ESAB Precision Plasmarc System with Electronic Flow Control Installation manual / Instruction manual

F-15-679

March, 2002

Installation, Operation and Maintenance Manual for the

PRECISION PLASMARC SYSTEM

with Electronic Flow Control

CUTTING SYSTEMS

411 s. Ebenezer Road
Florence, SC 29501-0545

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

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

ESAB Cutting Systems first priority is total customer

This manual is ESAB Part Number F15679

ESAB Cutting Systems first priority is total customer

ESAB Cutting Systems first priority is total customer ESAB Cutting Systems first priority is total customer
satisfaction. We constantly look for ways to

satisfaction. We constantly look for ways to

satisfaction. We constantly look for ways to satisfaction. We constantly look for ways to
improve our products, service and documentation.

improve our products, service and documentation.

improve our products, service and documentation. improve our products, service and documentation.
As a result, we make e

As a result, we make ennnnhancements and/or de

As a result, we make eAs a result, we make e
changes as r

changes as reeeequired. ESAB makes every possible

changes as rchanges as r
effort to ensure our documentation is current. We

effort to ensure our documentation is current. We

effort to ensure our documentation is current. We effort to ensure our documentation is current. We
cannot guarantee that each piece of docume

cannot guarantee that each piece of documennnntation

cannot guarantee that each piece of documecannot guarantee that each piece of docume
received by our customers reflects the latest design

received by our customers reflects the latest design

received by our customers reflects the latest design received by our customers reflects the latest design
enhancements. Therefore, the information

enhancements. Therefore, the information

enhancements. Therefore, the information enhancements. Therefore, the information
contain

contained in this document is subject to change

containcontain
without n

without nooootice.

without nwithout n
This manual is ESAB Part Number F15679

This manual is ESAB Part Number F15679This manual is ESAB Part Number F15679
New Date (April,01) given to reflect added cable
part Nos. section 2.
(June01) reflects document formatting changes
(Dec01) Corrected/clarified p7-35 part nos.

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.

ed in this document is subject to change

ed in this document is subject to change ed in this document is subject to change

quired. ESAB makes every possible

quired. ESAB makes every possible quired. ESAB makes every possible

tice.

tice.tice.

hancements and/or design

hancements and/or dehancements and/or de

sign

sign sign

tation

tation tation

Printed in U.S.A.

©©©© ESAB Cutting Systems, 2001

Precision Plasma Electronic Flow Control Table of Contents

Page
Section 1 Safety

1.1 Introduction......................................................................................... 1

1.2 Safety Notations And Symbols............................................................. 1

1.3 General Safety Information................................................................... 2

1.4 Installation Precautions........................................................................ 3

1.5 Electrical Grounding ............................................................................ 4

1.6 Operating A Plasma Cutting Machine................................................... 4

1.7 Service Precautions............................................................................. 8

1.8 Safety References ............................................................................... 9

Section 2 Description

2.1 General............................................................................................... 1

2.2 Scope................................................................................................. 1

2.3 Package Options Available .................................................................. 1-2

2.4 Technical Specifications

2.4.1 Precision Plasma System ............................................................ 2-3

2.4.2 Plasma Gas................................................................................. 4

2.4.3 Start Gas..................................................................................... 4

2.4.4 Secondary Gas............................................................................ 4

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

3.5 Interconnecting Lines .......................................................................... 4

Precision Plasmarc Component Interconnecting Diagram..................... 8

3.6 Torch Mounting................................................................................... 10

3.7 Torch Coolant ..................................................................................... 11

3.8 Inspection of Gas and Coolant Lines.................................................... 11

3.9 Replacement of EPROM in the Plasmarc Power Source

Programmable Logic Controller (PLC) .................................................. 12

i

Precision Plasma Electronic Flow Control Table of Contents

Section 4 Operation

4.1 Power Supply Controls

4.1.1 Main Power Switch ..................................................................... 1

4.1.2 Pilot Arc Switch........................................................................... 1

4.1.3 Fault Indicator Lights................................................................... 2

4.1.4 Meters........................................................................................ 2

4.1.5 Current Control Switch................................................................ 3

4.2 Cut Quality

4.2.1 Introduction ................................................................................ 4

4.2.2 Cut Angle.................................................................................... 5

4.2.3 Cut Flatness................................................................................ 6

4.2.4 Surface Finish ............................................................................. 7

4.2.5 Dross.......................................................................................... 8

4.2.6 Dimensional Accuracy................................................................. 10

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction ................................................................................ 11

4.3.2 Aluminum.................................................................................... 11

4.3.3 Carbon Steel............................................................................... 12

4.3.4 Stainless Steel............................................................................. 13

4.4 Process Data

4.4.1 Introduction ................................................................................ 15

4.4.2 Process Data Settings................................................................. 16

Plasma Marking Data .......................................................... 56

4.4.3 Relationship of Kerf Width to Amperes and Material Thickness..... 78

4.4.3.1 Aluminum Kerf Values.......................................................... 78

4.4.3.2 Carbon Steel Kerf Values..................................................... 80

4.4.3.3 Stainless Steel Kerf Values O2/N2/O2.................................... 83

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4................................ 84

4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4................................. 85

4.4.3.6 Stainless Steel Kerf Values N2/N2......................................... 86

4.4.3.7 Stainless Steel Kerf Values Air/Air ....................................... 88

ii

Precision Plasma Electronic Flow Control Table of Contents

Section 5 Maintenance

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

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

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

5.4 Torch Maintenance.............................................................................. 5

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

5.6 PT-24 Torch Re-Assembly................................................................... 9

Section 6 Troubleshooting

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

6.2 Programmable Logic Controller (PLC) ................................................. 1

6.2.1 PLC LED Introduction................................................................. 2

6.2.2 PLC LED Functions .................................................................... 2

6.3 Troubleshooting Guide

6.3.1 Reduced Consumable Life........................................................... 3

6.3.2 Poor Cut Quality.......................................................................... 4

6.3.3 No Pilot Arc................................................................................. 4

6.3.4 No Arc Transfer ........................................................................... 4

6.3.5 No Preflow .................................................................................. 4

6.3.6 Torch Fails to Fire........................................................................ 4

6.3.7 Nozzle Life Extremely Short.......................................................... 5

6.3.8 Short Electrode Life ..................................................................... 5

6.3.9 Short Electrode AND Nozzle Life.................................................. 5

6.4 Flow Control Schematic....................................................................... 6

6.5 Gas Flow Schematic............................................................................ 7

6.6 Junction Box Wiring Diagram............................................................... 8

6.7 Junction Box Schematic....................................................................... 9

6.8 Precision Plasma Power Module Wiring Diagram.................................. 10-11

6.9 Power Module Schematic.................................................................... 12

6.10 Power Source Wiring Diagrams ......................................................... 13-17

6-11 Power Source Schematic.................................................................. 18-19

iii

Precision Plasma Electronic Flow Control Table of Contents

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

6.12.1 Precision Process Timers .......................................................... 21

6.12.2 Process Timer Values................................................................ 22

6.12.3 Process Window Key Functions ................................................ 23

6.12.4 Proportional Valve Analog Values for PARAM.CUT

PARAM.CUT and DEF.TEC

PARAM.CUTPARAM.CUT

DEF.TEC 24

DEF.TECDEF.TEC

6.12.5 Process Gas Selection Requirements........................................ 25

6.12.6 EFC Process Gas Flow Chart .................................................... 26

6.12.7 Station On, Flush/Pressurize Cycle Timers................................. 27

6.12.8 Solenoid/Proportional Valve Requirements and
Gas Error Monitoring

Carbon Steel PG-O2, SG-O2..................................................... 28

Carbon Steel PG-O2, SG-N2/O2................................................. 30

Carbon Steel PG-O2, Sg-O2...................................................... 32

Stainless Steel PG-N2, SG-N2.................................................. 34

Stainless Steel PG-N2, SG-N2/CH4............................................ 36

Stainless Steel PG-Air, SG-Air .................................................. 38

Stainless Steel PG-Air, SG-Air/CH4........................................... 40

Aluminum PG-N2, SG- N2......................................................... 42

Aluminum PG-N2, SG-N2/CH4................................................... 44

Marking PG-Argon, SG-Air....................................................... 46

Section 7 Replacement Parts

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

7.2 Ordering ............................................................................................. 2

7.3 Plasmarc Power Source – Exterior Components.................................. 3

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

7.5 Power Source Module......................................................................... 18

7.6 EFC Junction Box............................................................................... 26

7.7 Electronic Flow Control Box ................................................................ 32

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

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

7.10 PT-24 Torch Assembly – Version 1.................................................... 40

7.11 Solenoid Assembly - EFC Torch – Version 1 ...................................... 42

Customer/Technical Information Back Manual Cover

iv

SECTION 1 SAFETY

1.1 Introduction

The process of cutting metals with plasma equipment

1.2 Safety Notations And Symbols

provides industry with a valuable and versatile tool.
ESAB cutting machines are designed to provide both
operation safety and efficiency. 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.

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

!

DANGER

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

or potential equipment failure exists. Used in
concurrence with other symbols and information.

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

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

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

Used to call attention to minor hazards to
equipment.

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

Precision Plasma with Electronic Flow Control – 1-1

SECTION 1 SAFETY

1.3 General Safety Information

WARNING

!

Machine starts automatically.

This equipment moves in various directions and

This equipment moves in various directions and

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

speeds.

speeds.speeds.

• Moving machinery can crush.

Moving machinery can crush.

Moving machinery can crush.Moving machinery can crush.

• Only qualified personnel should operate or service

Only qualified personnel should operate or service

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

equipment.

equipment.equipment.

• Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not

Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not
involved in production process

involved in production process clear of entire

involved in production process involved in production process
system area.

system area.

system area.system area.

• Keep gear racks and rails clear of debris or

Keep gear racks and rails clear of debris or

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

obstructions, such as tools or clothing.

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

• Fence off entire work cell to prevent personnel

Fence off entire work cell to prevent personnel

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

from passing through area or standing in the

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

working envelope of the equipment.

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

• Post approp

Post appropriate WARNING signs at every work

Post appropPost approp
cell entrance.

cell entrance.

cell entrance. cell entrance.

riate WARNING signs at every work

riate WARNING signs at every work riate WARNING signs at every work

clear of entire

clear of entire clear of entire

• Follow lockout procedure before servicing.

Follow lockout procedure before servicing.

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

Failure to follow operating instructions

WARNING

!

could result in death or serious injury.

Read and understand this operator’

Read and understand this operator’s manual before

Read and understand this operator’Read and understand this operator’
using machine.

using machine.

using machine.using machine.

• Read entire procedure before operating or

Read entire procedure before operating or

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

performing any system maintenance.

performing any system maintenance. performing any system maintenance.

• Special attention must be given to all hazard

Special attention must be given to all hazard

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

warnings that provide essential information

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

regarding personnel safety and/or possible

regarding personnel safety and/or possible regarding personnel safety and/or possible
equipment dama

equipment damage.

equipment damaequipment dama

• All safety precautions relevant to electrical

All safety precautions relevant to electrical

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

equipment and process operations must be

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

strictly observed by all having system

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

responsibility or access.

responsibility or access. responsibility or access.

• Read all safety publications made available by

Read all safety publications made available by

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

your company.

your company.your company.

ge.

ge.ge.

s manual before

s manual before s manual before

Precision Plasma with Electronic Flow Control – 1-2

SECTION 1 SAFETY

Failure to follow safety warning label

WARNING

!

1.4 Installation Precautions

instructions could result in death or
serious injury.

Read and understand all safety warning labels on

Read and understand all safety warning labels on

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

machine.

machine.machine.

Refer to operator’s manual for additional safety

Refer to operator’s manual for additional safety

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

information.

information.information.

WARNING

!

Improperly installed equipment can cause
injury or death.

Follow these guidelines while installing

Follow these guidelines while installing machine:

Follow these guidelines while installingFollow these guidelines while installing
Do not connect a cylinder directly to machine inlet. An

Do not connect a cylinder directly to machine inlet. An

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

appropriate cylinder regulator must be installed on a

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

fuel gas cylinder to reduce pressure to a reasonable

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

inlet supply pressure. Machine regulator is then used

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

to obtain pressure required by torches.

to obtain pressure requiredto obtain pressure required
Contact your ESAB representative before installation.

Contact your ESAB representative before installation.

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

He can suggest certain precautions regarding piping

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

installation and machine lifting, etc. to ensure

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

maximum security.

maximum security.maximum security.
Never attempt any machine modifications or apparatus

Never attempt any machine modifications or apparatus

Never attempt any machine modifications or apparatus Never attempt any machine modifications or apparatus
additions withou

additions without first consulting a qualified ESAB

additions withouadditions withou
representative.

representative.

representative.representative.
Observe machine clearance requirements for proper

Observe machine clearance requirements for proper

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

operation and personnel safety.

operation and personnel safety. operation and personnel safety.

t first consulting a qualified ESAB

t first consulting a qualified ESAB t first consulting a qualified ESAB

by torches.

by torches. by torches.

machine:

machine: machine:

Precision Plasma with Electronic Flow Control – 1-3

SECTION 1 SAFETY

1.5 Electrical Grounding

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

Electric shock hazard.

WARNING

!

Impr

Improper grounding can cause severe injury or death.

oper grounding can cause severe injury or death.

ImprImpr

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

WARNING

!

Machine must be properly grounded before put into

Machine must be properly grounded before put into

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

service.

service.service.

Improper grounding can damage machine
and electrical components.

• Machine must be properly grounded before put

Machine must be properly grounded before put

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

into service.

into service. into service.

• Cutting table must be properly grounded to

Cutting table must be properly grounded to a good

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

Earth ground rod.

Earth ground rod.Earth ground rod.

a good

a good a good

1.6 Operating A Plasma Cutting Machine

WARNING

!

WARNING

!

Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear

Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear
goggles to protect eyes

goggles to protect eyes from burns and flying

goggles to protect eyesgoggles to protect eyes
debris generated during operation.

debris generated during operation.

debris generated during operation.debris generated during operation.

• Chipped slag may be hot and fly far. Bystanders

Chipped slag may be hot and fly far. Bystanders

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

should also wear goggles and safety glasses.

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

• From plasma arc can damage hearing. Wear

From plasma arc can damage hearing. Wear

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

correct ear protection when cutting above water.

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

from burns and flying

from burns and flying from burns and flying

Burn hazard.

Hot metal can burn.

Hot metal can burn.

Hot metal can burn.Hot metal can burn.

• Do not touch metal plate or parts immediately after

Do not touch metal plate or parts immediately after

Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after
cutting. Allow metal time

cutting. Allow metal time to cool, or douse with

cutting. Allow metal timecutting. Allow metal time
water.

water.

water.water.

• Do not touch plasma torch immediately after

Do not touch plasma torch immediately after

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

cutting. Allow torch time to cool.

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

to cool, or douse with

to cool, or douse with to cool, or douse with

Precision Plasma with Electronic Flow Control – 1-4

SECTION 1 SAFETY

WARNING

!

Hazardous voltages. Electric shock
can kill.

• Do NOT touch plasma torch, cutting table or cable

Do NOT touch plasma torch, cutting table or cable

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

connections during plasma cutting process.

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

• Always turn power off to plasma power supplies

Always turn power off to plasma power supplies

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

before touching or servicing plasma torch.

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

• Always turn po

Always turn power off to plasma power supplies

Always turn poAlways turn po
before opening or servicing plasma plumbing or

before opening or servicing plasma plumbing or

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

flow control box.

flow control box.flow control box.

• Do not touch live electrical parts.

Do not touch live electrical parts.

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

• Keep all panels and covers in place when machine

Keep all panels and covers in place when machine

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

is connected to power source.

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

• Insulate yourself from workpiece and electr

Insulate yourself from workpiece and electrical

Insulate yourself from workpiece and electrInsulate yourself from workpiece and electr
ground: wear insulating gloves, shoes and

ground: wear insulating gloves, shoes and

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

clothing.

clothing.clothing.

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

Keep gloves, shoes, clothing, work area, and

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

equipment dry.

equipment dry.equipment dry.

WARNING

!

Pinch hazard.

wer off to plasma power supplies

wer off to plasma power supplies wer off to plasma power supplies

ical

ical ical

Moving vertical slides can crush or pinch.

Moving vertical slides can crush or pinch.

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

Keep hands clear of torch and slide during operation.

Keep hands clear of torch and slide during operation.

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

Fume hazard.

WARNING

!

Fumes and gases generated by the plasma cutting

Fumes and gases generated by the plasma cutting

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

process can be hazardous to your health.

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

• Do NOT breathe fumes.

Do NOT breathe fumes.

Do NOT breathe fumes.Do NOT breathe fumes.

• Do not operate plasma torch without fume removal

Do not operate plasma torch without fume removal

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

system operating properly.

system operating properly. system operating properly.

• Use additional ventilat

Use additional ventilation to remove fumes if

Use additional ventilatUse additional ventilat
necessary.

necessary.

necessary.necessary.

• Use approved respirator if ventilation is not

Use approved respirator if ventilation is not

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

adequate.

adequate.adequate.

ion to remove fumes if

ion to remove fumes if ion to remove fumes if

Precision Plasma with Electronic Flow Control – 1-5

SECTION 1 SAFETY

WARNING

Radiation hazard.

!

Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn skin.

Arc rays can injure eyes and burn skin.Arc rays can injure eyes and burn skin.

• Wear correct eye and body protection.

Wear correct eye and body protection.

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

• Wear dark safety glasses or goggles with side

Wear dark safety glasses or goggles with side

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

shields. Refer to following chart for recommended

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

lens shades for plasma cutting:

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

Arc Current

Arc Current Lens Shade

Arc CurrentArc Current

Up

Up to 100 Amps

to 100 Amps Shade No. 8

Up Up

to 100 Ampsto 100 Amps

100

100----200 Amps

200 Amps Shade No. 10

100100

200 Amps200 Amps

200

200----400 Amps

400 Amps Shade No. 12

200200

400 Amps400 Amps

Over 400 Amps

Over 400 Amps Shade No. 14

Over 400 AmpsOver 400 Amps

• Replace glasses/goggles when lenses are pitted or

Replace glasses/goggles when lenses are pitted or

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

broken

brokenbroken

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

Warn others in area not to look directly at the arc

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

unless wearing appropriate safety glasses....

unless wearing appropriate safety glassesunless wearing appropriate safety glasses

• Prepare cutting area to reduce reflection and

Prepare cutting area to reduce reflection and

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

transmission of ultraviolet light.

transmission of ultraviolet light.transmission of ultraviolet light.

• Paint walls and other surfaces with dark colors to

Paint walls and other surfaces with dark colors to

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

reduce reflections.

reduce reflections.reduce reflections.

• Install protective screens or curtains to reduce

Install protective screens or curtains to reduce

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

ultraviolet transmission.

ultraviolet transmission.ultraviolet transmission.

Lens Shade

Lens Shade Lens Shade

Shade No. 8

Shade No. 8Shade No. 8

Shade No. 10

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

Shade No. 12Shade No. 12

Shade No. 14

Shade No. 14Shade No. 14

WARNING

!

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and violently

Mishandling gas cylinders can rupture and violently

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

release gas.

release gas. release gas.

• Avoid rough handling of cylinders.

Avoid rough handling of cylinders.

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

• Keep cylinder valves closed when not in use.

Keep cylinder valves closed when not in use.

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

• Maintain hoses and fittings in good condition.

Maintain hoses and fittings in good condition.

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

• Always secure cylinders in an upright position by

Always secure cylinders in an upright position by

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

chain or strap to a suitable stable object not part of

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

an electrical circuit.

an electrical circuit.an electrical circuit.

• Locate cylinders away from heat, sparks and

Locate cylinders away from heat, sparks and

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

flames. Never strike an arc on a cylinder.

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

• Refer to CGA Standard P

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

Refer to CGA Standard PRefer to CGA Standard P
Handling of Compressed Gases in Cylinders

Handling of Compressed Gases in Cylinders”,

Handling of Compressed Gases in CylindersHandling of Compressed Gases in Cylinders
available from Compressed Gas Association.

available from Compressed Gas Association.

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

1, “Precautions for Safe

1, “Precautions for Safe 1, “Precautions for Safe

”,

”, ”,

Precision Plasma with Electronic Flow Control – 1-6

SECTION 1 SAFETY

WARNING

!

CAUTION

Spark hazard.

Heat, spatter, and sparks cause fire a

Heat, spatter, and sparks cause fire and burns.

Heat, spatter, and sparks cause fire aHeat, spatter, and sparks cause fire a

• Do not cut near combustible material.

Do not cut near combustible material.

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

• Do not cut containers that have held combustibles.

Do not cut containers that have held combustibles.

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

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

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

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

butane lighter).

butane lighter).butane lighter).

• Pilot arc can cause burns. Keep torch nozzle

Pilot arc can cause burns. Keep torch nozzle

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

away from yourself and others when activating

away from yourself and others when activatiaway from yourself and others when activati
plasma process.

plasma process.

plasma process.plasma process.

• Wear correct eye and body protection.

Wear correct eye and body protection.

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

• Wear gauntlet gloves, safety shoes and hat.

Wear gauntlet gloves, safety shoes and hat.

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

• Wear flame

Wear flame----retardant clothing that covers all

Wear flameWear flame
exposed areas.

exposed areas.

exposed areas.exposed areas.

• Wear cuffless trousers to prevent entry of sparks

Wear cuffless trousers to prevent entry of sparks

Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks
and slag.

and slag.

and slag.and slag.

retardant clothing that covers all

retardant clothing that covers all retardant clothing that covers all

nd burns.

nd burns. nd burns.

ng

ng ng

POOR PERFORMANCE WILL RESULT
WHEN CUTTING ABOVE WATER.

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

Cutting above water may result in:

Cutting above water may result in:

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

• reduced consumable life

reduced consumable life

reduced consumable lifereduced consumable life

• degradation of cut quality

degradation of cut quality

degradation of cut qualitydegradation of cut quality

Cutting above water may result in poor cutting

Cutting above water may result in poor cutting

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

performance. Water vapor created when hot material

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

or sparks contact liquid may cause arcing inside torch.

or sparks contact liquid may cause arcing inside torch.or sparks contact liquid may cause arcing inside torch.
When cutting on a water table, reduce the water level

When cutting on a water table, reduce the water level

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

to provide maximum clearance between water and

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

material.

material. material.

material

material material

Precision Plasma with Electronic Flow Control – 1-7

SECTION 1 SAFETY

WARNING

!

1.7 Service Precautions

CAUTION

Explosion hazard.

Certain molten aluminum

Certain molten aluminum----lithium (Al

Certain molten aluminumCertain molten aluminum
cause explosions when plasma cut OVER water.

cause explosions when plasma cut OVER water.

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

Do not plasma cut the following Al

Do not plasma cut the following Al----Li alloys with

Do not plasma cut the following AlDo not plasma cut the following Al
water:

water:

water:water:
Al

Alithlite (Alcoa)

ithlite (Alcoa) X8192 (Alcoa)

AlAl

ithlite (Alcoa)ithlite (Alcoa)

Alithally (Alcoa)

Alithally (Alcoa) Navalite (US Navy)

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

2090 Alloy (Alcoa) Lockalite (Lockheed)

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

X8090A (Alcoa) Kalite (Kaiser)

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

X8092 (Alcoa) 8091 (Alcan)

X8092 (Alcoa)X8092 (Alcoa)

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

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

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

• DO NOT dry cut over water.

DO NOT dry cut over water.

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

• Contact your

Contact your aluminum supplier for additional

Contact yourContact your
safety information regarding hazards associated

safety information regarding hazards associated

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

with these alloys

with these alloyswith these alloys

Establish and adhere to preventive maintenance. A

Establish and adhere to preventive maintenance. A

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

composite program can be established from

composite program can be established from composite program can be established from
recommended schedules in the

recommended schedules in the instruction literature.

recommended schedules in the recommended schedules in the

aluminum supplier for additional

aluminum supplier for additional aluminum supplier for additional

lithium (Al----Li) alloys can

lithium (Allithium (Al

X8192 (Alcoa)

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

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

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

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

8091 (Alcan)8091 (Alcan)

Li) alloys can

Li) alloys can Li) alloys can

Li alloys with

Li alloys with Li alloys with

.

instruction literature.

instruction literature.instruction literature.

Avoid leaving test equipment or hand tools on

Avoid leaving test equipment or hand tools on

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

machine. Severe electrical or mechanical damage

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

could occur to equipment or machine.

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

Extreme caution should be used when probing

Extreme caution should be used when probing

Extreme caution should be used when probing Extreme caution should be used when probing

CAUTION

!

circuitry with an oscilloscope or voltmeter. Int

circuitry with an oscilloscope or voltmeter. Integrated

circuitry with an oscilloscope or voltmeter. Intcircuitry with an oscilloscope or voltmeter. Int
circuits are susceptible to over voltage damage.

circuits are susceptible to over voltage damage.

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

Power off before using test probes to prevent

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

accidental shorting of components.

accidental shorting of components.accidental shorting of components.
All circuit boards securely seated in sockets, all cables

All circuit boards securely seated in sockets, all cables

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

properly connected, all cabinets closed and locked, all

properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all
gua

guards and covers replaced before power is turned

rds and covers replaced before power is turned

guagua

rds and covers replaced before power is turned rds and covers replaced before power is turned

on.

on.

on.on.
Never plug or unplug a printed circuit board while

Never plug or unplug a printed circuit board while

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

machine power is on. Instantaneous surges of voltage

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

and current can damage electronic components.

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

egrated

egrated egrated

Precision Plasma with Electronic Flow Control – 1-8

SECTION 1 SAFETY

1.8 Safety References

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

• “Precautions and Safe Practices in Welding and Cutting with

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

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

Form 52-529. ESAB Cutting Systems.

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

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

• “Recommended Safe Practices for Shielded Gases for Welding and

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

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

American Welding Society.

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

Welding Society.

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

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

Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.

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

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

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

Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.

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

ESAB Cutting Systems.

• “ Precautions for Safe Handling of Compressed Gases in

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

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

Precision Plasma with Electronic Flow Control – 1-9

SECTION 1 SAFETY

This page intentionally left blank.

Precision Plasma with Electronic Flow Control – 1-10

SECTION 2 DESCRIPTION

x

2.1 General

2.2 Scope

2.3 Package Options Available

Precision Plasmarc package options available through your ESAB dealer

Precision Plasmarc Power Source (

(required) - CE Version

Electronic Flow Control Box (required) P/N 22406
Junction Box (required) P/N 22407

PT-24 Torch Electronic Flow Series A/M (one required)

Power Bundle (one required)

Gas Line Bundle (one required)

Control Lead – Flow Console to Junction Bo
(one required)

Flex cable (recommended for

200/230/380/415/460/575) 3-phase 50/60 Hz

power track applications)

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

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

P/N 37358

4.5 ft. (1.4 m) P/N 0558001463
12 ft. (4.4 m) P/N 0558001877
17 ft. (5.2 m) P/N 0558001464
12 ft. (3.6 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 37533
20 ft. (6 m) P/N 37534
30 ft. (9 m) P/N 37535
60 ft. (18 m) P/N 37536
100 ft. (30 m) P/N 37537
10 ft. (3 m) P/N 21917
20 ft. (6 m) P/N 21918

Standard Cable

30 ft. (9 m) P/N 21919
60 ft. (18 m) P/N 21920
100 ft. (30 m) P/N 21921
10 ft. (3 m) P/N 56997111
20 ft. (6 m) P/N 56997112
30 ft. (9 m) P/N 56997113
40 ft. (12 m) P/N 0560986745
60 ft. (18 m) P/N 56997114
100 ft. (30 m) P/N 56997115

Precision Plasma with Electronic Flow Control –

2-1

SECTION 2 DESCRIPTION

30 ft. (9.1 m ) P/N 57002248
50 ft. (15.2 m) P/N 57002249

Control Lead – Power Source to Cutting Machine I/O

High Frequency Power Cable – Power Supply to Junction
Box – or- Power Supply to Cutting Machine I/O, depending
on configuration

Torch Coolant (one gallon (3.8 l) containers. four gallons (15 l) 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.

2.4 Precision Plasma Technical Specifications

75 ft. (22.8 m ) P/N 57002250
100 ft. (30.5 m) P/N 57002251
160 ft. (48.8 m) P/N 57002252
3 ft. (.9 m) P/N 57000419
50 ft. (15.2 m) P/N 57000420
75 ft. (22.8 m) P/N 57000421
100 ft. (30.5 m) P/N 57000422
125 ft. (38.1 m) P/N 57000423
150 ft. (45.7 m) P/N 57000424
175 ft. (53.3 m) P/N 57000425
200 ft. (61 m) P/N 57000426

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

2-2

Precision Plasma with Electronic Flow Control –

SECTION 2 DESCRIPTION

A

A

S

S

S

S

Power Supply

CONTROL

CURRENT

RECISION PLASMARC

PILOT

RC

POWER

Junction Box

44"

(1118 mm)

19.75" (502mm)

10.62" (270mm)

42" (1067mm) Weight = 26.5 lbs (12 kg)

22" (559mm)

Weight = 560 lbs. (254 kg)

Electronic Flow Control Box

6.75"

(171mm)

14.5"

(1118mm)

IR

PLASMA GA

NO.1

NITROGEN

AIR

12.25" (311mm)

ARGON

SHIELD GA

NO.2

SHIELD GA

NO.1

PLASMA GA

NITROGEN

NO.2

NITROGEN

OXYGEN

METHANE

OXYGEN

HYDROGEN

AIR

METH

H-35

N2

N2

O2

AIR

O2

N2

12" (305mm)

Weight = 51 lbs. (23 kg)

Precision Plasma with Electronic Flow Control –

2-3

SECTION 2 DESCRIPTION

2.4.2 Plasma Gas Technical Specifications

Type O
Pressure 125 psig (8.6 bars)
Flow 100 cfh (47 l/min) max. (varies with application)

Purity Required*

Recommended Liquid Cylinder Service
Regulators

Recommended Cylinder 2-Stage Regulators

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

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

2.4.3 Start Gas Technical Specifications

, N2, Air

2

-99.995%

O

2

N

-99.995%

2

Air-clean, dry and oil free
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
Oxygen: R-77-150-540 (P/N 998337
Hydrogen/Methane:R-77-150-350 (P/N 998342)
Nitrogen: R-77-150-580 (P/N 998344)
Industrial Air: R-77150=590 (P/N 998348)

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

R-6703 (P/N 22236)

Type N

, Air

2

Pressure 125 psig (8.6 bar)
Flow 60 cfh (28 l/min) max (varies with application)
Minimum Purity Required 99.995%

2.4.4 Secondary Gas Technical Specifications

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

Pressure

100 psig (6.6 bar) H-35, Methane; 125 psig (8.6
bar) N

, O2, Air

2

Flow 60 cfh (28 l/min) max (varies with application)
Minimum Purity Required 99.995%

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 Electronic 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

CAUTION

!

• Gas Supply and Hoses. Gas supply may be from

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

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

connecting workpiece to power source.

• Primary Input Cable.

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

supply side for the EFC to function properly.

• Ventilation is necessary to provide proper cooling

of the power supply.

• Minimize dirt, dust and exposure to external heat

sources.

• Allow a minimum of two feet clearance around the

power supply for free air movement.

Do Not Restrict Air Flow

Restricting intake air with any type of filter on or a

Restricting intake air with any type of filter on or around

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

the power supply may void the warranty.

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

round

round round

Precision Plasma with Electronic Flow Control - 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

!

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 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.

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 Size

Recommended Sizes For Input Conductors And Line Fuses

Recommended SizeRecommended Size

Input requirements

Volts Phase Amps

s For Input Conductors And Line Fuses

s For Input Conductors And Line Fusess For Input Conductors And Line Fuses

Input & ground

conductor,

cu/awg/mm

2

Fuse ratings /

phase, amps

Precision Plasma with Electronic Flow Control - 3-2

SECTION 3 INSTALLATION

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

A. Remove right side panel.

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

1

K1

PHASE 1

PHASE 2

PHASE 3

2

3

4

5

Factory Wired

for 575 Volts

B. Ensure input power cable is disconnected from all

electrical sources.

C. Route input power cable through the strain relief

located at the rear panel.

D. 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.

E. Connect input power cable ground wire to the

ground lug provided on the base of the power
source.

F. Connect three power leads of the input power

cable to the terminals located atop the main
contactor. Secure the leads by tightening each
screw.

G. 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

Input Power Jumper Connection

Input PowerInput Power

Jumper Connection

Jumper Connection Jumper Connection

Ensure each input power jumper cable is connected to

Ensure each input power jumper cable is connected to

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

the correct input voltage on auto transformer.

the correct input voltage on auto transformer.the correct input voltage on auto transformer.

Factory wired for 575 V.

Factory wired for 575 V.

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

H. Connect jumper wire to the proper input voltage

connector located on the 7-position terminal block.
TB2

Precision Plasma with Electronic Flow Control - 3-3

SECTION 3 INSTALLATION

3.5 Interconnecting Lines

1

2

3

4

A. All interconnecting service lines supplied are

numbered or color coded on each end with
corresponding numbers/colors marked on
the cabinets.

5

1 Black hose
2 Red or orange hose
3 Yellow hose
4 Blue hose
5 Mounting plate (Spacer)

Gas Line Bundle

B. Connect all four lines in Gas Line Bundle to

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

Precision Plasma with Electronic Flow Control - 3-4

SECTION 3 INSTALLATION

x

x

Power supply and EFC Connections to J

Power supply and EFC Connections to J----Bo

Power supply and EFC Connections to JPower supply and EFC Connections to J

Box

BoxBo

Power Supply Bundle

1

C. Connect power and coolant lines in Power

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

2

6

5

3

4

1 Power supply negative connection
2 #7 hose connection (from power source)
3 Gas bundle connections
4 Control lead from EFC
5 #6 hose connection (to power source)
6 Pilot arc connection

Precision Plasma with Electronic Flow Control - 3-5

SECTION 3 INSTALLATION

Junction Box to torch connections

Junction Box to torch connections

Junction Box to torch connectionsJunction Box to torch connections

4

1

Torch Hose/Power Cable Connection

2

Torch Solenoid Electrical Connection

3

Torch Pilot Arc Connection

4

Torch Bundle

1

2

3

D. Connect Torch Bundle Leads/Hoses to

Junction box. (see Interconnecting Block
Diagram)

Precision Plasma with Electronic Flow Control - 3-6

SECTION 3 INSTALLATION

Precision Plasmarc Component Interconnecting Diagram

1

2

3

4

ASIOB

5

10

14

1 25 micron gas filters
2 electronic flow control box (EFC)
3 Control lead EFC to junction box
4 machine computer control (CNC)
5 High frequency 120 volts AC
6 Gas line bundle
7 High frequency 120 volts AC
8 Power bundle

9 Precision Plasmarc junction box
10 PT-24 torch
11 Cutting table
12 Work lead (negative)
13 Primary power cable
14 Ground rod
15 Control lead – power supply to CNC

9

11

N2O

7

6

2

AirCH

4

Ar

8

12

13

15

Precision Plasma with Electronic Flow Control - 3-7

SECTION 3 INSTALLATION

Gas Line Contamination Will Damage

CAUTION

!

Proportional Valves

Purge Gas Lines

Before connecting gas delivery lines to the

Before connecting gas delivery lines to the

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

Electronic Flow Control, purge all lines thoroughly.

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

Residue from the hose manufacturing process may

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

clog/damage the proportional valves in your EFC.

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

1/4 NPT

E. Purge gas lines between supply and the

EFC before connecting. Proportional valves
in the EFC are very sensitive to dust and
other foreign particles.

F. Connect Gas Delivery lines to Electronic

Flow Control. Install 25 micron Gas filters in
all delivery lines between gas source and
EFC.

Gas filter

25 micron filters

N

O

2

2

AirCH

4

Ar

Precision Plasma with Electronic Flow Control - 3-8

SECTION 3 INSTALLATION

Pilot Arc

Work

Torch

Remove access cover

Pilot Arc

G. Remove panel from rear of console and attach

the pilot-arc, torch and work lead.

Work

Torch

1

2

3

4

8

7

5
6

1 Power cable from wall
2 600 amp Bus fuse
3 CNC Control Lead
4 Flow Control Lead
5 Coolant IN from torch (#6 connection)
6 Coolant OUT to torch (#7 connection)
7 Serial Tag
8 Rating Label

Control Lead

H. Connect control lead between the console and

the Electronic Flow Control. Connect coolant
lines of the Power Bundle.

Precision Plasma with Electronic Flow Control - 3-9

SECTION 3 INSTALLATION

3.6 Torch Mounting

1.812" (46mm)

1.812" (46mm)

1.812" (46mm)1.812" (46mm)
diameter collar

diameter collar

diameter collardiameter collar

CAUTION

2.0" (51mm)

2.0" (51mm)

2.0" (51mm)2.0" (51mm)

diameter sleeve

diameter sleeve

diameter sleevediameter sleeve

Vent Hole

Do Not Cover Vent Hole.

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

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

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

the side of the sleeve. This hole allows coolant to

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

drain from inside the sleeve should a leak occur in a

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

service line.

service line.service line.

Torch Mounting Options.

Torch Mounting Options.

Torch Mounting Options.Torch Mounting Options.

• The torch is normally mounted by the 2.0 inch

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

• For custom alternative mounting, the torch can be

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

• Use only specified mounting surfaces

Precision Plasma with Electronic Flow Control - 3-10

SECTION 3 INSTALLATION

3.7 Torch Coolant

T

O
L
I
P

C

R

L
O
R

T

N
O
C

T
N
E

R
R
U

C

RECISION PLASMARC

A

R
E

W

O

P

• 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).

• Do not fill above maximum level

• Reinstall Cap.

Coolant Fill cap

Commercial Antifreeze Will Cause Torch To

CAUTION

!

Malfunction

Use Special Torch Coolant! P/N156F05

Due to high electrical conductivity, DO NOT use tap

Due to high electrical conductivity, DO NOT use tap

Due to high electrical conductivity, DO NOT use tap Due to high electrical conductivity, DO NOT use tap
water or commercial

3.8 Inspection of Gas and Coolant Lines

water or commercial antifreeze for torch cooling. A

water or commercialwater or commercial
specially formulated torch coolant is REQUIRED. This

specially formulated torch coolant is REQUIRED. This

specially formulated torch coolant is REQUIRED. This specially formulated torch coolant is REQUIRED. This
coolant also protects for freezing to

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

coolant also protects for freezing to coolant also protects for freezing to
Operating the unit without coolant will cause

Operating the unit without coolant will cause

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

permanent damage to the coolant pump.

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

antifreeze for torch cooling. A

antifreeze for torch cooling. A antifreeze for torch cooling. A

34° C.

34° C.34° C.

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

Precision Plasma with Electronic Flow Control - 3-11

SECTION 3 INSTALLATION

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

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

CAUTION

!

CAUTION

!

CAUTION

!

Using the Wrong EPROM Could Result In
Damaged System Components

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

Mishandling Can Damage Electronic
Components.

Handle electronic components with care.

• Do not drop

• Do not bend pins

• Do not touch circuit components- handle

along edges when possible

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

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

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

Wear a protective ground strap when handling
sensitive electronic components.

WARNING

!

Precision Plasma with Electronic Flow Control - 3-12

Electric shock Can Kill!

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

SECTION 3 INSTALLATION

L

O
R

T

N

C

O

N

T

E

R

R

U
C

S

I

C

E

R

Left Side Panel

T
O
L

I

P

C
R

A

R

E
W
O

P

C

R

A

M

S

A

L

P

N

O

I

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

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

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

PLC

EFC EPROM package location

Precision Plasma with Electronic Flow Control - 3-13

SECTION 3 INSTALLATION

Using An EPROM Puller Tool May Damage

CAUTION

Socket

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

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

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

5. Remove the EFC EPROM from the packaging.

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

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

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

EPPESA= Series “A” EPROM, manual flow control

EPROM locked in place

P/N 99513607

EPPSEFC= EFC EPROM, electronic flow control
P/N 99513608

EPROM Lock Released

Precision Plasma with Electronic Flow Control - 3-14

SECTION 4 OPERATION

LOW

4.1 Power Supply Controls

4.1.1 Main Power Switch

DO NOT SWITCH
WHILE CUTTING

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

EMERGENCY

STOP

CAUTION

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

POWER

ON

Adjusting Pilot Arc While in Operation Could
Damage Torch.

Do not adjust pilot arc switch while in operation.

Adjust before torch starts.

Precision Plasma with Electronic Flow Control -

4-1

SECTION 4 OPERATION

4.1.3 Fault Indicator Lights

4.1.4 Meters

Fault Indicator Lights

• Coolant flow will show low coolant flow. When

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

• Plasma Gas Pressure fault indicator -- low

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

• Start Gas Pressure fault indicator -- low start gas

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

used for the EFC.

used for the EFC.used for the EFC.

• P/S Temp fault indicator -- over temperature in the

inverter power source. Power source will shut
down.

• 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.

Not used for the EFC.

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

Not

Not Not

• Cutting Current Meter (A) -- Displays actual

cutting current in amperes.

• Cutting Voltage Meter (V) -- Displays actual

cutting voltage.

4-2

Precision Plasma with Electronic 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

• Output Current Dial – sets the cutting current

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

• Remote Position – output current is set by the

CNC (or remote pot) with an analog dc signal

0-10 Vdc = 0-100 Adc

Precision Plasma with Electronic 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 Electronic Flow Control -

SECTION 4 OPERATION

4.2.2 Cut Angle

Negative Cut Angle

Part

Top dimension is greater than the bottom.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• Standoff low (arc voltage)

• Cutting speed slow (machine travel rate)

Drop Part

Part

Drop 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

recommended current level for specific nozzles).

Precision Plasma with Electronic Flow Control -

4-5

SECTION 4 OPERATION

4.2.3 Cut Flatness

Drop

Part

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).

Top Edge Undercut

• Standoff low (Arc Voltage)

Drop

4-6

Part

Precision Plasma with Electronic 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

Machine Induced

or

Process Induced

Roughness

Roughness

• Worn or damaged consumables

MMMMachine 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 owners
manual).

• Carriage wheel adjustment

Precision Plasma with Electronic Flow Control -

4-7

SECTION 4 OPERATION

4.2.5 Dross

Lag Lines

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

Cut Face

High Speed Dross

Material weld or rollover on bottom surface along kerf.

Roll over

Difficult to remove. May require grinding or chipping.
“S” shaped lag lines.

• Standoff high (arc voltage)

• Cutting speed fast

Side view

Lag Lines Cut Face

Globules

Side View

Slow Speed Dross

Forms as globules on bottom along kerf. Removes
easily.

• Cutting speed slow

4-8

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Side View

Splatter

Cut Face

Top Dross

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

• Cutting speed fast

• Standoff high (arc voltage).

Intermittent Dross

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

• Possible worn consumables

Other Factors Affecting Dross;

• Material temperature

• Heavy mill scale or rust

• High carbon alloys

Precision Plasma with Electronic 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 Electronic 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

4.3.2 Aluminum

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

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

• Smooth cut face

• Virtually no dross

Shield Gas:

Shield Gas: Nitrogen/Methane

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

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

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

Precision Plasma with Electronic 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:

Material Thickness:

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Oxygen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Oxygen/Nitrogen

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

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

• Smooth cut face

• Virtually no dross

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

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

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Oxygen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

• Smooth cut face

• Virtually no dross

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

4-12

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Refer to Cutting Process Data in the PT24

NOTICE

4.3.4 Stainless Steel

Material Thickness:

Material Thickness:

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen/Methane

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

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

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

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

• Positive cut angle

• Excellent dross performance

• Shiny cut surface.

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

• Dark cut face

• Virtually dross free

• Improved cut squareness

Manual for recommended flow/pressure
settings.

Plasma Gas:

Plasma Gas: Oxygen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Oxygen/Nitrogen

Shield Gas:Shield Gas:

Low amperage cutting/slower speeds produce squarer cuts in thin

Discussion:

Discussion:

Discussion:Discussion:

Material Thickness:

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

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Air

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Air

Shield Gas:Shield Gas:

Discussion:

Discussion:

Discussion:Discussion:

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

• Cut edge dark

• good dross performance

• Good cut angle

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 Electronic Flow Control -

4-13

SECTION 4 OPERATION

NOTICE

Stainless Steel

Material Thickness:

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

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

Plasma Gas:

Plasma Gas: Air

Plasma Gas:Plasma Gas:

Material Thickness:

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

Material Thickness:Material Thickness:

Cut Qualities:

Cut Qualities:

Cut Qualities:Cut Qualities:

• Matted cut edge appearance

• Light gray color

• Much smoother finish

• Possible slight increase in cut angle

Shield Gas:

Shield Gas: Air/Methane

Shield Gas:Shield Gas:

Too much methane in the shield gas mixture can result in more dross

Discussion:

Discussion:

Discussion:Discussion:

formation. 4:1 ratio air to methane is recommended. Because methane
is a fuel gas, possible slight increase in cut angles could be experienced.

• Dark cut face similar to air

• Excellent dross performance

• Good cut angle

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

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen

Shield Gas:Shield Gas:

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

Discussion:

Discussion:

Discussion:Discussion:

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

Material Thickness:

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

Material Thickness:Material Thickness:

• Shiny cut face

Cut Qual

Cut Qualities:

Cut QualCut Qual

ities:

ities:ities:

• Lip formation at the bottom

• Dross formation can be extensive and difficult to remove

Plasma Gas:

Plasma Gas: Nitrogen

Plasma Gas:Plasma Gas:

Shield Gas:

Shield Gas: Nitrogen/Methane

Shield Gas:Shield Gas:

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

Discussion:

Discussion:

Discussion:Discussion:

flow/pressure results in a positive cut angle. Nitrogen to methane ratio is
10 to 14 parts N

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

2

severe, making Nitrogen/Methane shield gas combination unsuitable for
some finished part applications.

4-14

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

4.4 Process Data

4.4.1 Introduction

4.4.1 Introduction

4.4.1 Introduction4.4.1 Introduction

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

• cutting aluminum, carbon and stainless steel

• arc voltage (standoff)

• cutting speed

• current (amperes)

• gas flow rates for all plasma/shield gas

combinations

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

Also included is information on consumable part

numbers for current being used.

Precision Plasma with Electronic Flow Control -

4-15

SECTION 4 OPERATION

)

)

)

4.4.2 Process Data

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
30

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86

P/N 86W62

P/N 86P/N 86
OOOO----Ring

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle



P/N

P/N 21536 (3 holes

P/N P/N



 Nozzle



P/N

P/N 21541, "B"

P/N P/N
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insul

Insulator Shield Retainer

InsulInsul
w/O

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

w/Ow/O

W62

W62W62

Ring

RingRing

Ring

RingRing

Swirl Baffle

Swirl Baffle Swirl Baffle

21536 (3 holes)

21536 (3 holes

21536 (3 holes

Nozzle

Nozzle Nozzle

21541, "B"

21541, "B"21541, "B"

ator Shield Retainer

ator Shield Retainer ator Shield Retainer

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-16

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.062 0.075 0.090 0.125 0.187 0.250

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45 45 45

SG1- Cut 20 20 20 20 20 20

30 Amperes

Aluminum

PG

PG SG1

PGPG

N

0 0 0 0 0 0

40 40 40 40 40 40

55 55 55 55 55 55

2

SG1 SG2

SG1SG1

N

SG2

SG2SG2

CH

2

4

SG2- Cut Flow 10 10 10 10 10 10

Flow Reading

Arc Voltage (standoff)

150 152 153 158 170 189

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

150 135 105 78 30 25

3810 3429 2667 1981 762 635

Precision Plasma with Electronic Flow Control -

4-17

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
55

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-18

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w

Cup shield w/Retainer

Cup shield wCup shield w
P/N 22531

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

/Retainer

/Retainer/Retainer

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

55 Amperes

Aluminum Aluminum

PG

PG

SG1

PGPG

Material Thickness

IN 0.062 0.125 0.187 0.250

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

Pierce Delay (SEC.)

N

0 0 0 0

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

CH

2

4

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 55 55 55 55

SG1- Cut 20 20 20 20

45 45 45 45

75 75 75 85

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

136 139 152 168

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

170 130 78 46

4318 3302 1981 1168

Precision Plasma with Electronic Flow Control -

4-19

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
70

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N

P/N 638797

638797

P/NP/N

638797 638797

OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insu

Shield Cup Insulator

Shield Cup InsuShield Cup Insu
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

lator

latorlator

4-20

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45

SG1- Cut 20 20 20 20

70 Amperes

Aluminum

PG

PG

SG1

PGPG

N

0 0 0.1 0.2

65 65 65 65

100 100 100 100

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

CH

2

4

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

150 157 168 178

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 65 55 30

2032 1651 1397 762

Precision Plasma with Electronic Flow Control -

4-21

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
100

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N

P/N 21539

21539

P/N P/N

2153921539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-22

OOOO----Ring

Ring -

- Shie

Shield Retainer .

--

Shie Shie

ld Retainer .

ld Retainer . ld Retainer .

Ring Ring

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 31 31 31 31

100 Amperes

Aluminum

PG

PG

SG1

PGPG

N

0 0 0.1 0.1

80 80 80 80

100 100 100 100

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

CH

2

4

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

155 160 166 174

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

65 80 65 50

2413 2032 1778 1270

Precision Plasma with Electronic Flow Control -

4-23

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
16

Oxygen (O2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21852 (2 holes

21852 (2 holes)

21852 (2 holes

21852 (2 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21540, "A"

21540, "A"

P/N P/N

21540, "A"21540, "A"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-24

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield

Cup shield w/Retainer

Cup shield Cup shield
P/N 22531

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

w/Retainer

w/Retainerw/Retainer

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

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

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 20 20 20 20 20 20

SG1- Cut 0 0 0 0 0 0

16 Amperes

Carbon Steel

PG

PG

SG1

PGPG

O

0 0 0 0.1 0.5 0.5

20 20 20 20 20 20

11 11 11 11 11 11

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

O

2

SG2- Cut Flow 6 6 6 6 6 7

Flow Reading

Arc Voltage (standoff)

103 105 115 118 116 117

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

100 85 80 60 50 36

2540 2159 2032 1524 1270 914

Precision Plasma with Electronic Flow Control -

4-25

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
35

Oxygen (O2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 8

P/N 86W62

6W62

P/N 8P/N 8

6W626W62

OOOO----Ring

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21536 (3 holes

21536 (3 holes)

21536 (3 holes

21536 (3 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21541, "B"

21541, "B"

P/N P/N

21541, "B"21541, "B"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insul

Insulator Shield Retainer

ator Shield Retainer

InsulInsul

ator Shield Retainer ator Shield Retainer

w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-26

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 14GA 0.125 0.135 0.187 0.250

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 50 50 50 50 50

SG1- Cut 0 0 0 0 0

35 Amperes

Carbon Steel

PG

PG

SG1

PGPG

O

0 0 0 0 0

38 38 38 38 38

15 15 15 15 15

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

O

2

SG2- Cut Flow 6 6 6 6 6

Flow Reading

Arc Voltage (standoff)

113 119 120 122 124

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 55 52 40 30

3032 1397 1320 1016 762

Precision Plasma with Electronic Flow Control -

4-27

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
45

Oxygen (O2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-28

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528

(Ref. P/N 996528))))

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.135 0.187 0.250 0.375

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 50 50 50 50 50

SG1- Cut 18 18 18 18 10

45 Amperes

Carbon Steel

PG

PG

SG1

PGPG

O

0.3 0.3 0.3 0.3 0.4

50 50 50 50 50

20 20 20 20 20

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

O

2

SG2- Cut Flow 0 0 0 0 0

Flow Reading

Arc Voltage (standoff)

108 111 114 121 124

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

60 50 45 35 20

1524 1270 1143 889 508

Precision Plasma with Electronic Flow Control -

4-29

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
70

Oxygen (O2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Rin

Ringggg

RinRin

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cu

Shield Cup Insulator

Shield CuShield Cu
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

w/Ow/O

p Insulator

p Insulatorp Insulator

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-30

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.312 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60 60 60

SG1- Cut 33 33 33 33 20 20

70 Amperes

Carbon Steel

PG

PG

SG1

PGPG

O

0.3 0.3 0.3 0.4 0.5 0.5

60 60 60 60 60 60

25 25 25 25 25 25

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

O

2

SG2- Cut Flow 0 0 0 0 0 0

Flow Reading

Arc Voltage (standoff)

108 110 114 113 135 140

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

110 95 70 60 30 25

2794 2413 1778 1524 762 635

Precision Plasma with Electronic Flow Control -

4-31

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
100

Oxygen (O2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Oxygen (O2) @ 125 psi (8.6 bar)

TTTTorch Body

orch Body

orch Bodyorch Body

P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-32

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.312 0.375 0.500 0.625 0.750

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60 60

SG1- Cut 30 30 30 30 30

100 Amperes

Carbon Steel

PG

PG

SG1

PGPG

O

0.3 0.3 0.4 0.5 0.5

80 80 80 80 80

30 30 30 30 30

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

O

2

SG2- Cut Flow 0 0 0 0 0

Flow Reading

Arc Voltage (standoff)

115 120 132 137 143

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

90 80 50 30 25

2290 2030 1270 760 630

Precision Plasma with Electronic Flow Control -

4-33

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
30

Oxygen (O2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21536 (3 holes

21536 (3 holes)

21536 (3 holes

21536 (3 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21541, "B"

21541, "B"

P/N P/N

21541, "B"21541, "B"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-34

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N

(Ref. P/N 996528)

(Ref. P/N (Ref. P/N

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

996528)

996528)996528)

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 26GA 24GA 22GA 18GA 16GA

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 40 40 40 40 40

SG1- Cut 20 20 20 20 20

30 Amperes

Stainless Steel

PG

PG

SG1

PGPG

O

0 0 0 0 0

45 45 45 45 45

18 18 18 18 18

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

O

2

SG2- Cut Flow 5 5 5 5 5

Flow Reading

Arc Voltage (standoff)

105 105 107 109 111

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

250 200 190 140 100

6350 5080 4826 3556 2540

Precision Plasma with Electronic Flow Control -

4-35

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
50

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21542, "C"

21542, "C"

P/N P/N

21542, "C"21542, "C"

Nozzle Ret

Nozzle Retainer/Diffuser

Nozzle RetNozzle Ret
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

w/Ow/O

ainer/Diffuser

ainer/Diffuserainer/Diffuser

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-36

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.375

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45

SG1- Cut 35 35 35 35

50 Amperes

Stainless Steel

PG

PG

SG1

PGPG

Air Air Air

0 0 0.1 0.2

60 60 60 60

95 95 95 95

SG1SG1

SG1 SG2

SG2

SG2SG2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

134 140 145 157

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

90 60 40 22

2286 1524 1016 559

Precision Plasma with Electronic Flow Control -

4-37

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
PPPP/N 21539

/N 21539

/N 21539/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-38

OOOO----Ring

Ring -

Shield Retainer .

Shield Retainer .

Ring Ring

---

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 40 40 40 40

70 Amperes

Stainless Steel

PG

PG

SG1

PGPG

Air Air Air

0.3 0.4 0.5 0.6

70 70 70 70

95 95 95 95

SG1SG1

SG1 SG2

SG2

SG2SG2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

131 152 158 162

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

100 50 28 24

2540 1270 711 609

Precision Plasma with Electronic Flow Control -

4-39

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Air @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

P/N P/N
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

w/Ow/O

21923, "E"

21923, "E"21923, "E"

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-40

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 35 35 35 40

100 Amperes

Stainless Steel

PG

PG SG1

SG1 SG2

PGPG

SG1SG1

Air Air Air

0.3 0.4 0.5 0.6

80 80 80 80

65 65 65 70

SG2

SG2SG2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

129 135 142 150

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 60 35 25

2030 1520 889 635

Precision Plasma with Electronic Flow Control -

4-41

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Ret

Nozzle Retainer/Diffuser

Nozzle RetNozzle Ret
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

w/Ow/O

ainer/Diffuser

ainer/Diffuserainer/Diffuser

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-42

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.387 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60 60

SG1- Cut 40 40 40 40 40

70 Amperes

Stainless Steel

PG

PG

SG1

PGPG

Air Air CH

0.2 0.3 0.4 0.5 0.6

70 70 70 70 70

100 100 100 100 100

SG1SG1

SG1 SG2

SG2

SG2SG2

4

SG2- Cut Flow 10 10 10 10 10

Flow Reading

Arc Voltage (standoff)

131 146 154 166 175

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

120 80 50 30 24

3048 2032 1270 762 609

Precision Plasma with Electronic Flow Control -

4-43

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Air @ 125 psi (8.6 bar)

Air @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950

P/N 950714

P/N 950P/N 950
OOOO----Ring

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

P/N P/N
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
wwww/O

/O----Ring P/N 21712

/O/O

714

714714

Ring

RingRing

21692 (4 holes)

21692 (4 holes

21692 (4 holes

21923, "E"

21923, "E"21923, "E"

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-44

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 40 40 40 40

100 Amperes

Stainless Steel

PG

PG

SG1

PGPG

Air Air CH

0.3 0.4 0.5 0.6

80 80 80 80

100 100 100 100

SG1SG1

SG1 SG2

SG2

SG2SG2

4

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

140 150 159 170

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 60 35 25

2030 1524 889 635

Precision Plasma with Electronic Flow Control -

4-45

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
50

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Ba

Swirl Baffle

Swirl Ba Swirl Ba



P/N

P/N 21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21542, "C"

P/N P/N
Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

w/Ow/O

ffle

ffle ffle

21692 (4 holes)

21692 (4 holes

21692 (4 holes

21542, "C"

21542, "C"21542, "C"

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-46

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Re

(Ref. P/N 996528)

f. P/N 996528)

(Re(Re

f. P/N 996528)f. P/N 996528)

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.375

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45

SG1- Cut 35 35 35 35

50 Amperes

Stainless Steel

PG

PG

SG1

PGPG

N

0 0 0.1 0.2

60 60 60 60

85 85 85 85

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

128 133 144 155

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

90 60 40 22

2286 1524 1016 558

Precision Plasma with Electronic Flow Control -

4-47

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-48

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

Cup shield w/RetainerCup shield w/Retainer
P/N 2

P/N 22531

2531

P/N 2P/N 2

25312531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 40 40 40 40

70 Amperes

Stainless Steel

PG

PG

SG1

PGPG

N

0.3 0.4 0.5 0.6

70 70 70 70

95 95 95 95

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

132 150 154 159

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

75 50 28 24

1905 1270 711 609

Precision Plasma with Electronic Flow Control -

4-49

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-50

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 50 35 35 35

100 Amperes

Stainless Steel

PG

PG

SG1

PGPG

N

0.3 0.4 0.5 0.6

80 80 80 80

95 95 95 95

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

135 145 153 157

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 60 35 25

2032 1520 889 635

Precision Plasma with Electronic Flow Control -

4-51

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



 Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



 Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21543, "D"

21543, "D"

P/N P/N

21543, "D"21543, "D"

Nozzle Retain

Nozzle Retainer/Diffuser

Nozzle RetainNozzle Retain
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

er/Diffuser

er/Diffuserer/Diffuser

4-52

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 43 43 43 43

70 Amperes

Stainless Steel

PG

PG

SG1

PGPG

N

0.3 0.4 0.5 0.6

75 75 75 75

85 85 85 85

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

CH

2

4

SG2- Cut Flow 5 5 5 5

Flow Reading

Arc Voltage (standoff)

136 150 159 162

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

70 50 28 24

1778 1270 711 609

Precision Plasma with Electronic Flow Control -

4-53

SECTION 4 OPERATION

)

)

)

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Nitrogen (N2) @ 125 psi (8.6 bar)

Nitrogen (N2) @ 125 psi (8.6 bar)

Methane (CH4) @ 100 psi (6.9 bar)

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes

21692 (4 holes)

21692 (4 holes

21692 (4 holes

P/N P/N



Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator S

Insulator Shield Retainer

Insulator SInsulator S
w/O

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

w/Ow/O

hield Retainer

hield Retainer hield Retainer

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4-54

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 45 45 45 45

100 Amperes

Stainless Steel

PG

PG

SG1

PGPG

N

0.3 0.4 0.5 0.6

80 80 80 80

95 95 95 95

SG1SG1

2

N

SG1 SG2

SG2

SG2SG2

CH

2

4

SG2- Cut Flow 5 5 5 7

Flow Reading

Arc Voltage (standoff)

138 150 162 170

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 60 35 25

2032 1524 889 635

Precision Plasma with Electronic Flow Control -

4-55

SECTION 4 OPERATION

(

)

)

Plasma Marking “B” Nozzle

PT-24 Torch

Amperes:

10

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

WWWWater Baffle

ater Baffle

ater Baffleater Baffle

P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N 21536 (3 Holes)

P/N 21536 (3 Holes)

P/N 21536 (3 Holes

P/N 21536



Nozzle

Nozzle

Nozzle Nozzle



P/N 21541 “B”

P/N 21541 “B”

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

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N

P/N 22007

22007

P/NP/N

22007 22007

Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

3 Holes

4-56

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 35

SG1- Cut 35

SG2- Cut Flow 0

“B” Nozzle

10 Amperes

35

35

Arc Voltage (standoff)

77

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

200

5080

Precision Plasma with Electronic Flow Control -

4-57

SECTION 4 OPERATION

Plasma Marking “B” Nozzle

PT-24 Torch

Amperes:

15

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N 21536 3 holes

P/N 21536 3 holes

P/N 21536 3 holesP/N 21536 3 holes



Noz

Nozzle

zle

NozNoz

zle zle



P/N 21541 “B”

P/N 21541 “B”

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

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4-58

Precision Plasma with Electronic Flow Control -

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 35

SG1- Cut 35

SG2- Cut Flow 0

“B” Nozzle

15 Amperes

35

35

Arc Voltage (standoff)

77

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

300

7620

Precision Plasma with Electronic Flow Control -

4-59

SECTION 4 OPERATION

(

)

)

Plasma Marking “C” Nozzle

PT-24 Torch

Amperes:

10

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 2

P/N 21539

1539

P/N 2P/N 2

15391539



Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692



Nozzle

Nozzle

Nozzle Nozzle



P/N 21542 “C”

P/N 21542 “C”

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

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4 holes

4-60

OOOO----Ring

Ring -

- Shield Retainer

Shield Retainer .

Ring Ring

--

Shield Retainer Shield Retainer

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

.

. .

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 37

SG1- Cut 37

SG2- Cut Flow 0

“C” Nozzle

10 Amperes

62

62

Arc Voltage (standoff)

77

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

100

2540

Precision Plasma with Electronic Flow Control -

4-61

SECTION 4 OPERATION

(

)

)

Plasma Marking “C” Nozzle

PT-24 Torch

Amperes:

15

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86

P/N 86W62

P/N 86P/N 86
OOOO----Ring

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



Swirl Baffle



P/N

P/N 21692 (4 holes)

P/N P/N



Nozzle



P/N 21542 “C”

P/N 21542 “C”

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

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shie

Insulator Shield Retainer

Insulator ShieInsulator Shie
w/O

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

w/Ow/O

W62

W62W62

Ring

RingRing

Ring

RingRing

Swirl Baffle

Swirl Baffle Swirl Baffle

21692 (4 holes)

21692 (4 holes

21692

Nozzle

Nozzle Nozzle

Ring P/N 21712

Ring P/N 21712Ring P/N 21712

4 holes

ld Retainer

ld Retainer ld Retainer

4-62

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 35

SG1- Cut 35

SG2- Cut Flow 0

“C” Nozzle

15 Amperes

62

62

Arc Voltage (standoff)

77

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

200

5080

Precision Plasma with Electronic Flow Control -

4-63

SECTION 4 OPERATION

(

)

)

Plasma Marking “D” Nozzle

PT-24 Torch

Amperes:

10

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692



Nozzle

Nozzle

Nozzle Nozzle



P/N 21543 “D”

P/N 21543 “D”

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

Nozzle Retainer/Diffuser

Nozzle Retainer/DifNozzle Retainer/Dif
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4 holes

fuser

fuserfuser

4-64

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

P/N 22531P/N 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1

Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 100

SG1- Cut 100

SG2- Cut Flow 0

“D” Nozzle

10 Amperes

77

77

Arc Voltage (standoff)

77

Travel Speed

IPM

MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

100

2540

Precision Plasma with Electronic Flow Control -

4-65

SECTION 4 OPERATION

(

)

)

Plasma Marking “D” Nozzle

PT-24 Torch

Amperes:

15

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body

Torch Body

Torch BodyTorch Body
P/N 21758

P/N 21758

P/N 21758P/N 21758

Water Baffle

Water Baffle

Water BaffleWater Baffle
P/N 21725

P/N 21725

P/N 21725P/N 21725
OOOO----Ring

Ring

RingRing

P/N 638797

P/N 638797

P/N 638797P/N 638797
OOOO----Ring

Ring

RingRing

P/N 86W62

P/N 86W62

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

Ring

RingRing

P/N 950714

P/N 950714

P/N 950714P/N 950714
OOOO----Ring

Ring

RingRing

P/N 98W18

P/N 98W18

P/N 98W18P/N 98W18
Electrode

Electrode

ElectrodeElectrode
P/N 21539

P/N 21539

P/N 21539P/N 21539



Swirl Baffle

Swirl Baffle

Swirl Baffle Swirl Baffle



P/N

P/N 21692 (4 holes)

21692 (4 holes)

21692 (4 holes

P/N P/N

21692



Nozzle

Nozzle

Nozzle Nozzle



P/N

P/N 21923, "E"

21923, "E"

P/N P/N

21923, "E"21923, "E"

Nozzle Retainer/Diffuser

Nozzle Retainer/Diffuser

Nozzle Retainer/DiffuserNozzle Retainer/Diffuser
P/N 22007

P/N 22007

P/N 22007P/N 22007
Shield Cup Insulator

Shield Cup Insulator

Shield Cup InsulatorShield Cup Insulator
P/N 22010

P/N 22010

P/N 22010P/N 22010
Insulator Shield Retainer

Insulator Shield Retainer

Insulator Shield Retainer Insulator Shield Retainer
w/O

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

Ring P/N 21712

w/Ow/O

Ring P/N 21712Ring P/N 21712

4 holes

4-66

OOOO----Ring

Ring -

- Shield Retainer .

Shield Retainer .

Ring Ring

--

Shield Retainer . Shield Retainer .

(Ref. P/N 996528)

(Ref. P/N 996528)

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

Cup shield w/Retainer

Cup shield w/Retainer

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

P/N 22531

22531

P/N P/N

22531 22531



 Baffle and Nozzle are



the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -