plasmarc air curtain For use with m3 Plasma System and PT-36 Plasma Torch ESAB Assembly Number: Instruction Manual gas the bottom of the plate.

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1 plasmarc air curtain For use with m3 Plasma System and PT-36 Plasma Torch ESAB Assembly Number: Instruction Manual WARNING The Air Curtain 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 WARNING ELECTRIC SHOCK CAN KILL! Installation DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH- ING OR SERVICING THE Air Curtain AT THE TORCH. DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING. The Air Curtain is a device used to improve the performance of Plasmarc cutting torches when cutting underwater. The device mounts onto the torch and produces a curtain of air. This allows the plasma arc to operate in a relatively dry zone to reduce noise, fume, and arc radiation, even though the torch has been submerged. Compressed Air Supply (Air Curtain) Source: cfh ( m 3 h) Clean, dry & oil-free shop air Optional Accessories Adapt B-A/W*F B-A/W*M 90 deg assy P/N 19X19 7

8 Section 2 Installation WARNING ELECTRIC SHOCK CAN KILL! DISCONNECT POWER TO PLASMA POWER SOURCE BEFORE TOUCH- ING OR SERVICING THE AIR CURTAIN AT THE TORCH. DISCONNECT POWER TO CONTROL BOX BEFORE SERVICING. Plasma Torch Body P/N Reference Torch Body 1 2 P/N Split Level Bushing P/N Body P/N Nozzle Retaining Cup 3 P/N Reference Shield P/N Shield Retainer P/N Sleeve 4 5 P/N Retainer (1/16) in. 8

9 Section 2 Installation NOTE: Remove existing Nozzle Retaining Cup before installing air curtain. Installation of Air Curtain Assembly on plasma torch 1. Slide Split Bushing on to stainless steel body of torch as shown. 2. Slide the chrome plated Air Curtain Body, P/N 37438, onto the stainless steel body of the torch. Snug locking collar screw on air curtain body. Final positioning of air curtain will be done as a last step. NOTE: It will ease assembly if all o-rings in the air curtain body are lightly lubricated with silicone grease. 3. Install Nozzle Retaining Cup, P/N 37431, 4. Assemble shield in shield retainer separately to assure proper metal to metal contact. 5. Hand tighten shield and retainer assembly on torch. Double check shield / retainer for proper seating. 6. Install an Air Curtain Sleeve, P/N 37436, over the completely assembled torch and push it into the air curtain body until fully seated. 7. Secure the sleeve by installing the Air Curtain Retainer, P/N The retainer turns to engage or disengage with the locking pins. 8. Adjust the position of the Air Curtain Assembly on the torch until the shield gas cup clearance is 0.06 inch from the inside surface of the air curtain sleeve as illustrated. Lock the air curtain in place by tightening the Allen screw on the air curtain. NOTE: The Air Curtain Sleeve (37436) must remain completely bottomed in the Air Curtain Body for adjustment to be correct. 9

10 Section 2 Note: For a complete listing of all available lengths and part numbers for air curtain hose assemblies refer to m3 plasma system instruction manual. 25 Micron Filter Installation SGC or ACC Compressed Air Supply (Air Curtain) Source: cfh ( m 3 h) Use clean, dry, oil free shop air Air Curtain Hose PGC/BPR or CGC/BPR Torch Lead PT-36 Plasma Torch Workpiece Air Curtain Hose Air Curtain Assembly Earth Ground 10 Work Table

11 Section 3 replacement parts Replacement Parts for Air Curtain - P/N O-ring (Item 7) not supplied with assembly. Shown for reference only Item Part Number Description Split Bevel Bushing Air Curtain Body Air Curtain Retainer Nozzle Retaining Cup Assembly Shield Retainer, Insulated Air Curtain Sleeve 7 85W87 O-ring, Neoprene O-ring - use with Water Muffler ONLY O-ring, Neoprene O-ring, Silicone Rubber O-ring, Neoprene 11

12 NOTES 12

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15 revision history 15

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