PARTS & MAINTENANCE MANUAL for
F-15-031-B
July,1995
PT-15XL PLASMARC CUTTING TORCH
P/N 21307 ............................. 4 1/2' Leads for ESP System
P/N 21304 ............................. 6' Leads for ESP System
P/N 21305 ............................. 12' Leads for ESP System
P/N 21306 ............................. 17' Leads for ESP System
P/N 21301 ............................. 15' Leads for ESP System
P/N 21302 ............................. 20' Leads for ESP System
P/N 21303 ............................. 25' Leads for ESP System
P/N 16365 ............................. PT-15XL w/o Leads
P/N 20762 ............................. 6' Leads for PCM-8
P/N 602711 ........................... 8' Leads for PCM-8
!
CAUTION
These instructions are for experienced operators. If you are not fully familiar with the principles of
operation and safe practices for electric welding 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.
the safety precautions in this literature and in Form
15-116 “ESP-1000 system” or Form 12-528 “PCM-8
Plasma Cutting Outfit.” Also read form 52-529 “Precautions & Safe Practices, etc. and Form 14-373
“Hydrogen Explosion Hazard” both supplied with
this torch.
NOTICE: This torch and its components are protected by
various U.S. and foreign patents with additional patents
pending. It is the policy of ESAB Welding & Cutting
Products to react vigorously to patent infringement of
unauthorized manufacture, sale, or use of its patented
products or spare parts.
F-15-031B
!
I. INTRODUCTION
DANGER
High Voltage can kill
The PT-15XL torch, an improved version of the original
PT-15, is a component of the PCM-8 Plasmarc Mechanized Cutting Package (see Form 12-528) and the ESP1000 System (see Form 15-116). It is designed for
plasma water injection cutting using either nitrogen (up
to 750 amps DCSP), or oxygen (up to 360 amps DCSP),
or H-35 mixture (up to 1000 amps DCSP). Each gas
requires proper front end parts (see Table 1). With
nitrogen, 1/8-in. to 3-in. thick mild steel, stainless steel,
and aluminum can be cut. Steels up to 1-1/4 in. thick can
be cut using oxygen. A high-current nozzle is available
for cutting materials from 3-in. to 6-in. thick with the PT15XL at up to 1000 amps. The nozzle is water cooled and
requires the use of H-35 mixture (65 Ar-35 H2) for the cut
gas.
Disconnect Power supply from incoming electrical
power before touching or servicing the torch. Metal
parts of the torch can be at high voltage.
Plasma Cutting can produce Deadly Fumes, Fire, or
Explosion.
• Gases from plasma cutting can cause suffocation, fire, or explosion.
• Loud noise from plasma cutting can cause hearing loss.
!
DANGER
Before beginning use of the PT-15XL Torch refer to
Be sure this information reaches the operator.
You can get extra copies through your supplier.
ESAB
1
ESAB Welding &
Cutting Products
22
33
Table 1 - PT-15 XL Plasma Arc Cutting Torch
Front End Consumables
Nozzle
Electrode
Nitrogen w/
Water
Injection
Argon
H-35
600236
600236
ELECTRODE
HOLDER
2075343
2075343
NOZZLE ASSEMBLY
DIA.
.125
.156
.200
.230
P/N
2075691
2075611
2075612
2075613
RATING
250A
400A
600A
750A
.125 Rev.
.156 Rev.
.200 Rev.
.230 Rev.
2075692
2075614
2075615
2075690
250A
400A
600A
750A
.250
2075587
.099
20751*
21206B
SWIRL BAFFLES
OPTIONAL
STANDARD
**4 Hole
(Plastic)
2075341
**4 Hole
Reverse
(Plastic)
2075360
**8 Hole
875 A
(Pink Ceramic)
1000 A
2075586
**4Hole
(Pink Ceramic)
948142
**4 Hole Reverse
(Pink Ceramic)
948143
None
**8 Hole
(Pink Ceramic)
2075586
**4 Hole
(Pink Ceramic)
948142
**8 Hole
Reverse Swirl
(Pink Ceramic)
20918
**4 Hole
Reverse Swirl
(Pink Ceramic)
948143
260A
20920*
.099 Rev.
21207B
NOTES
Plastic baffles are usually preferred for nitrogen cutting.
Only ceramic baffles
may be used with over
800A .
Only ceramic baffles
may be used with oxygen cutting
20398
.116
.120
35666
(Flat)
Oxygen w/
Water
Injection
(Beveling)
Oxygen
Electrode
Holder
Oxygen
Nozzle
20763
Oxygen w/
Water
Injection
Baffle
Baffle
Retaining Cup
PROCESS ELECTRODE
Oxygen
Electrode
Gasket
Electrode Holder
34086
(PT-19
Long)
35662
35664
.116 Rev. 35663
.120 Rev. 35665
.0995
35568
.0995
35569
34084
Rev.
300A
340A
300A
340A
35660
Baffle, Std.
**8X.047
Dia Holes
(Pink Ceramic)
35661
Baffle, Rev.
**8X.047
Dia Holes
(Pink Ceramic)
Ceramic on Nozzle is
Replaceable
P/N 21193
None
2075586
**8 Hole
260A
Reverse
20918
**8 Hole
Reverse
*Nozzle, 21206B and 21207B have a replaceable insulator, P/N 21193; Nozzles 20751 and 20920 do not.
**8-Hole Baffles are recomended for ESP Units. 4-Hole Baffles are recomended for PCM-8.
4-Hole Optimizes Squareness.
8-Hole Optimizes Consumable Life
Cutting conditions have been developed which use the 340Amp nozzle at 360 Amps.
4
Used With PT-19XL
Air Curtain, P/N 34752
& P/N 35570 Retaining Cup
35570 -CUP, NOZZLE RETAINING
34086 - ELECTRODE, HF
2075586 -8 HOLE BAFFLE, GAS SWIRL, CERAMIC - 20918 REVERSE
948142 - 4 HOLE BAFFLE, CERAMIC - 848143 REVERSE
35568 - NOZZLE PT-15 O2
BEVEL - 35569 REVERSE
34084 - ELECTRODE HOLDER ASSY
CURRENT - 260 Amps
OXYGEN - SET O2 FLOW AT 100 SCFH, (Low 5 on ESP Flow Control)
WATER - SET WATER FLOW AT 0.51 GPM, (High 7 on ESP Flow Control)
INLET TO TORCH PRESSURE - 35-42 PSI AT TORCH - CUTTING
25 PSI AT TORCH - STARTING
PT-15XL Plasmarc Cutting Torch For Bevel Cut
Water Swirl•
Spacer•
Spacer•
Insulator
Water Swirl•
Nozzle Base
Insulator
Nozzle
Base
0.250" DIAM.
Gasket•
Gasket•
Centering Sleeve•
Centering Sleeve•
Nozzle Assy
High Current Nozzle Assy
Table 2 - Repair Parts for N2 and H-35 Nozzles
CURRENT
NOZZLE ASSY.
NOZZLE BASE
INSULATORS
RATING
Std. Swirl
Rev. Swirl
P/N
Orif. Dia
Std.
Orif. Dia
250A
2075691
2075692
2075694
.125
2075693
.140
400A
2075611
2075614
2075608
.156
2075617
.180
600A
2075612
2075615
2075609
.200
2075606
.225
750A
2075613
2075690
2075610
.230
2075607
.260
1000A
2075587
-
19810
.250
2075588
-
•Spacer - 996619
Gasket - 996628
Centering Sleeve - 996618
Std. Water Swirl Ring - 2075584
Rev. Water Swirl Ring - 2075616
5
PT-15 XL Plasma Arc Cutting Torch Retaining Cups
N2 & AR-H2 Retaining
Cup
P/N 20759
Standard cup with large feet
used for flat plate cutting with or
without standard water muffler
using Nitrogen or H-35.
Oxygen & Beveling Retaining Cup
P/N 20758
No Feet Retaining Cup
P/N 20973
Used where feet are an obstruction. This cup should not
be used with the Omni Height
Control.
Cup has smaller feet and steeper
sloping sides required for beveling
up to 45˚. It is also used for oxygen
cutting, straight cutting, beveling with
any gas, and is required with a bubble
muffler or air curtain. Note that long
beveling nozzles require a different
cup. (see Figure at top of page 5).
Corrosion Resistant
Retaining Cup P/N
21217
Same as oxygen beveling cup
but designed to resist corrosion
in service with conductive water.
RETAINING CUP NOTES
PT-15 XL cups are longer to engage an O-ring on the torch body protecting the threads when cutting underwater.
PT-15 "O" Original cups may be used with the PT-15 XL torch.
a) Some difficulty might be experienced getting the cup started onto the threads.
b) The threads will not be sealed.
PT-15 XL cups cannot be used with the PT-15 "O" torch assembly.
PT-15 "O" cups can be used with PT-15 XL torch bodies and front insulator body P/N 996232 without difficultly.
Notes on PT-15 "O" & PT-15 XL Replacement Parts
The following PT-15 "O" P/N's have been superseded
PT-15 "O"
996252
996240
PT-15 XL
20762
20754
Description
Torch Assembly
Body Assembly
The PT-15 XL body assembly is completely interchangeable with the PT-15
"O" body assembly and can be used to repair and maintain the PT-15 "O" as
standard PT-15 "O" assemblies
No other PT-15 "O" parts have been discontinued or superseded.
INTERCHANGEABILITY
The following components have not changed
between PT-15 "O" & PT-15XL:
XR Nozzles
Electrodes
Electrode Holder
Baffles
Boot Hose
Nozzle Removal Tool
Electrode Removal Tool
Power Cables
Gas Hose
Water Hose
Sleeve
O-Rings
Contact Ring
Clamp
FRONT INSULATOR BODIES AND
PILOT ARC COMPONENTS
The PT-15 "O" insulator body (P/N 996232) can be used in a PT-15 XL torch
assembly if:
The PT-15 "O" pilot arc cable (996251) is used and the
PT-15 XL torch is NOT used with oxygen.
The PT-15 XL insulator Body (P/N 20755 can be used in a PT-15 "O" torch
assembly if:
The PT-15 "O" pilot arc cable is replaced with:
P/N
20760
21082
20403
20408
20409
6
Description
Pilot Arc Cable
Pilot Arc Bus Wire
Pilot Arc Insulator
HF Connector
HF Connector Insulator
The PT-15XL is ruggedly designed to eliminate double
arcing, high frequency leakage, and electrolytic corrosion of parts. Marked improvements are made in electrode cooling and nozzle-electrode concentricity. As a
result, arc ignition is more reliable; the nozzle, electrode, and other components will last longer; and cut
angles will be uniform and will not vary when changing
the direction of torch travel. This makes the PT-15XL
ideal for shape cutting.
B. OPTIONAL ACCESSORIES
1. PT-15XL /N2 Cut Gas Spare Parts Kit, P/N 999906.
Recommended for maintaining the PT-15XL torch
with minimum downtime.
P/N 999906 Nitrogen Kit contains the following PT15XL, parts and tools:
4 - 0.125" Nozzle Assembly, P/N 2075691
8 - 0.156" Nozzle Assembly, P/N 2075611
6 - 0.200" Nozzle Assembly, P/N 2075612
2 - 0.230" Nozzle Assembly, P/N 2075613
10 - Electrode Tip, P/N 600236
1 - Electrode Tip Holder, P/N 2075343
4 - Gas Swirl Baffle, P/N 2075341
1 - Nozzle Retaining Cup, P/N 20759
1 - Insulator Body, P/N 20755
1 - Pilot Arc Cable, P/N 20760
1 - Contact Ring Assembly, P/N 996341
10 - O-ring, P/N 86W85
20 - O-ring, P/N 996526
10 - O-ring, P/N 996527
10 - O-ring, P/N 996528
1 - Nozzle/Elec. Tip Holder Removal Tool, P/N 999630
1 - Electrode Tip Removal Tool, P/N 996568
1 - 1/16" Allen Wrench, P/N 93750006
1 - Silicone Grease (1 oz. tube), P/N 17672
1 - Tool Box, P/N 950561
This booklet covers only the accessories, maintenance,
and replacement parts for the PT-15XL torch. For complete installation and operating instructions for the torch,
refer to the PCM-8 booklet, 12-528 or ESP 1000 Booklet
15-116.
II. ELECTRODES, NOZZLES, BAFFLES, &
CUPS
A. REQUIRED ACCESSORIES.
The PT-15XL torch is supplied with front end parts for
water injection cutting using nitrogen cutting gas with
currents up to 400 amps DCSP. Available nozzles and
electrodes are listed on page 4.
Typical cutting conditions on each nozzle assembly, are
in the operating table in the PCM-8 & ESP 1000 booklets.
ELECTRODE TIP (O2 )
Note:
All Set Screws Are Stainless Steel & Should Only
Be Replaced With Stainless Steel or Brass Screws.
TIP HOLDER (O2 ) - 20763
20763 (Pkg. OF 4)
Includes O-Ring - 86W99
O 2 NOZZLE ASS'Y
20751*
* See Table 1
For Options
Oxygen Cutting Parts
GAS SWIRL BAFFLE
(Ceramic) - 948142*
CONTACT RING ASS'Y - 996341
Includes: Setscrew, No. 6-32 X 3/16 lg.(Cup Point)
Screw, No. 6-32 X 1/2" lg.
View "A"
View "B"
Pilot Arc Cable
& Connections
NOZZLE RETAINING
CUP -20759
LOCATING PIN 996242
O-RING - 996528•
NOZZLE ASS'Y -2075611
(See Fig. 4)
Hose &Cable
Connections
(See Fig. 3)
(Supplied) See Table 1
O-RING - 996527•
B
A
ELECTRODE TIP (N2 )
600236
TIP HOLDER
*GAS SWIRL
BAFFLE -2075341
(Poly)
(N 2 ) -2075343
Includes: O-Ring - 86W99
FRONT BODY
INSULATOR ASS'Y
20755
(Includes Items Marked•)
BODY ASS'Y - 20754
NOT SHOWN:
O-RING - 86W85• (1/2" I.D.)
(2) O-RING - 996526• (5/32" I.D.)
O-RING - 2064106•
(1-5/16" I.D.)
Figure 1 - PT-15XL Torch Front End Parts
7
2. P/N 20813 Oxygen Kit contains the following PT15XL parts and tools:
4-0.098" Nozzle Assembly, P/N 21206B
8-Electrode Tip, P/N 20763
1-Electrode Tip Holder, P/N 20398
4-Gas Swirl Baffle, P/N 2075586
1-Nozzle Retaining Cup, P/N 20758
1-Insulator Body, P/N 20755
1-Pilot Arc Cable, P/N 20760
1-Contact Ring Assembly, P/N 996341
10-O-ring, P/N 86W85 .468 I.D.
20-O-ring, P/N 996526 .145 I.D.
10-O-ring, P/N 996527 1.30 I.D.
10-O-ring, P/N 996528 1.614 I.D.
1-Nozzle/Elec. Tip Holder Removal Tool, P/N 999630
1-Electrode Tip Removal Tool, P/N 996568
1-1/16" Allen Wrench, P/N 93750006
1-Silicone Grease (1 oz. tube), P/N 17672
1-Tool Box, P/N 950561
1-Retainer For Front Body Insulator P/N 33768
3.Reverse Swirl Nozzles and Gas Baffle
Standard swirl produces the least bevel on the right
hand side of the cut, as viewed in the direction of
travel. Sometimes, such as when mirror image cutting, it is desirable for the square side to be on the left.
This requires the use of reverse swirl Nozzles and
Baffles. See Table 1 for P/N's. DO NOT mix standard
and reverse swirl parts on the same torch!
A. Underwater cutting (N2 ONLY)
1. Simply immersing the top of the workpiece under 2" to
3" of water markedly reduces fume and noise. Materials up to 1" thick can generally be cut underwater
with slight reductions in speed and quality.
2. Underwater cutting substantially reduces speed and
quality on thicker plates, especially aluminum. Cutting
plates thicker than 3 inches underwater is not recommended.
3. Cutting underwater with Argon-Hydrogen is not recommended as explosive gas mixtures may collect in
the water table.
4. Underwater cutting with O2 requires the use of a
Bubble Muffler or Air Curtain.
B. Air Curtain - The air curtain directs a flow of air around
the arc which permits underwater cutting with O2 gas.
See Form 15-128 for details.
Standard Air Curtain Kit P/N 21385
Beveling Air Curtain Kit P/N 21404
C. Bubble Muffler - This device traps a bubble of air
around the arc using water recirculated from the water
table. This allows use of O2 under water. The water
flow acts as a shield to block radiation and trap fumes
so that protection is also afforded when cutting above
water. See form 15-127 for details.
4. Oxygen and Beveling Nozzle Retaining Cup, P/N
20758 - Permits beveling up to 450. Required for use
with Air Curtain or Bubble Muffler.
Bubble Muffler system P/N 2232615
5. Corrosion Resistant Nozzle Retaining Cup P/N
21217. This cup has the same shape as the cup,P/N
20758 above but is insulated to reduce corrosion in
service with conductive cut water. This insulation
does not make it safe to touch the torch with the
power source on.
D. Water Muffler - this device is used for suppression of
fume and noise when cutting with N2 above water.
Contact your cutting machine representative for details.
6. Two Piece O2 Nozzle Assemblies: 21206B (STD) &
21207B (Rev.) These nozzles have a replaceable
ceramic insulator (P/N 21193).
IV. Maintenance (Refer to Figures 2 thru 5)
7. Retainer for Front Body Insulators: 33768, can be
used to prevent movement of front body insulator
when servicing torch.
Electric Shock can kill.
Disconnect Power Source from incoming electrical
power before touching or servicing the torch. Metal
parts of the torch can be at high voltage.
III. FUME & NOISE REDUCTION
Never use oil or grease on this torch. Handle parts
only with clean hands on a clean surface. Oil and
grease are easily ignited and burn violently in the
presence of oxygen under pressure. Use silicone
lubricant only where directed.
!
!
WARNING
H2 explosions can kill. H2 explosions can result from
cutting underwater, especially when cutting active
metals such as aluminum or magnesium. See Form
14-373 (supplied with torch) or forms 12-528 or 15116 for more information.
DANGER
A. Removal & Replacement of Nozzle Assembly
1. Unscrew the nozzle retaining cup from the torch. If
the fine threads on the nozzle retaining cup and
torch body are dirty, clean and then spray the 8
threads with a commercially available silicone spray
to prevent thread damage or cross-threading during
reassembly.
2. To remove the nozzle assembly, grip the nozzle
assembly with the slotted tubular tool (999630 supplied with the torch) and pull straight out.
3. Apply a very light coating of silicone grease (17662,
1 oz. tube) around the outer periphery of the copper
body on the nozzle assembly. (This will lubricate the
O-ring in the torch body when inserting the nozzle
assembly.) Make sure the silicone rubber gasket is
set evenly around the shoulder of the ceramic nozzle
insulator on the nozzle assembly. Handle the nozzle
assembly carefully to avoid breaking the insulator.
4. Place the nozzle assembly inside the retaining cup by
locating the ceramic insulator through the hole of the
retaining cup.
5. Carefully assemble the retaining cup onto the torch
and tighten slowly until HAND TIGHT. The nozzle
assembly will seat against the gas swirl baffle. Do
NOT over-tighten. (Holes in the plastic gas swirl
baffle may squeeze close and restrict the gas flow,
ceramic baffles may break. Improper seating or a
poor gasket will be revealed by an uneven cutting
water spray once the torch is set up.)
B. REPLACING ELECTRODE AND GAS SWIRL BAFFLE
1. Remove retaining cup and nozzle assembly as described above in Sect. IV-A. Front insulator retainer
P/N 33768 may be installed to prevent movement of
front insulator body.
2. Remove electrode by using the 7/16" nut driver
(996568) supplied with the torch). If electrode holder
did not come out with the electrode, then remove it by
using removal tool (999630) supplied with the torch.
The lugs will engage with the slots on the top holder.
To avoid damaging the gas baffle when removing or
reassembling the electrode, hold the nut driver or
removal tool straight.
The gas swirl baffle should come out with the electrode holder. If it does not, remove by using one
finger.
3. If using nitrogen or H-35 for cutting gas, replace
electrode (600236) if the tungsten insert is pitted
more tha 0.030-in. Cracks in the insert are normal.
When using oxygen for cutting gas, replace electrode tip (20763) if the hafnium insert is pitted more
than .090-in. or if a crater more than 0.120-in.
diameter has formed.
4. Check O-ring (86W99) inside tip holder periodically. If nicked, it should be replaced exercising
care to avoid scratching the O-ring groove. Lubricate new O-ring lightly with silicone grease before
installing it into the tip holder.
5. Replace the gas swirl baffle if it is cracked or if the
front edge (nozzle seating surface) is chipped.
6. When reassembling slip the gas swirl baffle over
the electrode tip - tip holder assembly. Apply a light
coating of silicone grease (about 1/4-in. wide band)
just below the water exit holes and chamfer of the
tip holder. Then screw the electrode assembly into
the torch using 7/16" nut driver. Tighten firmly but
do NOT overtighten.
C. REPLACING THE INSULATOR BODY
The plastic insulator body (20755) should be removed
periodically and inspected for cracking and for possible
replacement of O-rings. To remove the insulator body,
do the following:
1. Remove nozzle retaining cup, nozzle assembly,
electrode tip, tip holder, and gas swirl baffle as
described previously.
2. Pull the insulator body straight out.
NOTE: The pilot arc cable will be attached, so allow
plenty of slack.
3. Lubricate the O-rings lightly with silicone grease. If
necessary, replace O-rings.
4. If replacing the insulator body, disconnected the
pilot arc cable by loosening the setscrew with the
1/16: Allen wrench (supplied with torch) at the
contact right assembly (996341). Remove contact
ring assembly from the insulator body by removing
one socket head screw with a 7/64" Allen wrench
(not supplied).
5. Reassemble in reverse order. Align insulator body
with locating pin (996242) and push in.
BOOT HOSE - 996647
CLAMP INSULATOR BUSHING - 996342
FRONT END
CLAMP - 996565
SLEEVE - 19483
(See Table 1)
Supplied:
Nozzle & Electrode Tip Removal Tool - 999630
Electrode Tip Removal Tool - (7/16" Nut Driver) - 996568
1/16" Allen Wrench - 93750006
Dimensions & Weight
Length
Diameter
Diam of Ins. Bushing
Weight (Less Service Lines)
Shipping Weight
15-1/2-in.
2-in.
2-1/4-in.
3.5 lbs.
16 lbs.
Figure 2 - PT-15XL Plasma Arc Cutting Torch Assembly
9
NOTE
For Service Lines Supplied
(See Figure 3)
GAS HOSE
CONNECTION
3/8 X 24 R.H.
"CUT WATER" INJECTION
HOSE CONNECTION
7/16 X 20 R.H.
WATER OUT
CABLE CONNECTION
7/16 X 20 R.H.
PILOT ARC CABLE (8') - 20760
Not Shown:
CONNECTOR - 20408
(2) SETSCREW - #6-32 X 1/4"
INSULATOR - 20409
COOLING WATER INJECTION
HOSE CONNECTION
7/16 X 20 L.H.
POWER CABLE (6')
996248*
7/16 X 20 L.H.
POWER CABLE (6')
996248*
WATER INJECTION
HOSE ASS'Y
(6') - 996250
5/18 X 18 R.H.
7/16 X 20 R.H.
5/18 X 18 R.H.
GAS HOSE ASS'Y
(6') - 996249
NOTE - 6 ft. Cables
and Hoses for 20762
Torch Shown.
Refer to Tables on
Page 11 For Other
Lengths.
* Note That 996248 Power Cables have 7/16 X 20 R.H. Thread At One End, 7/16 X 20 L.H. At The Other.
Figure 3 - PT-15XL Hose and Cable Assemblies (supplied with torch) and Connections
10
CONTACT RING ASS'Y
996341
PILOT ARC CABLE SET SCREW
Remove to Release Pilot Arc Cable
Use 1/16" Allen Wrench (Supplied with torch)
(2) O-RING - 951000
.176 ID X .050W
INSULATOR BODY
SOCKET HEAD SCREW
VIEW "A"
SEE
VIEW "A"
Remove to Release Contact Ring
Use 7/16" Allen Wrench (Not Supplied)
P.A. BUS INSULATOR - 20403
(4) SCREW - #6/32 X 1/8
Pilot
Arc Cable
CONNECTOR, HI-FREQ. - 20408
HI-FREQ.
CONNECTOR INSULATOR - 20409
PILOT ARC CABLE ASSEMBLY
Figure 4 - PT-15XL Pilot Arc Cable Assembly
D. INSPECTION & DISASSEMBLY OF NOZZLES
fully remove the deposits using a small brush or drill
bit. If using a drill bit, insert carefully and push it
back and forth. Do NOT twist the drill bit.
1. Check the copper nozzle for melting from excessive
current, gouges from internal arcing, tungsten particles in the throat, or nicks and deep scratches on
the outer O-ring sealing surface. If any of these
defects are visible, replace the nozzle assembly.
White Hf-O deposits are normal in O 2 nozzles.
5. To reassemble the nozzle assembly, snap the
centering sleeve onto the copper nozzle body
(bevel facing away from body). Insert the nylon
spacer.
2. To disassemble an XR nozzle assembly, pry off the
centering sleeve (996618) using a small screwdriver between the sleeve and nozzle body. Replace the parts shown in figure 2 if necessary.
6. Oxygen nozzles P/N's 20751 & 20920 are one
piece nozzles and do not come apart. They must
be replaced as complete units.
7. Two piece oxygen nozzles P/N's 21206B & 21207B
have a replaceable ceramic insulator P/N 21193.
Pry along the outside of the white ceramic to
remove it.
To install a new insulator, lubricate the red o-ring
with silicone grease and push the insulator on with
a twisting motion.
3. Replace the ceramic insulator if it is cracked. Check
the orifice diameter of the replacement insulator. It
should be 0.015 to 0.030-in. larger than the nozzle
body orifice. (See Table in Figure 2.)
4. In some locations, deposits left by evaporated hard
water may build up on the nozzle orifice tip Care11
E. REPLACING CABLES AND HOSES
1. To disconnect the two power cables, water injection
hose, and the gas hose at the back end of the torch,
unscrew the plastic sleeve (19483) from the stainless steel body.
2. Pilot arc cable (20760) is attached to a connector
(20408) under insulator tubing (20409). Loosen set
screw with 7/62" Allen wrench to remove cable
from connector. A 12-in. long 14 ga. copper wire is
connected to the contact ring assembly and to this
connector.
3. Straighten out all cables and hoses and make sure
the torch sleeve is straight when screwing it back
onto the torch body. Threads are rather fine and
easy to cross thread. Do not force the sleeve. A little
bit of silicone grease will help.
4. Make sure the boot hose (996647) is secured to
protect the service lines from arc radiation when
the torch is ready to operate, make sure the service
lines are well out of the way.
8. Cleaning of oxygen nozzles:
As the electrode wears considerable deposits of
hafnium oxide and silver can build up in the nozzle.
Calcium carbonate can build up at the nozzle exit
if the cut water is not adequately treated. These
deposits sometimes cause substantial reductions
in cut quality, speed, and consumable life.
Nozzle performance can be restored by removing
these deposits from the inside of the nozzle and the
nozzle exit. A twisted piece of sandpaper or crocus
cloth usually cleans the nozzle well enough. Care
must be taken not to damage the thin copper edge
at the nozzle exit. The 340 AMP nozzles P/Ns
35664 & 35665 have a heavier, less easily damaged exit as compared to the 260 AMP and 300
AMP nozzles.
Note that nozzle performance is also degraded by
nicks or elongation of the orifice due to double arcs
or mechanical damage. Cleaning will not restore
performance to a damaged nozzle.
Whenever a nozzle is removed for cleaning the
electrode should be inspected. If wear is greater
than .090 inches or very irregular the electrode
should be replaced.
PCM-8 Style Cable Bundle
BACK OF SLEEVE - 19483
Braid is taped in place, then folded back and taped again.
BRAIDED SHIELD - 72020003
5 inches
5 inches
BOOT
15 turns of tape to form barrier to slipage of braid.
ESP-1000 Style Cable Bundle
BACK OF SLEEVE - 19483
3
inches
Securely tape around hose bundle 2" wide.
Slide braid down and tape over 4-1/4".
2
inches
BOOT
SLEEVING
4 1/4
inches
NOTE: Braid does not go over Gas or Cut Water Hoses
Figure 5 - PT-15XL Cable and Hose Assembly
12
PT-15XL Cables and Hoses, Parts Information
PT-15XL 15ft. P/N 21301
Part No.
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
21266
21260
21257
21263
PT-15XL 20ft. P/N 21302
Part No.
PT-15XL 25ft. P/N 21303
Part No.
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
21267
21261
21258
21264
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
21268
21262
21259
21265
PT-15XL 6ft. P/N 21304
Part No.
PT-15XL 12ft. P/N 21305
Part No.
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
996248
34360
34354
34357
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
34363
34361
34355
34358
PT-15XL 17ft. P/N 21306
Part No.
PT-15XL 4-1/2ft. P/N 21307
Part No.
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
34364
34362
34356
34359
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
34775
34776
34777
34778
PT-15XL 6ft. For PCM-8 P/N 20762
Part No.
PT-15XL 8ft. For PCM-8 P/N 602711
Part No.
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
996248
996249
996250
20760
Power Cable (2) Required
Gas Hose
Water Injection Hose
Pilot Arc Cable
602712
602713
602714
602715
13
F-15-031-B 7/95
5C
14
ESAB
ESAB Welding & Cutting Products
PO Box 100545, Florence SC 29501-0545