Plasma Equipment Solutions From EsAB
Plasma equipmentsolutions from ESABA full line of cutting equipment for every application, industry and environment.
Plasmarc Cutting EquipmentTable of ContentsDescription PageProcess Description. 2Deciding When to use Manual Plasma Arc Cutting. 4Plasmarc Product Selection Guide. 6ConsolesPowerCut 400. 8PowerCut 700. 10PowerCut 900. 12PowerCut 1300. 14PowerCut 1600. 16ESP-101. 18ESP-150. 20Deuce Pack 150. 22Custom Ordering Options. 24m3 Plasma System. 26TorchesPT-17A / PT-17AM. 28PT-121. 30PT-25. 32PT-26. 34PT-27. 36PT-31XL / PT-31XLPC. 38PT-32EH. 40PT-38. 42PT-15XL. 45PT-19XLS. 47PT-20AMX / PT-21AMX. 49PT-36 / PT-36R. 51PT-37. 54PT-600. 57Accessories. 59The information contained herein is based on data and information developed in the laboratories of The ESAB Welding & CuttingProducts (Seller), but is presented without guarantee or warranty and the Seller makes no recommendation for and disclaims anyliability incurred from any use thereof, including without limitation, any use in a commercial process not controlled by the Seller, andany use in violation of any existing patent, foreign or domestic, or of applicable laws and regulations.THE SELLER MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, EXCEPT AS EXPRESSLY STATED IN SELLER’S SALESCONTRACT OR SALES ACKNOWLEDGMENT FORM.Material Safety Data Sheets (MSDS) are available from the ESAB WEBSITE, esabna.com, and click on HEALTH AND SAFETY thenSafety Data Sheets.1
PlasmarcProcess DescriptionPlasmarc Technology From the OriginatorsPlasma Arc ModesSince we developed the Plasmarc process in 1957, we haveintroduced a number of innovations to ensure peak performance inplasma cutting and gouging. Today ESAB’s Plasmarc product lineincludes a full range of systems designed to meet your specific needsand applications. From compact, portable packages to heavy dutyindustrial systems, our machines offer cutting capacities from1 8 in. (3.18 mm) to 4 in (101.6 mm).With their advanced inverter technology, ESAB’s portable andtransportable machines provide all the cutting power that normallyrequires larger, heavyweight consoles. The versatile Deuce Pack 150system offers 300 Amps of heavy duty cutting and gouging power fora variety of industrial applications—plus it can be separated into two150 Amp consoles for smaller scale operations. Also available are avariety of advanced ESP (ESAB Smart Plasma) heavy mechanizedsystems for high quality cutting in automation situations.Plasma Arc CuttingESAB’s commitment to plasma performance is carried through in thetop quality and innovation of the Plasmarc torches and consumables.From the innovative PT-31XL, the most compact 50 Amp torchavailable on the market with the capacity to cut up to 1 in. (25.4 mm),to the PT-26, with a 4 in. (101.6 mm) cutting capacity with Air, N2 orH-35, our complete line of torches is designed for superior cut qualityand maximum operator comfort. ESAB’s patented XT tips boostperformance and extend consumable life.Plasmarc gouging outperforms more conventional gougingmethods. Because it produces substantially less smoke and fumes,it significantly decreases operator exposure to air contaminants. Inaddition, Plasmarc gouging is faster, cleaner, less expensive and moreaccurate.Process DescriptionPlasma Arc GougingIn our patented Plasmarc process, an electrode is built into the torchnozzle, which has an arc constricting orifice. Plasma gas, usually air,is fed through the nozzle where it is heated to the plasma temperaturerange—as high as 50,000 F. The plasma arc that emerges from theorifice is hot enough to melt any metal.Because Plasmarc cutting is a relatively simple operation, it is widelyaccepted for cutting ferrous and non-ferrous metals. The plasma arc’sstraight, narrow, column-like shape and high current density allow theoperator to achieve cut consistency without maintaining a constantdistance between the nozzle and the workpiece.Plasmarc gouging is a variation of the Plasmarc cutting process. Thetorch nozzle configuration is designed to produce a lower velocity,broader arc. Rather than cutting completely through the metal, thetorch is held at an angle so the arc gouges a U-shaped groove in themetal.IMPORTANT PRODUCT SAFETY —Sound common sense proceduresmust be followed for personal protection and operating efficiency whenusing plasma arc welding and cutting equipment. Always comply withthe manufacturer’s recommendations for operating and maintaining theequipment as set forth in the instructions provided with each unit. Also, becertain to use all applicable safety precautions as described in Precautionsand Safe Practices for Arc Welding, Cutting and Gouging, F-52-529, which isavailable from your local ESAB welding products distributor or sales office.2Plasma Arc Cutting
PlasmarcFrom The Market LeadersESAB’s Plasmarc Technology is State of the ArtWhen it comes to superior performance for virtually anyplasma cutting and gouging application, ESAB offers theideal solution. Combine the advanced technology of anESAB portable or transportable cutting machine, or a heavyduty console, with the superior performance features ofa Plasmarc torch. And discover the true meaning ofprofessional results made easy.Staying on top of market trends, manufacturing techniquesand user needs has kept our Plasmarc products at theforefront of the industry and established ESAB as the plasmamarket leader.We continue to provide our customers with the best plasmacutting technologies available in the world for a full range ofapplications - from on the spot maintenance and repairs toheavy duty mechanized cutting.3
Deciding When to UseManual Plasma Arc CuttingPlasma arc cutting, which has been used for almost 40years, involves using a torch, com pressed gas, and a sourceof electric power to create a constricted arc that melts alocalized area of metal and removes the molten material witha high-velocity jet of hot, ionized gas.During plasma arc cutting, a com pressed gas and an electricarc are si multaneously passed through a small Orifice,which is typically 0.040 in. (1.0 mm) to 0.125 in. (3.18 mm)in diameter. An electric arc heats the gas to a plasma stateat a tempera ture as high as 50,000 degrees Fahren heit. Thissuperheated plasma jet is directed to the area to be cut, andthe jet melts a path through the metal. Because it is a meltingprocess, a plasma arc can cut almost any commercially usedmetal.Plasma arc cutting can be accom plished manually ormechanically. In mechanical setups, a plasma arc torch isdriven by an automatic machine that is typically regulated bya computer nu merical control (CNC) to cut a predeterminedshape. This article focuses on manual plasma arc cutting,in which the plasma arc torch is manipulated by hand toperform a variety of metal cut ting tasks.Manual systems are available in a va riety of sizes. Generallyrated in am perage output or cutting capacity, the units rangefrom about 15 to 300 A output, encompassing a cuttingcapacity ranging from 1 4 in. (6.35 mm) to about4 in. (101.6 mm).Manual units can also be divided into two general categories.Stationary or console systems generally are de signed toremain fixed in one place, although most are equipped withwheels that make it possible to roll them around a shop.Portable systems are designed to be carried about by one ortwo workers, allowing them to move the system where it isneeded rather than taking materials to be cut to one location.Most of these systems use ordinary shop compressed air asthe plasma cut ting gas, provided it is not too wet, dirty, oroily. Some systems can also use other compressed gasessuch as nitro gen or argon/hydrogen mixtures for cer taincutting tasks involving non ferrous metals.Typical Cutting NeedsIn most sheet metal shops, a variety of metal cuttingchores must be ac complished, and the need often arisesto cut unique or low-production shapes, modify a part, doprototype work, or modify a part in the field. Several optionsbesides plasma cut ting are available to accomplish thesecutting tasks. Nibblers are relatively in expensive and cancut shapes and con tours. They may run slow on thickermaterials, however, and they may dis tort the metal or leavescalloped or rough edges.4Shears are quick and leave a smooth edge, but they arerestricted to cutting straight edges. Similarly, circular sawsleave reasonably good-quality straight edges, but they arelimited to cutting straight lines. Saber saws are not limited tocutting straight lines, but they may run slower and are mostsuitable for thinner materials.Oxyfuel cutting may not be suitable for use ongauge-thickness materials because the preheating that isnecessary and relatively low travel speeds com bine to placea considerable amount of heat in the steel, which can causese vere distortion of thinner materials. It is also limited to useon carbon steel, because other metals create high melt ingpoint oxides that interfere with or stop the burning processof oxyfuel cut ting. However, oxyfuel cutting is con sidered abetter choice for cutting car bon steel thicknesses of morethan 1 1 2 in. (38.1 mm) because it is faster.The travel speed of oxyfuel is deter mined by the propagationrate of the burning reaction, which is relatively in dependentof the steel thickness. Typi cally, it is in the range of20 in. (508 mm) to 25 in. (635 mm) per minute. Plasma meltsits way through a material, however, so the cut ting speedis determined by material types and thicknesses. Typicalplasma cutting speeds can range from 5 in. (127 mm) tomore than 100 in. (2.54 mm) per minute.An appropriately sized manual plas ma arc cutting unit canhandle most cutting chores. The unit can cut con tours andstraight lines. Most units can follow a template or straightedge, so cutting does not necessarily have to be entirelyfreehand. In addition, circle cutting or other torch-guideat tachments can aid in cutting particular contours. If aplasma arc unit is sized properly for a job, cutting speedsshould be about 15 in. (381 mm) per minute or higher, whichhelps maintain good production rates while minimizingheat distortion of a workpiece. The resulting edge qualitycan vary, however, depending on the particular plasma unitbeing used, the material being cut, and the operator’s skill.Typically, using air as the plasma gas while cutting carbonsteel helps pro duce straight and relatively smooth edges.Any slag or dross that accumulates on the bottom of a cutknocks off easily. Air can also be used as the plas ma gasfor cutting stainless steel and aluminum, but some oxidationwill occur on the resulting edges. Aluminum develops arough appearance, and stain less steel becomes somewhatdiscolored. Using an inert gas such as nitrogen or argon/hydrogen instead of air as the plasma gas can eliminatethese prob lems, however.For cutting chores beyond the gauge thickness range,manual plasma is often a suitable choice. Plasma arc cuttingunits can cut, trim, or remove carbon steel as thick as4 in. (101.6 mm).
Deciding When to UseManual Plasma Arc CuttingPlasma uses no open flame, and no compressed gascylinders are needed if air is used as the plasma gas. Still,oxyfuel cutting is usu ally considered to be a better choice forcarbon steel thicknesses of more than 1 2 in. (12.7 mm) to2 in. (50.8 mm) because of its speed.To cut aluminum, the only alterna tive to plasma arc cuttingis mechanical cutting with saws, etc., although routers ornibblers can be used for edge prepara tion tasks. Using airas the gas to plasma arc cut aluminum will result in a roughedge. Substituting nitrogen or an argon/hydrogen mix for airwill general ly result in a smoother, cleaner cut face, but thosegases are more expensive to use.For thicker stainless steels, as well as cast iron and highalloy steels, plasma cutting may be the only practical cut tingoption. The tough composition of stainless steels makescutting them by mechanical means difficult. Again, if thecut face must not be discolored or oxidized, gases such asnitrogen or argon-hydrogen should be used instead of air.Cutting CapabilityChoosing the right manual plasma unit for your particularapplication can be perplexing if you are unfamiliar withmanual plasma cutting. Once you un derstand the basics,however, the job becomes easy. No industry standard ex istsfor rating the thickness cutting ca pability of a manual plasmaunit. How ever, cutting thickness claims made by most majormanufacturers are usually accurate.First, determine the maximum thick ness you plan to cutregularly. This thickness should be in the mid-range of theunit’s cutting capability. This is im portant because:l.When tackling their maximum cutting thicknesses, mostmanual plas ma units have slow travel speeds, typi cally lessthan 12 in. (304.8 mm) per minute.2. The higher cutting current of a larger-rated unit inhibitsdross or slag formation on the bottom of the cut on carbonsteel, producing a cleaner cut.Most plasma arc cutting units rated at more than 1 in.(25.4 mm) capacity cannot be transported easily, but theymay be wheeled about a shop or transported with a lifttruck or hoist.The Cutting TorchOne of the most important con siderations in choosing asystem is the front-end design of the plasma arc cut ting torch, because it controls the cut and most heavilyinfluences the operat ing costs of the setup. If reachingtight places is important, a torch with a small or narrowfront end is a good choice. A smaller front end may alsobe a better choice in applications that require a clear lineof vision to follow a cut line, because a larger front endcould obscure vision.In addition to the up-front costs for nozzles, electrodes,and other front-end parts, you should consider thedurability of the parts and the life in arc hours you canexpect from the nozzle and elec trode combination. Thesefactors are better indicators of operating costs than are theprices of the parts alone.Plasma arc cutting torch parts are generally made to veryhigh tolerances. Make sure that any replacement partsyou use are made to proper specifica tions. The wrongreplacement parts can result in poor performance anddamage to the torch head, which could necessi tate anexpensive repair.ConclusionFinally, the best way to evaluate a manual plasma arccutter for your ap plication is to ask for a demonstration.Many of the factors that determine which unit is right foryou become ob vious when you see the unit demon stratedin your own shop. Pay particular attention to cut speed,quality, ease of use, and portability, if that is an issue. Ifaccess is limited to an area to be cut, make sure that thecutter you evaluate can do the job.3. The reserve cutting capacity pro vides the capability tocut thicker mate rials if the need arises.Be careful to judge a unit by its ac tual cutting capability andnot by its electrical current rating, because differ ent designsdeliver dissimilar cutting performances from the sameamount of current. You should also remember that most cutthickness ratings are based on cutting carbon steel.Another consideration in selecting a unit is portability. Mostunits available with 1 in. (25.4 mm) or lower capacities aredesigned so that one or two workers can
ESAB’s commitment to plasma performance is carried through in the . its way through a material, however, so the cutting speed is determined by material types and thicknesses. Typical plasma cutting speeds can range from
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