 1 5. ADVERTENCIA~ Este producto cuando se uti- liza para soldaduras 0 cortes, produce humos 0 gases, los cuales contienen quimicos conocidos porelEstadode Cali- fornia decausardefectosen el nacimiento, oenalgunos casos, Cancer. (California Health & Safety Code §25249.5 et seq.) MANEJO DE CILINDROS- Los cilindros, si no son manejados correctamente, pueden romp- erse y liberar violentamente gases. Rotura repentina del cilindro, vélvula, 0 valvula de escape puede causar dafio 0 muerte. Por lo tanto: 1. Utilize el gas apropiado para el proceso y utilize un reguladordisefiado para operar y reducir la presién del cilindro de gas. No utilice adapta- dores. Mantenga las mangueras y las conexiones en buenas condiciones. Observe las instrucciones de operacién del manufacturero para montar el reguladoren elcilindro de gas comprimido. 2. Asegure siempre los cilindros en posicién vertical y amérrelos con una correa o cadena adecuada para asegurar el cilindro al carro, transportes, tab- llleros, paredes, postes,o armazén, Nunca asegure los cilindros a la mesa de trabajo o las piezas que son partedel ircuito de soldadura. Este puede ser parte del circuito elélectrico, 3. Cuando el cilindro no esté en uso, mantenga la valvula del cilindro cerrada. Ponga el capote de proteccién sobre la valvula si el regulador no esté conectado. Asegure y mueva los cilindros utilizando_un carro o transporte adecuado. Evite el manejo brusco de los A MANTENIMIENTO DEL EQUIPO -- Equipo defectuoso o mal mantenido puede cau- sar dafio o muerte. Por lo tanto: 1" SEGURIDAD 1. Siempre tenga personal cualificado para efec- tuar la instalaci6n, diagnéstico, y mantenimiento del equipo. No ejecute ningtin trabajo eléctrico a menos que usted esté cualificado para hacer el trabajo. 2. Antes de dar mantenimiento en el interior de la fuente de poder, desconecte la fuente de poder del suministro de electricidad primaria. Mantenga los cables, cable a tierra, conexciones, cable primatio y cualquier otra fuente de poder en buen estado operacional. No opere ningtn equipo en malas condiciones. 4, Noabuse del equipo y sus accesorios. Mantenga elequipo lejos de cosas que generen calor como hornos, también lugares hmedos como charcos de agua, aceite 0 grasa, atmésferas corrosivas y las inclemencias del tiempo. 5. Mantenga todos los articulos de seguridad y coverturas del equipo en su posicién y en buenas condiciones. 6, Use el equipo s6lo para el propésito que fue disefiado. No modifique el equipo en ninguna manera. INFORMACION ADICIONAL DE SEGU- RIDAD ~ Para més informacién sobre las Précticas de seguridad de los equipos de arcoeléctricoparasoldarycortar, pregunte a susuplidorporunacopiade "Precautions and Safe Practicesfor ArcWelding, Cutting and Gouging-Form 52-529. Las siguientes publicaciones, disponibles através de la American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, son recomendadas para usted: 1. ANSV/ASC 249.1 - "Safety in Welding and Cutting" 2. AWSCS.1-"Recommended Practices for Plasma Arc Welding* 3, AWS C5.2-"Recommended Practices for Plasma Arc Cutting” 4, AWSC5.3-"Recommended Practices for Air Carbon Arc Gouging and Cutting”SECTION 1 A PN PELIGRO] Amma AEE SIGNIFICADO DE LOS SIMBOLOS --Segtinustedavanzaenlalectura de este folleto: Los Simbolos Sig- nifican jAtencién! jEsté Alerta! Se trata de su seguridad. Significa riesgo inmediato que, de no ser evadido, puede resultar inmediatamente en serio daiio personal ola muerte. Significa el riesgo de un peligro potencial que puede resultar en serio dafio personal ola muerte. Significa el posible riesgo que puede resultaren menores dafios ala persona. 2 SEGURIDADSECTION 1 1.3. Safety-French AVERTISSEMENT : Ces régies de sécurité ont pour but dassurer votre protection. tls récapitulent les informations de précaution provenant des références dans la section des informations de sécurité supplémentaires. Avant de procéder8|'instalation ou dutilserl'unité,assurez-vous de lire et de suivre les précautions de sécurité ci-des- sous, dans les manuels, les fiches dinformation sur la sécurité dumatérieletsurlesétiquettes,etc. Tout défaut observer ces précautions de sécurité peut entrainer des blessures graves ou mortelles. PROTEGEZ-VOUS --Les processus de soudage, decoupage et de gougeage roduisentun niveau de bruit élevéet exige femploi d'une protection auditive. Larc, tout commelesoleil, émetdesrayonsultravioletsenplus d'autre rayons qui peuvent causerdesblessuresala peauetles yeux. Le métal incandescent peut causer des brilures. Une formation reliée a usage des processus et de I'équipement est essentielle pour révenirles accidents. Par conséquent: aZ 1. Portez des lunettes protectrices munies d'écrans la- ‘t€raux lorsque vous étes dans laire de travail, méme sivous devez porter un casque de soudeur, un écran facial ou des lunettes étanches. 2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou. et vos oreilles des étincelles et des rayons de larc lors d'une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant & proximité de ne pas re- garder larcet de ne pas sexposer aux rayons delarc Alectrique ou le métal incandescent. 3, Portez des gants ignifugiés a crispin, une chemise Epaisse 3 manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protégerdes rayonsdel'arc,desétincelleset dumétal incandescent, en plus d'un casque de soudeur ou casquette pour protégervoscheveux llestégalement recommandéde porter untablierininflammableafin de vous protéger des étincelles et de la chaleur par rayonnement. Lesétincellesetles projectionsdemétalincandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. lest recom mandé de garder boutonnés le col et les manches et de porter des vtements sans poches en avant. 5. Protégez toute personnese trouvant & proximité des étincelles et des rayonsde|'arca laide d'un rideau ou dune dloison ininflammable. 6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations décaillage ou de meulagedulatier. Les écaillesde laitierincandescent peuventétre projetéesades distances considérables. Les personnes se trouvant proximité doiventégale- ment porter des lunettes étanches par dessus leur lunettes de sécurité, B SECURITE INCENDIES ET EXPLOSIONS -- La chaleurprovenantdesflammesoude arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion, Par conséquent : o- 1. Eloignezsuffisamment tous les matériaux combus- tibles de l'aire de travail et recouvrez les matériaux avec un revétement protecteur ininflammable. Les matériaux combustibles incluent le bois, les véte- ments, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revétements, le papier, etc. 2. Les étincelles et les projections de meétal incan- descent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant a étage inférieur Assurez-vousquecesouverturessont bien protégées des étincelles et du métal incandescent. 3. Nrexécutez pas de soudure, de coupe ou autre tra- vail chaud avant d'avoir complétement nettoyé la surface de la piéce a traiter de facon a ce qui nat aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. Nexécutez pas de travail & chaud sur des contenants fermés ‘ar ces demiers pourraient exploser. Assurez-vous qu'un équipement d'extinction dincendie est disponible et prét a servir, tel qu'un tuyau d'arrosage, un seau d'eau, un seau de sable ou un extincteur portatif. Assurez-vous d'étre bien instruit par rapport a usage de cet équipement. 5. Assurez-vous de ne pas excéder la capacité de 'équipement. Par exemple, un cble de soudage surchargé peut surchauffer et provoquer un in- cendie. >. Unefois les opérationsterminées, inspectezl'airede travail pour assurer qu‘aucune étincelle ou projec tion de métal incandescent ne risque de provoquer nincendieultérieurement. Employezdesguetteurs diincendie au besoin. 7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 518, "Fire Prevention in UseofCuttingandWeldingProcesses’ disponibleau National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. CHOC ELECTRIQUE --Le contact avec des pieces électriques ou les pieces de mise a la terre sous tension peut causer des blessures graves ou mor- telles. NE PAS utiliser un courant de soudage ca. dans ur endroit humide, en espace restreint ou si un danger de chute se pose.SECTION 1 1, Assurez-vous que le chassis de la source dlalimentation est branché au systéme de mise a la terre de 'alimentation dentrée. 2. Branchez la piéce a traiter a une bonne mise de terre électrique. Branchez le cable de masse a la piéce a traiter et assurezunebonneconnexionafind’éviterlerisque de choc électrique mortel. . Utilisez toujours un équipement correctement entretenu, Remplacez les cables usés ou endom- magés. 5. Veillez gardervotreenvironnementsec, incluant les vétements, aire de travail, les c&bles, le porte- électrode/torche et la source d'alimentation. 6. Assurez-vous que tout votre corps est bien isolé de la pice a traiter et des pidces de la mise & la terre, 7. Sivousdevezeffectuer votretravaildansunespace restreint ou humide, ne tenez vous pas directe- ‘ment sur le métal ou sur la terre; tenez-vous sur des planches séches ou une plate-forme isolée et portez des chaussures a semelles de caoutchouc. 8. Avant de mettre l'équipement sous tension, isolez ‘vos mains avec des gants secs et sans trous. 2. Mettez equipement hors tension avant d'enlever vos gants. . Consultez ANSI/ASC Standard 249.1 (listé & la page suivante) pour des recommandations spécifiques concernant les procédures de mise & la terre. Ne pas confondre le céble de masse avec le cable de mise a la terre. ducteur produit des champs élec- triques et magnétiques localisés. Le soudage et le courant decoupagecréentdes champs électriques et magnétiques autour des cables de soudage et Véquipement. Par conséquent : CHAMPS ELECTRIQUES ET MAGNE- TIQUES — comportent un risque de danger. Le courant électrique 1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d'entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour cer- tains stimulateurs cardiaques. 2. Lexposition & des champs électriques et magné- tiques peut avoir des effets néfastes inconnus pour la santé, “4 SECURITE 3. Lessoudeursdoiventsuivreles procédures suivantes pourminimiser 'expositionauxchampsélectriques et magnétiques: A. Acheminez l'électrode et les cables de masse ‘ensemble. Fixez-lesa laided'une bandeadhésive lorsque possible. B. Nejamaisenroulerlatorche oulecable de masse autour de votre corps. C. Nejamais vous placerentrela torcheetles cables de masse. Achemineztouslescdblessurleméme été de votre corps. D. Branchez le cable de masse & la piece a traiter le plus prés possible de la section a souder. E. Veillez & garder la source d'alimentation pour le soudage et les cables a une distance appropriée de votre corps. LES VAPEURS ETLES GAZ peuvent causerunmalaiseoudesdommages corporels, plus particuligrement dans les espaces restreints. Ne re- spirez pas les vapeurs et les gaz. Le gaz de protection risque de causer Tasphyxie. Par conséquent : 1, Assurez en permanence une ventilation adéquate dans lire de travail en maintenant une ventila- tion naturelle ou a l'aide de moyens mécanique. Neffectuez jamais de travaux de soudage, de coup- age ou de gougeage sur des matériaux tels que Facier galvanisé, 'acier inoxydable, le cuivre, le zinc, le plomb, le beryliym ou le cadmium en absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux. 2. Neffectuez jamais de travaux & proximité dune opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou lerayonnement de''arcentreen contact aveces vapeursd'hydrocarbure chloré,cecipeutdéclencher la formation de phosgéne ou d'autres gaz irritants, tous extrémement toxiques. 3. Une irritation momentanéedes yeux, dunezoudela gorge au cours d'une opération indique que la ven- tilation n'est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer fa ventilation dans l'aire de travail. Ne poursuivez pas lopération si le malaise persiste. 4, Consultez ANSI/ASC Standard 249.1 (@ la page suivante) pour des recommandations spécifiques concernant la ventilation.SECTION 1 5, AVERTISSEMENT::Ce produit, lorsqu'llest utilisé dansune opération desoudageoude coupage, dégage des vapeurs ou des gaz contenant des chimiques consi dérespar''état dela Californiecomme étant une cause des malformations congénitales et dans certains cas, du cancer. (California Health & Safety Code §25249.5 et seq.) MANIPULATION DES CYLINDRES -- La manipulation d'un cylindre, sans E> observerlesprécautionsnécessaires, peut produire des fissures et un &chappement dangereux des gaz. Unebrisuresoudaineducylindre, delasoupapeou du dispositif de surpression peut causer des bles- sures graves ou mortelles. Par conséquent : A 1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié concu pour utilisation sur les cylindres de gaz comprimé. N'utilisez jamais d'adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d'opér du fabricant pour assembler le détendeur sur un oylindre de gaz comprimé. 2. Fixez les cylindres dans une position verticale, & "aide d'une chaine ou une sangle, sur un chariot manuel, un chassis de roulement, un bane, un mur, une colonne ou un support convenable. Ne fixez Jamaisuncylindreaun postedetravailoutouteautre dispositiffaisant partie d'un circuit électrique. 3, Lorsque les cylindres ne servent pas, gardez les soupapes fermées, Si le détendeur n'est pas bran- cché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les oylindres a l'aide d'un chariot manuel approprié. Toujours manipuler les cylindres avec soin. 4, Placez les cylindres a une distance appropriée de toute source de chaleur, des étincelles et des flammes. Ne jamais amorcer arc sur un cylindre. 5. Pour de l'information supplémentaire, consultez CGA Standard P-1, "Precautions for Safe Handling of Compressed Gases in Cylinders", mis a votre dis- position par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202. 15 SECURITE ENTRETIEN DEL'EQUIPEMENT--Un équipe- ment entretenu de facon défectueuse ou Inadéquate peut causer des blessures graves ou mortelles. Par conséquent : A fforcez-vous de toujours confier les taches installation, de dépannage et dientretien & un personnel qualifié, Neffectuez aucune réparation électrique & moins d'étre qualifié a cet effet. 2. Avant de procéder @ une tache d'entretien Vintérieur de la source d'alimentation, débranchez lalimentation électrique. 3, Maintenez les cables, les fils de mise a la terre, les, branchements,lecordon d'alimentationetlasource d'alimentation en bon état. Nutilisez jamais un équipement sil présente une défectuosité quel- conque. 4, Nlutilisezpas!'équipement de facon abusive. Gardez équipement a l'écart de toute source de chaleur, notamment des fours, de Ihumidité, des flaques dieau, de 'huile ou de la graisse, des atmospheres corrosives et des intempéries. 5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état. 6, Utilisez 'équipement conformément a son usage prévu et r'effectuez aucune modification. INFORMATIONS SUPPLEMENTAIRES RELA- TIVES A LA SECURITE -- Pour obtenir de Tinformation supplémentairesurlesragles de sécurité a observer pour 'équipement desoudageal'arcélectriqueetlecoupage, demandezunexemplairedulivret"Precau- tions and Safe Practices for Arc Welding, Cutting and Gouging’, Form 52-529. A Les publicationssuivantessontégalementrecomman- déesetmisesa votre disposition parlAmericanWelding Society, 550 N.W, Leluene Road, Miami, FL 33126 1. ANSI/ASC 49,1 - "Safety in Welding and Cutting" 2. AWSCS.1-"Recommended Practices for Plasma Arc Welding’ 3. AWSCS.2. Cutting 4, AWS C5.3-*Recommended Practices for AirCarbon ‘Arc Gouging and Cutting” "Recommended Practices for Plasma ArcSECTION 1 SIGNIFICATION DES SYMBOLES Cesymbole,utilisépartoutdanscemanuel, signifie "Attention" ! Soyez vigilant! Votre sécurité est en jeu. Anam Signifie un danger immédiat. La situation peut entrainer des blessures graves ou mortelles. AZIZ Signifieun danger potentiel qui peutentrainerdes blessures graves ou mortelles. A= Signifieun danger quipeutentrainerdesblessures corporelles mineures. 16 SECURITESECTION 2 PT-26 Torch DESCRIPTION This versatile, easy-to-use 300 amp torch provides superior performance for afull range of manual and mechanized cutting applications. PT-26 + Excellent cutting capaisity - cits up to 3-12 in, and severs 4 in. using alr nitrogen or argon-hydrogen at 300 amps + Produces clean, high quality cuts + Operates with shop or eyinder air, nitrogen or argon-hycrogen ‘at 300amps + Compact, ightweight design for ease of hancling + Longiifeelectrodes lower operating costs + Pilot are staring -even starts on paint + Gouging nazzle available + Intermittent cutting capacity for grate or expanded metal ‘applications ‘Gouging guard and stand-off guide avellable for operator convenience + One-year warranty Specifications Yohage class" (E5078) Cent Capt (A Seve Gass ond Presse) 100% dy CYC mn -—n-200ADCSP 60% duty cycle, Manual torches, 100%einline.-—— 300A DCSP Maxim Rote CURED woe nenennnn nn SODA DCSP Approved Service Gases PLS ae Oy Ai. H35 N/M Mores shield Ai, CO, Ar Mia. Gos Supp Flow Requirements SHILG 207A @ 85 pig (94 Vin. @ 5.0 BAR) Plast _vnnenne240 fh @ 80 psig (112 Vinin.@ 5.6 BAR) Length of Service Lines. 25 for 50ft 7.6: oF 152m) Weight nn san 5 R= T61D5 (7349) Sot 2 os. (12.7kg) ‘Max. Allowable llet G35 Pressure nen nsae—n 100 59 (5.9 BAR) Start Ga$ Pret nn 30 sig (2.1 BAR) ‘Minimirn Coolant Suppiy Flow Requirements 09 gpm @ 95 psig Bsuimine 66 BAR) Maximum Coolant inlet res 120 psig (83 BAR) Maximum Coolant Temperature. 105" (20°C) Ordering Information 71.26.90 281 ine 36558 Frae.2 30 ine mare Pre. 7 25 oe isso Frae.70 50m iow ~sse02209 Prasiniieste ‘o5s0132 PraciNune, 1 e 7536000133 Pre nine 25 5560000 Prac NN 30t —cTesseona NOTE: IN-LINE torches have 2"barrel diameter and come without rackor torch holder FFF 26SL INGLINE, 17 Fear eens ss6005620 P-L, IN-LINE, 25 = ‘se00s62t PP 26SL, IN-LINE, SO nn "0558008622 NOTE: IN-LINE Sttorches have 13/8" bore diameter and come with 32 pitch rack. 7 PT-26 IN-LINE @ Compatible Consoles £5P-150, ESP-200 and DEUCE PACK 150 Optional Accessories Plast Yorch Hen Protector For $oUgI nce ne 20006 258 Leather Sheath? Protect torch ins om abvaon and mate eta pacarly ‘esmmanded frp outages 500002 S01, Leathe Sheth enn 8800822 Torch olde 2 nnn 85802565 ‘Suomen Spore Pars kit Bese GEIECE gey ee Bee SHE Se ae elena Spare Par KI 150A nnn nnn BB5602864 ain a ; eagee Fea Suet ee tiih br 1 ERP ono om § SHE iit erie Mba 5 H = SRT GES 0 gh et oatve 38h He Bike a Te Cerca torSECTION2 PT-26 Manual Models ectrode Holder 34583 6865 - A trogn, 38566" Argon 9) (ning ocation- 2028680 (Ring Lcation-2110706 Thcudes Ofengs SW49 Upper 540347 er) eecrose ivogerniysrogan eae hilt NS eter ing 88097 DESCRIPTION surest Sooo) o abs PRR SE a sey os Sons en ubencaningraccgigtcore 1p ieee O78 foresame Mechanar Seapagnnte asszors6 mt 300° S57 25 ink O-Rings 210576 Upveh El PT-26 In-Line Models Toren Te esen2r0 Sreresa Jarmo) O-Ring Location- 2029450 ei Onestaatan aime DS cece ie ces oe ae Gps) af Tube-24585, Ve “These tensolong who bateratla- “in 0850003569 oe soped wth ttimechoried verson oh ch sai af nse 0556002383, petals Ong -D5ioarB cKO? Soe eee 36585-Al Mtsogen, Ntvogentsages ‘eben Argonpoges Ro) i 7 Gang Nae wa 0367 io 3 as Alindude O-8ngs 2110578 Upper) Ssoans2 (Loner 6 et Shied Marsal fren 34592 ‘eld Cp Mechented-os56009582 Figure 2.1 Assembly of PT-26 Front End Parts 18SECTION 2 DESCRIPTION 2.0 Description The PT-26 is a dual gas, water cooled, torch with a 70” or 90° head for manual cutting and gouging and an in-line head for mechanized cutting and gouging. Each of which is designed for use with certain plasma arc cutting packages. These pack: ages include the ESP-150, ESP-200 and properly equipped Deuce Pack 150 Systems. 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 EM- PLOYED CAN PRESENT A SAFETY HAZARD. BEFORE BEGINNING OP- ERATION OF THE PT-26 TORCH, REFER TO THE SAFETY PRECAUTIONS. RG ANDOPERATINGINSTRUCTIONS PACKED WITH YOURPOWERSOURCE PACKAGE. USING THE TORCH ON ANY UNIT NOT EQUIPPED WITH A MATING SAFETY INTERLOCK CIRCUIT WILL EXPOSE OPERATOR TO UNEXPECT- ED HIGH VOLTAGE. air He ene 633mm) (aim) [ 40x" Ta lL. (Gem = a 66 (2mm) >| Figure 2.2 PT-26 Dimensions 19SECTION 2 DESCRIPTION C a am Y Figure 2.3. PT-26 In-line Torch Dimensions TesSoan aun ! Ca wee uw eH. Figure 2.4 PT-26 “SL” In-line Torch Dimensions 20SECTION 3 INSTALLATION 3.0 Installation 3.1 Torch to Power Source Connections Consult your power source instruction literature to learn how to access the torch connections. The order in which the torch connections can be made will vary with the power source used, Study your power source to determine the order which will best allow you to make the connections correctly with a wrench, MAKE SURE POWER SWITCH ON CONSOLE IS IN THE OFF POSITION AND PRIMARY INPUT POWER IS DEENERGIZED. ‘THE PT-26 IS DESIGNED TO FORM A SAFE SYSTEM WITH CERTAIN POWER SOURCES WHICH HAVE MEANS FOR DETECTING A LOSS OF COOLANT FLOW RETURNING FROM THE TORCH AND WHICH WILL NOT ENERGIZE THE TORCH WHEN SUCH A LOSS OF COOLANTIS DE- ‘TECTED. THE REMOVAL ORLOOSENING OF THE TORCHHEAT SHIELD WILL CAUSE SUCH A COOLANT LOSS. DO NOT USE THE PT-26 ON POWER SOURCES WHICH ARE NOT EQUIPPED WITH SUCH A SYS- TEM. ‘The PT-26 torch uses a “C” sized left hand thread fitting for the negative terminal and coolant connection. Con- ect this fitting to the corresponding female fitting on the power source and tighten it firmly with a wrench, ‘After tightening the fitting, slide the rubber boot (49N83) on the power cable over the connection. The “8” sized right hand fitting is used to make the positive terminal and coolant connection. Tighten it firmly as well The plasma gas and shield gas connections are made with two "B" sized fittings, each with a different thread. Tighten them firmly with a wrench at the corresponding power source panel fitting. The torch switch connection is made with the 5-pin plug on the torch switch lead. Insert the plug into the socket on the power source and twist the locking ring to secure it in place. 3.2 Retrofits to Older Power Sources The PT-26 torch may be retrofitted to older Deuce Pack 150 power sources. This requires installation of a new plumbing box. The kit for this is P/N 000759. aSECTION 3 INSTALLATION 3.3. Gas Selection The PT-26 is a dual gas torch, allowing for one gas to be used for plasma gas and another to be used for shielding the cut zone, Recommended combinations of gases are listed below. USE ONLY THOSE GASES LISTED AS APPROVED IN THIS DOCUMENT. Air Plasma/Air Shield Best overall combination for cut quality, cut speed and economy on mild steel, stainless steel and aluminum, This combination causes some surface nitrating at cut face and some surface oxidation of alloying elements on stainless steels, Always use clean, dry ait. Moisture or oil in the air supply will reduce torch parts life. Nitrogen Plasma/Air Shield This combination provides improved parts life, especially for the electrode. Cut speeds will usually be slightly slower than with air plasma. It creates surface nitriding but provides cleaner cut face on stainless steels. Nitrogen or CO, may be substituted for cooling. H-35 Plasma/Nitrogen Shield This combination gives excellent parts life with minimum amount of cut surface contamination, providing ex- cellent weldability tis most often used for gouging on mild steel, aluminum, and stainless steel. It gives poor cut quality on mild steel, good cut quality on aluminum and stainless, particularly on thicker sizes. 40% Hydrogen - 60% Nitrogen Plasma/Air Shield On aluminum only, gives increased speed and thickness capability. Poor performance on stainless and mild steel. Oxygen Plasma/Air Shield Best quality for mechanized cutting of mild steel 1” thick or thinner with 150 to 300 amps. Highest metal removal rate for gouging on mild steel. 3.4 Gas Connections Refer to Section 1.2 for the list of approved service gases. Do not use gases which are not expressly approved for the PT-26 torch, After the gases for the job have been selected, connect the gas supply hoses to the fittings at the back of the power source. Note that there may be two fittings for each gas. Use the fitting which matches your hose. Make sure that the fittings not used are plugged with the plug attached to the power source. Note that the ESP-150 & ESP-200 power source has a gas connection labeled "Start Gas’. This allows a differ- ent plasma gas type and pressure setting to be used for the plasma gas at the start of the cut. This is done to increase electrode life during some types of mechanized plasma cutting, The start gas most typically used in manual cutting is either the same gas as that used for the cutting/gouging plasma or nitrogen. is not IMPORTANT! A gas supply MUST be supplied to the “Start Gas” connection at all times. If t done, the torch will be damaged. The start gas may be any of the approved Plasma gases listed in se above. 2SECTION 3 INSTALLATION 3.5 Assembling Front End Parts MAKE SURE POWER SWITCH ON POWER SOURCE IS IN THE OFF PO- SITION AND PRIMARY INPUT POWER IS DEENERGIZED. FAILURE TO INSTALL FRONT END PARTS PROPERLY CAN EXPOSE YOU TO HIGH VOLTAGE OR FIRE. FOLLOW ALL INSTRUCTIONS IN THE APPROPRIATE BOOKLET PACKED WITH YOUR POWER SOURCE PACKAGE. DO NOT INSTALL OR ATTEMPT TO OPERATE THIS TORCH WITHOUT FOLLOWING | WARNING | ‘THESE INSTRUCTIONS. THE TORCH FRONT END DESIGN CONTAINS COMPONENTS WHICH, WORKING TOGETHER WITH POWERSOURCE CIRCUITRY, PREVENT THE TORCH FROM BEING ACCIDENTLY EN- ERGIZED WHEN THE HEAT SHIELD IS REMOVED AND THE TORCH SWITCH IS CLOSED. Be sure: + AllO-Rings are in place (torch head, nozzle, electrode holder) + Electrode holder is tight + Baffle tube is installed and tight Electrode is installed and tight + Nozzle is installed Refer to figure 2.1 for the assembly of the front end parts into the torch head. First, inspect the torch body to ensure that no debris or o-rings are left inside, Remove any found, Inspect the electrode holder (34583) to make sure that both O-rings are in place. Thread the electrode holder into the torch head and tighten it firmly using a 3/16" (187) hexallen wrench. The holder must be tight, but avoid ‘overtightening to the point of rounding-off the hex inside the holder. Insert the baffle tube (34585) into the electrode holder and thread it into the torch head using the plastic hex allen wrench tool (19129 }. Take care not to overtighten the tube but make sure that it is secured. Insert the insulator (34593) into the torch head. Make sure the O-ring is in place on the insulator so that the insu- lator will hold its place in the head. Do not push the insulator too far back. When installed, the nozzle will push itto the correct position. ‘Thread the electrode (36565 or 36566) onto the thread of the electrode holder and tighten it in place with the hex socket end of the plastic tool (19129). Press the nozzle (36568 - 72) into the front of the torch head. This will probably push the insulator further into the head, This is normal. Make sure that both O-rings are in place and that the nozzle seats against the torch head. 23SECTION 3 INSTALLATION Thread the heat shield (34592) onto the torch head to retain the nozzle. The heat shield should be tightened as tight as possible by hand to prevent coolant leaks from the nozzle O-ring seal. If the optional stand-off guide (36648) is to be used, install it onto the heat shield by pushing or twisting in a CLOCKWISE direction until its fully seated on the shield. IMPORTANT - Do not twist the stand-off guide in the counter-clockwise direction as this will loosen the heat shield. 3.6 Stand-off Guide ‘The stand-off guide (36648) provides the operator with the ability to hold a consistent stand-off by keeping the guide's feed in contact with the work. Install the guide by sliding it onto the heat shield (heat shield should be in place on torch) with a clockwise ‘twisting motion. Always install or adjust the guide on the shield with a clockwise twisting motion to prevent loosening of the shield. If the fit of the stand-off guide is too tight on the shield, open the slot in the shield by twisting with a large flat, blade screw driver. Ifthe fit is too loose, close the slot by squeezing the guide in a bench wise. 3.7 Loose Consumables : Proper performance of the torch will rely on proper and secure installation of the front end consumable parts, particularly the electrode holder, baffle tube, electrode, and heat shield as well as the associated o-rings. 1. Make sure that the electrode holder is fully threaded into the torch head and securely tightened using a 3/16" hex allen wrench. Use a metal allen wrench. The plastic wrench is not strong enough for this. Also make sure that the baffle tube is fully installed into the torch and seated against the electrode holder, use the plastic allen wrench (19129) for this, 2. Fully tighten the electrode onto the electrode holder using the hex socket end of the plastic wrench (19129). 3. Make sure that the nozzle is secured and its o-rings sealed by fully tightening the heat shield. “Fully” means as tightly as possible using the hands alone, do not use wrenches, Improperly installed front end parts will cause coolant leaks which may cause poor cutting or gouging perfor- mance and may cause damage to the torch itself from internal arcing. 3.8 Installation of Swirl Baffle To install the swirl baffle use the swirl baffle installation tool, p/n 0558003584. This tool allows the o-ring on the Inside of the swirl baffle to easily go onto the O.D. of the electrode holder. Installing swirl baffle hand-tight will be sufficient. 24SECTION 4 OPERATION 4.0 Opera Wear the usual protective gloves, clothing, ear protection and hel- met. Read Safety Precautions covered in the instruction manual packed with your power source. The torch is now ready for cutting or gouging operation. Refer to the instructions for your power source for mak- ing any control adjustments. NEVER TOUCH ANY PARTS FORWARD OF THE TORCH HANDLE (NOZ- ZLE, HEAT SHIELD, ELECTRODE, ETC.) UNLESS THE POWER SWITCH ON THE POWER SOURCE IS IN THE OFF POSITION. 1. Tum the gas test or gas mode switch to the test or set-up position. NOTE: ‘The "CUT" position isto set the cutting plasma gas. The “START/SHIELD” position is to set the starting plasma gas and the shield gas. Ifthe starting plasma gas and the cutting plasma gas are to be the same and supplied by the same regulator, Use the START/SHIELD position only, the CUT position is not needed. 2. ‘Tumm the power switch to the ON position. Gas should now flow at the torch. 3. Adjust the gas pressure settings at the gas supply regulators to the values given in the operating parameters section, Turn the gas test or gas mode switch to the operating position, Gas Flow should now stop. Adjust. the current control to the correct setting for the nozzle. 4. Bring the torch into the proper position for cutting or gouging. For cutting, the torch stand-off (nozzle-to- work distance) should be approximately 1/4". If possible, start the cut from an edge on the workpiece. If piercing must be done, tit the torch at an angle to deflect the molten metal away from the torch and op- erator until the pierce is complete, then bring the torch back to the vertical and begin the cut. For gouging, place the torch over the work at an angle of 35° to 45° from the horizontal. Lower your protective helmet. 6. Push down and hold the torch switch button. The gas should start flowing. Two seconds later, the main contactor should close and the arc should transfer to the workpiece. NOTE: Your power source may allow the preflow time to be extended longer than twa seconds, usually up to four or five secands. If,at the end of the preflow time, the pilot arc does not ignite, release the torch switch and check the gas pressure settings. Ifthe pilot arc does ignite but does not transfer to the work, release the torch switch and check to see that the torch isin the proper distance from the work and that the work clamp is firmly connected to the work piece. 25SECTION 4 OPERATION 7. When cutting, maintain the torch stand-off at a distance of between 3/16" and 1/2. When cutting thinner plates, the stand-off should be closer to the lower end of the range and it should be closer to the upper end of the range for thicker plates. Maintain a cutting speed which gives a cut of the desired quality and pro- duces a stream of molten metal emitting from the bottom of the workpiece. 8. When gouging, maintain an angle and speed which causes the desired amount of metal to be removed on each pass. Maintain the torch angle so that all the molten metal is blown directly away from the torch, along the top surface of the plate or down the groove of the previous pass. Gouging at too steep an angle will cause molten metal to fly directly back at the torch. 9. IF the main arc is lost during the cut (or gougel, the pilot arc will immediately reignite as long as the torch switch is depressed. At this time the torch should quickly be repositioned at the workpiece to re-establish the main arc or else the torch switch should be released. 10. The main arc will automatically extinguish at the end of the cut as the torch is moved away from the work- piece. The torch switch should be released immediately to keep the pilot arc from reigniting, 11. When cutting (or gouging) operations are completed, wait a few minutes before placing the power switch Cn the power source in the OFF position to allow the fan to remove heat from the unit. After this time, shut off the primary power at the main disconnect switch 26SECTION4 OPERATION 4.1 Operating Parameters Recommended Gas Pressures - Start = 30 psig Plasma (CUttiNg) seni 50-70 PSIG Plasma (Gouging) 40-45 psig Shiel . 40 -50 psig Recommended Stand-off- 5/16" 1/2" Travel Speeds - Travel speeds for the PT-26 are giver Tables 4-1 through 4-4, 4.2 Cut Data ‘To ensure optimum cutting performance and aid in troubleshooting any cut quality problems, please refer to the following cutting parameters charts, PT-26 in-line torch cutting conditions: Data taken with Swirl Baffle (0558003583) and Shield Cup (0558003582). 65 Amp data uses standard Heat Shield (34592) or Close Proximity Heat Shield (37146) in place of Shield Cup (0558003582) and uses a 50 Amp Nozzle (36567), Table 4.1. 65 Amp Cut Data Sreld arena! | Thikness | standoff | speed | StrtGasand | CurGasand | Gas sr Pressure inch rm) | inch) | fp rr) fortSP150 ond 200 psig (bar) psig (bar) psig (bar) cnn PRAT cry | SORE arbor T9564 7002540) 0.50 (12.7) 0.25 (6.4) 30 (762) 2262 | oyqy Lamm] : : Auminum [025 64 row | Mt, | ft, peer aso (tz | o25@@) | 201508) 0123.2) 751805) stainless ona) ‘Steel 0.25 (6.4) 50 (1270) asoirz7 | 025A) | 201508) BySECTION 4 OPERATION Table 4.2 150 Amp Cut Data Shield Materiay | Thickness | standot | Speed | StaftGasand | cuRGasand | Gas and Pressure for inch) | inch ten) | yey sig (bar) sig (bar) eee ee ie psig (bar) 0.19 (4.8) 150 (3810) 025164) 730 630 019148) 0.38 (9.7) 80 (2032) Alc ON. °. mr, s 0501127 zor | NUN. ata 0.62 (15.7) 50 (1270) 0.75 (19.1) 0.25 (6.4) 35 (889) Carbon 1,00 (25.4) 20 (508) ‘Steel 0.19 (4.8) 0.19 (4.8) 150 (3810) 0.25 (6.4) 130 (3302) 0.38 (9.7) 80 (2032) 0.50 (12.7) 70 (1778) 025164) 062(057) 50270) 075183) 35609) 1.00 (25.4) 20 (508) Air 0.19 (4.8) 0.19 4.8) 175 (4445) 60 (4.1) 0.25 (6.4) 025064) 130 (3302) 0,38 (9.7) 90 (2286) ye f i i Aluminum [050(0279 7017) | set toatl 082(057) 501270 0,31 (7.9) 075 (83) 35 (589) 1,00 (25.4) 25 (635) 0.19 (4.8) 0.19 14.8) 165 (4191) 025 (64) 125 (65195) 025164) see Lost” 50 (2082) Stainless ain [osocan | osr@s [50270 0621057) 35 (889) 0.75 (19.1) 0.38 (9.7) 20 (508) 100(25.4) 10 254) 28SECTION 4 OPERATION Table 4.3 200 Amp Cut Data Shield wtrat | Thence | sundon | SRY | Senso | “ress | sueteres comm | poten | post) | oanozo psig (bar) 0.25 (6.4) 150 (3810) 0.38 (9.7) 0.19 (4.8) 95 (2413) Air 0.50 (12.7) 80 (2032), Air N, 0, 0 65) 0.62(15.7) 65 (1651) 30 (2.1) 55 (3.8) 0.75 (19.1) 50 (1270) Air Carbon 1.00 (25.4) 35 (889) 60 (4.1) Steel 0.25 (6.4) 135 (3429) 33867 25am) 250127 | jeigy [A 0.75 (19.1) 55 (1397) i054) 30069 0.25 (6.4) 130 (3302) 0,38 (9.7) 105 (2667) ‘Aluminum eso) 85 (2159) Air Air Air 0.62 (15.7) 031 (79) 75 (1905) 30(21) 55 (3.8) 80(5.5) 075680 cs 1.00 (25.4) 0.38 (9.7) 40 (1016) O25 a) Toa 0.38 (9.7) 0.25 (6.4) 115 (2921) Stainless 0.50 (12.7) 75 (1905) Steel 0.62 (15.7) 65 (1651) 1.00 (25.4) 20 (508) 29SECTION 4 OPERATION Table 4.4 300 Amp Cut Data Speed | SanGarad | Catesand | ane veteat | Tretress | standon | SER | Sess | “Presute | cacand row (mm/m) psig (bar) psig (bar) cf (Vm) 0.50 (12.7) 0.2564) 130 (3302) 062 157 25.241) (075 (19.1) 180 (2032) oO, 1,00 (25.4) eure 50 (1270) 75 (5.2) 1.50 (38.1) 0.38 (9.7) 20 (508) Carbon 2.00(508) | 0.50(12.7) 10 (254) Air Ny Air Steel 0.50 (12.7) 120 (3048) 30 (2.1) 210 (99.1) 2057] yy.q [saz 0.75 (19.1) 80 (2032) Air 1.00 (25.4) 55 (1397) 75 (5.2) 1.50 (38.1) 0.38 (9.7) 25 (635) 2.00 (50.8) 0.50 (12.7) 12 (305) 30SECTION 4 OPERATION Maximum Manual PT-26 Speeds PT-26 Steel Cutting Data 228 | TTTTTTTTTT Praga Gas: Air st 60 pg ua Shea Ga Stat Gas vs Standort S16" © io | L TEED & i so ae Bs 150. amps a | ee ee | 200 amps 2 5 — 300 amps 3 as 3 50 25 tr 5 : AEH 00 025 05 075 160 125 18) 175 200 225 25) 275 30) 3% 380 475 40 Material Thickness (in) PT-26 Aluminum Cutting Data 250 Se ee ea | fa Plasma Gat: #35 or At at $060 psig Shield Gas: Alt 50 psig Stan Gas : #35 Niogen or Aira 30 psig 200 | Stand.oft 16" go Fors Pasa p,e Nope oH ta ge £ FILLE Ly 5 150 200 amps H-35 Plasm 3 3 —— ~ 150 amps H-95 Plasma Bis 20 eam | - 200 amps AirPiasma 2 " ate E 100 2 + |—— 300 amps air Piasma é 7 [— = 300 am lasma Bee Ei 300 amps #35 Pi 50 AY 5 2 et et L eli a4 ° Gon 0% 08 OFS 100 125 150 175 200 22 250 275 800 525 980 375 400 Material Thickness (in) 3SECTION 4 OPERATION PT-26 Stainless Steel Cutting Data ass Go Ar HAD pats SONY TOP [evea aera 0 peigarivoper at pa. | fare A, Moyen or 3p A eee trl Tek PT-26 300 Amp Stainless SteelSECTIONS MAINTENANCE 5.0 Maintenance 5.1 Disassembly of Front End MAKE SURE POWER SWITCH ON POWER SOURCE IS IN THE OFF POSI- TION AND PRIMARY INPUT POWER IS DEENERGIZED. IF the stand-off guide is being used, remove it by twisting clockwise and pulling it from the heat shield Unscrew the heat shield and remove it from the torch. The nozzle should remain in the torch head. Some cool- ant leakage is normal as the shield is removed. Inspect the heat shield. There should be no signs of arcing any- Where inside the shield. The outer insulating jacket should not be severely worn or charred. Replace the shield ifany of the above mentioned damage is found. Pull the nozzle from the torch head and inspect it. The orifice should be round at both the entrance and the exit. Replace the nozzle if the orifice is oval shaped or damaged. The nozzle may have grey to black deposits on the inside surfaces. They may be cleaned with steel wool but care must be taken to remove all traces of the steel wool afterward. Inspect the electrode. If it has a pit more than 1/16" deep at its center, replace it. Each time the electrode is replaced, one should inspect the electrode holder. There should be no signs of arcing and the o-rings should not be worn or damaged. Inspect the insulator. If any signs of arcing are found, replace it. Ingpect the torch head o-rings. If they are worn or damaged, replace them. They wil last longer ifthey are kept covered with a thin film of silicone lubricant (17672). Use just enough to make the o-ring appear wet or shiny but do not leave clumps of excess lubricant. After all of the front end parts have been inspected and replaced as needed, reassemble the torch as described in the section “Assembling Front End Parts’, 5.2 General Periodically check the heat shield, electrode holder assembly and insulator. If any of these parts are damaged or excessively worn, replace them. Check the torch o-rings daily. any o-ring has nicks, cuts or other damage, replace it. ft is dry, lubricate it with a thin film of lubricant, P/N 17671. Ifno drag, caused by the o-ring, is felt when installing the heat shield, replace the o-ring, ‘The torch cable sleeving should be inspected periodically. f any damage to the sleeving is found, inspect the torch power and pilot arc cables for damage. If gas leaks or damage of any kind are found, replace the compo- nents in question. : 33SECTIONS MAINTENANCE 5.3 Dirt or Contamination Dirt or other contamination can cause premature failure of the PT:26 torch through internal arcing. To avoid this, Users are instructed to do the following: 1. Insure that clean, dry, oil-free air is used for plasma and/or shield gas. . Avoid excessive use of the silicone o-ring grease on the torch o-rings. A thin film is sufficient. 3. Wipe the torch body insulator clean with a cloth before installing each fresh set of consumables. The ability of the insulator to resist arc tracking over its surface is reduced when dirt or other contamination is allowed to collect there 4, When the torch is not in use, store it with a full set of front end parts installed. This will prevent dirt from col- lecting in the torch and will help protect the torch head in case it is accidentally dropped. 5.4 Removal and Replacement of Torch Head Note the position of all components and tape locations before performing tioning of components and tape during reassembly. Refer to Figure 6.1. sssembly to ensure proper posi- 1. Slide the flex support rearward, onto the cable sleeving until itis approximately 18" to the rear of the han- dle. 2. Remove the tape near the end of the torch handle. , 3._ Slide the switch band and switch rearward and off the handle, - 4, Slide the cable sleeving rearward. 5. Twistand pull the handle from the torch head and slide it rearward to expose the torch cable connections. 6.__Using two wrenches at each connection, unthread the two torch connections. The wrench sizes required are 3/8" and 7/16°. 7. Pull the torch head away from the cable assembly, including the piece of insulation attached. Position the new torch head and insulation back into the assembly. 8 Using two wrenches at each connection, tighten the two torch connections securely. The torque valve used a the factory for this step is 25-30 in-Ibs. 9, Thread the handle back onto the torch head. 10, Slide the switch band and switch onto the handle until itis two (2) inches from the torch head. The red splice connections for the switch lead should be located just behind the handle end. 11, Pull the cable sleeving forward and tape in place behind the handle using vinyl electrical tape. 12, Slide the flex support back onto the handle until it contacts the switch band. Note When replacing the handle on the PT-26SL In-line torch, first slide the mylar insulating tube, p/n (0558005623, over the torch tubes & connections until it bottoms against the back of the torch body. J Mylar Insulating Tube torch body 34SECTIONS MAINTENANCE 5.5 Removal and Replacement of Torch Cables Disconnect the torch cable assembly from the power source. Referto your power source. Refer to your power source instruction booklet for detailed instructions. 2. Remove the torch head from the cable assembly as described in steps 1 through 7 of the previous section. Also remove the handle and flex support from the cable assembly. 3. Lay the cable assembly our straight. This should be done in an area about 1-1/2 times the length of the cables. 4, Using a piece of cord or sturdy twine about 1/2 the length of the torch cables, secure one end of the cord ‘around all of the torch cables at the torch end and secure the other end of the cord to a stationary object. 5, Remove the tape from the cable sleeving at the power source end of the cables. 6. Push the switch out of the switch band and slide the handle, switch band and flex support to the far end of the cord used in step 4. Secure the power source end of the cables and pull the cable sleeving completely onto the cord. 7. Untie the cord from the cables and replace the damaged cables or cables. 8. Resecure the torch ends of the cables with the cord and pull the cable sleeving back onto the cables, Tem- porarily secure the sleeving to the cables near the torch head end with vinyl electrical tape. 9. Pull the flex support, switch band and handle back off the cord and onto the cable sleeving. Remove the tape. 10. Untie the cord from the cables and follow steps 7 through 12 of the previous section to secure the torch head to the cable assembly. 11, Secure the cable sleeving to the cables at the power source end with vinyl electrical tape. 5.6 Replacement of Flex Support, Switch Band or Handle If damage to the flex support, switch band or torch handle causes the need for replacement of any of these items, follow the procedure in the section “Removal and Replacement of the Torch Head!” and replace the partis) in question during step 7 prior to reattaching the torch head. This process will be made easier by temporarily securing the sleeving to the cables with vinyl electrical tape. 5.7 Replacement of Torch Switch 1. Follow steps 1 through 3 of the section “Removal and Replacement of the Torch Head”. 2. Clip the black and white leads of the old switch as close as possible to the red splice connections. Strip 1/4" of insulation from the black and white leads, 3. Strip 1/4" of insulation from the new switch leads (P/N 18224). 4, Attach the switch leads to the switch cable using the two new splice connections included with the replace- ment switch. Be sure to use a crimping tool made for crimping this type of splice connection. 5. Reverse steps 1 through 3 of the section “Removal and Replacement of the Torch Head" to finish. 35SECTION 5 MAINTENANCE 5.8 Measuring Torch Gas Flows If low gas flow is suspected of causing poor cutting performance or short consumable life, the flow can be checked by using Plasma Torch Flow Measuring Kit (P/N 19765). The kit includes a hand held rotameter (flowme- ter) which will indicate the gas flow rate exiting the torch. The kit also includes a set of instructions which should be followed exactly to insure safe and accurate use of the rotameter, See form F-14-391. The PT-26'sair or nitrogen flow rates should be as follows: Shield Flow ESP-150 & ESP-200 .. Deuce Pack 150,215.. 135 - 145cfh @ 50 psig 225 cfh @ 50 psig Plasma Flow.. 115 - 140 cfh @ 50 psig Total Flow ESP-150 & ESP-200 .. Deuce Pack 150,330 250 - 285 cth @ 50 psig 365 cfh @ 50 psig Measure the flow rates using a new 200 amp nozzle (36569), a new electrode and a new heat shield. Make sure that all parts are properly installed and that the torch o-ring (2029450) is in good condition and not leaking. Measure the flows individually if possible, if not measure the total. Gas flow rates less than those above indicate a restriction or a leak in the gas plumbing of the torch or power source. 36SECTION 6 REPLACEMENT PARTS 6.0 Replacement Parts 6.1 General Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on the unit nameplate. 6.2 Ordering To ensure proper operation, itis recommended that only genuine ESAB parts and products be used with this ‘equipment. The use of non-ESA8 parts may void your warranty. 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 alist of customer service phone numbers. Note Bill of material items that have blank part numbers are provided for customer information only. Hardware items should be available through local sources. 7REPLACEMENT PARTS SECTIONG saypuan (om Busn 505 no) s6umy vai ‘Aqurossy y>10) 92-14 SeTNIOEszenbioy uowiareiday 9 aunbig D6 GVH DW Zzsz008s60" 1408 \ee008ss0- 1352 Sais (a1 9684295) ‘Laks ON3 LNOM tse -sOuaNS x3T4 19996- aNVaHOUMS zeazoo9sso-HOUMS esese-sIONWH 38REPLACEMENT PARTS SECTION6 exnoszos- se xine de> Ad ‘Arquiessy 10) euy-u 971d suey wowareydoy 2"9 a:nBiy ‘Sar pan) om Burs sane) m9} ys oozoze 0057 0577 a1¥¢nant pape (0057-0961 afoH duvet etzonasso- anaas ‘0L17008550 6908 39REPLACEMENT PARTS SECTION 6 Aiquiossy y>s01 2uy-ul 1, 97-10 ~ sued wwewiare|doye"9 9inb 4 5) sues pu uots so1ensu 00g spn Du) EDDBSEO PPAYS OH weaso09sso spay gag eno0eaze~ oos-05¢7 cluemAAL PEPE ays 1208 40NOTES a