plasmarc™ air curtainFor use with m3 Plasma Systemand PT-36 Plasma TorchESAB Assembly Number: 37440

Instruction Manual

0558006404 08/2011

The AIr CurTAIn CAn nOT be used when usIng h-35 Or Ch4 gAs MIxes. The wATer level MusT be lOwered 4 TO 6 InChes be-neATh The bOTTOM Of The plATe.

fAIlure TO COMply TO ThIs wArnIng CAn resulT In A hydrO-gen deTOnATIOn.

wArnIng

This equipment will perform in conformity with the description thereof contained in this manual and accompa-nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc-tions 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 imme-diately. 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 ser-vice facility designated by the manufacturer.

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 be-fore installing or operating this equipment.

CAuTIOn

user respOnsIbIlITy

reAd And undersTAnd The InsTruCTIOn MAnuAl befOre InsTAllIng Or OperATIng.

prOTeCT yOurself And OThers!

TAble Of COnTenTs

1.0 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.0 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3.0 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

section / Title page

4

TAble Of COnTenTs

5

seCTIOn 1 sAfeTy preCAuTIOns

1.0 safety precautionsUsers 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.

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 in-tended to be used outside during precipitation unless sheltered.

enclosure Class

MaximumTilt Allowed

15°

CAuTIOnIf equipment is placed on a surface that slopes more than 15°, toppling over may oc-cur. personal injury and / or significant dam-age to equipment is possible.

6

seCTIOn 1 sAfeTy preCAuTIOns

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!

wArnIng

This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage.CAuTIOn

CAuTIOnTo avoid personal injury and/or equipment damage, lift using method and attachment points shown here.

7

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.

wArnIng

Compressed Air supply(Air Curtain)

Source: 80 psi @ 1200cfh (5.5 bar @ 34 m3h)

Clean, dry & oil-free shop air

DATE

RELEASED FOR

ENGLISH DWG

TITLE

REPRO MADE FROM

SIMILAR TO

SUP.

SUP. BY

APPROVED

BY

DATE

CHECKED

BY

DATE

DRAWN

BY

DATE

SCALE

FIRST MADE FOR

ESAB WELDING & CUTTING PRODUCTS

FLORENCE, SC 29501

UNLESS OTHERWISE

SPECIFIED, DIM ARE

IN INCHES.

TOL .XX

.XXX

ANGLES

CHAMFERS & C'SINKS

2SURFACE ROUGHNESS IS IN

REMOVE ALL BURRS

BREAK SHARP EDGES

MICROINCHES

MCHANGE

BY

DATE

CH'KD

THIS DRAWING CONTAINS PROPRIETARY CONFIDENTIAL INFORMATION OF ESAB WELDING

&

CUTTING PRODUCTS AND IS LOANED WITH THE EXPRESS AGREEMENT THAT THIS DRAWING

(1) WILL NOT BE REPRODUCED OR COPIED, (2) WILL NOT BE USED OTHER THAN IN WORK

FOR ESAB WELDING & CUTTING PRODUCTS, AND (3) WILL NOT BE DISCLOSED EXCEPT

TO EMPLOYEES OF THE PARTY TO WHOM THIS DRAWING IS LOANED ON A CONFIDENTIAL

BASIS.

A-

A-

MATERIAL:

.015

.005

PRO/ENGINEER DWG.

NOV.1994

A A

19X19

ADAPT B-A/W*F B-A/W*M 90

ASSY

19X19

BLP

10/23/08

63

2

1:1

FINISH:

BRIGHT DIP PER SPI 45.315.3 METHOD 6

P/N QTY DESCRIPTION

1. 836Z40 1 NUT HOSE B/A-W* .63-18F RH OLD

2. 03Z59 1 NPL B/SIZE .425ODX 0.81LG

3. 19Z48 1 BODY FOR 90

AIR WATER ADAPTOR

4. 6270869 1 RING SSBAG-1 0.438KDX.03D STD

"E" CN-083187 REVISED

& RED BLP

WSS

10/23/08

WSS

10/23/08 WSS

10/23/08

1

23

4

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.

seCTIOn 2 InsTAllATIOn

Optional Accessories

Adapt B-A/W*F B-A/W*M 90 deg assy

P/N 19X19 1

8

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.

5

4

2

6

3

7

1

Plasma Torch Body

wArnIng

P/N ReferenceTorch Body

P/N 21380Split Level Bushing

P/N 37438Body

P/N 37431Nozzle Retaining Cup

P/N ReferenceShield

P/N 0558009395Shield Retainer

P/N 37436Sleeve

P/N 37435Retainer

0.06 (1/16) in.

8

seCTIOn 2 InsTAllATIOn

9

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. After installing nozzle retaining cup, assemble shield, diffuser and shield retainer separately to assure proper contact.

5. Hand tighten nozzle retaining cup and retainer assembly on torch. Double check shield / retainer for proper seating.

6. Install 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 37435. 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 cor-

rect.

nOTe:Remove existing Nozzle Retaining Cup before installing air curtain.

seCTIOn 2 InsTAllATIOn

10

Plasma Gas Box

Shield Gas Box

Air Curtain Hose

Air Curtain Assembly37440

Air Curtain Hose

25 MicronFilter

EarthGround

Work Table

TorchLead

Workpiece

PT-36 Plasma Torch

note:For a complete listing of all available lengths and part numbers for air curtain hose assemblies refer to m3 plasma sys-

tem instruction manual.

see detail "A"

see detail "d"

see detail "C"

see detail "b"

See Detail D for location of air pressure regulator / gauge

seCTIOn 2 InsTAllATIOn

Compressed Air supply(Air Curtain)

Source: 80 psi @ 1200cfh (5.5 bar @ 34 m3h)

Use clean, dry, oil free shop air

11

plasma gas box 0560941491

detail "A"

detail "b"

Torch Leads

Air CurtainConnection

note:For air curtain hose assembly connec-tor details refer to m3 plasma system

instruction manual.

For torch lead connection details re-fer to m3 plasma system instruction

manual.

Air Curtain Connection(to air curtain assembly)

seCTIOn 2 InsTAllATIOn

12

detail "d"

detail "C"

shield gas box 0560941536

Air Curtain Connection

Air Curtain Connection(air supply)

note:For air curtain hose assembly connec-tor details refer to m3 plasma system

instruction manual.

Air Pressure RegulatorRemove outer enclosure and

adjust between 18-22 psi(1.2-1.5 bar)

Air PressureGauge

seCTIOn 2 InsTAllATIOn

13

replacement parts for Air Curtain - p/n 37440

1

2

4

3

5

7

8

9

10

11

6

Item part number description1 21380 Split Bevel Bushing2 37438 Air Curtain Body3 37435 Air Curtain Retainer4 37431 Nozzle Retaining Cup Assembly5 0558009395 Shield Retainer, Insulated6 37436 Air Curtain Sleeve7 996528 O-ring, Neoprene8 519369 O-ring - use with Water Muffler ONLY9 443315 O-ring, Neoprene

10 2221978 O-ring, Silicone Rubber11 92114581 O-ring, Neoprene

O-ring (Item 7) not supplied with as-

sembly. Shown for reference only

seCTIOn 3 replACeMenT pArTs

14

nOTes

15

revIsIOn hIsTOry

Revision 03/2010 - added 19X19 to optional accessories.Revision 08/2011 - Updated BOM's, changed p/n 0558004616 to p/n 0558009395 per CCARES 110608095137.

A. CUSTOMER SERVICE QUESTIONS: Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST Order Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693 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) 664-4452 Hours: 8:00 AM to 5:00 PM EST Part Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS: Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST Repair Estimates Repair Status

F. WELDING EQUIPMENT TRAINING Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST Training School Information and Registrations

G. WELDING PROCESS ASSISTANCE: Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES: Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

If yOu dO nOT KnOw whOM TO CAll

Telephone: (800) ESAB-123 Fax: (843) 664-4462

Hours: 7:30 AM to 5:00 PM ESTor

visit us on the web at http://www.esabna.comThe ESAB web site offers

Comprehensive Product InformationMaterial Safety Data Sheets

Warranty RegistrationInstruction Literature Download Library

Distributor LocatorGlobal Company Information

Press ReleasesCustomer Feedback & Support

esAb welding & Cutting products, florence, sCCOMMunICATIOn guIde - CusTOMer servICes