For use with PT-19XLS / PT-600 ESAB Assembly Number: 37439

Transcription

1 Bubble Muffler System For use with PT-19XLS / PT-600 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. F /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! 2

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 The Bubble Muffler System creates a bubble of air so that a PT-19XLS 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 Optional Accessories 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/Water Nut 3/8" ID Hose Nipple P/N Fittings 3/8" Hose to Bubble Muffler P/N 36Z40 1 R.H. Air Water 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 Bubble Muffler System 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

8 Section 2 installation A. Installation of Bubble Muffler Assembly on PT-19XLS Torch (Figure 2) 1. Remove the Nozzle Retaining Cup from the torch. 2. Slide the chrome plated Air Curtain Body, P/N 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 air curtain body are lightly lubricated with silicone grease. 3. Install Nozzle Retaining Cup P/N 37431, and any front-end parts you may have removed from the torch including the nozzle, shield, diffuser and shield retainer. 4. Install Air Curtain Sleeve, P/N 37436, over the completely assembled torch and snap it into the Air Curtain Body. Secure the sleeve by installing the Bubble Muffler Retainer, P/N 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 1/16 inch from the end of the air curtain sleeve as illustrated in Fig. 1. Lock the Bubble Muffler in place by tightening the Allen screw on the Bubble Muffler. NOTE: The Air Curtain Sleeve must remain completely bottomed in the Curtain Body for the adjustment in step 5 to be correct. B. Installation of the Water Pump (P/N ) WARNING If a bubble muffler is being used, turn off water recirculating pump. Figure 1. Installation of Water Pump 8

9 Section 2 installation 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 V 380 V 400 V 415 V Multiply Nameplate HP By C. Installation of the Control Box Assembly (P/N 33383) 1. Mount the control box at a convenient location and use the 3/8" ID hose to connect the box with the Bubble Muffler mounted on the torch. 2. Connect the control box to a source of oil free shop air capable of delivering at least 20 scfm at 80 psig. The hose used should be at least 3/8" ID. 3. Use SJO wire to connect the control to the water pump, in parallel with the 115VAC signal from the ESP or cutting machine control. The connection of the control is made at the terminals marked F. C. 4. The user supplied 115 V ac may be connected to the terminals so marked. This will allow manual operation of the air curtain control. 5. Connect a ground wire to the stud provided in the control box. D. Operation 1. Provide control box with oil free air at 80 psig minimum. Energize solenoid in control box and adjust regulator screw on box to 15 psig delivery. Some adjustment up or down of pressure may be required to get best cut quality. 2. Place switch to AUTO. The system should turn on when the preflow begins. The pump will recirculate approximately 20 gpm from the water table. 9

10 Section 2 installation 10

11 Section 3 replacement parts E. Servicing Refer to Figure 2 for Bubble Muffler O-ring part numbers and Figure 3 for air curtain box assembly component part numbers. Replacement parts may be ordered from an ESAB distributor or from: ESAB Welding & Cutting Products Attn: Customer Service Dept. P.O. Box S. Ebenezer Road Florence, SC Torch Body (Ref.) Figure 2. Bubble Muffler PT-19XLS, P/N " Ref. 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. 11

12 Section 3 replacement parts 8*, * Air Regulator and pressure gauge are supplied together as item 8. Regulator w/gauge P/N Figure 3, Air Curtain Control Box Assembly, P/N ITEM QTY. PART NO. REQ. NO. description W38 CONNECTOR, STRAIN RELIEF TERMINAL, BLOCK, 4 POSITIONS SWITCH, DPDT 3 POSITIONS V75 ADAPT. BULKHD. B SIZE, 1/4 NPT W82 ELBOW, STREET 90 BRASS SOLENOID VALVE NIPPLE, CLOSE, 1/4 NPT BR. M TO M REGULATOR W/GAUGE PLUG, 1/8" NPT ALLEN HEAD NIPPLE, 2" LG. 1/4NPT BRASS M TO M TEE, 1/4 NPT BRASS 12

13 NOTES 13

14 NOTES 14

15 revision history 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