ESAB Precision Plasmarc Installation, Operation And Maintenance Manual For Residential Installation

F-15-480-D

October, 2000

Installation, Operation and Maintenance Manual for the

PRECISION PLASMARC SYSTEM

with Electronic Flow Control

CUTTING SYSTEMS

411 s. Ebenezer Road
Florence, SC 29501-0545

The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.

Purchaser is solely responsible for the safe
operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.

Every effort was made to ensure the accuracy
and completeness of this manual. Information
in this document is subject to change without
notice.

This manual is ESAB Part Number F15480

This manual is ESAB Part Number F15480

This manual is ESAB Part Number F15480This manual is ESAB Part Number F15480

This manual is for the convenience and use of the
cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.

©©©© ESAB Cutting Systems, 2000

Printed in U.S.A.

Precision Plasma Electronic Flow Control Table of Contents

Page

Section 1 Safety

1.1 Introduction 1

1.2 Safety Notations And Symbols 1

1.3 General Safety Information 2

1.4 Installation Precautions 3

1.5 Electrical Grounding 4

1.6 Operating A Plasma Cutting Machine 4

1.7 Service Precautions 8

1.8 Safety References 9

Section 2 Description

2.1 General 1

2.2 Scope 1

2.3 Package Options Available 1

2.4 Technical Specifications

2.4.1 Precision Plasma System 2

2.4.2 Plasma Gas 3

2.4.3 Start Gas 3

2.4.4 Secondary Gas 3

2.4.5 PT-24 Torch 3

Section 3 Installation

3.1 General 1

3.2 Equipment Required 1

3.3 Location 1

3.4 Primary Electrical Input Connections 2

3.5 Interconnecting Lines 4

Precision Plasmarc Component Interconnecting Diagram 8

3.6 Torch Mounting 10

3.7 Torch Coolant 11

3.8 Inspection of Gas and Coolant Lines 11

3.9 Replacement of EPROM in the Plasmarc Power Source
Programmable Logic Controller (PLC)

12

i

Precision Plasma Electronic Flow Control Table of Contents

Section 4 Operation

4.1 Power Supply Controls

4.1.1 Main Power Switch 1

4.1.2 Pilot Arc Switch 1

4.1.3 Fault Indicator Lights 2

4.1.4 Meters 2

4.1.5 Current Control Switch 2

4.2 Cut Quality

4.2.1 Introduction 3

4.2.2 Cut Angle 3

4.2.3 Cut Flatness 4

4.2.4 Surface Finish 5

4.2.5 Dross 6

4.2.6 Dimensional Accuracy 8

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction 9

4.3.2 Aluminum 9

4.3.3 Carbon Steel 10

4.3.4 Stainless Steel 11

4.4 Process Data

4.4.1 Introduction 13

4.4.2 Process Data Settings 14

Plasma Marking Data 54

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness 76

4.4.3.1 Aluminum Kerf Values 76

4.4.3.2 Carbon Steel Kerf Values 78

4.4.3.3 Stainless Steel Kerf Values O2/N2/O

2

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH

4.4.3.5 Stainless Steel Kerf Values N2/N2/CH

4

4

81

82

83

4.4.3.6 Stainless Steel Kerf Values N2/N

4.4.3.7 Stainless Steel Kerf Values Air/Air 86

2

ii

84

Precision Plasma Electronic Flow Control Table of Contents

Section 5 Maintenance

5.1 General 1

5.2 Inspection and Cleaning 1

5.3 PT-24 Torch Description 2

5.4 Torch Maintenance 5

5.5 PT-24 Consumable Disassembly and Inspection 7

5.6 PT-24 Torch Re-Assembly 9

Section 6 Troubleshooting

6.1 General Safety 1

6.2 Programmable Logic Controller (PLC) 1

6.2.1 PLC LED Introduction 2

6.2.2 PLC LED Functions 2

6.3 Troubleshooting Guide

6.3.1 Reduced Consumable Life 3

6.3.2 Poor Cut Quality 4

6.3.3 No Pilot Arc 4

6.3.4 No Arc Transfer 4

6.3.5 No Preflow 4

6.3.6 Torch Fails to Fire 4

6.3.7 Nozzle Life Extremely Short 5

6.3.8 Short Electrode Life 5

6.3.9 Short Electrode AND Nozzle Life 5

6.4 Flow Control Schematic 6

6.5 Gas Flow Schematic 7

6.6 Junction Box Wiring Diagram 8

6.7 Junction Box Schematic 9

6.8 Precision Plasma Power Module Wiring Diagram 10-11

6.9 Power Module Schematic 12

6.10 Power Source Wiring Diagrams 13-17

6-11 Power Source Schematic 18-19

iii

Precision Plasma Electronic Flow Control Table of Contents

6.12 Technical Guide to Using/Understanding the Operation of the EFC 20

6.12.1 Precision Process Timers 21

6.12.2 Process Timer Values 22

6.12.3 Process Window Key Functions 23

6.12.4 Proportional Valve Analog Values for PARAM.CUT

PARAM.CUT and DEF.TEC

PARAM.CUTPARAM.CUT

DEF.TEC 24

DEF.TECDEF.TEC

6.12.5 Process Gas Selection Requirements 25

6.12.6 EFC Process Gas Flow Chart 26

6.12.7 Station On, Flush/Pressurize Cycle Timers 27

6.12.8 Solenoid/Proportional Valve Requirements and
Gas Error Monitoring

Carbon Steel PG-O2, SG-O

Carbon Steel PG-O2, SG-N2/O

Carbon Steel PG-O2, Sg-O

Stainless Steel PG-N2, SG-N

2

2

2

2

Stainless Steel PG-N2, SG-N2/CH

4

28

30

32

34

36

Stainless Steel PG-Air, SG-Air 38

Stainless Steel PG-Air, SG-Air/CH

Aluminum PG-N2, SG- N

Aluminum PG-N2, SG-N2/CH

2

4

4

40

42

44

Marking PG-Argon, SG-Air 46

Section 7 Replacement Parts

7.1 General 1

7.2 Ordering 2

7.3 Plasmarc Power Source – Exterior Components 3

7.4 Plasmarc Power Source – Internal Components 8

7.5 Power Source Module 18

7.6 EFC Junction Box 26

7.7 Electronic Flow Control Box 32

7.8 PT-24 Torch Assembly EFC Series A/M 36

7.9 T Gas Shut-off Valve Assembly - Series A/M Torch 38

7.10 PT-24 Torch Assembly – Version 1 40

7.11 Solenoid Assembly - EFC Torch – Version 1 42

Customer/Technical Information Back Manual Cover

iv

SECTION 1 SAFETY

1.1 Introduction

The process of cutting metals with plasma equipment
provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. However, as with any
machine tool, sensible attention to operating
procedures, precautions, and safe practices is
necessary to achieve a full measure of usefulness.
Whether an individual is involved with operation,
servicing, or as an observer, compliance with
established precautions and safe practices must be
accomplished. Failure to observe certain precautions
could result in serious personnel injury or severe
equipment damage. The following precautions are
general guidelines applicable when working with
cutting machines. More explicit precautions pertaining
to the basic machine and accessories are found in the
instruction literature. For a wide scope of safety
information on the field of cutting and welding
apparatus, obtain and read the publications listed in
the Recommended References.

1.2 Safety Notations And Symbols

!

DANGER

!

WARNING

!

CAUTION

!

CAUTION

The following words and symbols are used throughout
this manual. They indicate different levels of required
safety involvement.

ALERT or ATTENTION. Your safety is involved
or potential equipment failure exists. Used in
concurrence with other symbols and information.

Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury or loss of life.

Used to call attention to potential hazards
that could result in personal injury or loss of
life.

Used to call attention to hazards that could
result in minor personal injury or equipment
damage.

Used to call attention to minor hazards to
equipment.

NOTICE

Used to call attention to important
installation, operation or maintenance
information not directly related to safety
hazards.

1-1

SECTION 1 SAFETY

1.3 General Safety Information

Machine starts automatically.

WARNING

!

This equipment moves in various directions and

This equipment moves in various directions and

This equipment moves in various directions andThis equipment moves in various directions and
speeds.

speeds.

speeds.speeds.

• Moving machinery can crush.

Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

• Only qualified personnel should operate or service

Only qualified personnel should operate or service

Only qualified personnel should operate or serviceOnly qualified personnel should operate or service
equipment.

equipment.

equipment.equipment.

• Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment notKeep all personnel, materials, and equipment not
involved in production process clear of entire

involved in production process clear of entire

involved in production process clear of entireinvolved in production process clear of entire
system area.

system area.

system area.system area.

• Keep gear racks and rails clear of debris or

Keep gear racks and rails clear of debris or

Keep gear racks and rails clear of debris orKeep gear racks and rails clear of debris or
obstructions, such as tools or clothing.

obstructions, such as tools or clothing.

obstructions, such as tools or clothing.obstructions, such as tools or clothing.

• Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnelFence off entire work cell to prevent personnel
from passing through area or standing in the

from passing through area or standing in the

from passing through area or standing in thefrom passing through area or standing in the
working envelope of the equipment.

working envelope of the equipment.

working envelope of the equipment.working envelope of the equipment.

WARNING

!

• Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every work

Post appropriate WARNING signs at every workPost appropriate WARNING signs at every work
cell entrance.

cell entrance.

cell entrance.cell entrance.

• Follow lockout procedure before servicing.

Follow lockout procedure before servicing.

Follow lockout procedure before servicing.Follow lockout procedure before servicing.

Failure to follow operating instructions
could result in death or serious injury.

Read and understand this operator’s manual before

Read and understand this operator’s manual before

Read and understand this operator’s manual beforeRead and understand this operator’s manual before
using machine.

using machine.

using machine.using machine.

• Read entire procedure before operating or

Read entire procedure before operating or

Read entire procedure before operating orRead entire procedure before operating or
performing any system maintenance.

performing any system maintenance.

performing any system maintenance.performing any system maintenance.

• Special attention must be given to all hazard

Special attention must be given to all hazard

Special attention must be given to all hazardSpecial attention must be given to all hazard
warnings that provide essential information

warnings that provide essential information

warnings that provide essential informationwarnings that provide essential information
regarding personnel safety and/or possible

regarding personnel safety and/or possible

regarding personnel safety and/or possibleregarding personnel safety and/or possible
equipment damage.

equipment damage.

equipment damage.equipment damage.

• All safety precautions relevant to electrical

All safety precautions relevant to electrical

All safety precautions relevant to electricalAll safety precautions relevant to electrical
equipment and process operations must be

equipment and process operations must be

equipment and process operations must beequipment and process operations must be
strictly observed by all having system

strictly observed by all having system

strictly observed by all having systemstrictly observed by all having system
responsibility or access.

responsibility or access.

responsibility or access.responsibility or access.

• Read all safety publications made available by

Read all safety publications made available by

Read all safety publications made available byRead all safety publications made available by
your company.

your company.

your company.your company.

1-2

SECTION 1 SAFETY

Failure to follow safety warning label

WARNING

!

1.4 Installation Precautions

instructions could result in death or
serious injury.

Read and understand all safety warning labels on

Read and understand all safety warning labels on

Read and understand all safety warning labels onRead and understand all safety warning labels on
machine.

machine.

machine.machine.

Refer to operator’s manual for additional safety

Refer to operator’s manual for additional safety

Refer to operator’s manual for additional safetyRefer to operator’s manual for additional safety
information.

information.

information.information.

WARNING

!

Improperly installed equipment can cause
injury or death.

Follow these guidelines while installing machine:

Follow these guidelines while installing machine:

Follow these guidelines while installing machine:Follow these guidelines while installing machine:

Do not connect a cylinder directly to machine inlet. An

Do not connect a cylinder directly to machine inlet. An

Do not connect a cylinder directly to machine inlet. AnDo not connect a cylinder directly to machine inlet. An
appropriate cylinder regulator must be installed on a

appropriate cylinder regulator must be installed on a

appropriate cylinder regulator must be installed on aappropriate cylinder regulator must be installed on a
fuel gas cylinder to reduce pressure to a reasonable

fuel gas cylinder to reduce pressure to a reasonable

fuel gas cylinder to reduce pressure to a reasonablefuel gas cylinder to reduce pressure to a reasonable
inlet supply pressure. Machine regulator is then used

inlet supply pressure. Machine regulator is then used

inlet supply pressure. Machine regulator is then usedinlet supply pressure. Machine regulator is then used
to obtain pressure required by torches.

to obtain pressure required by torches.

to obtain pressure required by torches.to obtain pressure required by torches.

Contact your ESAB representative before installation.

Contact your ESAB representative before installation.

Contact your ESAB representative before installation.Contact your ESAB representative before installation.
He can suggest certain precautions regarding piping

He can suggest certain precautions regarding piping

He can suggest certain precautions regarding pipingHe can suggest certain precautions regarding piping
installation and machine lifting, etc. to ensure

installation and machine lifting, etc. to ensure

installation and machine lifting, etc. to ensureinstallation and machine lifting, etc. to ensure
maximum security.

maximum security.

maximum security.maximum security.

Never attempt any machine modifications or apparatus

Never attempt any machine modifications or apparatus

Never attempt any machine modifications or apparatusNever attempt any machine modifications or apparatus
additions without first consulting a qualified ESAB

additions without first consulting a qualified ESAB

additions without first consulting a qualified ESABadditions without first consulting a qualified ESAB
representative.

representative.

representative.representative.

Observe machine clearance requirements for proper

Observe machine clearance requirements for proper

Observe machine clearance requirements for properObserve machine clearance requirements for proper
operation and personnel safety.

operation and personnel safety.

operation and personnel safety.operation and personnel safety.

1-3

SECTION 1 SAFETY

1.5 Electrical Grounding

Electrical grounding is imperative for proper machine
operation and SAFETY. Refer to this manual’s
Installation section for detailed grounding instructions.

Electric shock hazard.

WARNING

!

Improper grounding can cause severe injury or death.

Improper grounding can cause severe injury or death.

Improper grounding can cause severe injury or death.Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into

Machine must be properly grounded before put into

Machine must be properly grounded before put intoMachine must be properly grounded before put into
service.

service.

service.service.

Improper grounding can damage machine

WARNING

!

and electrical components.

• Machine must be properly grounded before put

Machine must be properly grounded before put

Machine must be properly grounded before putMachine must be properly grounded before put
into service.

into service.

into service.into service.

1.6 Operating A Plasma Cutting Machine

WARNING

!

WARNING

!

• Cutting table must be properly grounded to

Cutting table must be properly grounded to a good

Cutting table must be properly grounded toCutting table must be properly grounded to
Earth ground rod.

Earth ground rod.

Earth ground rod.Earth ground rod.

a good

a gooda good

Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. WearHot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flying

goggles to protect eyes from burns and flyinggoggles to protect eyes from burns and flying
debris generated during operation.

debris generated during operation.

debris generated during operation.debris generated during operation.

• Chipped slag may be hot and fly far. Bystanders

Chipped slag may be hot and fly far. Bystanders

Chipped slag may be hot and fly far. BystandersChipped slag may be hot and fly far. Bystanders
should also wear goggles and safety glasses.

should also wear goggles and safety glasses.

should also wear goggles and safety glasses.should also wear goggles and safety glasses.

• From plasma arc can damage hearing. Wear

From plasma arc can damage hearing. Wear

From plasma arc can damage hearing. WearFrom plasma arc can damage hearing. Wear
correct ear protection when cutting above water.

correct ear protection when cutting above water.

correct ear protection when cutting above water.correct ear protection when cutting above water.

Burn hazard.

Hot metal can burn.

Hot metal can burn.

Hot metal can burn.Hot metal can burn.

• Do not touch metal plate or parts immediately after

Do not touch metal plate or parts immediately after

Do not touch metal plate or parts immediately afterDo not touch metal plate or parts immediately after
cutting. Allow metal time to cool, or douse with

cutting. Allow metal time to cool, or douse with

cutting. Allow metal time to cool, or douse withcutting. Allow metal time to cool, or douse with
water.

water.

water.water.

• Do not touch plasma torch immediately after

Do not touch plasma torch immediately after

Do not touch plasma torch immediately afterDo not touch plasma torch immediately after
cutting. Allow torch time to cool.

cutting. Allow torch time to cool.

cutting. Allow torch time to cool.cutting. Allow torch time to cool.

1-4

SECTION 1 SAFETY

WARNING

!

Hazardous voltages. Electric shock
can kill.

• Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cable
connections during plasma cutting process.

connections during plasma cutting process.

connections during plasma cutting process.connections during plasma cutting process.

• Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies
before touching or servicing plasma torch.

before touching or servicing plasma torch.

before touching or servicing plasma torch.before touching or servicing plasma torch.

• Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies
before opening or servicing plasma plumbing or

before opening or servicing plasma plumbing or

before opening or servicing plasma plumbing orbefore opening or servicing plasma plumbing or
flow control box.

flow control box.

flow control box.flow control box.

• Do not touch live electrical parts.

Do not touch live electrical parts.

Do not touch live electrical parts.Do not touch live electrical parts.

• Keep all panels and covers in place when machine

Keep all panels and covers in place when machine

Keep all panels and covers in place when machineKeep all panels and covers in place when machine
is connected to power source.

is connected to power source.

is connected to power source.is connected to power source.

• Insulate yourself from

Insulate yourself from workpiece and electrical

Insulate yourself from Insulate yourself from
ground: wear insulating gloves, shoes and

ground: wear insulating gloves, shoes and

ground: wear insulating gloves, shoes andground: wear insulating gloves, shoes and
clothing.

clothing.

clothing.clothing.

• Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, and

Keep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, and
equipment dry.

equipment dry.

equipment dry.equipment dry.

workpiece and electrical

workpiece and electricalworkpiece and electrical

WARNING

!

WARNING

!

Pinch hazard.

Moving vertical slides can crush or pinch.

Moving vertical slides can crush or pinch.

Moving vertical slides can crush or pinch.Moving vertical slides can crush or pinch.

Keep hands clear of torch and slide during operation.

Keep hands clear of torch and slide during operation.

Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.

Fume hazard.

Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cuttingFumes and gases generated by the plasma cutting
process can be hazardous to your health.

process can be hazardous to your health.

process can be hazardous to your health.process can be hazardous to your health.

• Do NOT breathe fumes.

Do NOT breathe fumes.

Do NOT breathe fumes.Do NOT breathe fumes.

• Do not operate plasma torch without fume removal

Do not operate plasma torch without fume removal

Do not operate plasma torch without fume removalDo not operate plasma torch without fume removal
system operating properly.

system operating properly.

system operating properly.system operating properly.

• Use additional ventilation to remove fumes if

Use additional ventilation to remove fumes if

Use additional ventilation to remove fumes ifUse additional ventilation to remove fumes if
necessary.

necessary.

necessary.necessary.

• Use approved respirator if ventilation is not

Use approved respirator if ventilation is not

Use approved respirator if ventilation is notUse approved respirator if ventilation is not
adequate.

adequate.

adequate.adequate.

1-5

SECTION 1 SAFETY

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn

Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn Arc rays can injure eyes and burn

• Wear correct eye and body protection.

Wear correct eye and body protection.

Wear correct eye and body protection.Wear correct eye and body protection.

• Wear dark safety glasses or goggles with

Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with Wear dark safety glasses or goggles with
shields. Refer to following chart for recommended

shields. Refer to following chart for recommended

shields. Refer to following chart for recommendedshields. Refer to following chart for recommended
lens shades for plasma cutting:

lens shades for plasma cutting:

lens shades for plasma cutting:lens shades for plasma cutting:

Arc Current

Arc Current Le

Arc CurrentArc Current
Up to 100 Amps

Up to 100 Amps Shade No. 8

Up to 100 AmpsUp to 100 Amps
100-200 Amps

100-200 AmpsShade No. 10

100-200 Amps100-200 Amps
200-400 Amps

200-400 AmpsShade No. 12

200-400 Amps200-400 Amps
Over 400 Amps

Over 400 Amps Shade No. 14

Over 400 AmpsOver 400 Amps

• Replace glasses/goggles when lenses are pitted or

Replace glasses/goggles when lenses are pitted or

Replace glasses/goggles when lenses are pitted orReplace glasses/goggles when lenses are pitted or
broken

broken

brokenbroken

• Warn others in area not to look directly at the arc

Warn others in area not to look directly at the arc

Warn others in area not to look directly at the arcWarn others in area not to look directly at the arc
unless wearing appropriate safety glasses.

unless wearing appropriate safety glasses.

unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.

• Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection andPrepare cutting area to reduce reflection and
transmission of ultraviolet light.

transmission of ultraviolet light.

transmission of ultraviolet light.transmission of ultraviolet light.

• Paint walls and other surfaces with dark colors to

Paint walls and other surfaces with dark colors to

Paint walls and other surfaces with dark colors toPaint walls and other surfaces with dark colors to
reduce reflections.

reduce reflections.

reduce reflections.reduce reflections.

Lens Shade

Le Le

Shade No. 10

Shade No. 10Shade No. 10
Shade No. 12

Shade No. 12Shade No. 12

skin.

skin.skin.

ns Shade

ns Shadens Shade

Shade No. 8

Shade No. 8Shade No. 8

Shade No. 14

Shade No. 14Shade No. 14

side

sideside

WARNING

!

• Install protective screens or curtains to reduce

Install protective screens or curtains to reduce

Install protective screens or curtains to reduceInstall protective screens or curtains to reduce
ultraviolet transmission.

ultraviolet transmission.

ultraviolet transmission.ultraviolet transmission.

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and violently

Mishandling gas cylinders can rupture and violently

Mishandling gas cylinders can rupture and violentlyMishandling gas cylinders can rupture and violently
release gas.

release gas.

release gas.release gas.

• Avoid rough handling of cylinders.

Avoid rough handling of cylinders.

Avoid rough handling of cylinders.Avoid rough handling of cylinders.

• Keep cylinder valves closed when not in use.

Keep cylinder valves closed when not in use.

Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.

• Maintain hoses and fittings in good condition.

Maintain hoses and fittings in good condition.

Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.

• Always secure cylinders in an upright position by

Always secure cylinders in an upright position by

Always secure cylinders in an upright position byAlways secure cylinders in an upright position by
chain or strap to a suitable stable object not part of

chain or strap to a suitable stable object not part of

chain or strap to a suitable stable object not part ofchain or strap to a suitable stable object not part of
an electrical circuit.

an electrical circuit.

an electrical circuit.an electrical circuit.

• Locate cylinders away from heat, sparks and

Locate cylinders away from heat, sparks and

Locate cylinders away from heat, sparks andLocate cylinders away from heat, sparks and
flames. Never strike an arc on a cylinder.

flames. Never strike an arc on a cylinder.

flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.

• Refer to CGA Standard P-1, “Precautions for Safe

Refer to CGA Standard P-1, “Precautions for Safe

Refer to CGA Standard P-1, “Precautions for SafeRefer to CGA Standard P-1, “Precautions for Safe
Handling of Compressed Gases in Cylinders”,

Handling of Compressed Gases in Cylinders”,

Handling of Compressed Gases in Cylinders”,Handling of Compressed Gases in Cylinders”,
available from Compressed Gas Association.

available from Compressed Gas Association.

available from Compressed Gas Association.available from Compressed Gas Association.

1-6

SECTION 1 SAFETY

WARNING

!

Spark hazard.

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire and burns.Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

Do not cut near combustible material.

Do not cut near combustible material.Do not cut near combustible material.

• Do not cut containers that have held combustibles.

Do not cut containers that have held combustibles.

Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.

• Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g.

Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g.
butane lighter).

butane lighter).

butane lighter).butane lighter).

• Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzlePilot arc can cause burns. Keep torch nozzle
away from yourself and others when activating

away from yourself and others when activating

away from yourself and others when activatingaway from yourself and others when activating
plasma process.

plasma process.

plasma process.plasma process.

• Wear correct eye and body protection.

Wear correct eye and body protection.

Wear correct eye and body protection.Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

• Wear flame-retardant clothing that covers all

Wear flame-retardant clothing that covers all

Wear flame-retardant clothing that covers allWear flame-retardant clothing that covers all
exposed areas.

exposed areas.

exposed areas.exposed areas.

• Wear

Wear cuffless trousers to prevent entry of sparks

cuffless trousers to prevent entry of sparks

Wear Wear

cuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparks

and slag.

and slag.

and slag.and slag.

CAUTION

POOR PERFORMANCE WILL RESULT
WHEN CUTTING ABOVE WATER.

The PT-24 is designed to be a dry cutting
process.

Cutting above water may result in:

Cutting above water may result in:

Cutting above water may result in:Cutting above water may result in:

• reduced consumable life

reduced consumable life

reduced consumable lifereduced consumable life

• degradation of cut quality

degradation of cut quality

degradation of cut qualitydegradation of cut quality

Cutting above water may result in poor cutting

Cutting above water may result in poor cutting

Cutting above water may result in poor cuttingCutting above water may result in poor cutting
performance. Water vapor created when hot material

performance. Water vapor created when hot material

performance. Water vapor created when hot materialperformance. Water vapor created when hot material
or sparks contact liquid may cause arcing inside torch.

or sparks contact liquid may cause arcing inside torch.

or sparks contact liquid may cause arcing inside torch.or sparks contact liquid may cause arcing inside torch.

When cutting on a water table, reduce the water level

When cutting on a water table, reduce the water level

When cutting on a water table, reduce the water levelWhen cutting on a water table, reduce the water level
to provide maximum clearance between water and

to provide maximum clearance between water and

to provide maximum clearance between water andto provide maximum clearance between water and
material.

material.

material.material.

1-7

SECTION 1 SAFETY

WARNING

!

1.7 Service Precautions

Explosion hazard.

Certain molten aluminum-lithium (Al-

Certain molten aluminum-lithium (Al-Li) alloys can

Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Al­cause explosions when plasma cut OVER water.

cause explosions when plasma cut OVER water.

cause explosions when plasma cut OVER water.cause explosions when plasma cut OVER water.

Do not plasma cut the following Al-

Do not plasma cut the following Al-Li alloys with

Do not plasma cut the following Al-Do not plasma cut the following Al­water:

water:

water:water:

Alithlite (Alcoa)

Alithlite (Alcoa) X8192 (Alcoa)

Alithlite (Alcoa)Alithlite (Alcoa)
Alithally (Alcoa)

Alithally (Alcoa) Navalite (US Navy)

Alithally (Alcoa)Alithally (Alcoa)
2090 Alloy (Alcoa)

2090 Alloy (Alcoa) Lockalite (Lockheed)

2090 Alloy (Alcoa)2090 Alloy (Alcoa)
X8090A (Alcoa)

X8090A (Alcoa) Kalite (Kaiser)

X8090A (Alcoa)X8090A (Alcoa)
X8092 (Alcoa)

X8092 (Alcoa) 8091 (

X8092 (Alcoa)X8092 (Alcoa)

• These alloys should only be dry cut on a dry table.

These alloys should only be dry cut on a dry table.

These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.

• DO NOT dry cut over water.

DO NOT dry cut over water.

DO NOT dry cut over water.DO NOT dry cut over water.

• Contact your aluminum supplier for additional

Contact your aluminum supplier for additional

Contact your aluminum supplier for additionalContact your aluminum supplier for additional
safety information regarding hazards associated

safety information regarding hazards associated

safety information regarding hazards associatedsafety information regarding hazards associated
with these alloys

with these alloys.

with these alloyswith these alloys

X8192 (Alcoa)

X8192 (Alcoa)X8192 (Alcoa)
Navalite (US Navy)

Navalite (US Navy)Navalite (US Navy)
Lockalite (Lockheed)

Lockalite (Lockheed)Lockalite (Lockheed)
Kalite (Kaiser)

Kalite (Kaiser)Kalite (Kaiser)
8091 (Alcan)

8091 (8091 (

Li) alloys can

Li) alloys canLi) alloys can

Li alloys with

Li alloys withLi alloys with

Alcan)

Alcan)Alcan)

CAUTION

CAUTION

!

Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. A
composite program can be established from

composite program can be established from

composite program can be established fromcomposite program can be established from
recommended schedules in the instruction literature.

recommended schedules in the instruction literature.

recommended schedules in the instruction literature.recommended schedules in the instruction literature.

Avoid leaving test equipment or hand tools on

Avoid leaving test equipment or hand tools on

Avoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damage

machine. Severe electrical or mechanical damagemachine. Severe electrical or mechanical damage
could occur to equipment or machine.

could occur to equipment or machine.

could occur to equipment or machine.could occur to equipment or machine.

Extreme caution should be used when probing

Extreme caution should be used when probing

Extreme caution should be used when probingExtreme caution should be used when probing
circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Integratedcircuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage.
Power off before using test probes to prevent

Power off before using test probes to prevent

Power off before using test probes to preventPower off before using test probes to prevent
accidental shorting of components.

accidental shorting of components.

accidental shorting of components.accidental shorting of components.

All circuit boards securely seated in sockets, all cables

All circuit boards securely seated in sockets, all cables

All circuit boards securely seated in sockets, all cablesAll circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all

properly connected, all cabinets closed and locked, all

properly connected, all cabinets closed and locked, allproperly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned

guards and covers replaced before power is turned

guards and covers replaced before power is turnedguards and covers replaced before power is turned
on.

on.

on.on.

Never plug or unplug a printed circuit board while

Never plug or unplug a printed circuit board while

Never plug or unplug a printed circuit board whileNever plug or unplug a printed circuit board while
machine power is on. Instantaneous surges of voltage

machine power is on. Instantaneous surges of voltage

machine power is on. Instantaneous surges of voltagemachine power is on. Instantaneous surges of voltage
and current can damage electronic components.

and current can damage electronic components.

and current can damage electronic components.and current can damage electronic components.

1-8

SECTION 1 SAFETY

1.8 Safety References

The following nationally recognized publications on safety in welding
and cutting operations are recommended. These publications have
been prepared to protect persons from injury or illness and to protect
property from damage, which could result from unsafe practices.
Although some of these publications are not related specifically to this
type of industrial cutting apparatus, the principles of safety apply
equally.

• “Precautions and Safe Practices in Welding and Cutting with

Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting

Systems.

• “Precautions and Safe Practices for Electric Welding and Cutting,”

Form 52-529. ESAB Cutting Systems.

• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding

Society, 2501 NW 7th Street, Miami, Florida, 33125.

• “Recommended Safe Practices for Shielded Gases for Welding and

Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.

• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,

American Welding Society.

• “Recommended Practices for Arc Cutting” - AWS C5.2, American

Welding Society.

• “Safe Practices” - AWS SP, American Welding Society.

• “Standard for Fire Protection in Use of Cutting and Welding

Procedures” - NFPA 51B, National Fire Protection Association, 60

Batterymarch Street, Boston, Massachusetts, 02110.

• “Standard for Installation and Operation of Oxygen - Fuel Gas

Systems for Welding and Cutting” - NFPA 51, National Fire

Protection Association.

• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting

Systems. Obtainable through your ESAB representative or local
distributor.

• "Design and Installation of Oxygen Piping Systems," Form 5110.

ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed Gases in

Cylinders”, CGA Standard P-1, Compressed Gas Association.

Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.

1-9

SECTION 1 SAFETY

This page intentionally left blank.

1-10

SECTION 2 DESCRIPTION

2.1 General

2.2 Scope

The Precision Plasmarc System consists of four
separate components. The power source, the
junction box, the flow control box, and the PT-24
torch. The power source provides power and
coolant to the PT-24 torch via the junction box.

The purpose of this manual is to provide the
operator with all the information required to install
and operate the Precision Plasmarc System.
Technical reference material is also provided to
assist in troubleshooting the cutting package.

2.3 Package Options Available

Precision Plasmarc package options available through your ESAB dealer

Precision Plasmarc Power Source (200/ 230/380/415/460/575) 3-phase 50/60

Hz (required)

Electronic Flow Control Box (required) P/N 22406

Junction Box (required) P/N 22407

4.5 ft. (1.4 m) P/N 0558001463

12 ft. (4.4 m) P/N 0558001877PT-24 Torch Electronic Flow Series A/M (one required)

17 ft. (5.2 m) P/N 0558001464

12 ft. (3.6 m) P/N 22428

25 ft. (7.6 m) P/N 21905

Power Bundle (one required)

Gas Line Bundle (one required)

Control Lead Flow Console to Junction Box
(one required)

Torch Coolant (one gallon (3.8 l) containers. four gallons (15 l) required) P/N 156F05

NOTES:

40 ft. (12.2 m) P/N 22504

60 ft. (18 m) P/N 21906

80 ft. (24.4 m) P/N 22505

100 ft. (30 m) P/N 21907

10 ft. (3 m) P/N 37533

20 ft. (6 m) P/N 37534

30 ft. (9 m) P/N 37535

60 ft. (18 m) P/N 37536

100 ft. (30 m) P/N 37537

10 ft. (3 m) P/N 21917

20 ft. (6 m) P/N 21918

30 ft. (9 m) P/N 21919

60 ft. (18 m) P/N 21920

100 ft. (30 m) P/N 21921

P/N 37357

• Control lead from the power source to customer CNC is supplied based on customer order.

• Gas supply, hoses, work lead and input primary cable are all supplied by the customer.

• See Process Data Sheets for a list of torch consumable parts.

2-1

SECTION 2 DESCRIPTION

2.4 Precision Plasma Technical Specifications

2.4.1 System

Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz

Input Current 65/60/50/ 40/30/25 amps per phase

Power Factor 0.95

Output Current Range 15-100 amps dc

Output Load Voltage 120 V dc

Duty Cycle 100%

Open Circuit Voltage 315 V dc

JUNCTION BOX

JUNCTION BOX

JUNCTION BOXJUNCTION BOX

42" (1067mm)

WEIGHT = 560 lbs. (254 kg)

WEIGHT = 560 lbs. (254 kg)

WEIGHT = 560 lbs. (254 kg)WEIGHT = 560 lbs. (254 kg)

POWER SUPPLY

POWER SUPPLY

POWER SUPPLYPOWER SUPPLY

L

RO

NT

O

C

NT
E

URR

C

L

P

N

O

I

S

I

C

E

R

22" (559mm)

6.75" (171mm)

T
O
L

PI

ARC

R
E

OW

P

19.75" (502mm)

C

R

A

M

S

A

WEIGHT = 26.5 lbs.(12 kg)

WEIGHT = 26.5 lbs.(12 kg)

WEIGHT = 26.5 lbs.(12 kg)WEIGHT = 26.5 lbs.(12 kg)

10.62" (270mm)

44" (1118mm)

ELECTRONIC FLOW CONTROL BOX

ELECTRONIC FLOW CONTROL BOX

ELECTRONIC FLOW CONTROL BOX ELECTRONIC FLOW CONTROL BOX

14.5" (1118mm)

H

T

E

M

5

-

3

H

N

2

N

2

2

O

I

R

2

A

O

2
N

R

A

12.25" (311mm)

I

G
A
M

S

A

L

P

.

2

S

A

O

G

N

A

M
S
A

L

P

N

.

1

E
Y

G

O

X

N

O

N

E
O

G

R

I

T

N

I

R
A

N
G

O
R

A

S

A

G
D
L

I

E
H

S

.

2

S

O

A

N

G

D
L
E

I

H

S

N

.

1

E

S

O

O

G

A

N

T

R

I

N

N

E

O

G
R
I

T
N

E
N
A

T

H

E

M

N

E
Y

G

X
O

E

N
G
O

D

R

Y

H

I

R

A

12" (305mm)

2-2

WEIGHT = 51 lbs. (23 kg)

WEIGHT = 51 lbs. (23 kg)

WEIGHT = 51 lbs. (23 kg)WEIGHT = 51 lbs. (23 kg)

SECTION 2 DESCRIPTION

2.4.2 Plasma Gas Technical Specifications

Type O2, N2, Air

Pressure 125 psig (8.6 bars)

Flow

Purity Required*

Recommended Liquid Cylinder Service
Regulators

Recommended Cylinder 2-Stage
Regulators

Recommended Heavy –Duty Hi-flow
Station or Pipeline Regulators
Recommended High-capacity Station
or Pipeline Regulators

100 cfh (47 l/min) max. (varies with
application)
O2-99.995%
N2-99.995%
Air-clean, dry and oil free
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
Oxygen: R-77-150-540 (P/N 998337
Hydrogen/Methane:R-77-150-350 (P/N

998342)
Nitrogen: R-77-150-580 (P/N 998344)
Industrial Air: R-77150=590 (P/N

998348)

Oxygen: R-76-150-024 (P/N 19151)

R-6703 (P/N 22236)

Gas Filter Required 25 micron w/bowl guard (P/N 56998133)

2.4.3 Start Gas Technical Specifications

Type N2, Air

Pressure 125 psig (8.6 bar)

Flow

Minimum Purity Required 99.995%

2.4.4 Secondary Gas Technical Specifications

Type N2, O2, H-35, Methane, Air

Pressure

Flow

Minimum Purity Required 99.995%

2.4.5 Pt-24 Torch Technical Specifications

60 cfh (28 l/min) max (varies with
application)

100 psig (6.6 bar) H-35,
Methane; 125 psig (8.6 bar) N2,
O2, Air
60 cfh (28 l/min) max (varies with
application)

Type Water-Cooled, Dual Gas

Rating 100 amps @ 100 % duty cycle

Dimensions See Package Options (2.3)

2-3

SECTION 2 DESCRIPTION

Page intentionally left blank.

2-4

SECTION 3 INSTALLATION

3.1 General

Proper installation can contribute materially to the

NOTICE

satisfactory and trouble-free operation of the Precision
Plasmarc System. It is suggested that each step in
this section be studied and carefully followed.

3.2 Equipment Required

3.3 Location

• Gas Supply and Hoses. Gas supply may be from

a bulk source or from a bank of manifold cylinders
and regulated to supply 125 psig (8.6 bar) to the
Flow Control (gas flowing).

• Work Lead. No. 4 AWG cable is recommended for

connecting workpiece to power source.

• Primary Input Cable.

• 25 micron gas filters (or better) are required on the

supply side for the EFC to function properly.

• Ventilation is necessary to provide proper cooling

of the power supply.

• Minimize dirt, dust and exposure to external heat

sources.

• Allow a minimum of two feet clearance around the

power supply for free air movement.

CAUTION

!

Do Not Restrict Air Flow

Restricting intake air with any type of filter on or around

Restricting intake air with any type of filter on or around

Restricting intake air with any type of filter on or aroundRestricting intake air with any type of filter on or around
the power supply may void the warranty.

the power supply may void the warranty.

the power supply may void the warranty.the power supply may void the warranty.

3-1

SECTION 3 INSTALLATION

3.4 Primary Electrical Input Connections

Electric Shock Can Kill!

DANGER

!

Provide maximum protection against electrical
shock.

Before any connections are made inside the
machine, open the line (wall) disconnect switch
and unplug the power cord.

Input Power Configuration

WARNING

!

Machine must be properly configured for your
input power.

The machine is shipped from the factory
configured for 575 V, 60 Hz input.

Do NOT connect a power source of any other
voltage unless machine is reconfigured. Damage
to the machine will occur.

Input Power Connection At Wall

A line (wall) disconnect switch with fuses or circuit
breakers should be provided at the main power panel.

Connect the input power cable of the power source
directly to the disconnect switch or a proper plug and
receptacle may be purchased from a local electrical
supplier. (See table on the next page for
recommended input conductors and fuses )

Recommended Sizes For Input Conductors And Line Fuses

Recommended Sizes For Input Conductors And Line Fuses

Recommended Sizes For Input Conductors And Line FusesRecommended Sizes For Input Conductors And Line Fuses

Input requirements

Volts Phase Amps

208 3 70 No. 4 25 100
230 3 60 No. 6 16 80
380 3 50 No. 8 10 80
415 3 40 No. 10 6 60
460 3 30 No. 10 6 50
575 3 25 No. 10 6 40

Input & ground

conductor,

cu/awg/mm

2

Fuse ratings /

phase, amps

3-2

SECTION 3 INSTALLATION

The following procedure explains the proper installation
steps for connecting primary electrical power to the
power source.

1. Remove right side panel.

2. Ensure input power cable is disconnected from all
electrical sources.

3. Route input power cable through the strain relief
located at the rear panel.

Ground Connection

TB2

200
230
380
415
460
575

PHASE 1

200
230
380
415
460
575

TB1

200
230
380

415
460
575

200
230
380
415
460
575

PHASE 2

PHASE 3

K1

Input Power Cable
(Customer supplied)

Main
Contactor

7 Position
Terminal Block

Auto
Transformer

Factory Wired
for 575 volts

4. Pull input power cable through the strain relief to
allow cable wires sufficient length to connect to the
main contactor. Tighten strain relief to ensure
input power cable is secured.

5. Connect input power cable ground wire to the
ground lug provided on the base of the power
source.

6. Connect three power leads of the input power
cable to the terminals located atop the main
contactor. Secure the leads by tightening each
screw.

7. Connect jumper power cables from the bottom of
the main contactor to the proper input voltage
marked on the auto transformer. The unit is
factory set for 575 V as shown to the left.

CAUTION

!

Input Power Jumper Connection

Input Power Jumper Connection

Input Power Jumper ConnectionInput Power Jumper Connection

Ensure each input power jumper cable is connected to

Ensure each input power jumper cable is connected to

Ensure each input power jumper cable is connected toEnsure each input power jumper cable is connected to
the correct input voltage on

the correct input voltage on auto transformer.

the correct input voltage on the correct input voltage on

Factory wired for 575 V.

Factory wired for 575 V.

Factory wired for 575 V.Factory wired for 575 V.

auto transformer.

auto transformer.auto transformer.

8. Connect jumper wire to the proper input voltage

connector located on the 7-position terminal block.
TB2

3-3

SECTION 3 INSTALLATION

3.5 Interconnecting Lines

Black
Red/Orange
Yellow
Blue

Mounting Plate

Gas Line Bundle

Gas Bundle
Installation

1. All interconnecting service lines supplied are
numbered or color coded on each end with
corresponding numbers/colors marked on the
cabinets.

2. Connect all four lines in Gas Line Bundle to Flow
Control Box and Junction Box. Lines and
connections are color coded. In addition,
mounting plate hole spacing is asymmetrical to
prevent improper connection. Order of colors
should be: blue, yellow, red/orange, black

3-4

SECTION 3 INSTALLATION

x

x

x

x

Power supply and EFC Connections to J-Bo

Power supply and EFC Connections to J-Bo

Power supply and EFC Connections to J-Bo

Power supply and EFC Connections to J-Bo

Power Supply Bundle

Power Supply Negative
Connection

Pilot Arc
Connection

#6 Hose Connection
(to power source)

#7 Hose
Connection
(from power
source)

Gas Bundle
Connections

Control Lead Connection
from EFC

3. Connect power and coolant lines in Power
Supply Bundle from power source to junction
box. Power bundle consists of #6 and # 7
coolant lines (with 5/8-18 L.H. fittings), power
cable (#3 AWG) and yellow pilot arc cable (#16
AWG). Both coolant lines are stamped with a 6
or 7 on the fitting to assist in identification.

3-5

SECTION 3 INSTALLATION

Junction Box to Torch Connections

Junction Box to Torch Connections

Junction Box to Torch ConnectionsJunction Box to Torch Connections

4. Connect Torch Bundle Leads/Hoses to
Junction box. (see Interconnecting Block
Diagram)

Torch Bundle

Torch Hose/Power
Cable Connection

Torch
Solenoid
Electrical
Connection

Torch Pilot Arc
Connection

3-6

SECTION 3 INSTALLATION

Precision Plasmarc Component Interconnecting Diagram

25 micron Filters

EFC

Control Lead

EFC/Junction

Box

N

CNC

ASIOB

High

Frequency

120VAC

High Frequency 120VAC

Gas Line Bundle

O

2

2

AirCH

4

Ar

Ground Rod

Torch

Cutting Table

Junction

Power Bundle

Box

Work Lead

Control Lead

Power Supply to CNC

Primary Power Cable

3-7

SECTION 3 INSTALLATION

r

r

Gas Line Contamination Will Damage

CAUTION

!

1/4 NPT

Proportional Valves

Purge Gas Lines

Before connecting gas delivery lines to the

Before connecting gas delivery lines to the

Before connecting gas delivery lines to theBefore connecting gas delivery lines to the
Electronic Flow Control, purge all lines thoroughly.

Electronic Flow Control, purge all lines thoroughly.

Electronic Flow Control, purge all lines thoroughly.Electronic Flow Control, purge all lines thoroughly.
Residue from the hose manufacturing process may

Residue from the hose manufacturing process may

Residue from the hose manufacturing process mayResidue from the hose manufacturing process may
clog/damage the proportional valves in your EFC.

clog/damage the proportional valves in your EFC.

clog/damage the proportional valves in your EFC.clog/damage the proportional valves in your EFC.

5. Purge gas lines between supply and the EFC
before connecting. Proportional valves in the
EFC are very sensitive to dust and other foreign
particles.

25 micron Gas Filte

25 micron Gas Filter

25 micron Gas Filter25 micron Gas Filte

25 µ Filters

N

O

2

6. Connect Gas Delivery lines to Electronic Flow
Control. Install 25 micron Gas filters in all
delivery lines between gas source and EFC.

2

AirCH

4

Ar

3-8

SECTION 3 INSTALLATION

Power Source

Rating

Label

Pilot Arc

Work

Torch

600 amp

Bus Fuse

Remove Access Cover

Pilot Arc

Work

Torch

CNC Control Lead

Flow Control

Lead

7. Remove panel from rear of console and attach the
pilot-arc, torch and work lead.

Serial

Tag

Coolant In from Torch
# 6 Connection

Coolant Out to Torch

8. Connect control lead between the console and the
Electronic Flow Control. Connect coolant lines of
the Power Bundle.

CONTROL LEAD

3-9

SECTION 3 INSTALLATION

3.6 Torch Mounting

CAUTION

1.812" (46mm)
Diameter Collar

2.0" (51mm)
Diameter Sleeve

Vent Hole

Do Not Cover Vent Hole.

When mounting, do not to cover the small vent hole in

When mounting, do not to cover the small vent hole in

When mounting, do not to cover the small vent hole inWhen mounting, do not to cover the small vent hole in
the side of the sleeve. This hole allows coolant to

the side of the sleeve. This hole allows coolant to

the side of the sleeve. This hole allows coolant tothe side of the sleeve. This hole allows coolant to
drain from inside the sleeve should a leak occur in a

drain from inside the sleeve should a leak occur in a

drain from inside the sleeve should a leak occur in adrain from inside the sleeve should a leak occur in a
service line.

service line.

service line.service line.

Torch Mounting Options.

Torch Mounting Options.

Torch Mounting Options.Torch Mounting Options.

• The torch is normally mounted by the 2.0 inch

diameter (51mm) sleeve. Do not cover vent hole.

• For custom alternative mounting, the torch can be

mounted by the 1.812" (46 mm) dia collar shown.
This insulated collar and its shoulder are machined
relative to the nozzle retainer thread on the torch
body.

• Use only specified mounting surfaces

3-10

SECTION 3 INSTALLATION

3.7 Torch Coolant

PILOT

RC

OL

NTR

CO

NT
URRE
C

RECISION PLASMARC

A

POWER

• Remove coolant fill cap at front of console and fill

coolant tank with 4 gallons (15 liters) of plasma
coolant, P/N 156F05 (one gallon).

Coolant
Fill Cap

CAUTION

!

• Do not fill above maximum level

• Reinstall Cap.

Commercial Antifreeze Will Cause Torch To
Malfunction

Use Special Torch Coolant! P/N156F05

Due to high electrical conductivity, DO NOT use tap

Due to high electrical conductivity, DO NOT use tap

Due to high electrical conductivity, DO NOT use tapDue to high electrical conductivity, DO NOT use tap
water or commercial antifreeze for torch cooling. A

water or commercial antifreeze for torch cooling. A

water or commercial antifreeze for torch cooling. Awater or commercial antifreeze for torch cooling. A
specially formulated torch coolant is REQUIRED. This

specially formulated torch coolant is REQUIRED. This

specially formulated torch coolant is REQUIRED. Thisspecially formulated torch coolant is REQUIRED. This
coolant also protects for freezing to –34° C.

coolant also protects for freezing to –34° C.

coolant also protects for freezing to –34° C.coolant also protects for freezing to –34° C.

3.8 Inspection of Gas and Coolant Lines

Operating the unit without coolant will cause

Operating the unit without coolant will cause

Operating the unit without coolant will causeOperating the unit without coolant will cause
permanent damage to the coolant pump.

permanent damage to the coolant pump.

permanent damage to the coolant pump.permanent damage to the coolant pump.

To complete installation, it is necessary to inspect
field assembled connections for leaks.

• Gas lines, use a standard soap solution.

Pressurize the system from the control (SDP file)

• Coolant- check connections for signs of

moisture at connections

3-11

SECTION 3 INSTALLATION

3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic
Controller (PLC)

The Precision Plasmarc System may be shipped
configured for a manual flow control (Series “A”). If
so, the EPROM in the Programmable Logic
Controller must be replaced with an EFC EPROM.
This EFC EPROM is shipped with the power source.

Using the Wrong EPROM Could Result In

CAUTION

!

CAUTION

!

Damaged System Components

The Series “A” and the EFC EPROMs are
programmed with different software. The EFC
EPROM ignores the process gas pressure
switch inputs and does not include the
process gas purge required for the Series “A”.

Mishandling Can Damage Electronic
Components.

CAUTION

!

WARNING

!

Handle electronic components with care.

• Do not drop

• Do not bend pins

• Do not touch circuit components- handle

along edges when possible

Electronic Components Are Subject To
Electro-Static-Discharge (ESD) Damage

Integrated Circuit parts are sensitive to over
voltages. The damage may not be seen
immediately but show up as a premature
failure.

The EFC EPROM is shipped in an anti-static
bag. Store EPROM in this bag.

Wear a protective ground strap when handling
sensitive electronic components.

Electric shock Can Kill!

Unplug power cable from wall to power source
before any connections or adjustments are
made inside power source.

3-12

SECTION 3 INSTALLATION

T

O

PIL

C

R

A

R

WE
P

O

C

R

A

M

S

A

L

P

N

O

I

S

I

1. Ensure the Plasmarc Power Source is
disconnected from electricity source.

2. Expose the PLC by removing the left side panel
of the Plasmarc Power Source.

3. Pop the EPROM cover on the PLC to expose
the EPROM.

PLC

Left Side Panel

L

O

T

R

N
C

O

N

T

E

R

R
U
C

C

E

R

EFC EPROM

Package Location

3-13

SECTION 3 INSTALLATION

Using An EPROM Puller Tool May Damage

CAUTION

EPROM Locked In Place

Socket

Forcibly removing a clamped EPROM in the
PLC may cause the socket/EPROM to break.

Special Zero Force EPROM Socket is used to
eliminate the need for special tools.

4. Remove the EPROM from the socket. THIS
DOES NOT REQUIRE A PULLER. Release the
clamp locking the EPROM in place, lift the
Series “A” EPROM from the socket.

5. Remove the EFC EPROM from the packaging.

6. Carefully align the EFC EPROM pins with the
socket holes and insert.

7. Lock the EPROM by moving the lever back
while holding the EPROM in place.

EPROM Lock Released

8. Replace the EPROM cover and the Power
Source left side panel.

EPPESA= Series “A” EPROM, manual flow control

P/N 99513607

EPPSEFC= EFC EPROM, electronic flow control

P/N 99513608

3-14

SECTION 4 OPERATION

ARC

4.1 Power Supply Controls

4.1.1 Main Power Switch

LOW

EMERGENCY

STOP

DO NOT SWITCH
WHILE CUTTING

Main Power Switch
Controls the input power to the fan, water cooler and
the PC Board. Amber indicator light to the left of the
switch.

4.1.2 Pilot Arc Switch

EMERGENCY

STOP

CAUTION

Pilot Arc Switch
Used to select HIGH or LOW Start Pilot Arc depending
on cutting conditions. See Process Data for more
information on which conditions High and Low Start
are used.

POWER

ON

OFF

Adjusting Pilot Arc While in Operation Could
Damage Torch.

Do not adjust pilot arc switch while in operation.

Adjust before torch starts.

4-1

SECTION 4 OPERATION

4.1.3 Fault Indicator Lights

Fault Indicator Lights

• Coolant flow will show low coolant flow. When

unit is turned on, the light will briefly show a fault
and then go out.

• Plasma Gas Pressure

Plasma Gas Pressure. Torch will not fire when
indicated. Not used for the EFC.

Not used for the EFC.

Not used for the EFC.Not used for the EFC.

• Start Gas Pressure

pressure. Torch will not fire when indicated. Not
used for the EFC.

used for the EFC.

used for the EFC.used for the EFC.

• P/S Temp

inverter power source. Power source will shut
down.

• P/S Fault

in the inverter power source. Power source will
shut down.

fault indicator -- over temperature in the

Indicator – fault in plasma control PCB

• Over-Under Voltage

input voltage is above or below the tolerances of
the PCU console. Will latch until power is recycled
by main power switch.

• Emergency Stop

Interlock condition. Power Source will not work.

fault indicator -- low

fault indicator -- low start gas

Not

NotNot

fault Indicator -- indicate

fault indicator -- shows CNC

4.1.4 Meters

4.1.5 Current Control Switch

• Cutting Current Meter (A) -- Displays actual

cutting current in amperes.

• Cutting Voltage Meter (V) -- Displays actual

cutting voltage.

Control Remote/Panel Switch

• Panel Position –

output current dial

• Output Current Dial –

when current setting is made from the console
front panel. Dial reads 0 to 99.9 amps. 70.0 amps
shown.

• Remote Position – output current is set by the

CNC (or remote pot) with an analog dc signal

Output current is set by the

sets the cutting current

0-10 Vdc = 0-100 Adc

4-2

SECTION 4 OPERATION

4.2 Cut Quality

4.2.1 Introduction

Causes affecting cut quality are interdependent.
Changing one variable affects all others. Determining a
solution may be difficult. The following guide offers
possible solutions to different undesirable cutting
results. To begin select the most prominent condition:

§ 4.2.2 Cut Angle, negative or positive

§ 4.2.3 Cut not flat, rounded or undercut

§ 4.2.4 Surface roughness

§ 4.2.5 Dross

Usually the recommended cutting parameters will give
optimal cut quality, occasionally conditions may vary
enough that slight adjustments will be required. If so:

• Make small incremental adjustments when

making corrections.

• Adjust Arc Voltage in 5 volt increments, up or

down as required.

• Adjust cutting speed 5% or less as required

until conditions improve.

NOTICE

4.2.2 Cut Angle

Part

Before attempting ANY corrections, check cutting
variables with the factory recommended
settings/consumable part numbers listed in
Process Data.

Negative Cut Angle

Top dimension is greater than the bottom.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• Standoff low (arc voltage)

• Cutting speed slow (machine travel rate)

Drop

Part

4-3

SECTION 4 OPERATION

Positive Cut Angle

Part

Top dimension is less than the bottom dimension.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• High standoff High (arc voltage)

• Cutting speed fast

• Current high or low. (See Process Data for

PartDrop

recommended current level for specific nozzles).

4.2.3 Cut Flatness

Drop

Top And Bottom Rounded

Condition usually occurs when material is .25” thick
(6,4mm) or less.

• High current for given material thickness (See

Process Data for proper settings).

Part

4-4

SECTION 4 OPERATION

Top Edge Undercut

• Standoff low (Arc Voltage)

Drop

4.2.4 Surface Finish

Top View

Part

Process Induced Roughness

Cut face is consistently rough. May or may not be
confined to one axis.

• Incorrect Shield Gas mixture (See Process Data)

• Worn or damaged consumables

Cut Face

MMMMachine Induced Roughness
Can be difficult to distinguish from Process Induced
Roughness. Often confined to only one axis.
Roughness is inconsistent.

Machine
Induced

or
Process
Induced
Roughness

Roughness

• Dirty rails, wheels and/or drive rack/pinion. (Refer

to Maintenance Section in machine owners
manual).

• Carriage wheel adjustment

4-5

SECTION 4 OPERATION

4.2.5 Dross

Dross is a by-product of the cutting process. It is the
undesirable material that remains attached to the part.
In most cases, dross can be reduced or eliminated
with proper torch and cutting parameter setup. Refer
to Process Data.

Cut

Lag

Lines

Face

High Speed Dross

Material weld or rollover on bottom surface along kerf.
Difficult to remove. May require grinding or chipping.
“S” shaped lag lines.

Rollover

• Standoff high (arc voltage)

Side View

Lag

Lines

• Cutting speed fast

Cut Face

Slow Speed Dross

Forms as globules on bottom along kerf. Removes
easily.

Globules

• Cutting speed slow

Side View

4-6

SECTION 4 OPERATION

Side View

Splatter

Top Dross

Appears as splatter on top of material. Usually
removes easily.

• Cutting speed fast

• Standoff high (arc voltage).

Cut
Face

Intermittent Dross

Appears on top or bottom along kerf.
Non-continuous. Can appear as any kind of dross

• Possible worn consumables

Other Factors Affecting Dross;

• Material temperature

• Heavy mill scale or rust

• High carbon alloys

4-7

SECTION 4 OPERATION

4.2.6 Dimensional Accuracy

Generally using the slowest possible speed (within
approved levels) will optimize part accuracy. Select
consumables to allow a lower arc voltage and slower
cutting speed.

NOTICE

NOTICE

Recommended cutting speed and arc voltage will
give optimal cutting performance in most cases.

Small incremental adjustments may be needed
due to material quality, material temperature and
specific alloy. The operator should remember
that all cutting variables are interdependent.
Changing one setting affects all others and cut
quality could deteriorate. Always start at the
recommended settings.

Before attempting ANY corrections, check
cutting variables with the factory recommended
settings/consumable part numbers listed in the
Process Data.

4-8

SECTION 4 OPERATION

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction

All gases are not suitable for all situations. Certain
gases assist in cutting specific materials and
thickness. The following explains why certain gases
are selected and their influence on the finished part.
Other influences such as arc voltage and gas
flow/pressure are covered in the Process Data.

NOTICE

4.3.2 Aluminum

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

All thickness’ between .062" to .625" (1,6 mm to 15,9 mm)

• Smooth cut face

• Virtually no dross

Shield Gas:

Shield Gas: Nitrogen/Methane

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1
part methane ratio is desired. Incorrect ratio results in heavy dross.

Refer to Cutting Process Data in this section for
recommended flow/pressure settings.

4-9

SECTION 4 OPERATION

Refer to Cutting Process Data in the PT24

NOTICE

4.3.3 Carbon Steel

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm)

Manual for recommended flow/pressure
settings.

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Oxygen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Oxygen/Nitrogen

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Oxygen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen

Shield Gas:Shield Gas:

• Smooth cut face

• Virtually no dross

Shield gas is normally nitrogen. A small amount of oxygen combined
with nitrogen can effectively improve dross formation on thin material of
26 GA to 10 GA carbon steel. Also, an oxygen only shield may provide
acceptable results on thinner materials.

.125" to .75" (3,2 mm to 19,1 mm)

• Smooth cut face

• Virtually no dross

Cutting carbon steel with oxygen results in an exothermic reaction. This

Discussion:

Discussion:

Discussion:Discussion:

chemical reaction causes the carbon in the material to burn similar to
when oxy-fuel cutting. This plus the electrical energy uses lower
amperage levels without sacrificing cut speed.

4-10

SECTION 4 OPERATION

Refer to Cutting Process Data in the PT24

NOTICE

Manual for recommended flow/pressure
settings.

4.3.4 Stainless Steel

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

22 GA (.028") to 16 GA (.062") (0,7 mm to 1,6 mm)

• Positive cut angle

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

• Excellent dross performance

• Shiny cut surface.

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen/Methane

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

Material Thickness: 26 GA (.018") to 16 GA (.062") (0,5 mm to 1,6 mm)

Material Thickness:Material Thickness:

Because of high cut speeds, a positive cut face angle is expected. Use
a 70-amp nozzle at 50 amps to allow more gas to exit the nozzle.

• Dark cut face

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

• Virtually dross free

• Improved cut squareness

Plasma Gas:

Plasma Gas: Oxygen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Oxygen/Nitrogen

Shield Gas:Shield Gas:

Low amperage cutting/slower speeds produce squarer cuts in thin

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)

Material Thickness:Material Thickness:

materials. The oxygen allows for a lower arc voltage, improving cut
squareness. The “B” nozzle is used at 30 amps

• Cut edge dark

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

• good dross performance

• Good cut angle

Plasma Gas:

Plasma Gas: Air

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Air

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

When they are the same, the shield and plasma gases combine. This
combination has the effect of increasing the cut gas flow/pressure. This
increased flow/pressure directly influences cut squareness.

4-11

SECTION 4 OPERATION

Stainless Steel

Material Thickness:

Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)

Material Thickness:Material Thickness:

NOTICE

• Matted cut edge appearance

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Air

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Air/Methane

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

• Light gray color

• Much smoother finish

• Possible slight increase in cut angle

Too much methane in the shield gas mixture can result in more dross
formation. 4:1 ratio air to methane is recommended. Because methane
is a fuel gas, possible slight increase in cut angles could be experienced.

Refer to Cutting Process Data for recommended
flow/pressure settings.

Material Thickness:

Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)

Material Thickness:Material Thickness:

• Dark cut face similar to air

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

• Excellent dross performance

• Good cut angle

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen

Shield Gas:Shield Gas:

Shield and plasma gases combine, the volume/pressure of shield gas

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

Material Thickness: .187" to .625" (4,7 mm to 15,9 mm)

Material Thickness:Material Thickness:

can negatively affect cut squareness. Higher shield volume produces a
negative cut angle. A lower volume, produces a positive angle.

• Shiny cut face

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

• Lip formation at the bottom

• Dross formation can be extensive and difficult to remove

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen/Methane

Shield Gas:Shield Gas:

Because methane is a fuel gas, flow/pressure rates can affect the cut
angle. High flow/pressure results in a negative cut angle, low

Discussion:

Discussion:

Discussion:Discussion:

flow/pressure results in a positive cut angle. Nitrogen to methane ratio is
10 to 14 parts N
severe, making Nitrogen/Methane shield gas combination unsuitable for
some finished part applications.

/ 1 part CH4. The lip formed on the cut face bottom is

2

4-12

SECTION 4 OPERATION

4.4 Process Data

4.4.1 Introduction

4.4.1 Introduction

4.4.1 Introduction4.4.1 Introduction

The following information is a result of many hours of
testing and is a general guide for setting up and
cutting with a PT-24 Precision Plasmarc System. In
most cases these settings will provide a quality cut.
The data contains values for:

• cutting aluminum, carbon and stainless steel

• arc voltage (standoff)

• cutting speed

• current (amperes)

• gas flow rates for all plasma/shield gas

combinations

This same data is contained in SDP files. (See your
control manual for more information on SDP files.)

Also included is information on consumable part
numbers for current being used.

4-13

SECTION 4 OPERATION

(

)

)

4.4.2 Process Data

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
30

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21536 (3 holes)

21536 (3 holes)

21536 (3 holes

P/N P/N

21536

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21541, "B"

21541, "B"

P/N P/N

21541, "B"21541, "B"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

3 holes

4-14

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.062 0.075 0.090 0.125 0.187 0.250

MM 1,61,92,33,24,76,4

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 454545454545

30 Amperes

Aluminum

PG

PG SG1

PGPG

N2 N2 CH4

000000

40 40 40 40 40 40

55 55 55 55 55 55

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 202020202020

SG2- Cut Flow 10 10 10 10 10 10

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

150 152 153 158 170 189

150 135 105 78 30 25

3810 3429 2667 1981 762 635

4-15

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
55

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-16

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.062 0.125 0.187 0.250

MM 1,6 3,2 4,7 6,4

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 55555555

55 Amperes

Aluminum

PG

PG SG1

PGPG

N2 N2 CH4

0000

45 45 45 45

75 75 75 85

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 20202020

SG2- Cut Flow 10 10 10 10

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

136 139 152 168

170 130 78 46

4318 3302 1981 1168

4-17

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
70

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-18

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

MM 4,7 6,4 9,5 12,7

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 45454545

70 Amperes

Aluminum

PG

PG SG1

PGPG

N2 N2 CH4

0 0 0.1 0.2

65 65 65 65

50 50 100 100

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 20202020

SG2- Cut Flow 10 10 10 10

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

150 157 168 182

80 65 55 30

2032 1651 1397 762

4-19

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
100

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-20

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

MM 6,4 9,5 12,7 15,9

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

100 Amperes

Aluminum

PG

PG SG1

PGPG

N2 N2 N2

0 0 0.1 0.1

80 80 80 80

100 100 100 100

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 31313131

SG2- Cut Flow 10 10 10 10

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

155 160 166 174

65 80 65 50

2413 2032 1778 1270

4-21

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
16

Oxygen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Oxygen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21852 (2 holes)

21852 (2 holes)

21852 (2 holes

P/N P/N

21852

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21540, "A"

21540, "A"

P/N P/N

21540, "A"21540, "A"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

2 holes

4-22

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 20GA 18GA 16GA 14GA 12GA 10GA

MM 0,91,21,62,02,73,4

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 202020202020

16 Amperes

Carbon Steel

PG

PG SG1

PGPG

O2 N2 O2

0 0 0 0.1 0.5 0.1

20 20 20 20 20 20

11 11 11 11 11 11

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 000000

SG2- Cut Flow666666

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

103 105 115 118 116 117

1008580605036

2540 2159 2032 1524 1270 914

4-23

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
35

Oxygen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Oxygen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21536 (3 holes)

21536 (3 holes)

21536 (3 holes

P/N P/N

21536

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21541, "B"

21541, "B"

P/N P/N

21541, "B"21541, "B"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

3 holes

4-24

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 14GA 0.125 0.135 0.187 0.250

MM 1,93,23,44,76,4

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 5050505050

35 Amperes

Carbon Steel

PG

PG SG1

PGPG

O2 N2 O2

00000

38 38 38 38 38

15 15 15 15 15

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 00000

SG2- Cut Flow66666

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

113 119 120 122 124

80 55 52 40 30

3032 1397 1320 1016 762

4-25

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
45

Oxygen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Oxygen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-26

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.135 0.187 0.250 0.375

MM 3,23,44,76,49,5

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 5050505050

45 Amperes

Carbon Steel

PG

PG SG1

PGPG

O2 N2 O2

0.30.30.30.30.4

50 50 50 50 50

20 20 20 20 20

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 1616161610

SG2- Cut Flow00000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

108 111 114 121 124

60 50 45 35 20

1524 1270 1143 889 508

4-27

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
70

Oxygen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Oxygen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-28

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.312 0.375 0.500 0.625

MM 4,7 6,4 7,9 9,5 12,7 12,9

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 606060606060

70 Amperes

Carbon Steel

PG

PG SG1

PGPG

O2 N2 O2

0 0 0 0.1 0.2 0.5

60 60 60 60 60

25 25 25 25 25 25

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 333333332020

SG2- Cut Flow000000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

108 110 114 113 135 140

110 100 70 60 30 25

2794 2413 1778 1524 762 635

4-29

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
100

Oxygen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Oxygen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-30

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.312 0.375 0.500 0.625 0.750

MM 7,9 9,5 12,9 15,9 19,1

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 6060606060

100 Amperes

Carbon Steel

PG

PG SG1

PGPG

O2 N2 O2

0 0 0.1 0.1 0.1

80 80 80 80 80

30 30 30 30 30

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 3030303030

SG2- Cut Flow00000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

115 120 132 137 143

90 80 50 30 25

2290 2030 1270 760 630

4-31

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
30

Oxygen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Oxygen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21536 (3 holes)

21536 (3 holes)

21536 (3 holes

P/N P/N

21536

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21541, "B"

21541, "B"

P/N P/N

21541, "B"21541, "B"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

3 holes

4-32

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 26GA 24GA 22GA 18GA 16GA

MM 0,40,60,71,21,6

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 4040404040

30 Amperes

Stainless Steel

PG

PG SG1

PGPG

O2 N2 O2

00000

45 45 45 45 45

18 18 18 18 18

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 2020202020

SG2- Cut Flow55555

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

105 105 107 109 111

250 200 190 140 100

6350 5080 4826 3556 2540

4-33

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
50

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-34

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.375

MM 3,2 4,7 6,4 9,5

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 45454545

50 Amperes

Stainless Steel

PG

PG SG1

PGPG

Air Air Air

0 0 01 0.2

60 60 60 60

95 95 95 95

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 35353535

SG2- Cut Flow0000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

134 140 145 155

90 60 40 18

2286 1524 1016 457

4-35

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-36

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

MM 4,7 6,4 9,5 12,7

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

70 Amperes

Stainless Steel

PG

PG SG1

PGPG

Air Air Air

0.3 0.4 0.5 0.6

70 70 70 70

95 95 95 95

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 40404040

SG2- Cut Flow0000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

131 152 158 162

100 50 28 20

2540 1270 711 609

4-37

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-38

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

MM 6,4 9,5 12,7 15,9

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

100 Amperes

Stainless Steel

PG

PG SG1

SG1 SG2

PGPG

SG1SG1

Air Air Air

0.3 0.4 0.5 0.6

80 80 80 80

65 65 65 70

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 35353540

SG2- Cut Flow0000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

129 135 142 150

80 60 35 25

2030 1520 889 635

4-39

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-40

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.387 0.500

MM 3,2 4,7 6,4 9,5 12,7

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 6060606060

70 Amperes

Stainless Steel

PG

PG SG1

PGPG

Air Air CH4

0.20.30.40.50.6

70 70 70 70 70

100 100 100 100 100

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 4040404040

SG2- Cut Flow 10 10 10 10 10

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

131 146 154 166 175

12080503024

3048 2032 1270 762 609

4-41

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Air @ 125 PSI / 8.6 Bar

Air @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-42

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

MM 6,4 9,5 12,7 15,9

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

100 Amperes

Stainless Steel

PG

PG SG1

PGPG

Air Air CH4

0.3 0.4 0.5 0.6

80 80 80 80

100 100 100 100

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 40404040

SG2- Cut Flow 7 10 10 10

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

140 150 159 170

80 60 35 25

2030 1524 889 635

4-43

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
50

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-44

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.375

MM 3,2 4,7 6,4 9,5

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 45454545

50 Amperes

Stainless Steel

PG

PG SG1

PGPG

N2 N2

0 0 0.1 0.2

60 60 60 60

85 85 85 85

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 35353535

SG2- Cut Flow0000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

128 133 144 155

90 60 40 22

2286 1524 1016 558

4-45

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-46

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

MM 4,7 6,4 9,5 12,7

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

70 Amperes

Stainless Steel

PG

PG SG1

PGPG

N2 N2

0.3 0.4 0.5 0.6

70 70 70 70

95 95 95 95

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 40404040

SG2- Cut Flow0000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

132 150 154 159

75 50 28 24

1905 1270 711 609

4-47

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-48

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

MM 6,4 9,5 12,7 15,9

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

100 Amperes

Stainless Steel

PG

PG SG1

PGPG

N2 N2

0.3 0.4 0.5 0.6

80 80 80 80

95 95 95 95

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 50353535

SG2- Cut Flow0000

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

135 145 153 157

80 60 35 25

2032 1520 889 635

4-49

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

 Nozzle

Nozzle

Nozzle Nozzle

P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-50

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two
replaceable torch
front-end parts that
may vary with
amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

MM 4,7 6,4 9,5 12,7

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 60606060

70 Amperes

Stainless Steel

PG

PG SG1

PGPG

N2 N2 CH4

0.3 0.4 0.5 0.6

75 75 75 75

85 85 85 85

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 43434343

SG2- Cut Flow5555

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

136 150 159 162

75 50 28 24

1905 1270 711 609

4-51

SECTION 4 OPERATION

(

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Nitrogen @ 125 PSI / 8.6 Bar

Nitrogen @ 125 PSI / 8.6 Bar

Methane @ 100 PSI / 6.9 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

Nozzle

Nozzle

NozzleNozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-52

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

MM 6,4 9,5 12,7 5,9

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 50706042

100 Amperes

Stainless Steel

PG

PG SG1

PGPG

N2 N2 CH4

0.3 0.4 0.5 0.6

80 80 80 80

95 95 95 95

SG1 SG2

SG1SG1

SG2

SG2SG2

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 45454542

SG2- Cut Flow5557

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

138 150 162 170

80 60 35 25

2032 1524 889 635

4-53

SECTION 4 OPERATION

(

)

)

Plasma Marking “B” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

10

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N 21536 (3 Holes)

P/N 21536 (3 Holes)

P/N 21536 (3 Holes

P/N 21536

Nozzle

Nozzle

NozzleNozzle

P/N 21541 “B”

P/N 21541 “B”

P/N 21541 “B”P/N 21541 “B”
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

3 Holes

4-54

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 35

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 35

SG2- Cut Flow 0

“B” Nozzle

10 Amperes

35

35

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

77

200

5080

4-55

SECTION 4 OPERATION

Plasma Marking “B” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

15

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N 21536 3 holes

P/N 21536 3 holes

P/N 21536 3 holesP/N 21536 3 holes

Nozzle

Nozzle

NozzleNozzle

P/N 21541 “B”

P/N 21541 “B”

P/N 21541 “B”P/N 21541 “B”
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4-56

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 35

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 35

SG2- Cut Flow 0

“B” Nozzle

15 Amperes

35

35

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

77

300

7620

4-57

SECTION 4 OPERATION

(

)

)

Plasma Marking “C” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

10

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

Nozzle

Nozzle

NozzleNozzle

P/N 21542 “C”

P/N 21542 “C”

P/N 21542 “C”P/N 21542 “C”
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-58

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 37

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 37

SG2- Cut Flow 0

“C” Nozzle

10 Amperes

62

62

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

77

100

2540

4-59

SECTION 4 OPERATION

(

)

)

Plasma Marking “C” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

15

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

Nozzle

Nozzle

NozzleNozzle

P/N 21542 “C”

P/N 21542 “C”

P/N 21542 “C”P/N 21542 “C”
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-60

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 35

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 35

SG2- Cut Flow 0

“C” Nozzle

15 Amperes

62

62

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

77

200

5080

4-61

SECTION 4 OPERATION

(

)

)

Plasma Marking “D” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

10

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

Nozzle

Nozzle

NozzleNozzle

P/N 21543 “D”

P/N 21543 “D”

P/N 21543 “D”P/N 21543 “D”
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-62

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 100

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 100

SG2- Cut Flow 0

“D” Nozzle

10 Amperes

77

77

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

77

100

2540

4-63

SECTION 4 OPERATION

(

)

)

Plasma Marking “D” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

15

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

Nozzle

Nozzle

NozzleNozzle

P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-64

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

SG1-Start 37

Shield Gas

(Flow Reading)

Flow Reading

SG1- Cut 37

SG2- Cut Flow 0

“D” Nozzle

15 Amperes

62

62

Arc Voltage (standoff)

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

77

300

7620

4-65

SECTION 4 OPERATION

(

)

)

Plasma Marking “D” Nozzle

PT-24 Torch

Amperes:

Plasma Gas:

Shield Gas:

20

Argon @ 125 PSI / 8.6 Bar

Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
O-Ring

O-Ring

O-RingO-Ring
P/N 638797

P/N 638797

P/N 638797P/N 638797
O-Ring

O-Ring

O-RingO-Ring
P/N 86W62

P/N 86W62

P/N 86W62P/N 86W62
O-Ring

O-Ring

O-RingO-Ring
P/N 950714

P/N 950714

P/N 950714P/N 950714
O-Ring

O-Ring

O-RingO-Ring
P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539

Swirl Baffle

Swirl Baffle

Swirl BaffleSwirl Baffle

P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692

Nozzle

Nozzle

NozzleNozzle

P/N 21543 “D”

P/N 21543 “D”

P/N 21543 “D”P/N 21543 “D”
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield RetainerInsulator Shield Retainer
w/ O-Ring P/N 21712

w/ O-Ring P/N 21712

w/ O-Ring P/N 21712w/ O-Ring P/N 21712

4 holes

4-66

O-Ring

O-Ring - Shield

O-Ring O-Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

(Ref. P/N 996528)(Ref. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/ Retainer
P/N 22531

P/N 22531

P/N 22531P/N 22531

- Shield Retainer .

- Shield - Shield

Retainer .

Retainer .Retainer .

 Baffle and Nozzle

are the only two

replaceable torch

front-end parts that

may vary with

amperage