0156603002 - ESAB Intermediate Nozzle for PSF Fume Extraction Guns (5/64-3/32)

Technical Specifications: ESAB PSF Intermediate Nozzle

The ESAB 0156603002 Intermediate Nozzle is a specialized consumable designed for the front-end assembly of PSF K-Series Fume Extraction MIG guns. This component is machined to precise tolerances to handle the thermal and electrical loads associated with high-amperage welding using large diameter wires (2.0mm to 2.4mm / 5/64" to 3/32").

In the PSF torch architecture, the intermediate nozzle functions as both a tip holder and a gas diffuser. It threads directly into the swan neck (torch neck) and provides the mounting point for the contact tip. Its geometry is optimized to allow smooth laminar gas flow around the contact tip while the outer fume shroud (nozzle) captures welding fumes. Because it sits deep within the thermal zone, the high-quality brass construction is essential for resisting deformation and maintaining thread integrity over repeated heating cycles.

Compatibility Notes:

• Torch Models: Primarily designed for PSF 405 K and PSF 505 K fume extraction systems.
• Wire Sizes: Calibrated for 5/64" (2.0mm) and 3/32" (2.4mm) wires. Using this nozzle with significantly smaller wires may result in improper gas turbulence or fitment issues with the corresponding contact tips.

Regular inspection of the intermediate nozzle is recommended during contact tip changes. Signs of wear, such as thread galling or spatter buildup blocking gas ports, indicate the need for replacement to prevent porosity and ensure efficient fume capture.