ESAB Precision PLASMARC Cutting and High Speed Marking System with Integrated Flow Control Installation manual / Instruction manual

F-15-652

November, 2003

Installation, Operation and Maintenance Manual for the

Precision PLASMARC Cutting

and High Speed Marking SYSTEM

with Integrated Flow Control

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 by ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liabilit y.

ESAB Cutting Systems first priority is total customer

satisfaction. We constantly look for ways to
improve our products, service and documentation.
As a result, we make enhancements and/or design
changes as required. ESAB makes every possible
effort to ensure our documentation is current. We
cannot guarantee that each piece of documentation
received by our customers reflects the latest design
enhancements. Therefore, the information
contained in this document is subject to change

without notice.

This manual is ESAB Part Number F15-652

Rev A indicates new IFC Schematic, installation
instructions (p13-14) and fluid schematic mod.
December: Updated Torch solenoid wiring, updated
parts section

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, 2001

Printed in U.S.A.

Precision Plasma Integrated Flow Control - CE 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 .................................................. 4-9

1.7 Service Precautions............................................................................. 9

1.8 Safety References............................................................................... 10

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 Cut Gas ..................................................................................... 3

2.4.5 PT-24 Torch ............................................................................... 4

Section 3 Installation

3.1 General............................................................................................... 1

3.2 Equipment Required ........................................................................... 1

3.3 Location.............................................................................................. 1

3.4 Primary Electrical Input Connections.................................................... 2-3

3.5 Alternate Connection Locations for IFC................................................ 4

3.6 IFC Basic Component Identification..................................................... 4

3.7 Interconnecting Lines .......................................................................... 5-10

3.8 Precision Plasmarc Component Interconnecting Diagram .................... 7

3.9 Torch Mounting................................................................................... 11

3.10 Torch Coolant.................................................................................... 12

3.11 Inspection Of Gas And Coolant Lines.................................................. 12

3.12 Using the 5 Solenoid Torch Manifold.................................................. 13

3.13 Adapting to use a 4 Solenoid Torch Manifold..................................... 14

i

Precision Plasma Integrated Flow Control - CE Table of Contents

Page
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 ......................................................................................... 6-7

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................................................................. 14-55

Aluminum ............................................................................ 14-21

Carbon Steel........................................................................ 22-31

Stainless Steel ..................................................................... 32-55

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness..... 56

4.4.3.1 Aluminum Kerf Values ......................................................... 56

4.4.3.2 Carbon Steel Kerf Values..................................................... 58

4.4.3.3 Stainless Steel Kerf Values O2/N2/O2................................... 61

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4................................ 62

4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4................................. 63

4.4.3.6 Stainless Steel Kerf Values N2/N2........................................ 64

4.4.3.7 Stainless Steel Kerf Values Air/Air ....................................... 66

Plasma Marking Data .......................................................... 68

ii

Precision Plasma Integrated Flow Control - CE Table of Contents

Page
Section 5 Maintenance

5.1 General............................................................................................... 1

5.2 Inspection and Cleaning ...................................................................... 1

5.3 PT-24 Torch Description ..................................................................... 2-4

5.4 IFC Fluid Schematic ............................................................................ 3

5.4 Torch Maintenance ............................................................................. 5-6

5.5 PT-24 Consumable Disassembly and Inspection.................................. 7-10

5.6 PT-24 Torch Re-Assembly .................................................................. 10-11

5.7 Flow Control ....................................................................................... 12

5.8 Proportional Valve Removal................................................................. 13

Section 6 Troubleshooting

6.1 General Safety .................................................................................... 1

6.2 Troubleshooting Guide ........................................................................ 1

6.2.1 Reduced Consumable Life........................................................... 2

6.2.2 Poor Cut Quality.......................................................................... 2

6.2.3 No Pilot Arc................................................................................. 3

6.2.4 No Arc Transfer........................................................................... 3

6.2.5 No Preflow.................................................................................. 3

6.2.6 Torch Fails to Fire........................................................................ 3

6.2.7 Nozzle Life Extremely Short ......................................................... 4

6.2.8 Short Electrode Life..................................................................... 4

6.2.9 Short Electrode AND Nozzle Life.................................................. 4

6.3 IFC Fluid Schematic ............................................................................ 5

IFC Manifold Valve Identification................................................... 5

6.4 IFC Electrical Schematic...................................................................... 6-7

6.5 Precision Plasma Power Source Electrical Schematic........................... 8-9

6.6 Precision Plasma Power Source Wiring Diagram (includes CE Version) 10-14

6.7 Power Module Schematic – CE Version ............................................... 15

6.8 Precision Plasma Power Module Wiring Diagram – CE Version............. 16-17

6.9 Torch Manifold.................................................................................... 18

iii

Precision Plasma Integrated Flow Control - CE Table of Contents

Page

Section 7 Replacement Parts

7.1 General .............................................................................................. 1

7.2 Ordering............................................................................................. 1

7.3 Plasmarc Power Source – Exterior Components.................................. 2-7

7.4 Plasmarc Power Source – Internal Components .................................. 8-17

7.5 Power Source Module ........................................................................ 18-25

7.6 IFC..................................................................................................... 26-27

7.7 IFC Manifold....................................................................................... 28-29

7.8 PT-24 Torch Assembly IFC Series with Marking..................................

7.9 Torch Manifold with marking ...............................................................

7.10 Interface Cables and Hoses ..............................................................

30-31

32-33

34-35

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.

Precision Plasma with Integrated Flow Control -

1-1

SECTION 1 SAFETY

1.2 Safety Notations And Symbols

!

DANGER

!

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 with
other symbols and information.

Used to call attention to immediate hazards
which, if not avoided, will result in serious
personal injury o r lo ss o f life.

WARNING

!

CAUTION

!

CAUTION

NOTICE

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.

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

1-2

Precision Plasma with Integrated Flow Control -

SECTION 1 SAFETY

1.3 General Safety Information

WARNING

!

Machine starts automatically.

This equipment moves in various directions and
speeds.

· Moving machinery can crush.

· Only qualified personnel should operate or service

equipment.

· Keep all personnel, materials, and equipment not
involved in production process clear of entire
system area.

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

· Fence off entire work cell to prevent personnel
from passing through area or standing in the
working envelope of the equipment.

· Post appropriate WARNING signs at every work
cell entrance.

· Follow lockout procedure before servicing.

Failure to follow operating instructions

WARNING

!

could result in death or serious injury.

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

· Read entire procedure before operating or

performing any system maintenance.

· Special attention must be given to all hazard

warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.

· All safety precautions relevant to electrical

equipment and process operations must be
strictly observed by all having system
responsibility or access.

· Read all safety publications made available by

your company.

Precision Plasma with Integrated Flow Control -

1-3

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
machine.

Refer to operator’s manual for additional safety
information.

WARNING

!

Improperly Installed Equipment Can Cause
Injury Or Death.

Follow these guidelines while installing machine:

· Do not connect a cylinder directly to machine inlet.

An appropriate cylinder regulator must be installed
on a fuel gas cylinder to reduce pressure to a
reasonable inlet supply pressure. Machine
regulator is then used to obtain pressure required
by torches.

· Contact your ESAB representative before

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

· Never attempt any machine modifications or

apparatus additions without first consulting a
qualified ESAB representative.

· Observe machine clearance requirements for

proper operation and personnel safety.

· Always have qualified personnel perform

installation, troubleshooting and maintenance of
this equipment.

1-4

· Provide a wall mounted disconnect switch with

proper fuse sizes close to the power supply.

Precision Plasma with Integrated Flow Control -

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.

Machine must be properly grounded before put into
service.

Improper Grounding Can Damage

WARNING

!

Machine And Electrical Components.

· Machine must be properly grounded before put
into service.

· Cutting table must be properly grounded to a good

Earth ground rod.

Precision Plasma with Integrated Flow Control -

1-5

SECTION 1 SAFETY

1.6 Operating A Plasma Cutting Machine

WARNING

!

WARNING

!

Flying debris and loud noise hazards.

· Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and flying
debris generated during operation.

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

· Noise from plasma arc can damage hearing. Wear

correct ear protection when cutting above water.

Burn hazard.

Hot metal can burn.

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

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

1-6

Precision Plasma with Integrated Flow Control -

SECTION 1 SAFETY

WARNING

!

Hazardous voltages. Electric shock
can kill.

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

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

· Always turn power off to plasma power supplies
before servicing any system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when machine

is connected to power source.

· Wear insulating gloves, shoes and clothing to
insulate yourself from workpiece and electrical
ground.

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

equipment dry.

· Replace worn or damaged cables.

Fume hazard.

WARNING

!

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

· Do NOT breathe fumes.

· Do not operate plasma torch without fume removal

system operating properly.

· Use additional ventilation to remove fumes if
necessary.

· Use approved respirator if ventilation is not

adequate.

·

Provide positive mechanical ventilation when
cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe these
fumes.

·

Do not operate near degreasing and spraying
operations. Heat or arc rays can react with
chlorinated hydrocarbon vapors to form phosgene,
a highly toxic gas and other irritant gases.

Precision Plasma with Integrated Flow Control -

1-7

SECTION 1 SAFETY

WARNING

Radiation hazard.

!

Arc rays can injure eyes and burn skin.

· Wear correct eye and body protection.

· Wear dark safety glasses or goggles with side

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

Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 Amps Shade No. 10
200-400 Amps Shade No. 12
Over 400 Amps Shade No. 14

· Replace glasses/goggles when lenses are pitted or
broken

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

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

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

§ Install protective screens or curtains to

reduce ultraviolet transmission.

WARNING

!

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and violently
release gas.

· Avoid rough handling of cylinders.

· Keep cylinder valves closed when not in use.

· Maintain hoses and fittings in good condition.

· Always secure cylinders in an upright position by

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

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

· Use approved pressure reducing regulator for the
specific gas.

· Refer to CGA Standard P-1, “Precautions for Safe
Handling of Compressed Gases in Cylinders”,
available from Compressed Gas Association.

1-8

Precision Plasma with Integrated Flow Control -

SECTION 1 SAFETY

WARNING

!

Heat, spatter, and sparks cause fire and burns.

· Do not cut near combustible material.

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

butane lighter).

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

CAUTION

· Wear correct eye and body protection.

· Wear gauntlet gloves, safety shoes and hat.

· Wear flame-retardant clothing covering all exposed

areas.

· Wear cuff-less trousers to prevent entry of sparks
and slag.

· Have fire extinguishing equipment available for use.

Poor Performance Will Result When
Cutting Above Water.

Burn Hazard.

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

Cutting above water may result in:

· reduced consumable life

· degradation of cut quality

Cutting above water may result in poor cutting
performance. Water vapor created when hot material
or sparks contact liquid may cause arcing inside torch.

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

Precision Plasma with Integrated Flow Control -

1-9

SECTION 1 SAFETY

WARNING

!

WARNING

!

Explosion hazard.

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

cause explosions when plasma cut OVER water.

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

§ DO NOT dry cut over water.

§ Contact your aluminum supplier for

additional safety information regarding
hazards associated with these alloys

· Do not cut in atmospheres containing explosive

dust or vapors.

Do not carry any combustibles on your person

·

(e.g. butane lighter)

· Do not cut containers that have held combustibles.

.

Pinch hazard.

Moving vertical slides can crush or pinch.

Keep hands clear of torch and slide during operation.

1-10

Precision Plasma with Integrated Flow Control -

SECTION 1 SAFETY

1.7 Service Precautions

WARNING

!

Hazardous voltages. Electric shock
can kill.

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

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

· Always turn power off to plasma power supplies
before removing covers or panels to service any
system component.

· Do not touch live electrical parts.

· Keep all panels and covers in place when machine

is connected to power source.

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

equipment dry.

· Inspect power and ground leads cables for wear or

cracking. Replace worn or damaged cables. Do
not use if damaged.

· Never bypass safety interlocks.

· Follow lock-out procedures.

Establish and adhere to preventive maintenance. A

CAUTION

CAUTION

!

composite program can be established from
recommended schedules.

Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical damage
could occur to equipment or machine.

Extreme caution should be used when probing
circuitry with an oscilloscope or voltmeter. Integrated
circuits are susceptible to over voltage damage.
Power off before using test probes to prevent
accidental shorting of components.

All circuit boards securely seated in sockets, all cables
properly connected, all cabinets closed and locked, all
guards and covers replaced before power is turned
on.

Precision Plasma with Integrated Flow Control -

1-11

SECTION 1 SAFETY

1.8 Safety References

Domestic

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.

1-12

Precision Plasma with Integrated Flow Control -

SECTION 1 SAFETY

International

Accident Prevention

VBG 1 General Provisions

VDE Regulations

VBG 4 Electrical Equipment and operating

Equipment

VBG 15 Welding, Cutting and related working

methods

VBG 48 Shot Blasting Works
VBG 61 Gases
VBG 62 Oxygen
VBG 87 Operating liquid jet cutting machines
VBG 93 Laser beams, accident prevention and

Electro-technology

VBG 121 Noise

VDE 0100 Erection of power installations with normal

voltages up to 1000 volts

VDE0113 Electrical equipment of industrial machines

VDE 0837 Radiation safety of laser products; users

guide (DIN EN 60825)

VDE 0837-

Specification for laser guards

50

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC-204 Acetylene lines

TRG Technical Rules for Pressure gases

Precision Plasma with Integrated Flow Control -

TRAC-206 Acetylene cylinder battery systems
TRAC-207 Safety devices

TRG 100 Gener al regulat ions for pressure gases
TRG 101 Pressur e gases
TRG 102 Technical gas mixtures
TRG 104 Pressur e gases; alterative use of

compressed gas tanks

1-13

SECTION 1 SAFETY

DIN Standards

DIN EN ISO Harmonized Standards

DIN 2310

Part 1

DIN 2310

Part 2

DIN 2310

Part 4

DIN 2310

Part 5

DIN 4844

Thermal cutting; terminology and
nomenclature
Thermal cutting; determination of quality of cut
faces
Thermal cutting; arc plasma cutting; process
principles, quality, dimensional tolerances
Thermal cutting; laser beam cutting of metallic
materials; process principles
Safety markings (DIN EN 7287)

Part 1

DIN EN

Safety of machinery
292/1 and 2
DIN EN 559 Hoses for welding, cutting and allied

processes
DIN EN 560 Hose connections and hose couplings for

equipment for welding, cutting and allied

processes
DIN EN 561 Gas welding equipment hose couplings

VDI Guidelines

DIN EN

626-1

DIN EN

848-1

DIN EN

1829

DIN EN

9013

DIN EN

12584

DIN EN

12626

DIN EN

28206

DIN EN

31252

DIN EN

31553

DIN EN

60204-1

DIN EN

60825

DIN EN 999 Arrangement of protection devices

Safety of machines, reduction of risks to

health

Single spindle vertical milling machines

High pressure water jet machines

Thermal cutting, oxygen cutting, process

principles, dimensional tolerances

Imperfections in oxy/fuel flame cuts, laser

beam cuts and plasma

Laser processing machines

Acceptance testing for oxygen cutting

machines

Laser Equipment

Laser and laser related equipment

Electrical equipment of machines

Radiation safety of laser products

VDI 2906 Quality of cut faces on metallic workpieces;

abrasive water jet cutting and arc plasma

cutting

VDI 2084 Room air; Technical systems for welding

workshops

1-14

Precision Plasma with Integrated Flow Control -

SECTION 2 DESCRIPTION

2.1 General

2.2 Scope

2.3 Package Options Available

Precision Plasmarc® Integrated Flow Control package options available through your ESAB dealer

Precision Plasmarc® Power Source (200/230/380/415/460/575) 3-phase 50/60 Hz
(required) CNC Controllable/Without PLC

Integrated Flow Control Box P/N 0558002069

PT-24 Torch with high speed marking

Power Bundle (one required)

Control Lead, CNC to Power Supply (one required)

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

NOTES:

• 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.

The PT-24 Precision Plasmarc Integrated Flow
Control System provides programmable gas
switching and pressure control. The IFC is the next
generation electronic flow control combining
junction and flow control box components for:
a reduced combined footprint,
fewer parts,
improved reliability,
and improved high speed marking option.

The gas pressure and switching is controlled
through the cutting machine CNC eliminating the
need for other programmable controls.

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.

CE Version (covered in this manual)

4.5 ft. (1.4 m) P/N 0558002337

12 ft. (3.7 m) P/N 0558002338

20 ft. (6.1 m) P/N 0558002339

12 ft. (3.7 m) P/N 22428

25 ft. (7.6 m) P/N 21905

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 0560987422

20 ft. (6.1 m) P/N 0560987423

30 ft. (9 m) P/N 0560987424

60 ft. (18 m) P/N 0560987425

100 ft. (30 m) P/N 0560987426

P/N 0558002263

Precision Plasma with Integrated Flow Control -

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

42" (1067mm)

Power Supply

CONTROL

CURRENT

RECISION PLASMARC

22" (559mm)

WEIGHT = 560 lbs. (254 kg)

POWER

44" (1118mm)

20 " (50.8 mm)

PT-24 Torch and Torch Bundle

Integrated Flow Control

7.5 " (19.0 mm)

14.5 " (36.8 mm)

2-2

WEIGHT = 59 lbs. (130 kg)

Precision Plasma with Integrated Flow Control -

SECTION 2 DESCRIPTION

2.4.2 Plasma Gas Technical Specifications

Type O

Pressure

, N2, Ar, Air

2

150 psig (10.4 bars) O2, N2, Air: 85 psig (5.9 bars) Ar

Flow 100 cfh (47 l/min) max. (varies with application)

-99.8 to 99.995%

O

2

Purity Required*

N

, Ar-99.995%

2

Air-clean, dry and oil free
Recommended Liquid Cylinder
Service Regulators

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
Recommended Cylinder 2-Stage
Regulators

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)
Recommended Heavy –Duty Hi­flow Station or Pipeline Regulators
Recommended High-capacity
Station or Pipeline Regulators

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 N

Pressure

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

Minimum Purity Required N2, Ar - 99.995% Air –Clean, Dry

, Ar, Air

2

150 psig (10.4 bars) N2, Air: 85 psig (5.9 bars) Ar

2.4.4 Secondary Gas Technical Specifications

Type N2, O2, Methane, Air

Pressure

Flow

Minimum Purity Required N2, O2, CH4 - 99.995% Air –Clean, Dry

2.4.5 Cut Gas Technical Specifications

Type N2, O2, Air

Pressure 150 psig (10.4 bar) N2, O2, Air

Flow

Minimum Purity Required 99.995% N2, 99.8% O

Precision Plasma with Integrated Flow Control -

100 psig (6.6 bar) H-35, Methane;
150 psig (10.4 bar) N

, O2, Air

2

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

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

and Air

2

2-3

SECTION 2 DESCRIPTION

2.4.5 Pt-24 Torch Technical Specifications

Type Water-Cooled, Dual Gas

Rating 100 amps @ 100 % duty cycle

Dimensions See Package Options (2.3)

2-4

Precision Plasma with Integrated Flow Control -

SECTION 3 INSTALLATION

3.1 General

NOTICE

Proper installation can contribute materially to
the 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 150 psig (10.4 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 (P/N 56998133) are required

on the supply side for the IFC 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.

Restricting Air Flow Will Cause Over-Heating

CAUTION

!

Precision Plasma with Integrated Flow Control -

Restricting intake air with any type of filter on or
around the power supply will cause over-heating
and 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.

WARNING

!

Input Power Configuration

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.

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 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

Input requirements

Volts Phase Amps

Input & ground

conductor,

cu/awg/mm

2

Fuse ratings /

phase, amps

3-2

Precision Plasma with Integrated Flow Control -

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.

Ground Connection

TB2

TB1

200
230
380
415
460
575

200
230
380
415
460
575

200
230
380

415
460
575

200
230
380
415
460
575

K1

PHASE 1 PHASE 2 PHASE 3

Input Power Cable
(Customer supplied)

Main
Contactor

7 Position
Terminal Block

Auto
Transformer

Factory Wired
for 575 volts

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

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

Ensure each input power jumper cable is
connected to the correct input voltage on auto
transformer.

Factory wired for 575 V.

8. Connect jumper wire to the proper input voltage

connector located on the 7-position terminal block.
TB2

Precision Plasma with Integrated Flow Control -

3-3

SECTION 3 INSTALLATION

orch Solenoid Connection (not seen)

3.5 Alternate Connection Locations For IFC

I/O Strain Relief

Alternate
I/O

There are two locations for the I/O 24v input and for
the torch. This provides flexibility while mounting
the box to a machine.

NOTE:

IN

POWER

TORCH

X3

X1

X2

PILOT ARC

TORCH

Torch

Alternate torch

When changing over to an alternate
connection location, be sure to replace hole
covers to keep the box sealed.
Plug unused I/O strain relief holes to seal box.

3.6 IFC Basic Component Identification And Connection Points (Cover Removed)

Pilot Arc
Connection

Process Gas
Connections

Torch Power
Connection

Power/Pilot Arc Strain Relief

Proportional Valves

Solenoid Valves

Torch Bundle
Strain Relief

T

Torch Cooling Water Return/Pilot Arc Cable

Cooling Water to Torch/Power Cable

Process ASIOB

Voltage
Selector
Switch

Process Control I/O
Strain Relief

3-4

Precision Plasma with Integrated Flow Control -

SECTION 3 INSTALLATION

3.7 Interconnecting Lines

Cooling
water
return/Pilot
arc cable

Torch Bundle

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

Gas lines

Cooling
water to
torch

Cables /Hoses
enter here

Solenoid
Cable

2. Connect lines in torch bundle IFC Box. Lines
and connections are labeled and/or color
coded.

Connections, top to bottom:

Shield 2 =black
Shield 1 = orange
Plasma 2 = yellow
Plasma 1 = blue
Argon = red

Precision Plasma with Integrated Flow Control -

3-5

SECTION 3 INSTALLATION

Power supply and IFC connections

Power Supply Bundle

Coolant IN
Coolant Out

Supply Bundle from power source to IFC 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).

3. Connect power and coolant lines in Power

Pilot Arc
Connection

Coolant lines are stamped with a 6 or 7 on the
fitting to assist in identification.

Power Supply
Negative
Connection

Power Supply
Strain Relief

Voltage Selector Switch is preset for IFC input
voltage of 115 V / 60 Hz applications. An alternate
setting accommodates 230 V / 50 Hz IFC input

IFC Voltage
Selector
Switch

voltage.

3-6

Precision Plasma with Integrated Flow Control -

SECTION 3 INSTALLATION

3.8 Precision Plasmarc® Component Interconnecting Diagram

8

9

10

11

20

7

13

12

6

5

3

4

14

15

17

16

2

18

1

19

Ar

O

N

CH

4

2

2

1 wall disconnect (cust. sup.)
2 primary power cable
3 precision plasma power source
4 power bundle
5 power supply I/O cable
6 earth ground
7 work cable (+)
8 torch and height control
9 height control I/O cable
10 torch bundle

Air

11 height control ASIOB enclosure
12 integrated flow control box
13 height control ASIOB cable*(see note)
14 process ASIOB cable
15 120 vac/24vdc cable
16 CNC
17 process gas lines
18 25 micron filters
19 process gas supply (cust. sup.)
20 cutting table

Note: #13 height control ASIOB cable comes from a junction with #14 process ASIOB cable inside the IFC.

Precision Plasma with Integrated Flow Control -

3-7

SECTION 3 INSTALLATION

Gas Line Contamination Will

CAUTION

!

Damage Proportional Valves And
Check Valves

Purge Gas Lines

Before connecting gas delivery lines to the
Integrated Flow Control, purge all lines
thoroughly. Residue from the hose
manufacturing process may clog/damage the
proportional valves in your flow control.

4. Purge gas lines between supply and the IFC
before connecting. Proportional and check
valves are very sensitive to dust and other
foreign particles.

CAUTION

!

Unfiltered Gases Will Damage Flow
Control System.

Unfiltered cut and shield gases will clog or
damage small orifices and gas seals.

25µ filters are required for all cut and
shield gases including nitrogen, oxygen,
argon, methane, and air.

3-8

Precision Plasma with Integrated Flow Control -

SECTION 3 INSTALLATION

Gas connections and
I/O Strain Relief

1/4 NPT

5. Connect gas delivery lines to integrated flow
control. Install 25 micron gas filters in all
delivery lines between gas source and IFC.

25 micron Gas Filter

CH

H-35

4

N

CAUTION

25µ Fi lters

Ar

O

2

2

Air

Proportional And Check Valves Are
Sensitive To Dirt And Debris.

Thoroughly purge the gas delivery system with

before connecting to the IFC. Hose

N

2

manufacturing often leaves a fine dust inside.
This dust may cause proportional valves to
prematurely fail. Check valves may become
clogged.

Precision Plasma with Integrated Flow Control -

3-9

SECTION 3 INSTALLATION

Power Source

Rating

Label

7 Amp 500
VAC Fuse

Pilot Arc

Work

Torch

Remove Access Cover

6. Remove panel from rear of console and attach the

P

pilot-arc, torch and work lead.

Flow Control

Lead

7. Connect power supply I/O cable between the

Serial

Tag

console and the CNC.

Coolant In from IFC (return from torch)
Coolant Out to IFC (deliver to torch)

8. Connect coolant lines of the power bundle to
power supply and IFC

3-10

Precision Plasma with Integrated Flow Control -

SECTION 3 INSTALLATION

3.9 Torch Mounting

CAUTION

Do Not Cover Vent Hole.

When mounting, do not to cover the small vent
hole in the side of the sleeve. This hole allows
coolant to drain from inside the sleeve should a
leak occur in a service line.

Torch Mounting Options.

1.812" (46mm)
Diameter Collar

" (51mm)

2.0
Diameter Sleeve

Vent Hole

· 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

Precision Plasma with Integrated Flow Control -

3-11

SECTION 3 INSTALLATION

3.10 Torch Coolant

L

O

T

R

N

O

C

T

N

E

R
U

R

C

L

P

N

O

I

S

I

C

E

R

E

R

W
O
P

C

R

A

M

S

A

· 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 water or commercial antifreeze for torch
cooling. A specially formulated torch coolant is
REQUIRED. This coolant also protects for
freezing to –34° C.

3.11 Inspection of Gas and Coolant Lines

3-12

Precision Plasma with Integrated Flow Control -

Operating the unit without coolant will cause
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

SECTION 3 INSTALLATION

3.12 Using a 5 Solenoid Torch Manifold

The 5 solenoid torch manifold allows 1 second
conversion from cutting to marking and back to
cutting compared to 7 to 10 second switching
delay.

The IFC is shipped configured to use the 5 solenoid
torch manifold.

Marking with the PT-24 torch and the IFC

NOTICE

3.13 Converting Integrated Flow Control Manifold to Accommodate a 4 Solenoid Torch
Manifold

does not utilize a proportional valve to
regulate Argon pressure. An external
regulator for the argon supply must be set
to 85 PSI (5,6 bar). See marking process
data for more information.

3

4

2

Flow Control Manifold

Argon inlet connection

1

Argon Solenoid

2

Marking Conversion Access 1/8 NPT

3

Air / Argon manifold outlet

4

1

accommodate a 5 solenoid torch. Some
modification is required to permit marking with the
IFC and a 4 solenoid torch.

The Integrated Flow Control manifold is setup to

Ar

Precision Plasma with Integrated Flow Control -

3-13

SECTION 3 INSTALLATION

To plasma
gas outlet

From
argon solenoid

Cross Section Views of Argon Marking
Port

Plasma

View A-A

B

From

plasma gas

A

View B-B

B

Remove

access plug

to expose

port plug

A

Remove 1/16
NPT plug to
open Ar port

Marking Gas Solenoid

Gas Out

th

(5

Solenoid)

inlet

Procedure to modify IFC manifold for 4 solenoid
torch manifold.

A. Locate and remove access plug (1/8 NPT) next
to the argon flow control solenoid as shown.

B. Remove port plug (1/16 NPT) from bottom of
access hole.

C. Replace access plug.

Note: If necessary, use a oxygen safe commercially
available pipe sealant. DO NOT USE Teflon Tape.
Pieces of tape may break free resulting in poor cut
quality or torch failure.

Schematic for Marking with IFC and 4 Solenoid
torch manifold.

Proportional

Valve 1

Pressure

Vent

PS

Removable

Plug shown

removed

Switch 1

Air -2

N

-2

2

To Air-1

To N

-1 and

2

N

-3

2

Air In

Argon In

N2 In

With the plug installed and a 5 solenoid torch,
Argon gas goes directly to the 5

th

solenoid (Argon).

Argon is diverted across and out the plasma gas
line with the plug removed and a 4 solenoid torch.
The line to the fifth torch solenoid is capped with a
one way quick release fitting (acts similar to a check
valve)

3-14

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

4.1 Power Supply Controls

4.1.1 Main Power Switch

EMERGENCY

STOP

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

Precision Plasma with Integrated Flow Control -

Pilot Arc Switch
Previously a manual setting. This switch has been
eliminated from the CNC controllable power console.
Now handled by the machine CNC control 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.

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.

· P/S Fault Indicator – fault in plasma control PCB in
the inverter power source. Power source will shut
down.

· Over-Under Voltage fault Indicator -- indicate input
voltage is above or below the tolerances of the
PCU console. Will latch until power is recycled by
main power switch.

· Emergency Stop fault indicator -- shows CNC

Interlock condition. Power Source will not work.

4.1.4 Meters

· Cutting Current Meter (A) -- Displays actual cutting

current in amperes.

· Cutting Voltage Meter (V) -- Displays actual cutting

voltage.

4-2

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

4.1.5 Current Control Switch

Control Remote/Panel Switch

· Panel Position – Output current is set by the output
current dial

· Remote Position – output current is set by the
CNC (or remote pot) with an analog dc signal

0-10 Vdc = 0-100 Adc

· Current Adjust – used to manually adjust current in

panel mode. View Amp meter for values.

Precision Plasma with Integrated Flow Control -

4-3

SECTION 4 OPERATION

4.2 Cut Quality

4.2.1 Introduction

NOTICE

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.

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

4-4

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

4.2.2 Cut Angle

Negative Cut Angle

Top dimension is greater than the bottom.

Part

· Misaligned torch

· Bent or warped material

· Worn or damaged consumables

· Standoff low (arc voltage)

· Cutting speed slow (machine travel rate)

Drop

Part

Part

Positive Cut Angle

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

Part Drop

Precision Plasma with Integrated Flow Control -

recommended current level for specific nozzles).

4-5

SECTION 4 OPERATION

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

Drop

Top Edge Undercut

· Standoff low (Arc Voltage)

Part

4-6

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

4.2.4 Surface Finish

Process Induced Roughness

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

· Incorrect Shield Gas mixture (See Process Data)

Top View

· Worn or damaged consumables

Cut Face

Machine Induced Roughness

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

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

to Maintenance Section in machine operation
manual).

· Carriage wheel adjustment

Process
Induced
Roughness

or

Machine
Induced
Roughness

Precision Plasma with Integrated Flow Control -

4-7

SECTION 4 OPERATION

4.2.5 Dross

Lag

Lines

Side View

Cut Face

Rollover

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.

High Speed Dross

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

· Standoff high (arc voltage)

· Cutting speed fast

Lag

Lines

Cut Face

Globules

Slow Speed Dross

Forms as globules on bottom along kerf. Removes
easily.

· Cutting speed slow

Side View

4-8

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Side View

Splatter

Top Dross

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

· Cutting speed fast

Cut Face

Intermittent Dross

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

· Possible worn consumables

· Standoff high (arc voltage).

Other Factors Affecting Dross;

· Material temperature

· Heavy mill scale or rust

· High carbon alloys

Precision Plasma with Integrated Flow Control -

4-9

SECTION 4 OPERATION

4.2.6 Dimensional Accuracy

NOTICE

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.

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.

NOTICE

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

4-10

Precision Plasma with Integrated Flow Control -

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

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

4.3.2 Aluminum

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

· Smooth cut face

· Virtually no dross

Nitrogen

Nitrogen/Methane
Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1 part

methane ratio is desired. Incorrect ratio results in heavy dross.

Precision Plasma with Integrated Flow Control -

4-11

SECTION 4 OPERATION

Refer to Cutting Process Data in the PT24

NOTICE

Manual for recommended flow/pressure
settings.

4.3.3 Carbon Steel

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

· Smooth cut face

· Virtually no dross

Oxygen

Oxygen/Nitrogen
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

Oxygen

Nitrogen

Cutting carbon steel with oxygen results in an exothermic reaction. This
chemical reaction causes the carbon in the material to burn similar to when oxy­fuel cutting. This plus the electrical energy uses lower amperage levels without
sacrificing cut speed.

4-12

Precision Plasma with Integrated Flow Control -

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:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

· Positive cut angle

· Excellent dross performance

· Shiny cut surface.

Nitrogen

Nitrogen/Methane

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

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

· Dark cut face

· Virtually dross free

· Improved cut squareness

Oxygen

Oxygen/Nitrogen
Low amperage cutting/slower speeds produce squarer cuts in thin materials.

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

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

· Cut edge dark

· good dross performance

· Good cut angle

Air

Air

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.

Precision Plasma with Integrated Flow Control -

4-13

SECTION 4 OPERATION

NOTICE

Stainless Steel

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

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

· Matted cut edge appearance

· Light gray color

· Much smoother finish

· Possible slight increase in cut angle

Air

Air/Methane
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.

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

· Dark cut face similar to air

· Excellent dross performance

· Good cut angle

Nitrogen

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

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

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

· Shiny cut face

· Lip formation at the bottom

· Dross formation can be extensive and difficult to remove

Nitrogen

Nitrogen/Methane

Because methane is a fuel gas, flow/pressure rates can affect the cut
angle. High flow/pressure results in a negative cut angle, low
flow/pressure results in a positive cut angle. Nitrogen to methane ratio is
10 to 14 parts N2/ 1 part CH4. The lip formed on the cut face bottom is
severe, making Nitrogen/Methane shield gas combination unsuitable for
some finished part applications.

4-14

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

4.4 Process Data

4.4.1 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.

Precision Plasma with Integrated Flow Control -

4-15

SECTION 4 OPERATION

4.4.2 IFC PT-24 Process Data

Initial Amperes: 15

Final Amperes: 30

®

Shield Mix Gas:

Material: Aluminum

Plasm a Gas:

Shield Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21536 (3 holes)

! Nozzle

P/N 21541, "B"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-16

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 0.062 0.075 0.09 0.125 0.187 0.250

mm

1,6 1,9 2,3 3,2 4,7 6,4

Timers

Pierce Delay (sec.)

0 0 0 0 0 0

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

93.1
/6.3

132.0
/9.0

42.9
/2.9

16.5
/1.3

12.3
/0.8

2

132.0

93.1
/6.3

/9.0

42.9
/2.9

16.5
/1.3

12.3
/0.8

15 Initial / 30 Final Amperes

Aluminum

93.1
/6.3

132.0
/9.0

42.9
/2.9

16.5
/1.3

12.3
/0.8

N

2

93.1
/6.3

132.0
/9.0

42.9
/2.9

16.5
/1.3

12.3
/0.8

93.1
/6.3

132.0
/9.0

42.9
/2.9

16.5
/1.3

12.3
/0.8

CH

4

93.1
/6.3

132.0
/9.0

42.9
/2.9

16.5
/1.3

12.3
/0.8

Arc Voltage (standoff) 150 152 153 165 180 189

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54 2,54 2,54

In. .150 .150 .150 .160 .220 .250

mm 6,35 6,35 6,35 4,04 5,59 6,35

In. .125 .130 .135 .165 .220 .250

mm 3,18 3,30 3,43 4,19 5,59 6,35

Travel Speed

IPM 150 135 105 78 45 40

MM/MIN

Notes:
Pilot Arc –LOW.

Precision Plasma with Integrated Flow Control -

3810 3429 2667 1981 1143 1016

4-17

SECTION 4 OPERATION

Material: Aluminum

Initial Amperes: 28

Final Amperes: 55

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21542, "C"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-18

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 0.062 0.125 0.125 0.250

mm

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

Timers

Pierce Delay (sec.)

0 0 0 0

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

64

/4.4

100.3
/6.8

42.9
/2.9

16

/1.1

12.3
/0.8

2

100.3

64

/4.4

/6.8

42.9
/2.9

16

/1.1

12.3
/0.8

28 Initial – 55 Final Amperes

Aluminum

64

/4.4

100.3
/6.8

42.9
/2.9

16

/1.1

12.3
/0.8

N

2

64

/4.4

112.3
/7.6

42.9
/2.9

16

/1.1

12.3
/0.8

CH

4

Arc Voltage (standoff) 136 139 152 168

Initial Height

Pierce Height

Cutting Height

In. 100 100 100 100

mm 2,54 2,54 2,54 2,54

In. .09 .09 .180 .150

mm 2,29 2,29 4,57 3,81

In. .09 0.9 .180 .225

mm

2,29 2,29 4,57 5,72

Travel Speed

IPM 170 130 78 46

MM/MIN

4318 3302 1981 1168

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-19

SECTION 4 OPERATION

Material: Aluminum

Initial Amperes: 35

Final Amperes: 70

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-20

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 0.187 0.250 0.375 0.500

mm

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

Timers

Pierce Delay (sec.)

0 0 0.1 0.2

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

76.6
/5.2

68.6
/4.7

43.8
/3.0

15.4
/1.0

11.7
/0.8

2

108.5

76.6
/5.2

/7

43.8
/3.0

15.4
/1.0

11.7
/0.8

35 Initial / 70 Final Amperes

Aluminum

76.6
/5.2

108.5
/7

43.8
/3.0

15.4
/1.0

11.7
/0.8

N

2

76.6
/5.2

108.5
/7

43.8
/3.0

15.4
/1.0

11.7
/0.8

CH

4

Arc Voltage (standoff) 150 157 168 182

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .190 .150 .240 .260

mm 4,83 3,81 6,10 6,60

In. .190 .225 .240 .260

mm 4,83 5,72 6,10 6,60

Travel Speed

IPM 80 65 66 30

MM/MIN

3032 1651 1397 762

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-21

SECTION 4 OPERATION

Material: Aluminum

Initial Amperes: 50

Final Amperes: 100

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21923, "E"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-22

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 0.250 0.375 0.500 0.625

mm

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

Timers

Pierce Delay (sec.)

0 0 0.1 0.1

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

76.4
/5.2

95.6
/6.5

61.5
/4.2

27.3
/1.9

17.9
/1.2

2

76.4
/5.2

95.6
/6.5

61.5
/4.2

27.3
/1.9

17.9
/1.2

50 Initial / 100 Final Amperes

Aluminum

76.4
/5.2

95.6
/6.5

61.5
/4.2

27.3
/1.9

17.9
/1.2

N

2

76.4
/5.2

95.6
/6.5

61.5
/4.2

27.3
/1.9

17.9
/1.2

CH

4

Arc Voltage (standoff) 155 160 166 174

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .190 .225 .260 .285

mm 4,83 5,72 6,60 7,24

In. .190 .225 .260 .285

mm 4,83 5,72 6,60 7,24

Travel Speed

IPM 95 80 65 50

MM/MIN

2413 2032 1778 1270

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-23

SECTION 4 OPERATION

Material: Carbon Steel

Initial Amperes: 16

Final Amperes: 16

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Oxygen (O2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Oxygen (O2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21852 (2 holes)

! Nozzle

P/N 21540, "A"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-24

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

O

Material Thickness

In. 20Ga 18Ga 16Ga 14Ga 12Ga 10Ga

mm

0,9 1,2 1,6 2,0 2,7 3,4

Timers

Pierce Delay (sec.)

0 0 0 0.1 0.5 0.5

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

71.3
/4.9

83.2
/5.7

12.9
/0.8

2.0

/0.1

2.2

/0.1

2

71.3
/4.9

83.2
/5.7

12.9
/0.8

2.0

/0.1

2.2

/0.1

16 Initial / 16 Final Amperes

Carbon Steel

71.3
/4.9

83.2
/5.7

12.9
/0.8

2.0

/0.1

2.4

/0.2

N

2

71.3
/4.9

83.2
/5.7

12.9
/0.8

2.4

/0.2

3.0

/0.2

71.3
/4.9

83.2
/5.7

12.9
/0.8

2.0

/0.1

2.2

/0.1

O

2

71.3
/4.9

83.2
/5.7

12.9
/0.8

2.4

/0.2

3.0

/0.2

Arc Voltage (standoff) 103 105 115 118 116 117

Initial Height

Pierce Height

Cutting Height

In. .04 .04 .04 .04 .04 .04

mm 1,02 1,02 1,02 1,02 1,02 1,02

In. .06 .06 .06 .06 .115 .115

mm 1,52 1,52 1,52 1,52 2,92 2,92

In. .108 .118 .140 .144 .126 .126

mm 2,74 2,74 3,56 3,66 3,20 3,20

Travel Speed

IPM 100 85 80 60 50 36

MM/MIN

Notes:
Pilot Arc –LOW.

Precision Plasma with Integrated Flow Control -

2540 2159 2032 1524 1270 914

4-25

SECTION 4 OPERATION

Material: Carbon Steel

Initial Amperes: 18

Final Amperes: 35

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Oxygen (O2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Oxygen (O2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21536 (3 holes)

! Nozzle

P/N 21541, "B"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-26

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

O

Material Thickness

In. 14Ga 0.125 0.135 0.187 0.250

mm

1,9 3,2 3,4 4,7 6,4

Timers

Pierce Delay (sec.)

0 0 0 0 0.2

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

86.9
/5.9

102.9
/7.0

46.5
/3.2

0 0 0 0 0

2.5

/0.2

2

102.9

86.9
/5.9

/7.0

46.5
/3.2

2.5

/0.2

18 Initial / 35 Final Amperes

Carbon Steel

86.9
/5.9

102.9
/7.0

46.5
/3.2

2.5

/0.2

N

2

86.9
/5.9

102.9
/7.0

46.5
/3.2

2.5

/0.2

86.9
/5.9

102.9
/7.0

46.5
/3.2

2.5

/0.2

O

2

Arc Voltage (standoff) 113 119 120 122 124

Initial Height

Pierce Height

Cutting Height

In. .04 .04 .04 .04 0.4

mm 1,02 1,02 1,02 1,02 1,02

In. .103 .113 .118 .118 .130

mm 2,62 2,87 3,00 3,00 3,30

In. .103 .113 .118 .118 .130

mm 2,62 2,87 3,00 3,00 3,30

Travel Speed

IPM 80 55 52 40 30

MM/MIN

3032 1397 1320 1016 762

Notes:
Pilot Arc –LOW.

Precision Plasma with Integrated Flow Control -

4-27

SECTION 4 OPERATION

Material: Carbon Steel

Initial Amperes: 23

Final Amperes: 45

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Oxygen (O2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Oxygen (O2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21542, "C"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-28

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

O

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.125 0.135 0.187 0.250 0.375

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

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

0 0.3 0.3 0.3 0.4

73.8
/5.0

86.2
/5.9

48.1
/3.3

11.2
/0.8

0 0 0 0 0

2

73.8
/5.0

86.2
/5.9

48.1
/3.3

11.2
/0.8

23 Initial / 45 Final Amperes

Carbon Steel

73.8
/5.0

86.2
/5.9

48.1
/3.3

11.2
/0.8

N

2

73.8
/5.0

86.2
/5.9

48.1
/3.3

11.2
/0.8

73.8
/5.0

86.2
/5.9

48.1
/3.3

11.2
/0.8

O

2

Arc Voltage (standoff) 108 111 114 121 124

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100 .100

mm 25,4 25,4 25,4 25,4 25,4

In. .145 .155 .145 .205 .164

mm 3,68 3,94 3,68 5,21 2,41

In. .145 .155 .145 .205 .164

mm 3,68 3,94 3,68 5,21 2,41

Travel Speed

IPM 60 50 45 35 20

MM/MIN

1524 1270 1143 889 508

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-29

SECTION 4 OPERATION

Material: Carbon Steel

Initial Amperes: 35

Final Amperes: 70

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Oxygen (O2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Oxygen (O2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-30

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

O

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.187 0.250 0.312 0.375 0.500 0.625

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

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

0.3 0.3 0.3 0.4 0.5 0.5

66.7
/4.5

81.6
/5.6

49.1
/3.3

20.6
/1.4

0 0 0 0 0 0

2

66.7
/4.5

81.6
/5.6

49.1
/3.3

28.4
/1.9

35 Initial / 70 Final Amperes

Carbon Steel

66.7
/4.5

81.6
/5.6

49.1
/3.3

20.6
/1.4

N

2

66.7
/4.5

81.6
/5.6

49.1
/3.3

28.4
/1.9

66.7
/4.5

81.6
/5.6

49.1
/3.3

13.5
/0.9

O

2

66.7
/4.5

81.6
/5.6

49.1
/3.3

135.
/0.9

Arc Voltage (standoff) 108 110 114 113 135 140

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54 2,54 2,54

In. .140 .140 .165 .160 .275 .315

mm 3,56 3,56 4,19 4,06 6,99 8,00

In. .140 .140 .165 .160 .275 .315

mm 3,56 3,56 4,19 4,06 6,99 8,00

Travel Speed

IPM 110 95 70 60 30 25

MM/MIN

Notes:
Pilot Arc –HIGH.

2794 2413 1778 1524 762 635

Precision Plasma with Integrated Flow Control -

4-31

SECTION 4 OPERATION

Material: Carbon Steel

Initial Amperes: 50

Final Amperes: 100

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Oxygen (O2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Oxygen (O2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21923, "E"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-32

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

O

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.312 0.375 0.500 0.625 0.750

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

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

0.3 0.3 0.4 0.5 0.5

77.5
/5.2

89.5
/6.1

60.5
/4.1

26.3
/1.8

0 0 0 0 0

2

77.5
/5.2

89.5
/6.1

60.5
/4.1

26.3
/1.8

50 Initial / 100 Final Amperes

Carbon Steel

77.5
/5.2

89.5
/6.1

60.5
/4.1

26.3
/1.8

N

2

77.5
/5.2

89.5
/6.1

60.5
/4.1

26.3
/1.8

77.5
/5.2

89.5
/6.1

60.5
/4.1

26.3
/1.8

O

2

Arc Voltage (standoff) 115 120 132 137 142

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54 2,54

In. .175 .190 .280 .290 .320

mm 4,45 4,83 7,11 7,37 8,13

In. .175 .190 .280 .290 .320

mm 4,45 4,83 7,11 7,37 8,13

Travel Speed

IPM 90 80 50 30 25

MM/MIN

2290 2030 1270 760 630

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-33

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 15

Final Amperes: 30

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Oxygen (O2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Oxygen (O2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21536 (3 holes)

! Nozzle

P/N 21541, "B"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-34

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

O

Material Thickness

In. 26Ga 24Ga 22Ga 18Ga 16Ga

mm

0,4 0,6 0,7 1,2 1,6

Timers

Pierce Delay (sec.)

0 0 0 0 0

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

99.8
/6.8

116.8
/7.9

32.7
/2.2

10.3
/0.7

7.1

/0.5

2

116.8

99.8
/6.8

/7.9

32.7
/2.2

10.3
/0.7

7.1

/0.5

15 Initial / 30 Final Amperes

Stainless Steel

99.8
/6.8

116.8
/7.9

32.7
/2.2

10.3
/0.7

7.1

/0.5

N

2

99.8
/6.8

116.8
/7.9

32.7
/2.2

10.3
/0.7

7.1

/0.5

99.8
/6.8

116.8
/7.9

32.7
/2.2

10.3
/0.7

7.1

/0.5

O

2

Arc Voltage (standoff) 105 105 107 109 111

Initial Height

Pierce Height

Cutting Height

In. .06 .06 .06 .06 .06

mm 1,52 1,52 1,52 1,52 1,52

In. .105 .120 .107 .109 .111

mm 2,67 3,05 2,72 2,77 2,82

In. .105 .120 .107 .109 .111

mm 2,67 3,05 2,72 2,77 2,82

Travel Speed

IPM 250 200 190 140 100

MM/MIN

6350 5080 4826 3556 2540

Notes:
Pilot Arc –LOW.

Precision Plasma with Integrated Flow Control -

4-35

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 25

Final Amperes: 50

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Air @ 150 psi / 10.4 bar
Air @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21542, "C"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-36

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.125 0.187 0.250 0.375

mm

Pierce Delay (sec.)

125.7

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

Air Air

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

0 0 0.1 0.2

77

/5.2

/8.5

44.5
/3.0

31.9
/2.2

0 0 0 0

77

/5.2

125.7
/8.5

44.5
/3.0

31.9
/2.2

25 Intial / 50 Final Amperes

Stainless Steel

77

/5.2

125.7
/8.5

44.5
/3.0

31.9
/2.2

77

/5.2

125.7
/8.5

44.5
/3.0

31.9
/2.2

Arc Voltage (standoff) 134 140 145 157

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .145 .165 .160 .220

mm 3,68 4,19 4,06 5,59

In. .145 .165 .160 .220

mm 3,68 4,19 4,06 5,59

Travel Speed

IPM 90 60 40 18

MM/MIN

2286 1524 1016 457

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-37

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 35

Final Amperes: 70

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Air @ 150 psi / 10.4 bar
Air @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-38

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.187 0.250 0.375 0.500

mm

Pierce Delay (sec.)

105.5

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

Air Air

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

0.3 0.4 0.5 0.6

79.1
/5.4

/7.2

62.6
/4.3

38.3
/2.6

0 0 0 0

79.1
/5.4

105.5
/7.2

62.6
/4.3

38.3
/2.6

35 Initial / 70 Final Amperes

Stainless Steel

79.1
/5.4

105.5
/7.2

62.6
/4.3

38.3
/2.6

79.1
/5.4

105.5
/7.2

62.6
/4.3

38.3
/2.6

Arc Voltage (standoff) 131 152 158 157

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .150 .240 .280 .280

mm 3,81 6,10 7,11 7,11

In. .150 .240 .280 .280

mm 3,81 6,10 7,11 7,11

Travel Speed

IPM 100 50 28 20

MM/MIN

2540 2270 711 609

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-39

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 50

Final Amperes: 100

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Air @ 150 psi / 10.4 bar
Air @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21923, "E"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-40

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.250 0.375 0.500 0.625

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

Air Air

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

0.3 0.4 0.5 0.6

79.1
/5.4

69.3
/4.7

62

/4.2

37.8
/2.6

0 0 0 0

79.1
/5.4

69.3
/4.7

62

/4.2

37.8
/2.6

50 Initial / 100 Final Amperes

Stainless Steel

79.1
/5.4

69.3
/4.7

62

/4.2

37.8
/2.6

79.1
/5.4

69.3
/4.7

62

/4.2

37.8
/2.6

Arc Voltage (standoff) 129 135 142 150

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .220 .265 .295 .325

mm 5,59 6,73 7,49 8,26

In. .220 .265 .295 .325

mm 5,59 6,73 7,49 8,26

Travel Speed

IPM 80 60 35 25

MM/MIN

2030 1520 889 635

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-41

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 35

Final Amperes: 70

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Air @ 150 psi / 10.4 bar
Air @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-42

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

Material Thickness

In. 0.125 0.187 0.250 0.375 0.500

mm

Timers

Pierce Delay (sec.)

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

111.1

Air Air CH

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

0.2 0.3 0.4 0.5 0.6

80.5
/5.5

111.1

/7.6

61.5
/4.2

40.3
/2.7

26.7
/1.8

80.5
/5.5

/7.6

61.5
/4.2

40.3
/2.7

26.7
/1.8

35 Initial / 70 Final Amperes

Stainless Steel

4

80.5
/5.5

111.1
/7.6

61.5
/4.2

40.3
/2.7

26.7
/1.8

80.5
/5.5

111.1
/7.6

61.5
/4.2

40.3
/2.7

26.7
/1.8

80.5
/5.5

111.1
/7.6

61.5
/4.2

40.3
/2.7

26.7
/1.8

Arc Voltage (standoff) 131 146 154 166 175

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54 2,54

In. .115 .170 .210 .230 .275

mm 2,92 4,32 5,33 5,84 6,99

In. .115 .170 .210 .230 .275

mm 2,92 4,32 5,33 5,84 6,99

Travel Speed

IPM 120 80 50 30 24

MM/MIN

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

3048 2032 1270 762 609

4-43

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 50

Final Amperes: 100

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Air @ 150 psi / 10.4 bar
Air @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21923, "E"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-44

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

Material Thickness

In. 0.250 0.375 0.500 0.625

mm

Timers

Pierce Delay (sec.)

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

Air Air CH

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

0.3 0.4 0.5 0.6

78.6
/5.3

96

/6.5

62

/4.2

40.8
/2.7

28.2
/1.9

78.6
/5.3

96

/6.5

62

/4.2

40.8
/2.7

28.2
/1.9

50 Initial / 100 Final Amperes

Stainless Steel

4

78.6
/5.3

96

/6.5

62

/4.2

40.8
/2.7

28.2
/1.9

78.6
/5.3

96

/6.5

62

/4.2

40.8
/2.7

28.2
/1.9

Arc Voltage (standoff) 140 150 159 170

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .175 .210 .225 .250

mm 4,54 5,33 5,72 6,35

In. .175 .210 .225 .250

mm 4,54 5,33 5,72 6,35

Travel Speed

IPM 80 60 35 25

MM/MIN

2030 1524 889 635

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-45

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 25

Final Amperes: 50

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21542, "C"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-46

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.125 0.187 0.250 0.375

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

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

0 0 0.1 0.3

78.5
/5.3

116.4
/7.9

42.4
/2.9

27.3
/1.9

0 0 0 0

2

116.4

78.5
/5.3

/7.9

42.4
/2.9

27.3
/1.9

25 Intial / 50 Final Amperes

Stainless Steel

78.5
/5.3

116.4
/7.9

42.4
/2.9

27.3
/1.9

N

2

78.5
/5.3

116.4
/7.9

42.4
/2.9

27.3
/1.9

Arc Voltage (standoff) 128 135 144 155

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .05 .09 .130 .180

mm 1,27 2,29 3,30 4,57

In. .05 .09 .130 .180

mm 1,27 2,29 3,30 4,57

Travel Speed

IPM 90 60 40 22

MM/MIN

2286 1524 1016 558

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-47

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 35

Final Amperes: 70

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-48

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.187 0.250 0.375 0.500

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

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

0.3 0.4 0.5 0.6

81.1
/5.5

107.1
/7.3

61

/4.1

35.1
/2.4

0 0 0 0

2

107.1

81.1
/5.5

/7.3

61

/4.1

35.1
/2.4

35 Initial / 70 Final Amperes

Stainless Steel

81.1
/5.5

107.1
/7.3

61

/4.1

35.1
/2.4

N

2

81.1
/5.5

107.1
/7.3

61

/4.1

35.1
/2.4

Arc Voltage (standoff) 132 150 154 159

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .120 .190 .170 .220

mm 3,05 4,83 4,32 5,59

In. .120 .190 .170 .220

mm 3,05 4,83 4,32 5,59

Travel Speed

IPM 75 50 28 24

MM/MIN

1905 1270 711 609

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-49

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 50

Final Amperes: 100

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21923, "E"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-50

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

Timers

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

In. 0.250 0.375 0.500 0.625

mm

Pierce Delay (sec.)

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

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

0.3 0.4 0.5 0.6

79.1
/5.4

93.1
/6.3

61

/4.1

27.9
/1.9

0 0 0 0

2

79.1
/5.4

93.1
/6.3

61

/4.1

27.9
/1.9

50 Initial / 100 Final Amperes

Stainless Steel

79.1
/5.4

93.1
/6.3

61

/4.1

27.9
/1.9

N

2

79.1
/5.4

93.1
/6.3

61

/4.1

27.9
/1.9

Arc Voltage (standoff) 135 145 153 157

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .180 .235 .250 .272

mm 4,57 5,97 6,35 6,91

In. .180 .235 .250 .272

mm 4,57 5,97 6,35 6,91

Travel Speed

IPM 80 60 35 25

MM/MIN

2032 1520 889 635

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-51

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 25

Final Amperes: 50 --

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Plasm a Gas:

Shield Gas:

using 70A nozzle

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-52

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 22Ga 20Ga 18Ga 16Ga

mm

0,7 0,9 1,2 1,6

Timers

Pierce Delay (sec.)

0.3 0.4 0.5 0.6

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

78.5
/5.3

93.1
/6.3

25.1
/1.7

27.3
/1.9

25.8
/1.7

2

78.5
/5.3

93.1
/6.3

25.1
/1.7

27.3
/1.9

25.8
/1.7

25 Initial / 50 Final Amperes*

Stainless Steel

78.5
/5.3

93.1
/6.3

25.1
/1.7

27.3
/1.9

25.8
/1.7

N

2

78.5
/5.3

93.1
/6.3

25.1
/1.7

27.3
/1.9

25.8
/1.7

CH

4

Arc Voltage (standoff) 130 130 130 130

Initial Height

Pierce Height

Cutting Height

In. .06 .06 .06 .100

mm 1,52 1,52 1,52 2,54

In. .100 .100 .130 .100

mm 2,54 2,54 3,30 2,54

In. .100 .100 .130 .100

mm 2,54 2,54 3,30 2,54

Travel Speed

IPM 550 475 350 225

MM/MIN

13970 12065 8890 5081

Notes:
Pilot Arc –HIGH.
*50 Amp cutting using 70 Amp Nozzle (P/N 21543)

Precision Plasma with Integrated Flow Control -

4-53

SECTION 4 OPERATION

)

Initial Amperes: 35

Final Amperes: 70

®

Shield Mix Gas:

Material: Stainless Steel

Plasm a Gas:

Shield Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes

! Nozzle

P/N 21543, "D"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-54

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 0.187 0.250 0.375 0.500

mm

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

Timers

Pierce Delay (sec.)

0.3 0.4 0.5 0.6

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

79.6
/5.4

93.6
/6.4

60.5
/4.1

37.6
/2.6

20.7
/1.4

2

79.6
/5.4

93.6
/6.4

60.5
/4.1

37.6
/2.6

20.7
/1.4

35 Initial / 70 Final Amperes

Stainless Steel

79.6
/5.4

93.6
/6.4

60.5
/4.1

37.6
/2.6

20.7
/1.4

N

2

79.6
/5.4

93.6
/6.4

60.5
/4.1

37.6
/2.6

20.7
/1.4

CH

4

Arc Voltage (standoff) 136 150 159 162

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54

In. .154 .225 .240 .232

mm 3,91 5,72 6,10 5,89

In. .154 .225 .240 .232

mm 3,91 5,72 6,10 5,89

Travel Speed

IPM 75 50 28 24

MM/MIN

1905 1270 711 609

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-55

SECTION 4 OPERATION

Material: Stainless Steel

Initial Amperes: 50

Final Amperes: 100

Plasm a Gas:

Shield Gas:

®

Shield Mix Gas:

PT-24 Torch with Integrated Flow Control

Nitrogen (N2) @ 150 psi / 10.4 bar
Nitrogen (N2) @ 150 psi / 10.4 bar
Methane (CH4) @ 100 psi / 6.9 bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle

P/N 21692 (4 holes)

! Nozzle

P/N 21923, "E"
Nozzle Retainer/Diffuser

P/N 22007
Shield Cup Insulator

P/N 22010
Insulator Shield Retainer

w/O-Ring P/N 21712

4-56

O-Ring - Shield Retainer .
(Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are the

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

Precision Plasma with Integrated Flow Control -

SECTION 4 OPERATION

Process Data

Precision Plasma Integrated Flow Control

Plasma Gas Shield Gas 1 Shield Gas 2

N

Material Thickness

In. 0.250 0.312 0.375 0.500 0.625

mm

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

Timers

Pierce Delay (sec.)

0.3 0.3 0.4 0.5 0.6

Initial to Final Current (sec.) 0.2 0.2 0.2 0.2 0.2

Setup Parameters

Plasma Start Gas 1- psi/bar

Plasma Cut Gas 1- psi/bar

Shield Gas

1-Start - psi/bar

1- Cut - psi/bar

2- Cut - psi/bar

79.6
/5.4

97.2
/6.6

60.5
/4.1

39.7
/2.7

22.7
/1.5

2

79.6
/5.4

97.2
/6.6

60.5
/4.1

39.7
/2.7

22.7
/1.5

50 Initial / 100 Final Amperes

Stainless Steel

79.6
/5.4

97.2
/6.6

60.5
/4.1

39.7
/2.7

22.7
/1.5

N

2

79.6
/5.4

97.2
/6.6

60.5
/4.1

39.7
/2.7

22.7
/1.5

79.6
/5.4

97.2
/6.6

60.5
/4.1

39.7
/2.7

22.7
/1.5

CH

4

Arc Voltage (standoff) 138 140 150 162 170

Initial Height

Pierce Height

Cutting Height

In. .100 .100 .100 .100 .100

mm 2,54 2,54 2,54 2,54 2,54

In. .138 .165 .190 .252 .290

mm 3,51 4,19 4,83 6,40 7,37

In. .138 .165 .190 .252 .290

mm 3,51 4,19 4,83 6,40 7,37

Travel Speed

IPM 80 70 60 35 25

MM/MIN

2032 1778 1524 889 635

Notes:
Pilot Arc –HIGH.

Precision Plasma with Integrated Flow Control -

4-57

SECTION 4 OPERATION

4.4.3.1 Aluminum Kerf Values N2/N2/CH4

Aluminum N2/N2/CH4 30 Amperes

Material Thickness (mm)

1.575 1.905 2.286 3.175 4.750 6.350

0.140

0.120

0.100

2.210

0.080

1.524

0.060

1.2701.270

Kerf (inches)

0.040

0.020

0.000

0.050

0.062 0.075 0.090 0.125 0.187 0.250

0.050

1.270

0.060

0.050

1.651

0.065

0.087

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

Aluminum N2/N2/CH4 50 Amperes

1.575 3.175 4.775 6.350

Material Thickness (mm)

4-56

0.140

0.120

0.100

0.080

0.060

1.524

1.651

0.065

2.032

0.080

2.362

0.093

0.060

Kerf (inches)

0.040

0.020

0.000

0.062 0.125 0.188 0.250

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

Precision Plasma with Integrated Flow Control - CE

SECTION 4 OPERATION

Aluminum N2/N2/CH4 70 Amperes

4.750 6.350 9.525 12.700

0.190

0.170

0.150

0.130

2.845

0.110

Kerf (inches)

0.090

0.070

0.050

2.540

0.100

0.187 0.250 0.375 0.500

0.112

2.540

0.100

3.048

0.120

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

Material Thickness (inches)

Material Thickness (mm)

Aluminum N

/CH4 100 Amperes

2/N2

Material Thickness (mm)

6.350 9.525 12.700 15.875

0.190

0.170

0.150

3.302

0.130

2.921

0.110

Kerf (inches)

0.090

0.070

0.050

2.540

0.100

0.250 0.375 0.500 0.625

2.667

0.105

0.115

0.130

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

Material Thickness (inches)

Precision Plasma with Integrated Flow Control - CE

4-57

SECTION 4 OPERATION

4.4.3.2 Carbon Steel Kerf Values O2/N2/O2

Carbon Steel O2/N2/O2 16 Amperes

Material Thickness (mm)

1.219 3. 404

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

1.118

0.044

0.048 0. 134

1.473

0.058

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

Carbon Steel O2/N2/O2 35 Amperes

Material Thickness (mm)

1.524 3.175 6.350

4-58

0.140

0.120

0.100

0.080

0.060

1.168

Kerf (inches)

0.040

0.020

0.000

0.046

0.060 0.125 0.250

1.321

0.052

1.499

0.059

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

Precision Plasma with Integrated Flow Control - CE

SECTION 4 OPERATION

Carbon Steel O2/N2/O2 45 Amperes

Material Thickness (mm)

3.175 6.350 9.525

0.140

0.120

0.100

0.080

0.060

1.626

0.064

1.930

0.076

2.413

0.095

Kerf (inches)

0.040

0.020

0.000

0.125 0.250 0.375

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

Carbon Steel O2/N2/O2 70 Amperes

Material Thickness (mm)

3.429 6.350 9.525 12.700

0.140

0.120

2.540

0.100

0.100

0.080

0.060

1.575

1.778

0.070

2.032

0.080

0.062

Kerf (inches)

0.040

0.020

0.000

0.135 0.250 0.375 0.500

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

Precision Plasma with Integrated Flow Control - CE

4-59

SECTION 4 OPERATION

Carbon Steel O2/N2/O2 100 Amperes

Material Thickness (mm)

9.525 12.700 19.050

0.140

3.048

0.120

0.120

0.100

0.080

0.060

2.540

2.337

0.100

0.092

Kerf (inches)

0.040

0.020

0.000

0.375 0.500 0.750

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

Material Thickness (inches)

4-60

Precision Plasma with Integrated Flow Control - CE