PT-32EH

PLASMA ARC CUTTING TORCHES

Instruction Manual (GB)

0558003746
 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 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.
 TABLE OF CONTENTS
SECTION TITLE PAGE
PARAGRAPH

SECTION 1 SAFETY ............................................................................................................ 61

SECTION 2 DESCRIPTION ................................................................................................. 63

2.1 General ............................................................................................................. 65
2.2 Scope ................................................................................................................ 65

SECTION 3 INSTALLATION ................................................................................................ 67

3.1 Fitting the PT-32EH Torch ................................................................................ 67
3.2 General ............................................................................................................. 68
3.3 Assembly .......................................................................................................... 68

SECTION 4 OPERATION .................................................................................................... 69

4.1 Steel Heat Shield Guards ................................................................................. 69
4.2 Cutting with the PT-32EH ................................................................................. 70

SECTION 5 MAINTENANCE ............................................................................................... 211

5.1 General ............................................................................................................. 211
5.2 Inspection and Cleaning of Consumables ........................................................ 211
5.3 Removing/Replacing Torch Head and Switch from Service Line ...................... 212

SECTION 6 REPLACEMENT PARTS ................................................................................. 213

6.1 General ............................................................................................................. 213
6.2 Parts ................................................................................................................. 213

i
TABLE OF CONTENTS

ii
SECTION 1 SAFETY

Full responsibility for safety of personnel working on or near system rests on user of ESAB Welding
Equipment.

Wrong operation can lead to abnormal situation, injure operator and damage equipment.

All personnel working with welding equipment must be fully familiar with

- handling of equipment
- location of emergency stops
- functions of equipment
- applicable safety regulations
- cutting

Operator must make sure

- no one stays inside work area while machine starts

- no one is unprotected while arc is being struck

Work area must be

- free of machine parts, tools and other objects that can obstruct operator moving within area
- so arranged, that emergency stop buttons are easily accessible
- free from draughts

Personal safety equipment

- always use proper safety equipment such as goggles, non flammable clothing, protective gloves
- never wear loose clothing, belts, bracelets, rings etc., which may catch on equipment or cause burns

Miscellaneous

- only authorised personnel may operate electrical equipment

- check whether return cables are properly fitted and earthen
- requisite fire fighting equipment should be easily available in specially and clearly marked areas
- lubrication and maintenance of welding equipment must not be proceeded during operation.

61
SECTION 1 SAFETY

! WARNING !
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUTIONS WHEN WELDING OR CUTTING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES
THAT SHOULD BE BASED ON MANUFACTURER’S HAZARD DATA.

ELECTRIC SHOCK - Can kill

- Install and earth welding equipment in accordance with obligatory standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes.
- Insulate yourself from earth and workpiece.
- Ensure your work position is safe.

FUMES AND GASES - Can be dangerous to your health

- Keep your head away from fumes.

- Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and surroundings.

ARC RAYS - Can injure eyes and burn skin

- Protect your eyes and skin. Use correct welding screens, filter lens and wear protective clothes.
- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make therefore sure there are no inflammable materials nearby.

NOISE - Excessive noise can damage your hearing.

- Protect your ears. Use ear defenders or other hearing protection.

- Warn bystanders of the risk.

MALFUNCTION - Call expert assistance in event of malfunction.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT

PROTECT YOURSELF AND OTHERS !

62
SECTION 2 DESCRIPTION

PT-32EHTorch
Designed for superior cutting performance and ease of
handling, the PT-32EH produces clean, exceptionally
high quality cuts.

■ Most compact 90 amp torch on the market

■ Excellent cutting capacity - cuts up to 1-1/2 in. (38mm)
■ Uses shop air, cylinder air or nitrogen for superior
versatility
■ Pilot arc starting - even starts through paint
■ Choice of 25 ft (7.6m). or 50ft. (15.2m) line length
■ Excellent consumable life
■ Parts in place design
■ Patented torch and safety circuit
■ Exclusive 40 amp Drag Nozzle
■ One-year warranty

Specifications
Cuts up to 1-1/2 in. (38mm)
Current Capacity .............................. 90 amps @ 100% duty cycle
Air Supply ............. 350cfh @ 75-80psig (165 l/min @5.2-5.5bar))
Length of Service Lines ....................... 25 (7.6m) or 50 ft.(15.2m)
Dimensions
Overall Length ............................................... 8.2 in. (208 mm) Ordering Information
Length of Head ................................................. 3.0 in. (76 mm)
PT-32EH, 90°, 25 ft. (7.6m) line ................................... 0558003548
PT-32EH, 90°, 50 ft. (15.2) line .................................... 0558003549
CompatibleESABConsoles Torches and torch body assemblies are supplied without electrode,
PowerCut-875, PowerCut-1125, PowerCut-1250 nozzle, heat shield and valve pin. Order complete spare parts kits or
individual components shown with PT-32EH parts breakdown on
PowerCut-1500 next page.

PT-32EH CUTTING SPEEDS

OUTPUT CURRENT 40AMPS w/AIR @ 75psi (5.2bar)
PT-32EH CUTTING SPEEDS
OUTPUT CURRENT 60, 70 & 90AMPS w/AIR @ 75psi (5.2bar)
Thickness Cutting Speed
Material mm (in.) mm/m (ipm) 4000

Carbon Steel 1.6 (1/16) 5,080 (200)

3.2 (1/8) 2,489 (98)
6.4 (1/4) 914 (36) 3000
Cut Speed, mm/m

90 Amps
9.5 (3/8) 457 (18)
12.7 (1/2) 279 (11)
70 Amps
Stainless Steel 1.6 (1/16) 3,505 (138) 2000
3.2 (1/8) 1,473 (58) 60 Amps

6.4 (1/4) 457 (18)

9.5 (3/8) 254 (10)
12.7 (1/2) 152 (6) 1000

Aluminum 1.6 (1/16) 5,080 (200)

3.2 (1/8) 2,794 (110)
0
6.4 (1/4) 1,219 (48)
9.5 (3/8) 432 (17) 6.4mm 12.7mm 19.1mm 25.4mm 31.8mm 38.1mm
12.7 (1/2) 356 (14) Material Thickness

63
SECTION 2 DESCRIPTION

Optional Accessories:
50/70 amp Spare Parts Kit (PC-875/1125) ..................0558002822
70 amp Spare Parts Kit (PC-1500) .............................0558003508
90 amp Spare Parts Kit (PC-1500) .............................0558003062
Plasma Flow Measuring Kit:
This valuable troubleshooting tool allows measurement of
the actual plasma gas flow through the torch ...........0558000739
Torch Guide Kit:
This complete kit, in a rugged plastic carrying case, includes
attachments for circle and straight line cutting on ferrous and
non-ferrous metals.
Deluxe, 1-3/4" - 42" (44.5mm-106cm) Radius, ......... 0558003258
Basic, 1-3/4” - 28” (44.5mm-71cm) Radius ..............0558002675
Stand-off Guide
For proper stand-off distance when drag cutting .......0558002393
40 amp Drag Nozzle ................................................. 0558002908
Gouging Nozzle .......................................................... 0558003089
Heat Shield Gouging ................................................ 0558003090
Heat Shield Long "CE" ............................................... 0558003110
Drag Heat Shield ......................................................... 0558003374

O-Ring - 0558003694
PT-32EH Torch Head
(Supplied with head)
0558003412
Valve Pin
0558001959
Electrode
0558001969

Heat Shield
0558001957
Heat Shield (CE)
0558003110

Nozzle
40 AMP - 0558002908 (Drag Cutting)*
50/70 AMP - 0558002618 (PC-875, PC-1125, & PC-1250)
90 AMP - 0558002837 (PC-1500 Only)
*PC-875, PC-1125, 1250, & PC-1500

Contents of PT-32EH Spare Parts Kits

PC-875/1125 PC-1250 PC-1500 PC-1500 (CE)
P/N 0558002822 P/N 0558003508 P/N 0558003062 P/N 0558003557
50/70 Amp 70 Amp 90 Amp 90 Amp
Description P/N Quantity Quantity Quantity Quantity
Heat Shield 0558001957 2 2 2 -
Heat Shield 0558003110 - - - 2
50/70 amp Nozzle 0558002618 4 4 2 -
90 amp Nozzle 0558002837 - - 4 4
40 amp drag Nozzle 0558002908 1 1 1 1
Electrode 0558001969 3 3 3 3
Valve Pin 0558001959 1 1 1 1
Fuse 2amp, 600vdc 0558003075 - 1 1 1
Stand-off Guide 0558002393 1 1 1 1
Wrench 0558000808 1 1 1 1
Lubricant 0558000443 1 1 1 1

64
SECTION 2 DESCRIPTION

2.1 GENERAL 2.2 SCOPE

The patent pending PT-32EH is a manual torch with a This manual is intended to provide the operator with all
90° head designed for use with several Plasma Arc the information required to assemble, operate, and
Cutting Packages using clean, dry air as the plasma repair the PT-32EH Plasma Arc Cutting Torch. For
gas. The service line lengths available with the PT- additional safety precautions, process instructions, and
32EH torch are 25 feet (7.6 m) and 50 feet (15.2 m). system troubleshooting; refer to the appropriate in-
The PT-32EH torch is rated to operate at a maximum struction manual for your Plasma Arc Cutting Package.
of 90 amperes at 100% duty cycle.

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 employed can present a safety hazard.
Before beginning operation with the PT-32EH torch, refer to the Safety
Precautions and operating instructions in the appropriate power source
instruction manual.

Using the torch on any unit not equipped with a mating safety interlock
circuit may expose operator to unexpected high voltage.

65
SECTION 2 DESCRIPTION

66
SECTION 3 INSTALLATION
3.1 FITTING THE PT-32EH TORCH 5. Connect the Pilot Arc Leads. Make sure the power
cable connection is wrench-tight.
6. Plug in the switch leads to the torch switch recep-
tacle on the output terminal board.
Before any maintenance is attempted on this torch,
7. Reassemble the access door to the power source.
make sure the power switch on the console is in the
Retighten Strain Relief to secure power cable, but
"OFF" position and the primary input is deenergized.
do not overtighten.

1. For operator safety, the torch connections are

located on the output terminal board behind the
lower portion of the front panel.
2. Thread the power cable, pilot arc cable and switch FOR COMPLETE SAFETY AND INSTALLATION
leads of the PT-32EH through the Strain Relief on PROCEDUREES, CONSULT THE INSTRUCTION LIT-
the Access Cover. ERATURE SPECIFIC TO THE CONSOLE BEING
4. Connect power cable to the torch fitting (left-hand USED.
threads) and tighten securely.

NOTE:
This Illustration depicts connections for
Powercut 1250 and 1500. Other Powercut
models; i.e., 875 and 1125 have identical
fittings but the connection points are
configured in different locations on the front
panel. Consult the specific console literature
for complete information.

TORCH TRIGGER
PILOT ARC LEADS CONNECTION
CONNECTION

POWER
CABLE (2
)W
CONNECTION HI
TE
LE
AD
S

PIL
OT
AR
C
LE
AD
PO
WE
RC
AB
LE

Figure 3-1. Typical Connection Assembly

67
SECTION 3 INSTALLATION

3.2 GENERAL 3.3 ASSEMBLY

Install PT-32EH front end parts as shown in Figure 3-

2.
Make sure power switch on console is in the "OFF"
position and primary input power is deenergized.

The torch head contains a gas flow check valve and a nozzle back pressure tap that
act in conjunction with circuitry within the power source. This system prevents the
torch from being energized with high voltage if the torch switch is accidentally closed
when the shield is removed. ALWAYS REPLACE TORCH WITH THE PROPER TORCH
MANUFACTURED BY ESAB SINCE IT ALONE CONTAINS ESAB'S PATENTED SAFETY
INTERLOCK.

1. PLACE THE VALVE PIN INTO THE ELEC- 2. PLACE NOZZLE INTO HEAT SHIELD AND
TRODE AND SCREW THE ELECTRODE INTO THREAD THIS ASSEMBLY TO THE TORCH BODY
THE TORCH HEAD AND TIGHTEN SECURELY AND HAND TIGHTEN.
WITH WRENCH #0558000808.

ELECTRODE
VALVE PIN * NOZZLE

SHIELD

3. IMPORTANT!
MAKE SHIELD VERY TIGHT!
* The valve pin is a crucial member of the system. Its func-
tion is to open the gas flow check valve that is permanently
assembled within the torch head. If the pin is not correctly
placed in the electrode, the valve will not open and the sys-
tem will not function. The valve pin also improves electrode
cooling by increasing the velocity of air over the inner surface
of the electrode.

Figure 3-2. Assembly of PT-32EH Torch Front End Parts

68
SECTION 4 OPERATION

4.1 STEEL HEAT SHIELD GUARDS

(Refer to Figure 4-1)

Drag Cutting with the PT-32EH Torch

If drag cutting is desired, attach ESAB's standoff guide

(P/N 0558002393). For thin material, under 3/8" (9mm),
remove 50-70 amp or 90 amp nozzle from torch head,
insert ESAB's 40 amp nozzle (P/N 0558002908). Lower
current level to 40 amps or lower.

ADJUST GUIDE BY TURNING IN A

CLOCKWISE DIRECTION ONLY. THIS
WILL PREVENT ACCIDENTAL LOOS-
ENING OF SHIELD.

NOTICE
Drag cutting, even with lower current levels may signifi-
cantly reduce the life of torch consumables. Attempting
to Drag Cut with higher currents (above 40 amps) may
cause immediate catastrophic consumable damage.

STEEL GUARD
STAND OFF GUIDE
P/N 0558002393

IF GUIDE IS TOO
TIGHT ON SHIELD,
OPEN SLOT WITH
SCREWDRIVER.

IF TOO LOOSE, CLOSE

GUIDE AGAINST SLOT WITH VISE OR
STRAIGHT EDGE LARGE PLIERS.
OR FREE-HAND
CUT

3/16" (4.7 mm)

TORCH-TO-WORK

Figure 4-1. Installation and Operation of Steel Heat Shield Guards

69
SECTION 4 OPERATION

4.2 CUTTING WITH THE PT-32EH

Use the following procedures to cut with the PT-32EH torch (Figure 4-4).
ELECTRIC SHOCK can kill.
• Do NOT operate the unit with the 1. Make sure that the wall disconnect switch is on. Turn on the Power
cover removed.
• Do NOT apply power to the unit while
Switch to the cutting power source console.
holding or carrying the unit. 2. Set Pressure Regulator to 75-80 psig (5.2-5.5 bar).
• Do NOT touch any torch parts 3. Hold the torch nozzle approximately 1/8 in. to 3/16 in. (3.2mm-
forward of the torch handle (nozzle, 4.7mm) above the work and tilted at about 15 - 30°. This reduces
heat shield, electrode, etc.) with
power switch on.
the chance of spatter entering the nozzle. If the PT-32EH's standoff
guide P/N 0558002393 is being used, the distance between
Electrode and Work Piece will be approx. 3/16in. (.47mm).
4. Depress the torch switch. Air should flow from the torch nozzle.
5. Two seconds after depressing the torch switch, the pilot arc should
start. The main arc should immediately follow, allowing the cut to
begin. (If using the trigger LOCK mode, torch switch may be
ARC RAYS can burn eyes and skin; released after establishing the cutting arc.)
NOISE can damage hearing. 6. After starting the cut, the torch should be maintained at a 5-15°
• Wear welding helmet with No. 6 or 7 forward angle (Figure 4-2). This angle is especially useful in
lens shade.
• Wear eye, ear, and body protection. helping to create a "drop" cut. When not using the standoff guide,
the nozzle should be held approximately 1/4 in. (6.4mm) from the
work.

5° to 15°

CUT
DIRECTION

Figure 4-2. Proper Torch Angle

IMPORTANT!!!
Maintain Proper
Stand-Off Distance
Figure 4-4. Piercing & Cutting Techniques using the PT-32EH
Power Output increases
with Stand Off Distance!

3/16 - 1/4 Inch

4.7 - 6.4 mm

Figure 4-3. Standoff vs. Power Output

70
SECTION 5 MAINTENANCE

5.1 GENERAL
b. Nozzle: Replace if the orifice is clogged,
nicked, or out-of-round.

c. Electrode: When replacing the nozzle, al-

Before any maintenance is attempted on this torch, ways inspect the electrode for wear. If more
make sure the power switch on the console is in the than .06" (1.5mm) of electrode Hafnium has
"OFF" position and the primary input is deenergized. eroded, replace the electrode. If the elec-
trode is used beyond this recommended
wear limit, damage to the torch and power
5.2 INSPECTION AND CLEANING OF source may occur. Nozzle life is also greatly
reduced when using the electrode below the
CONSUMABLES
recommended limit. Refer to Figure 5-1.

1. Disassemble the front end of the PT-32EH as d. Shield: The face of the shield will gradually
follows: erode from the heat and molten metal spray.
Replace the shield if more than 1/8 inch (3.2
a. Position torch head in a downward direction mm) has eroded from the face. Refer to
(refer to Figure 3-2) and remove the shield. Figure 3-2.
The nozzle will drop from the head and re-
main in the shield. Unscrew the electrode to e. O-ring: Lubricate as per Figure 5-1. Replace
remove it and the valve pin. Remove these if cut or worn. Air leaking past this seal will
components and inspect for wear. The nozzle reduce cutting performance.
and electrode will generally wear at the same
rate. For best performance, replace together. 2. To replace the above front end components,
refer to Figure 3-2.

LUBRICANT (P/N 0558000443) CAN BE

APPLIED TO O-RING OR HEAT SHIELD.

HEAT SHIELD
O-RING
THE HEAT SHIELD FACE WILL
GRADUALLY ERODE WITH USE.
SEE PARAGRAPH 5.2.1.d

NEW WORN
Replace when eroded beyond
.06"(1.5mm) Depth.

REPLACE ELECTRODE BEFORE PITTING

BECOMES DEEPER THAN .06 INCH (1.5 MM)

Figure 5-1. O-ring, Electrode, and Shield Maintenance

211
SECTION 5 MAINTENANCE

5.3 REMOVING / REPLACING TORCH HEAD

4. If the torch head is to be replaced, remove the
AND SWITCHES FROM SERVICE LINE power cable from the Torch Head by using two
wrenches to prevent twisting brass tube.

Before any maintenance is attempted on this torch,

make sure the power switch on the console is in the
"OFF" position and the primary input is deenergized.

1. Remove six screws from handle. Separate the

two halves of the handle
POWER CABLE

5. Next, remove the Pilot Arc connection from the

Torch Head using two wrenches to prevent twisting
stainless steel tube.
PILOT ARC
CONNECTION

2. Carefully remove the torch body and switches

from the assembly. Pull the insulating sleeves
back to expose the hose and cable connections.
If the switch is to be replaced, remove switch
and snip leads (2) at the spliced connections.
(Replacement switches are supplied with new
splices and extra long leads)

6. Place the torch head into the assembly and

guide the cables and tubes into the housing.
Fold the wiring into the cavity, being careful not
to overlap any mating surfaces of the housing.
Replace the other half of the housing and tighten
the six screws. Tighten screws until there is no
gap between the two halves

3. Replace insulation as shown. Replace switches in

assembly. Proceed to step 6.

212
SECTION 6 REPLACEMENT PARTS
6.1 General Replacement parts may be ordered from your ESAB
distributor or from:
Replacement parts are illustrated on the following fig-
ures. When ordering replacement parts, order by part ESAB Welding & Cutting Products
number and part name, as listed. Always provide the Attn.: Customer Service Dept.
series or serial number of the unit on which the parts will PO Box 100545, Ebenezer Road
be used. The serial number is stamped on the unit Florence, SC, 29501-0545
nameplate.
Refer to the Communication Guide located on the last
Torches and torch body assemblies purchased individually
are supplied without electrode, nozzle, heat shield and valve page of this manual for a list of customer service phone
pin. Order complete spare parts kits or individual components numbers.
as required (see Section 2).

6.2 Parts
SWITCH
0558000818
SPLICE
TORCH BODY/HEAD -
0558004020
0558003412 HANDLE
0558003322

SWITCH
0558000818
TERMINAL FASTENER
0558004021

(2) W
HITE
LEAD
S

PILOT ARC LEAD

CABLE
POWER

CABLE ASSEMBLY
25FT. (7.6m) - 0558002841
50FT. (15.2m) - 0558002842

213
Notes

214
 Revision History

Original Release on February 13, 2003

05/2003 - revised fuse part number from 0558001379 to 0558003075.

215
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0558003746 05 / 2003