BUBBLE MUFFLER SYSTEM

Transcription

1 BUBBLE MUFFLER SYSTEM For use with m3 Plasma System and the PT-36 Plasma Torch ESAB Assembly Number: Instruction Manual WARNING The Bubble Muffler CAN NOT be used when using H-35 or CH 4 gas mixes. The water level must be lowered 4 to 6 inches beneath the bottom of the plate. Failure to comply to this warning can result in a hydrogen detonation /2011

2 Be sure this information reaches the operator. You can get extra copies through your supplier. caution 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 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 before installing or operating this equipment. USER RESPONSIBILITY This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions 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 immediately. 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 service facility designated by the manufacturer. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS!

3 table of contents Section / Title Page 1.0 Safety Precautions Installation Replacement Parts

4 table of contents 4

5 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. Enclosure Class The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP23S may be stored, but is not intended to be used outside during precipitation unless sheltered. CAUTION If equipment is placed on a surface that slopes more than 15, toppling over may occur. Personal injury and / or significant damage to equipment is possible. Maximum Tilt Allowed 15 5

6 section 1 safety precautions WARNING WELDING AND PLASMA CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING OR 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 INSTALLING OR OPERATING. PROTECT YOURSELF AND OTHERS! CAUTION This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage. CAUTION To avoid personal injury and/or equipment damage, lift using method and attachment points shown here. 6

7 Section 2 INstallation ELECTRIC SHOCK CAN KILL! WARNING DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH- ING OR SERVICING THE BUBBLE MUFFLER AT THE TORCH. DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING. The Bubble Muffler System creates a bubble of air so that a Plasmarc Cutting Torch can be used underwater with slight sacrifice of cut quality. This system also permits operation above water as the flow of water through the muffler reduces fume, noise, and arc U.V. radiation. Compressed Air Supply (Air Curtain) Source: cfh ( m 3 h) Clean, dry & oil-free shop air Bubble Muffler System Optional Accessories Bubble Muffler PT-19XLS P/N Strainer P/N Water Pump P/N Adaptor, F 3/4" Hose P/N Adaptor, 3/4" NPTM, 3/4" Hose P/N PIP, Pipe S.ST 2.357X2.00 CL P/N Bushing Pipe 2X3/4 P/N Control Box Assembly P/N Control Cable, 18 GA, 3-Cond P/N ft. Control Cable, 18 GA, 3-Cond P/N ft. Control Cable, 18 GA, 3-Cond P/N ft. Control Cable, 18 GA, 3-Cond P/N ft. Control Cable, 18 GA, 3-Cond P/N ft. Fittings 3/8" Hose Control Box P/N 10N40 1 B-Air/ Nut 3/8" ID Hose Nipple P/N Fittings 3/8" Hose to Bubble P/N 36Z40 1 Muffler R.H. Air Nut P/N 03Z74 1 3/8" ID Hose Nipple Hose, 3/4" ID for Water P/N Specify Length Hose, 3/8" ID for Air P/N Specify Length Adapt B-A/W*F B-A/W*M 90 deg assy P/N 19X19 1 7

8 Section 2 INstallation A. Installation of Bubble Muffler Assembly on Plasma Torch (Figure 2) 1. Remove the Nozzle Retaining Cup from the torch. 2. Slide the chrome plated Bubble Muffler Body on to the stainless steel body of the torch. Split Bushing P/N should be in place. NOTE: It will ease assembly if all o-rings in the bubble muffler body are lightly lubricated with silicone grease. 3. Install Nozzle Retaining Cup P/N and any front-end parts you may have removed from the torch including the nozzle, shield, diffuser and shield retainer. 4. Install Bubble Muffler Sleeve over the completely assembled torch and snap it into the Bubble Muffler Body. Secure the sleeve by installing the Bubble Muffler Retainer. The Retainer turns to engage or disengage with the locking pins. 5. Adjust the position of the Bubble Muffler Assembly on the torch until the nozzle extends 0.06" from the end of the bubble muffler sleeve as illustrated in Figure 1. Lock the Bubble Muffler in place by tightening the Allen screw on the Bubble Muffler. NOTE: The Bubble Muffler Sleeve must remain completely bottomed in the Muffler Body for the adjustment in Step 5 to be correct. 8

9 Section 2 INstallation B. Installation of the Water Pump (P/N ) WARNING If a bubble muffler is being used, turn off water recirculating pump. m3 Plumbing Box 0.75" ID Hose Pump Water Torch Bubble Muffler Water Table Inlet Strainer Control Cable Pump Appropriate Amphenol Connector On Back Cutting Machine CNC Power Figure 1. Installation of Water Pump Bubble Muffler Pump Input Voltage 50 Hz Operation of ESAB 60 Hz Motors To Use On Hertz Hertz Operational Voltage Motor Ratings +5% 230 V 190 V 200 V 208 V 460/575 V 380 V 400 V 415 V Multiply Nameplate HP By 9

10 Section 2 Note: For a complete listing of all available lengths and part numbers for bubble muffler hose assemblies refer to m3 plasma system instruction manual. 25 Micron Filter See Detail "D" INstallation Shield Gas Box Compressed Air Supply (Air Curtain) Source: cfh ( m 3 h) Use clean, dry, oil free shop air See Detail D for location of air pressure regulator / gauge Bubble Muffler Hose See Detail "C" See Detail "B" Plasma Gas Box See Detail "A" Torch Lead Bubble Muffler Hose Bubble Muffler Assembly Plasma Torch Workpiece Earth Ground 10 Work Table

11 Section 2 INstallation Detail "A" Note: For Bubble Muffler hose assembly connector details refer to m3 plasma system instruction manual. Torch Leads For torch lead connection details refer to m3 plasma system instruction manual. Bubble Muffler Connection (to air curtain assembly) Plasma Gas Box Detail "B" 11 Bubble Muffler Connection

12 Section 2 Detail "C" INstallation Note: For Bubble Muffler hose assembly connector details refer to m3 plasma system instruction manual. Bubble Muffler Connection Shield Gas Box Air Pressure Regulator Remove outer enclosure and adjust between psi ( bar) Air Pressure Gauge Bubble Muffler Connection (air supply) Detail "D" 12

13 Section 3 replacement parts Replacement Parts for Bubble Muffler - P/N Torch Body (Ref.) " Ref. Figure 2 - Bubble Muffler Item Part Number Description BUSHING SPLIT BEVEL A/C BODY A/C RETAINER BUBBLE MUFFLER CUP NOZZLE RETAINING O-RING, 3" ID X 3-3/16" O.D. X 3/32" O-RING, ID X.103W NEOPRENE O-RING, ID X.103W SILICONE RUBBER O-RING, ID X.070W NEOPRENE 70A SLEEVE PT-19XLS A/C Shield Retainer, Insulated O-RING, ID X.139W NEOPRENE NOTE: 4 each of the above o-rings are supplied. 13

14 NOTES 14

15 revision history Revision 03/ added 19X19 to optional accessories. Revision 08/ Updated BOM's, changed p/n to p/n per CCARES

16 ESAB Welding & Cutting Products, Florence, SC COMMUNICATION GUIDE - CUSTOMER SERVICES A. CUSTOMER SERVICE QUESTIONS: Telephone: (800) / Fax: (800) Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns B. ENGINEERING SERVICE: Telephone: (843) / Fax : (800) Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations D. LITERATURE REQUESTS: Telephone: (843) / Fax: (843) E. WELDING EQUIPMENT REPAIRS: Telephone: (843) / Fax: (843) Repair Estimates Repair Status F. WELDING EQUIPMENT TRAINING Telephone: (843) / Fax: (843) Training School Information and Registrations G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 3:30 PM EST Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 4:00 PM EST Hours: 7:30 AM to 5:00 PM EST IF YOU DO NOT KNOW WHOM TO CALL Telephone: (800) ESAB-123 Fax: (843) Hours: 7:30 AM to 5:00 PM EST or visit us on the web at The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback & Support