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
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
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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 -
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