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

F-15-480-D
October, 2000
Installation, Operation and Maintenance Manual for the
PRECISION PLASMARC SYSTEM
with Electronic Flow Control
CUTTING SYSTEMS
411 s. Ebenezer Road Florence, SC 29501-0545
Purchaser is solely responsible for the safe operation and use of all products purchased, including compliance with OSHA and other government standards. ESAB Cutting Systems has no liability for personal injury or other damage arising out of the use of any product manufactured or sold be ESAB. See standard ESAB terms and conditions of sale for a specific statement of ESAB’s responsibilities and limitations on its liability.
Every effort was made to ensure the accuracy and completeness of this manual. Information in this document is subject to change without notice.
This manual is ESAB Part Number F15480
This manual is ESAB Part Number F15480
This manual is ESAB Part Number F15480This manual is ESAB Part Number F15480
This manual is for the convenience and use of the cutting machine purchaser. It is not a contract or other obligation on the part of ESAB Cutting Systems.
©©©© ESAB Cutting Systems, 2000
Printed in U.S.A.
Precision Plasma Electronic Flow Control Table of Contents
Page
Section 1 Safety
1.1 Introduction 1
1.2 Safety Notations And Symbols 1
1.3 General Safety Information 2
1.4 Installation Precautions 3
1.5 Electrical Grounding 4
1.6 Operating A Plasma Cutting Machine 4
1.7 Service Precautions 8
1.8 Safety References 9
Section 2 Description
2.1 General 1
2.2 Scope 1
2.3 Package Options Available 1
2.4 Technical Specifications
2.4.1 Precision Plasma System 2
2.4.2 Plasma Gas 3
2.4.3 Start Gas 3
2.4.4 Secondary Gas 3
2.4.5 PT-24 Torch 3
Section 3 Installation
3.1 General 1
3.2 Equipment Required 1
3.3 Location 1
3.4 Primary Electrical Input Connect ion s 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 o f EPROM in the Plasmarc P o w er Source Programmable Logic Controller (PLC)
i
12
Precision Plasma Electronic Flow Control Table of Contents
Section 4 Operation
4.1 Power Supply Controls
4.1.1 Main Power Switch 1
4.1.2 Pilot Arc Switch 1
4.1.3 Fault Indicator Lights 2
4.1.4 Meters 2
4.1.5 Current Control Switch 2
4.2 Cut Quality
4.2.1 Introduction 3
4.2.2 Cut Angle 3
4.2.3 Cut Flatness 4
4.2.4 Surface Finish 5
4.2.5 Dross 6
4.2.6 Dimensional Accuracy 8
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction 9
4.3.2 Aluminum 9
4.3.3 Carbon Steel 10
4.3.4 Stainless Steel 11
4.4 Process Data
4.4.1 Introduction 13
4.4.2 Process Data Settings 14 Plasma Marking Data 54
4.4.3 Relationship of Kerf Width to Amperes and Material Thickness 76
4.4.3.1 Aluminum Kerf Values 76
4.4.3.2 Carbon Steel Kerf Values 78
4.4.3.3 Stainless Steel Kerf Values O2/N2/O
2
4.4.3.4 Stainless Steel Kerf Values Air/Air/CH
4.4.3.5 Stainless Steel Kerf Values N2/N2/CH
4
4
81 82 83
4.4.3.6 Stainless Steel Kerf Values N2/N
2
84
4.4.3.7 Stainless Steel Kerf Values Air/Air 86
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-O Carbon Steel PG-O2, SG-N2/O Carbon Steel PG-O2, Sg-O Stainless Steel PG-N2, SG-N
2
2
2
2
Stainless Steel PG-N2, SG-N2/CH
4
28 30 32 34
36 Stainless Steel PG-Air, SG-Air 38 Stainless Steel PG-Air, SG-Air/CH Aluminum PG-N2, SG- N Aluminum PG-N2, SG-N2/CH
2
4
4
40
42
44 Marking PG-Argon, SG-Air 46
Section 7 Replacement Parts
7.1 General 1
7.2 Ordering 2
7.3 Plasmarc Power Source – Exterior Components 3
7.4 Plasmarc Power Source – Internal Components 8
7.5 Power Source Module 18
7.6 EFC Junction Box 26
7.7 Electronic Flow Control Box 32
7.8 PT-24 Torch Assembly EFC Series A/M 36
7.9 T Gas Shut-off Valve Assembly - Series A/M Torch 38
7.10 PT-24 Torch Assembly – Version 1 40
7.11 Solenoid Assembly - EFC Torch – Version 1 42
Customer/Technical Information Back Manual Cover
iv
SECTION 1 SAFETY
1.1 Introduction
The process of cutting metals with plasma equipment provides industry with a valuable and versatile tool. ESAB cutting machines are designed to provide both operation safety and efficiency. However, as with any machine tool, sensible attention to operating procedures, precautions, and safe practices is necessary to achieve a full measure of usefulness. Whether an individual is involved with operation, servicing, or as an observer, compliance with established precautions and safe practices must be accomplished. Failure to observe certain precautions could result in serious personnel injury or severe equipment damage. The following precautions are general guidelines applicable when working with cutting machines. More explicit precautions pertaining to the basic machine and accessories are found in the instruction literature. For a wide scope of safety information on the field of cutting and welding apparatus, obtain and read the publications listed in the Recommended References.
1.2 Safety Notations And Symbols
!
DANGER
!
WARNING
!
CAUTION
!
CAUTION
The following words and symbols are used throughout this manual. They indicate different levels of required safety involvement.
ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used in concurrence with other symbols and information.
Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury or loss of life.
Used to call attention to potential hazards that could result in personal injury or loss of life.
Used to call attention to hazards that could result in minor personal injury or equipment damage.
Used to call attention to minor hazards to equipment.
NOTICE
Used to call attention to important installation, operation or maintenance information not directly related to safety hazards.
1-1
SECTION 1 SAFETY
1.3 General Safety Information
Machine starts automatically.
WARNING
!
This equipment moves in various directions and
This equipment moves in various directions and
This equipment moves in various directions andThis equipment moves in various directions and speeds.
speeds.
speeds.speeds.
Moving machinery can crus h .
Moving machinery can crus h .
Moving machinery can crus h .Moving machinery can crus h .
Only qualified personnel should operate or service
Only qualified personnel should operate or service
Only qualified personnel should operate or serviceOnly qualified personnel should operate or service equipment.
equipment.
equipment.equipment.
Keep all personnel, materials , an d equ ipment not
Keep all personnel, materials , an d equ ipment not
Keep all personnel, materials , an d equ ipment notKeep all personnel, materials , an d equ ipment not involved in production process clear of entire
involved in production process clear of entire
involved in production process clear of entireinvolved in production process clear of entire system area.
system area.
system area.system area.
Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris or
Keep gear racks and rails clear of debris orKeep gear racks and rails clear of debris or obstructions, such as tools or clothing.
obstructions, such as tools or clothing.
obstructions, such as tools or clothing.obstructions, such as tools or clothing.
Fence off entire work cell to prevent personn el
Fence off entire work cell to prevent personn el
Fence off entire work cell to prevent personn elFence off entire work cell to prevent personn el from passing through area or standing in the
from passing through area or standing in the
from passing through area or standing in thefrom passing through area or standing in the working envelope of the equipment.
working envelope of the equipment.
working envelope of the equipment.working envelope of the equipment.
WARNING
!
Post appropriate WARNING signs at every work
Post appropriate WARNING signs at every work
Post appropriate WARNING signs at every workPost appropriate WARNING signs at every work cell entrance.
cell entrance.
cell entrance.cell entrance.
Follow lockout procedure before servicing.
Follow lockout procedure before servicing.
Follow lockout procedure before servicing.Follow lockout procedure before servicing.
Failure to follow operating instructions could result in death or serious injury.
Read and understand this operator’s manual before
Read and understand this operator’s manual before
Read and understand this operator’s manual beforeRead and understand this operator’s manual before using machine.
using machine.
using machine.using machine.
Read entire procedure before operating or
Read entire procedure before operating or
Read entire procedure before operating orRead entire procedure before operating or performing any system maintenance.
performing any system maintenance.
performing any system maintenance.performing any system maintenance.
Special attention must be given to all hazard
Special attention must be given to all hazard
Special attention must be given to all hazardSpecial attention must be given to all hazard warnings that provide essential information
warnings that provide essential information
warnings that provide essential informationwarnings that provide essential information regarding personnel safety and/or possible
regarding personnel safety and/or possible
regarding personnel safety and/or possibleregarding personnel safety and/or possible equipment damage.
equipment damage.
equipment damage.equipment damage.
All safety precautions relevant to electrical
All safety precautions relevant to electrical
All safety precautions relevant to electricalAll safety precautions relevant to electrical equipment and process operations must be
equipment and process operations must be
equipment and process operations must beequipment and process operations must be strictly observed by all having system
strictly observed by all having system
strictly observed by all having systemstrictly observed by all having system responsibility or access.
responsibility or access.
responsibility or access.responsibility or access.
Read all safety publications made available by
Read all safety publications made available by
Read all safety publications made available byRead all safety publications made available by your company.
your company.
your company.your company.
1-2
SECTION 1 SAFETY
Failure to follow safety warning label
WARNING
!
1.4 Installation Precautions
instructions could result in death or serious injury.
Read and understand all safety warning labels on
Read and understand all safety warning labels on
Read and understand all safety warning labels onRead and understand all safety warning labels on machine.
machine.
machine.machine. Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safety
Refer to operator’s manual for additional safetyRefer to operator’s manual for additional safety information.
information.
information.information.
WARNING
!
Improperly installed equipment can cause injury or death.
Follow these guidelines while installing machine:
Follow these guidelines while installing machine:
Follow these guidelines while installing machine:Follow these guidelines while installing machine: Do not connect a cylinder directly to mach in e inlet. An
Do not connect a cylinder directly to mach in e inlet. An
Do not connect a cylinder directly to mach in e inlet. AnDo not connect a cylinder directly to mach in e inlet. An appropriate cylinder regulator must be installed on a
appropriate cylinder regulator must be installed on a
appropriate cylinder regulator must be installed on aappropriate cylinder regulator must be installed on a fuel gas cylinder to reduce pressure to a reasonable
fuel gas cylinder to reduce pressure to a reasonable
fuel gas cylinder to reduce pressure to a reasonablefuel gas cylinder to reduce pressure to a reasonable inlet supply pressure. Machine regulator is then used
inlet supply pressure. Machine regulator is then used
inlet supply pressure. Machine regulator is then usedinlet supply pressure. Machine regulator is then used to obtain pressure required by torches.
to obtain pressure required by torches.
to obtain pressure required by torches.to obtain pressure required by torches. Contact your ESAB representative before installation.
Contact your ESAB representative before installation.
Contact your ESAB representative before installation.Contact your ESAB representative before installation. He can suggest certain precautions regarding piping
He can suggest certain precautions regarding piping
He can suggest certain precautions regarding pipingHe can suggest certain precautions regarding piping installation and machine lifting, etc. to ensure
installation and machine lifting, etc. to ensure
installation and machine lifting, etc. to ensureinstallation and machine lifting, etc. to ensure maximum security.
maximum security.
maximum security.maximum security. Never attempt any machine modifications or apparatus
Never attempt any machine modifications or apparatus
Never attempt any machine modifications or apparatusNever attempt any machine modifications or apparatus additions without first consulting a qualified ESAB
additions without first consulting a qualified ESAB
additions without first consulting a qualified ESABadditions without first consulting a qualified ESAB representative.
representative.
representative.representative. Observe machine clearance requ irements for proper
Observe machine clearance requ irements for proper
Observe machine clearance requ irements for properObserve machine clearance requirements for proper operation and personnel safety.
operation and personnel safety.
operation and personnel safety.operation and personnel safety.
1-3
SECTION 1 SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper machine operation and SAFETY. Refer to this manual’s Installation section for detailed grounding instructions.
Electric shock hazard.
WARNING
!
Improper grounding can cause severe injury or deat h.
Improper grounding can cause severe injury or deat h.
Improper grounding can cause severe injury or deat h.Improper grounding can ca use seve re injury or de a t h. Machine must be properly grounded before put into
Machine must be properly grounded before put into
Machine must be properly grounded before put intoMachine must be properly grounded before put into service.
service.
service.service.
Improper grounding can damage machine
WARNING
!
and electrical components.
Machine must be properly grounded before put
Machine must be properly grounded before put
Machine must be properly grounded before putMachine must be properly grounded before put into service.
into service.
into service.into service.
1.6 Operating A Plasma Cutting Machine
WARNING
!
WARNING
!
Cutting table must be properly grounded to
Cutting table must be properly grounded to a good
Cutting table must be properly grounded toCutting table must be properly grounded to Earth ground rod.
Earth ground rod.
Earth ground rod.Earth ground rod.
a good
a gooda good
Flying debris and loud noise hazards.
Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. Wear
Hot spatter can burn and injure eyes. WearHot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying
goggles to protect eyes from burns and flying
goggles to protect eyes from burns and flyinggoggles to protect eyes from burns and flying debris generated during operation.
debris generated during operation.
debris generated during operation.debris generated during operation.
Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. Bystanders
Chipped slag may be hot and fly far. BystandersChipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses.
should also wear goggles and safety glasses.
should also wear goggles and safety glasses.should also wear goggles and safety glasses.
From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. Wear
From plasma arc can damage hearing. WearFrom plasma arc can damage hearing. Wear correct ear protection when cutting above water.
correct ear protection when cutting above water.
correct ear protection when cutting above water.correct ear protection when cutting above water.
Burn hazard.
Hot metal can burn.
Hot metal can burn.
Hot metal can burn.Hot metal can burn.
Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately after
Do not touch metal plate or parts immediately afterDo not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with
cutting. Allow metal time to cool, or douse with
cutting. Allow metal time to cool, or douse withcutting. Allow metal time to cool, or douse with water.
water.
water.water.
Do not touch plasma torch immediately after
Do not touch plasma torch immediately after
Do not touch plasma torch immediately afterDo not touch plasma torch immediately after cutting. Allow torch time to cool.
cutting. Allow torch time to cool.
cutting. Allow torch time to cool.cutting. Allow torch time to cool.
1-4
SECTION 1 SAFETY
WARNING
!
Hazardous voltages. Electric shock can kill.
Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cable
Do NOT touch plasma torch, cutting table or cableDo NOT touch plasma torch, cutting table or cable connections during plasma cutting process.
connections during plasma cutting process.
connections during plasma cutting process.connections during plasma cutting process.
Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies before touching or servicing plasma torch.
before touching or servicing plasma torch.
before touching or servicing plasma torch.before touching or servicing plasma torch.
Always turn power off to plasma power supplies
Always turn power off to plasma power supplies
Always turn power off to plasma power suppliesAlways turn power off to plasma power supplies before opening or servicing plasma plumbing or
before opening or servicing plasma plumbing or
before opening or servicing plasma plumbing orbefore opening or servicing plasma plumbing or flow control box.
flow control box.
flow control box.flow control box.
Do not touch live electrical parts.
Do not touch live electrical parts.
Do not touch live electrical parts.Do not touch live electrical parts.
Keep all panels and covers in place when machine
Keep all panels and covers in place when machine
Keep all panels and covers in place when machineKeep all panels and covers in place when machine is connected to power source.
is connected to power source.
is connected to power source.is connected to power source.
Insulate yourself from
Insulate yourself from workpiece and electrical
Insulate yourself from Insulate yourself from ground: wear insulating gloves, shoes and
ground: wear insulating gloves, shoes and
ground: wear insulating gloves, shoes andground: wear insulating gloves, shoes and clothing.
clothing.
clothing.clothing.
Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, and
Keep gloves, shoes, clothing, work area, andKeep gloves, shoes, clothing, work area, and equipment dry.
equipment dry.
equipment dry.equipment dry.
workpiece and electrical
workpiece and electricalworkpiece and electrical
WARNING
!
WARNING
!
Pinch hazard.
Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.
Moving vertical slides can crush or pinch.Moving vertical slides can crush or pinch. Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.
Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.
Fume hazard.
Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cutting
Fumes and gases generated by the plasma cuttingFumes and gases generated by the plasma cutting process can be hazardous to your health.
process can be hazardous to your health.
process can be hazardous to your health.process can be hazardous to your health.
Do NOT breathe fumes.
Do NOT breathe fumes.
Do NOT breathe fumes.Do NOT breathe fumes.
Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removal
Do not operate plasma torch without fume removalDo not operate plasma torch without fume removal system operating properly.
system operating properly.
system operating properly.system operating properly.
Use additional ventilation to remove fumes if
Use additional ventilation to remove fumes if
Use additional ventilation to remove fumes ifUse additional ventilation to remove fumes if necessary.
necessary.
necessary.necessary.
Use approved respirator if ventilation is not
Use approved respirator if ventilation is not
Use approved respirator if ventilation is notUse approved respirator if ventilation is not adequate.
adequate.
adequate.adequate.
1-5
SECTION 1 SAFETY
WARNING
!
Radiation hazard.
Arc rays can injure eyes and burn
Arc rays can injure eyes and burn skin.
Arc rays can injure eyes and burn Arc rays can injure eyes and burn
Wear correct eye and body protection .
Wear correct eye and body protection .
Wear correct eye and body protection .Wear correct eye and body protection.
Wear dark safety glasses or goggles with
Wear dark safety glasses or goggles with side
Wear dark safety glasses or goggles with Wear dark safety glasses or goggles with shields. Refer to following chart for recommended
shields. Refer to following chart for recommended
shields. Refer to following chart for recommendedshields. Refer to following chart for recommended lens shades for plasma cutting:
lens shades for plasma cutting:
lens shades for plasma cutting:lens shades for plasma cutting:
Arc Current
Arc Current Le
Arc CurrentArc Current Up to 100 Amps
Up to 100 Amps Shade No. 8
Up to 100 AmpsUp to 100 Amps 100-200 Amps
100-200 AmpsShade No. 10
100-200 Amps100-200 Amps 200-400 Amps
200-400 AmpsShade No. 12
200-400 Amps200-400 Amps Over 400 Amps
Over 400 Amps Shade No. 14
Over 400 AmpsOver 400 Amps
Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted or
Replace glasses/goggles when lenses are pitted orReplace glasses/goggles when lenses are pitted or broken
broken
brokenbroken
Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arc
Warn others in area not to look directly at the arcWarn others in area not to look directly at the arc unless wearing appropriate safety glasses.
unless wearing appropriate safety glasses.
unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.
Prepare cutting area to reduce reflection and
Prepare cutting area to reduce reflection and
Prepare cutting area to reduce reflection andPrepare cutting area to reduce reflection and transmission of ultraviolet light.
transmission of ultraviolet light.
transmission of ultraviolet light.transmission of ultraviolet light.
Paint walls and other surfaces with dark colors to
Paint walls and other surfaces with dark colors to
Paint walls and other surfaces with dark colors toPaint walls and other surfaces with dark colors to reduce reflections.
reduce reflections.
reduce reflections.reduce reflections.
Lens Shade
Le Le Shade No. 10
Shade No. 10Shade No. 10 Shade No. 12
Shade No. 12Shade No. 12
skin.
skin.skin.
ns Shade
ns Shadens Shade
Shade No. 8
Shade No. 8Shade No. 8
Shade No. 14
Shade No. 14Shade No. 14
side
sideside
WARNING
!
Install protective screens or curtains to reduce
Install protective screens or curtains to reduce
Install protective screens or curtains to reduceInstall protective screens or curtains to reduce ultraviolet transmission.
ultraviolet transmission.
ultraviolet transmission.ultraviolet transmission.
Ruptured Gas Cylinders Can Kill
Mishandling gas cylinders can ruptu re an d viol en tly
Mishandling gas cylinders can ruptu re an d viol en tly
Mishandling gas cylinders can ruptu re an d viol en tlyMishandling gas cylinders can rupture and violently release gas.
release gas.
release gas.release gas.
Avoid rough handling of cylinders.
Avoid rough handling of cylinders.
Avoid rough handling of cylinders.Avoid rough handling of cylinders.
Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.
Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.
Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.
Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.
Always secure cylinders in an upright position by
Always secure cylinders in an upright position by
Always secure cylinders in an upright position byAlways secure cylinders in an upright position by chain or strap to a suitable stable object not part of
chain or strap to a suitable stable object not part of
chain or strap to a suitable stable object not part ofchain or strap to a suitable stable object not part of an electrical circuit.
an electrical circuit.
an electrical circuit.an electrical circuit.
Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks and
Locate cylinders away from heat, sparks andLocate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.
flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.
Refer to CGA Standard P-1, “Precautions for Safe
Refer to CGA Standard P-1, “Precautions for Safe
Refer to CGA Standard P-1, “Precautions for SafeRefer to CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”,
Handling of Compressed Gases in Cylinders”,
Handling of Compressed Gases in Cylinders”,Handling of Compressed Gases in Cylinders”, available from Compressed Gas Association.
available from Compressed Gas Association.
available from Compressed Gas Association.available from Compressed Gas Association.
1-6
SECTION 1 SAFETY
WARNING
!
Spark hazard.
Heat, spatter, and sparks cause fire and burns.
Heat, spatter, and sparks cause fire and burns.
Heat, spatter, and sparks cause fire and burns.Heat, spatter, and sparks cause fire and burns.
Do not cut near combustible material.
Do not cut near combustible material.
Do not cut near combustible material.Do not cut near combustible material.
Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.
Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.
Do not have on your person any combustibles (e.g.
Do not have on your person any combustibles (e.g.
Do not have on your person any combustibles (e.g.Do not have on your person any combustibles (e.g. butane lighter).
butane lighter).
butane lighter).butane lighter).
Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzle
Pilot arc can cause burns. Keep torch nozzlePilot arc can cause burns. Keep torch nozzle away from yourself and others when activating
away from yourself and others when activating
away from yourself and others when activatingaway from yourself and others when activating plasma process.
plasma process.
plasma process.plasma process.
Wear correct eye and body protection .
Wear correct eye and body protection .
Wear correct eye and body protection .Wear correct eye and body protection.
Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.
Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.
Wear flame-retardant clothing that covers all
Wear flame-retardant clothing that covers all
Wear flame-retardant clothing that covers allWear flame-retardant clothing that covers all exposed areas.
exposed areas.
exposed areas.exposed areas.
Wear
Wear cuffless trousers to prevent entry of sparks
cuffless trousers to prevent entry of sparks
Wear Wear
cuffless trousers to prevent entry of sparkscuffless trousers to prevent entry of sparks
and slag.
and slag.
and slag.and slag.
CAUTION
POOR PERFORMANCE WILL RESULT WHEN CUTTING ABOVE WATER.
The PT-24 is designed to be a dry cutting process.
Cutting above water may result in:
Cutting above water may result in:
Cutting above water may result in:Cutting above water may result in:
reduced consumable life
reduced consumable life
reduced consumable lifereduced consumable life
degradation of cut quality
degradation of cut quality
degradation of cut qualitydegradation of cut quality
Cutting above water may result in poor cutting
Cutting above water may result in poor cutting
Cutting above water may result in poor cuttingCutting above water may result in poor cutting performance. Water vapor created when hot material
performance. Water vapor created when hot material
performance. Water vapor created when hot materialperformance. Water vapor created when hot material or sparks contact liquid may cause arcing inside torch.
or sparks contact liquid may cause arcing inside torch.
or sparks contact liquid may cause arcing inside torch.or sparks contact liquid may cause arcing inside torch. When cutting on a water table, reduce the water level
When cutting on a water table, reduce the water level
When cutting on a water table, reduce the water levelWhen cutting on a water table, reduce the water level to provide maximum clearance between water and
to provide maximum clearance between water and
to provide maximum clearance between water andto provide maximum clearance between water and material.
material.
material.material.
1-7
SECTION 1 SAFETY
WARNING
!
1.7 Service Precautions
Explosion hazard.
Certain molten aluminum-lithium (Al-
Certain molten aluminum-lithium (Al-Li) alloys can
Certain molten aluminum-lithium (Al-Certain molten aluminum-lithium (Al­cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water.
cause explosions when plasma cut OVER water.cause explosions when plasma cut OVER water.
Do not plasma cut the following Al-
Do not plasma cut the following Al-Li alloys with
Do not plasma cut the following Al-Do not plasma cut the following Al­water:
water:
water:water: Alithlite (Alcoa)
Alithlite (Alcoa) X8192 (Alcoa)
Alithlite (Alcoa)Alithlite (Alcoa) Alithally (Alcoa)
Alithally (Alcoa) Navalite (US Navy)
Alithally (Alcoa)Alithally (Alcoa) 2090 Alloy (Alcoa)
2090 Alloy (Alcoa) Lockalite (Lockheed)
2090 Alloy (Alcoa)2090 Alloy (Alcoa) X8090A (Alcoa)
X8090A (Alcoa) Kalite (Kaiser)
X8090A (Alcoa)X8090A (Alcoa) X8092 (Alcoa)
X8092 (Alcoa) 8091 (
X8092 (Alcoa)X8092 (Alcoa)
These alloys should only be dry cut on a dry table.
These alloys should only be dry cut on a dry table.
These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.
DO NOT d ry cut ove r water.
DO NOT d ry cut ove r water.
DO NOT d ry cut ove r water.DO NOT d ry cut ove r water.
Contact your aluminum supplier for additional
Contact your aluminum supplier for additional
Contact your aluminum supplier for additionalContact your aluminum supplier for additional safety information regarding hazards associated
safety information regarding hazards associated
safety information regarding hazards associatedsafety information regarding hazards associated with these alloys
with these alloys
with these alloyswith these alloys
X8192 (Alcoa)
X8192 (Alcoa)X8192 (Alcoa) Navalite (US Na vy)
Navalite (US Na vy)Navalite (US Navy) Lockalite (Lo ckheed)
Lockalite (Lo ckheed)Lockalite (Lo ckheed) Kalite (Kaiser)
Kalite (Kaiser)Kalite (Kaiser) 8091 (Alcan)
8091 (8091 (
.
Li) alloys can
Li) alloys canLi) alloys can
Li alloys with
Li alloys withLi alloys with
Alcan)
Alcan)Alcan)
CAUTION
CAUTION
!
Establish and adhere to preventive maintenance. A
Establish and adhere to preventive maintenance. A
Establish and adhere to preventive maintenance. AEstablish and adhere to preventive maintenance. A composite program can be established from
composite program can be established from
composite program can be established fromcomposite program can be established from recommended schedules in the instruction literature.
recommended schedules in the instruction literature.
recommended schedules in the instruction literature.recommended schedules in the instruction literature. Avoid leaving test equipment or hand tools on
Avoid leaving test equipment or hand tools on
Avoid leaving test equipment or hand tools onAvoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damage
machine. Severe electrical or mechanical damagemachine. Severe electrical or mechanical damage could occur to equipment or machine.
could occur to equipment or machine.
could occur to equipment or machine.could occur to equipment or machine.
Extreme caution should b e us ed when probing
Extreme caution should b e us ed when probing
Extreme caution should b e us ed when probingExtreme caution should b e us ed when probing circuitry with an oscilloscope or voltmeter. Integrated
circuitry with an oscilloscope or voltmeter. Integrated
circuitry with an oscilloscope or voltmeter. Integratedcircuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage.
circuits are susceptible to over voltage damage.circuits are susceptible to over voltage damage. Power off before using test probes to prevent
Power off before using test probes to prevent
Power off before using test probes to preventPower off before using test probes to prevent accidental shorting of components.
accidental shorting of components.
accidental shorting of components.accidental shorting of components. All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cables
All circuit boards securely seated in sockets, all cablesAll circuit boards securely seated in sockets, all cables properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, all
properly connected, all cabinets closed and locked, allproperly connected, all cabinets closed and locked, all guards and covers replaced before power is turned
guards and covers replaced before power is turned
guards and covers replaced before power is turnedguards and covers replaced before powe r is turned on.
on.
on.on. Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board while
Never plug or unplug a printed circuit board whileNever plug or unplug a printed circuit board while machine power is on. Instantaneous surges of voltage
machine power is on. Instantaneous surges of voltage
machine power is on. Instantaneous surges of voltagemachine power is on. Instantaneous surges of voltage and current can damage electron ic components.
and current can damage electron ic components.
and current can damage electron ic components.and current can damage electronic compon en t s .
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, Am erican Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
“Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
“Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
“Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
“Safe Practices” - AWS SP, American Welding Society.
“Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60 Batterymarch Street, Boston, Massachusetts, 02110.
“Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire Protection Association.
“Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting Systems. Obtainable through your ESAB representative or local distributor.
"Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
“Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with gaseous materials is also available from the Compressed Gas Association, Inc., 500 Fifth Ave., New York, NY 10036.
1-9
SECTION 1 SAFETY
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1-10
SECTION 2 DESCRIPTION
2.1 General
2.2 Scope
The Precision Plasmarc System consists of four separate components. The power source, the junction box, the flow control box, and the PT-24 torch. The power source provides power and coolant to the PT-24 torch via the junction box.
The purpose of this manual is to provide the operator with all the information required to install and operate the Precision Plasmarc System. Technical reference material is also provided to assist in troubleshooting the cutting package.
2.3 Package Options Available
Precision Plasmarc package options available through your ESAB dealer
Precision Plasmarc Power Source (
Hz (required)
Electronic Flow Control Box (required) P/N 22406 Junction Box (required) P/N 22407
Power Bundle (one required)
Gas Line Bundle (one required)
Control Lead Flow Console to Junction Box (one required)
Torch Coolant (one gallon (3.8 l) containers. four gallons (15 l) required) P/N 156F05
NOTES:
200/230/380/415/460/575) 3-phase 50/60
4.5 ft. (1.4 m) P/N 0558001463 12 ft. (4.4 m) P/N 0558001877PT-24 Torch Electronic Flow Series A/M (one required) 17 ft. (5.2 m) P/N 0558001464 12 ft. (3.6 m) P/N 22428 25 ft. (7.6 m) P/N 21905 40 ft. (12.2 m) P/N 22504 60 ft. (18 m) P/N 21906 80 ft. (24.4 m) P/N 22505 100 ft. (30 m) P/N 21907 10 ft. (3 m) P/N 37533 20 ft. (6 m) P/N 37534 30 ft. (9 m) P/N 37535 60 ft. (18 m) P/N 37536 100 ft. (30 m) P/N 37537 10 ft. (3 m) P/N 21917 20 ft. (6 m) P/N 21918 30 ft. (9 m) P/N 21919 60 ft. (18 m) P/N 21920 100 ft. (30 m) P/N 21921
P/N 37357
Control lead from the power source to customer CNC is supplied based on customer order.
Gas supply, hoses, work lead and input primary cable are all supplied by the customer.
See Process Data Sheets for a list of torch consumabl e par ts.
2-1
SECTION 2 DESCRIPTION
2.4 Precision Plasma Technical Specifications
2.4.1 System
Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz Input Current 65/60/50/40/30/25 amps per phase Power Factor 0.95 Output Current Range 15-100 amps dc Output Load Voltage 120 V dc Duty Cycle 100% Open Circuit Voltage 315 V dc
JUNCTION BOX
JUNCTION BOX
JUNCTION BOXJUNCTION BOX
42" (1067mm)
WEIGHT = 560 lbs. (254 kg)
WEIGHT = 560 lbs. (254 kg)
WEIGHT = 560 lbs. (254 kg)WEIGHT = 560 lb s. (254 kg)
POWER SUPPLY
POWER SUPPLY
POWER SUPPLYPOWER SUPPLY
L
O
R
T
N
O
C
T
N
E
R
R
U
C
L
P
N
O
I
S
I
C
E
R
22" (559mm)
6.75" (171mm)
T
O
L
I
P
C
R
A
R
E
W
O
P
19.75" (502mm)
C
R
A
M
S
A
WEIGHT = 26.5 lbs.(12 kg)
WEIGHT = 26.5 lbs.(12 kg)
WEIGHT = 26.5 lbs.(12 kg)WEIGHT = 26.5 lbs.(12 kg)
10.62" (270mm)
44" (1118mm)
ELECTRONIC FLOW CONTROL BOX
ELECTRONIC FLOW CONTROL BOX
ELECTRONIC FLOW CONTROL BOX ELECTRONIC FLOW CONTROL BOX
14.5" (1118mm)
H
T
E
M
5
-
3
H
2
N
2
N
2
O
I
2
R
A
O
2
N
R
I
12.25" (311mm)
A
G
A
M
S
A
L
P
.
2
S
A
O
G
N
A
M
S
A
L
P
N
.
1
E G
Y
O
X
N
O
N
E G
O
R T
I N
R
I A
N
O
G R
A
S
A
G
D
L
E
I
H
S
.
2
S
O
A
N
G
D
L
E
I
H
S
.
1
N
E
S
O
G
O
A
N
R
T I
N
N
E G
O
R T
I N
E N A
T
H
E
M
N
E G
Y
X O
N
E G O
R
D Y
H
R
I
A
12" (305mm)
2-2
WEIGHT = 51 lbs. (23 kg)
WEIGHT = 51 lbs. (23 kg)
WEIGHT = 51 lbs. (23 kg)WEIGHT = 51 lbs. (23 kg)
SECTION 2 DESCRIPTION
2.4.2 Plasma Gas Technical Specifications
Type O2, N2, Air Pressure 125 psig (8.6 bars)
Flow
Purity Required* Recommended Liquid Cylinder Service
Regulators
Recommended Cylinder 2-Stage Regulators
Recommended Heavy –Duty Hi-flow Station or Pipeline Regulators Recommended High-capacity Station or Pipeline Regulators
100 cfh (47 l/min) max. (varies with application)
-99.995%
O
2
-99.995%
N
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)
Gas Filter Required 25 micron w/bowl guard (P/N 56998133)
2.4.3 Start Gas Technical Specifications
Type N2, Air Pressure 125 psig (8.6 bar)
Flow Minimum Purity Required 99.995%
2.4.4 Secondary Gas Technical Specifications
Type N2, O2, H-35, Methane, Air
Pressure
Flow Minimum Purity Required 99.995%
2.4.5 Pt-24 Torch Technical Specifications
60 cfh (28 l/min) max (varies with application)
100 psig (6.6 bar) H-35, Methane; 125 psig (8.6 bar) N O
, Air
2
,
2
60 cfh (28 l/min) max (varies with application)
Type Water-Cooled, Dual Gas Rating 100 amps @ 100 % duty cycle Dimensions See Package Options (2.3)
2-3
SECTION 2 DESCRIPTION
Page intentionally left blank.
2-4
SECTION 3 INSTALLATION
3.1 General
Proper installation can contribute materially to the
NOTICE
satisfactory and trouble-free operation of the Precision Plasmarc System. It is suggested that each step in this section be studied and carefully followed.
3.2 Equipment Required
3.3 Location
Gas Supply and Hoses. Gas supply may be from
a bulk source or from a bank of manifold cylinders and regulated to supply 125 psig (8.6 bar) to the Flow Control (gas flowing).
Work Lead. No. 4 AWG cable is recommended for
connecting workpiece to power source.
Primary Input Cable.
25 micron gas filters (or better) are required on the
supply side for the EFC to function properly.
Ventilation is necessary to provide proper cooling
of the power supply.
Minimize dirt, dust and exposure to external heat
sources.
Allow a minimum of two feet clearance around the
power supply for free air movement.
CAUTION
!
Do Not Restrict Air Flow
Restricting intake air with any type of filter on or around
Restricting intake air with any type of filter on or around
Restricting intake air with any type of filter on or aroundRestricting intake air with any type of filter on or around the power supply may void the warranty.
the power supply may void the warranty.
the power supply may void the warranty.the power supply may void the warranty.
3-1
SECTION 3 INSTALLATION
3.4 Primary Electrical Input Connections
Electric Shock Can Kill!
DANGER
!
Provide maximum protection against electrical shock.
Before any connections are made inside the machine, open the line (wall) disconnect switch and unplug the power cord.
Input Power Configuration
WARNING
!
Machine must be properly configured for your input power.
The machine is shipped from the factory configured for 575 V, 60 Hz input.
Do NOT connect a power source of any other voltage unless machine is reconfigured. Damage to the machine will occur.
Input Power Connection At Wall
A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel.
Connect the input power cable of the power source directly to the disconnect switch or a proper plug and receptacle may be purchased from a local electrical supplier. (S ee table on the next page for recommended input conductors and fuses )
Recommended Sizes For Input Conductors And Line Fuses
Recommended Sizes For Input Conductors And Line Fuses
Recommended Sizes For Input Conductors And Line FusesRecommended Sizes For Input Conductors And Line Fuses
Input requirements
Volts Phase Amps
208 3 70 No. 4 25 100 230 3 60 No. 6 16 80 380 3 50 No. 8 10 80 415 3 40 No. 10 6 60 460 3 30 No. 10 6 50 575 3 25 No. 10 6 40
Input & ground
conductor,
cu/awg/mm
2
Fuse ratings /
phase, amps
3-2
SECTION 3 INSTALLATION
The following procedure explains the proper installation steps for connecting primary electrical power to the power source.
1. Remove right si de panel.
2. Ensure input power cable is disconnected from all electrical sources.
3. Route input power cable through the strain relief located at the rear panel.
Ground Connection
TB2
200 230 380 415 460 575
PHASE 1
200 230 380 415 460 575
TB1
200 230 380
415 460 575
200 230 380 415 460 575
PHASE 2
PHASE 3
K1
Input Power Cable (Customer supplied)
Main Contactor
7 Position Terminal Block
Auto Transformer
Factory Wired for 575 volts
4. Pull input power cable through the strain relief to allow cable wires sufficient length to connect to the main contactor. Tighten strain relief to ensure input power cable is secured.
5. Connect input power cable ground wire to the ground lug provided on the base of the power source.
6. Connect three power leads of the input power cable to the terminals located atop the main contactor. Secure the leads by tightening each screw.
7. Connect jumper power cables from the bottom of the main contactor to the proper input voltage marked on the auto transformer. The unit is factory set for 575 V as shown to the left.
CAUTION
!
Input Power Jumper Connection
Input Power Jumper Connection
Input Power Jumper ConnectionInput Power Jumper Connection
Ensure each input power jumper cable is connected to
Ensure each input power jumper cable is connected to
Ensure each input power jumper cable is connected toEnsure each input power jumper cable is connected to the correct input voltage on
the correct input voltage on auto transformer.
the correct input voltage on the correct input voltage on Factory wired for 575 V.
Factory wired for 575 V.
Factory wired for 575 V.Factory wired for 575 V.
8. Connect jumper wire to the proper input voltage
auto transformer.
auto transformer.auto transformer.
connector located on the 7-position terminal block. TB2
3-3
SECTION 3 INSTALLATION
3.5 Interconnecting Lines
Black Red/Orange Yellow Blue
Mounting Plate
Gas Line Bundle
Gas Bundle Installation
1. All interconnecting service lines supplied are numbered or color coded on each end with corresponding numbers/colors marked on the cabinets.
2. Connect all four lines in Gas Line Bundle to Flow Control Box and Junction Box. Lines and connections are color coded. In addition, mounting plate hole spacing is asymmetrical to prevent improper connection. Order of colors should be: blue, yellow, red/orange, black
3-4
SECTION 3 INSTALLATION
x
x
x
x
Power supply and EFC Connections to J-Bo
Power supply and EFC Connections to J-Bo
Power supply and EFC Connections to J-Bo
Power supply and EFC Connections to J-Bo
Power Supply Bundle
Power Supply Negative Connection
Pilot Arc Connection
#6 Hose Connection (to power source)
#7 Hose Connection (from power source)
Gas Bundle Connections
Control Lead Connection from EFC
3. Connect power and coolant lines in Power Supply Bundle from power source to junction box. Power bundle consists of #6 and # 7 coolant lines (with 5/8-18 L.H. fittings), power cable (#3 AWG) and yellow pilot arc cable (#16 AWG). Both coolant lines are stamped with a 6 or 7 on the fitting to assist in identification.
3-5
SECTION 3 INSTALLATION
Junction Box to Torch Connections
Junction Box to Torch Connections
Junction Box to Torch ConnectionsJunction Box to Torch Connections
4. Connect Torch Bundle Leads/Hoses to Junction box. (see Interconnecting Block Diagram)
Torch Bundle
Torch Hose/Power Cable Connection
Torch Solenoid Electrical Connection
Torch Pilot Arc Connection
3-6
SECTION 3 INSTALLATION
Precision Plasmarc Component Interconnecting Diagram
25 micron Filters
EFC
Control Lead
EFC/Junction
Box
N
CNC
ASIOB
High
Frequency
120VAC
High Frequency 120VAC
Gas Line Bundle
O
2
2
AirCH
4
Ar
Ground Rod
Torch
Cutting Table
Junction
Power Bundle
Box
Work Lead
Control Lead
Power Supply to CNC
Primary Power Cable
3-7
SECTION 3 INSTALLATION
r
r
Gas Line Contamination Will Damage
CAUTION
!
1/4 NPT
Proportional Valves
Purge Gas Lines
Before connecting gas delivery lines to the
Before connecting gas delivery lines to the
Before connecting gas delivery lines to theBefore connecting gas delivery lines to the Electronic Flow Control, purge all lines thoroughly.
Electronic Flow Control, purge all lines thoroughly.
Electronic Flow Control, purge all lines thoroughly.Electronic Flow Control, purge all lines thoroughly. Residue from the hose manufacturing process may
Residue from the hose manufacturing process may
Residue from the hose manufacturing process mayResidue from the hose manuf acturing process may clog/damage the proportional valves in your EFC.
clog/damage the proportional valves in your EFC.
clog/damage the proportional valves in your EFC.clog/damage the proportional valves in your EFC.
5. Purge gas lines between supply and the EFC before connecting. Proportional valves in the EFC are very sensitive to dust and other foreign particles.
25 micron Gas Filte
25 micron Gas Filter
25 micron Gas Filter25 micron Gas Filte
25µ Filters
N
O
2
6. Connect Gas Delivery lines to Electronic Flow Control. Install 25 micron Gas filters in all delivery lines between gas source and EFC.
2
AirCH
4
Ar
3-8
SECTION 3 INSTALLATION
Power Source
Rating
Label
Pilot Arc
Work
Torch
600 amp
Bus Fuse
Remove Access Cover
Pilot Arc
Work
Torch
CNC Control Lead
Flow Control
Lead
7. Remove panel from rear of console and attach the pilot-arc, torch and work lead.
Serial
Tag
8. Connect control lead between the console and the Electronic Flow Control. Connect coolant lines of the Power Bundle.
Coolant In from Torch # 6 Connection
Coolant Out to Torch
CONTROL LEAD
3-9
SECTION 3 INSTALLATION
3.6 Torch Mounting
CAUTION
1.812" (46mm) Diameter Collar
" (51mm)
2.0 Diameter Sleeve
Vent Hole
Do Not Cover Vent Hole.
When mounting, do not to cover the small vent hole in
When mounting, do not to cover the small vent hole in
When mounting, do not to cover the small vent hole inWhen mounting, do not to cover the small vent hole in the side of the sleeve. This hole allows coolant to
the side of the sleeve. This hole allows coolant to
the side of the sleeve. This hole allows coolant tothe side of the sleeve. This hole allows coolant to drain from inside the sleeve should a leak occur in a
drain from inside the sleeve should a leak occur in a
drain from inside the sleeve should a leak occur in adrain from inside the sleeve should a leak occur in a service line.
service line.
service line.service line.
Torch Mounting Options.
Torch Mounting Options.
Torch Mounting Options.Torch Mounting Options.
The torch is normally mounted by the 2.0 inch diameter (51mm) sleeve. Do not cover vent hole.
For custom alternative mounting, the torch can be mounted by the 1.812" (46 mm) dia collar shown. This insulated collar and its shoulder are machined relative to the nozzle retainer thread on the torch body.
Use only specified mounting surfaces
3-10
SECTION 3 INSTALLATION
3.7 Torch Coolant
T
O L I P
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L O R
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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).
Coolant Fill Cap
CAUTION
!
Do not fill above maximum level
Reinstall Cap.
Commercial Antifreeze Will Cause Torch To Malfunction
Use Special Torch Coolant! P/N156F05
Due to high electrical conductivity, DO NOT use tap
Due to high electrical conductivity, DO NOT use tap
Due to high electrical conductivity, DO NOT use tapDue to high electrical conductivity, DO NOT use tap water or commercial antifreeze for torch cooling. A
water or commercial antifreeze for torch cooling. A
water or commercial antifreeze for torch cooling. Awater or commercial antifreeze for torch cooling. A specially formulated torch coolant is REQUIRED. This
specially formulated torch coolant is REQUIRED. This
specially formulated torch coolant is REQUIRED. Thisspecially formulated torch coolant is REQUIRED. This coolant also protects for freezing to –34° C.
coolant also protects for freezing to –34° C.
coolant also protects for freezing to –34° C.coolant also protects for freezing to –34° C.
3.8 Inspection of Gas and Coolant Lines
Operating the unit without coolant will cause
Operating the unit without coolant will cause
Operating the unit without coolant will causeOperating the unit without coolant will cause permanent damage to the coolan t pu mp.
permanent damage to the coolan t pu mp.
permanent damage to the coolan t pu mp.permanent damage to the coolant pump .
To complete installation, it is necessary to inspect field assembled connections for leaks.
Gas lines, use a standard soap solution. Pressurize the system from the control (SDP file)
Coolant- check connections for signs of moisture at connections
3-11
SECTION 3 INSTALLATION
3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic Controller (PLC)
The Precision Plasmarc System may be shipped configured for a manual flow control (Series “A”). If so, the EPROM in the Programmable Logic Controller must be replaced with an EFC EPROM. This EFC EPROM is shipped with the power source.
Using the Wrong EPROM Could Result In
CAUTION
!
CAUTION
!
Damaged System Components
The Series “A” and the EFC EPROMs are programmed with different software. The EFC EPROM ignores the process gas pressure switch inputs and does not include the process gas purge required for the Series “A”.
Mishandling Can Damage Electronic Components.
CAUTION
!
WARNING
!
Handle electronic components with care.
Do not drop
Do not bend pins
Do not touch circuit components- handle
along edges when possible
Electronic Components Are Subject To Electro-Static-Discharge (ESD) Damage
Integrated Circuit parts are sensitive to over voltages. The damage may not be seen immediately but show up as a premature failure.
The EFC EPROM is shipped in an anti-static bag. Store EPROM in this bag.
Wear a protective ground strap when handling sensitive electronic components.
Electric shock Can Kill!
Unplug power cable from wall to power source before any connections or adjustments are made inside power source.
3-12
SECTION 3 INSTALLATION
T
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I
1. Ensure the Plasmarc Power Source is disconnected from electricity source.
2. Expose the PLC by removing the left side panel of the Plasmarc Power Source.
3. Pop the EPROM cover on the PLC to expose the EPROM.
PLC
Left Side Panel
L O R
T
N O
C
N
T E R
R U C
C
E
R
EFC EPROM
Package Location
3-13
SECTION 3 INSTALLATION
Using An EPROM Puller Tool May Damage
CAUTION
EPROM Locked In Place
Socket
Forcibly removing a clamped EPROM in the PLC may cause the socket/EPROM to break.
Special Zero Force EPROM Socket is used to eliminate the need for special tools.
4. Remove the EPROM from the socket. THIS DOES NOT REQUIRE A PULLER. Release the clamp locking the EPROM in place, lift the Series “A” EPROM from the socket.
5. Remove the EFC EPROM from the packaging.
6. Carefully align the EFC EPROM pins with the socket holes and insert.
7. Lock the EPROM by moving th e l eve r back while holding the EPROM in place.
EPROM Lock Released
8. Replace the EPROM cover and the Power Source left side panel.
EPPESA= Series “A” EPROM, manual flow control P/N 99513607
EPPSEFC= EFC EPROM, electronic flow con t ro l P/N 99513608
3-14
SECTION 4 OPERATION
ARC
4.1 Power Supply Controls
4.1.1 Main Power Switch
LOW
EMERGENCY
STOP
DO NOT SWITCH WHILE CUTTING
Main Power Switch Controls the input power to the fan, water cooler and the PC Board. Amber indicator light to the left of the switch.
4.1.2 Pilot Arc Switch
EMERGENCY
STOP
CAUTION
Pilot Arc Switch Used to select HIGH or LOW Start Pilot Arc depending on cutting conditions. See Process Data for more information on which conditions High and Low Start are used.
POWER
ON
OFF
Adjusting Pilot Arc While in Operation Could Damage Torch.
Do not adjust pilot arc switch while in operation.
Adjust before torch starts.
4-1
SECTION 4 OPERATION
4.1.3 Fault Indicator Lights
Fault Indicator Lights
Coolant flow will show low coolant flow. When unit is turned on, the light will briefly show a fault and then go out.
Plasma Gas Pressure fault indicator -- low Plasma Gas Pressure. Torch will not fire when indicated. Not used for the E FC.
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
NotNot
4.1.4 Meters
4.1.5 Current Control Switch
Cutting Cu rre nt Meter (A) -- Displays actual
cutting current in amperes.
Cutting Vo ltage Meter (V) -- Displays actual
cutting voltage.
Control Remote/Panel Switch
Panel Positi on – Output current is set by the output current dial
Out p ut Curr ent 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
4-2
0-10 Vdc = 0-100 Adc
SECTION 4 OPERATION
4.2 Cut Quality
4.2.1 Introduction
Causes affecting cut quality are interdependent. Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to different undesirable cutting results. To begin select the most prominent condition:
§ 4.2.2 Cut Angle, negative or positive
§ 4.2. 3 Cut not flat, rounded or undercut
§ 4.2.4 Surface roughness
§ 4.2.5 Dross
Usually the recommended cutting parameters will give optimal cut quality, occasionally conditions may vary enough that slight adjustments will be required. If so:
Make small incremental adjustments when
making corrections.
Adjust Arc Voltage in 5 volt increments, up or
down as required.
Adjust cutting speed 5% or less as required
until conditions improve.
NOTICE
4.2.2 Cut Angle
Part
Before attempting ANY corrections, check cutting variables with the factor y recommended settings/consumable part numbers listed in Process Data.
Negative Cut Angle
Top dimension is greater than the bottom.
Misaligned torch
Bent or warped material
Worn or damaged consumables
Standoff low (arc voltage)
Cutting speed slow (machine travel rate)
Drop
Part
4-3
SECTION 4 OPERATION
Positive Cut Angle
Part
Top dimension is less than the bottom dimension.
Misaligned torch
Bent or warped material
Worn or damaged consumables
High standoff High (arc voltage)
Cutting speed fast
Current high or low. (See Process Data for
PartDrop
recommended current level for specific nozzles).
4.2.3 Cut Flatness
Drop
Top And Bottom Rounded
Condition usually occurs when material is .25” thick (6,4mm) or less.
High current for given material thickness (See
Process Data for proper settings).
Part
4-4
SECTION 4 OPERATION
Top Edge Undercut
Standoff low (Arc Voltage)
Drop
4.2.4 Surface Finish
Top View
Part
Process Induced Roughness
Cut face is consistently rough. May or may not be confined to one axis.
Incorrect Shield Gas mixture (See Process Data)
Worn or damaged consumables
Cut Face
MMMMachine Induced Roughness Can be difficult to distinguish from Process Induced Roughness. Often confined to only one axis. Roughness is inconsistent.
or Process Induced Roughness
Machine Induced Roughness
Dirty rails, wheels and/or drive rack/pinion. (Refer
to Maintenance Section in machine owners manual).
Carriage wheel adjustment
4-5
SECTION 4 OPERATION
4.2.5 Dross
Dross is a by-product of the cutting process. It is the undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.
Cut
Lag
Lines
Face
High Speed Dross
Material weld or rollover on bottom surface along kerf. Difficult to remove. May require grinding or chipping. “S” shaped lag lines.
Rollover
Standoff high (arc voltage)
Side View
Lag
Lines
Cutting speed fast
Cut Face
Slow Speed Dross
Forms as globules on bottom along kerf. Removes easily.
Globules
Cutting speed slow
Side View
4-6
SECTION 4 OPERATION
Side View
Splatter
Top Dross
Appears as splatter on top of material. Usually removes easily.
Cutting speed fast
Standoff high (arc voltage).
Cut Face
Intermittent Dross
Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross
Possible worn consumables
Other Factors Affecting Dross;
Material temperature
Heavy mill scale or rust
High carbon alloys
4-7
SECTION 4 OPERATION
4.2.6 Dimensional Accuracy
Generally using the slowest possible speed (within approved levels) will optimize part accuracy. Select consumables to allow a lower arc voltage and slower cutting speed.
NOTICE
NOTICE
Recommended cutting speed and arc voltage will give optimal cutting performance in most cases.
Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings.
Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in the Process Data.
4-8
SECTION 4 OPERATION
4.3 Influence of Gas Options on Cut Quality
4.3.1 Introduction
All gases are not suitable for all situations. Certain gases assist in cutting specific materials and thickness. The f ollowing explains w h y certain gases are selected and their influence on the finished part. Other influences such as arc voltage and gas flow/pressure are covered in the Process Data.
NOTICE
4.3.2 Aluminum
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
All thickness’ between .062" to .625" (1,6 mm to 15,9 mm)
Smooth cut face
Virtually no dross
Shield Gas:
Shield Gas: Nitrogen/Methane
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Shield mixture is very important. Between 2 and 3 parts nitrogen, to 1 part methane ratio is desired. Incorrect ratio results in heavy dross.
Refer to Cutting Process Data in this section for recommended flow/pressure settings.
4-9
SECTION 4 OPERATION
Refer to Cutting Process Data in the PT24
NOTICE
4.3.3 Carbon Steel
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
26 GA (.018") to 10 GA (.135") (0,5 mm to 3,4 mm)
Manual for recommended flow/pressure settings.
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Oxygen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Oxygen/Nitrogen
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Oxygen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen
Shield Gas:Shield Gas:
Smooth cut face
Virtually no dross
Shield gas is normally nitrogen. A small amount of oxygen combined with nitrogen can effectively improve dross formation on thin material of 26 GA to 10 GA carbon steel. Also, an oxygen only shield may provide acceptable results on thinner materials.
.125" to .75" (3,2 mm to 19,1 mm)
Smooth cut face
Virtually no dross
Discussion:
Discussion:
Discussion:Discussion:
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 elect ric al en ergy uses lower amperage levels without sacrificing cut speed.
4-10
SECTION 4 OPERATION
Refer to Cutting Process Data in the PT24
NOTICE
Manual for recommended flow/pressure settings.
4.3.4 Stainless Steel
Material Thickness:
Material Thickness:
Material Thickness:Material Thickness:
22 GA (.028") to 16 GA (.062") (0,7 mm to 1,6 mm)
Positive cut angle
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Excellent dross performance
Shiny cut surface.
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen/Methane
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness: 26 GA (.018") to 16 GA (.062") (0,5 mm to 1,6 mm)
Material Thickness:Material Thickness:
Because of high cut speeds, a positive cut face angle is expected. Use a 70-amp nozzle at 50 amps to allow more gas to exit the nozzle.
Dark cut face
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Virtually dross free
Improved cut squareness
Plasma Gas:
Plasma Gas: Oxygen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Oxygen/Nitrogen
Shield Gas:Shield Gas:
Low amperage cutting/slower speeds produce squarer cuts in thin
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Material Thickness:Material Thickness:
materials. The oxygen allows for a lower arc voltage, improvin g cu t squareness. The “B” nozzle is used at 30 amps
Cut edge dark
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
good dross performance
Good cut angle
Plasma Gas:
Plasma Gas: Air
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Air
Shield Gas:Shield Gas:
When they are the same, the shield and plasma gases combine. This
Discussion:
Discussion:
Discussion:Discussion:
combination has the effect of increasing the cut gas flow/pressure. This increased flow/pressure directly influences cut squareness.
4-11
SECTION 4 OPERATION
Stainless Steel
Material Thickness:
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Material Thickness:Material Thickness:
NOTICE
Matted cut edge appearan ce
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Plasma Gas:
Plasma Gas: Air
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Air/Methane
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Light gray color
Much smoother finish
Possible slight increase in cut angle
Too much methane in the shield gas mixture can result in more dross formation. 4:1 ratio air to methane is recommended. Because methane is a fuel gas, possible slight increase in cut angles could be experienced.
Refer to Cutting Process Data for recommended flow/pressure settings.
Material Thickness:
Material Thickness: .125" to .625" (3,2 mm to 15,9 mm)
Material Thickness:Material Thickness:
Dark cut face similar to air
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Excellent dross performance
Good cut angle
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen
Shield Gas:Shield Gas:
Shield and plasma gases combine, the volume/pressure of shield gas
Discussion:
Discussion:
Discussion:Discussion:
Material Thickness:
Material Thickness: .187" to .625" (4,7 mm to 15,9 mm)
Material Thickness:Material Thickness:
can negatively affect cut squareness. Higher shield volume produces a negative cut angle. A lower volume, produces a positive angle.
Shiny cut face
Cut Qualities:
Cut Qualities:
Cut Qualities:Cut Qualities:
Lip formation at the bottom
Dross formation can be extensive and difficult to remove
Plasma Gas:
Plasma Gas: Nitrogen
Plasma Gas:Plasma Gas:
Shield Gas:
Shield Gas: Nitrogen/Methane
Shield Gas:Shield Gas:
Discussion:
Discussion:
Discussion:Discussion:
Because methane is a fuel gas, flow/pressure rates can affect the cut angle. High flow/pressure results in a negative cut angle, low flow/pressure results in a positive cut angle. Nitrogen to methane ratio is 10 to 14 parts N severe, making Nitrogen/Methane shield gas combination unsuitable for some finished part applications.
/ 1 part CH4. The lip formed on the cut face bottom is
2
4-12
SECTION 4 OPERATION
4.4 Process Data
4.4.1 Introduction
4.4.1 Introduction
4.4.1 Introduction4.4.1 Introduction
The following information is a result of many hours of testing and is a general guide for setting up and cutting with a PT-24 Precision Plasmarc System. In most cases these settings will provide a quality cut. The data contains values for:
cutting aluminum, carbon and stainless steel
arc voltage (standoff)
cutting speed
current (amperes)
gas flow rates for all plasma/shield gas
combinations
This same data is contained in SDP files. (See your control manual for more information on SDP files.)
Also included is information on consumable part numbers for current being used.
4-13
SECTION 4 OPERATION
(
)
)
4.4.2 Process Data
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Aluminum 30
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Baffle P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21536 (3 holes)
21536 (3 holes)
21536 (3 holes
P/N P/N
21536
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21541, "B"
21541, "B"
P/N P/N
21541, "B"21541, "B"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
3 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-14
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.062 0.075 0.090 0.125 0.187 0.250
MM 1,61,92,33,24,76,4
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 454545454545
30 Amperes
Aluminum
PG
PG SG1
PGPG
N2 N2 CH4
000000
40 40 40 40 40 40
55 55 55 55 55 55
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 202020202020
SG2- Cut Flow 10 10 10 10 10 10
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
150 152 153 158 170 189
150 135 105 78 30 25
3810 3429 2667 1981 762 635
4-15
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Aluminum 55
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21542, "C"
21542, "C"
P/N P/N
21542, "C"21542, "C"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-16
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.062 0.125 0.187 0.250
MM 1,6 3,2 4,7 6,4
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 55555555
55 Amperes
Aluminum
PG
PG SG1
PGPG
N2 N2 CH4
0000
45 45 45 45
75 75 75 85
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 20202020
SG2- Cut Flow 10 10 10 10
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
136 139 152 168
170 130 78 46
4318 3302 1981 1168
4-17
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Aluminum 70
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21543, "D"
21543, "D"
P/N P/N
21543, "D"21543, "D"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-18
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.187 0.250 0.375 0.500
MM 4,7 6,4 9,5 12,7
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 45454545
70 Amperes
Aluminum
PG
PG SG1
PGPG
N2 N2 CH4
0 0 0.1 0.2
65 65 65 65
50 50 100 100
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 20202020
SG2- Cut Flow 10 10 10 10
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
150 157 168 182
80 65 55 30
2032 1651 1397 762
4-19
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Aluminum 100
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-20
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.250 0.375 0.500 0.625
MM 6,4 9,5 12,7 15,9
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
100 Amperes
Aluminum
PG
PG SG1
PGPG
N2 N2 N2
0 0 0.1 0.1
80 80 80 80
100 100 100 100
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 31313131
SG2- Cut Flow 10 10 10 10
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
155 160 166 174
65 80 65 50
2413 2032 1778 1270
4-21
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Carbon Steel 16
Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Oxygen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21852 (2 holes)
21852 (2 holes)
21852 (2 holes
P/N P/N
21852
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21540, "A"
21540, "A"
P/N P/N
21540, "A"21540, "A"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
2 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-22
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 20GA 18GA 16GA 14GA 12GA 10GA
MM 0,91,21,62,02,73,4
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 202020202020
16 Amperes
Carbon Steel
PG
PG SG1
PGPG
O2 N2 O2
0 0 0 0.1 0.5 0.1
20 20 20 20 20 20
11 11 11 11 11 11
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 000000
SG2- Cut Flow666666
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
103 105 115 118 116 117
1008580605036
2540 2159 2032 1524 1270 914
4-23
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Carbon Steel 35
Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Oxygen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21536 (3 holes)
21536 (3 holes)
21536 (3 holes
P/N P/N
21536
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21541, "B"
21541, "B"
P/N P/N
21541, "B"21541, "B"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
3 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-24
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 14GA 0.125 0.135 0.187 0.250
MM 1,93,23,44,76,4
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 5050505050
35 Amperes
Carbon Steel
PG
PG SG1
PGPG
O2 N2 O2
00000
38 38 38 38 38
15 15 15 15 15
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 00000
SG2- Cut Flow66666
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
113 119 120 122 124
80 55 52 40 30
3032 1397 1320 1016 762
4-25
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Carbon Steel 45
Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Oxygen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21542, "C"
21542, "C"
P/N P/N
21542, "C"21542, "C"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-26
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.125 0.135 0.187 0.250 0.375
MM 3,23,44,76,49,5
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 5050505050
45 Amperes
Carbon Steel
PG
PG SG1
PGPG
O2 N2 O2
0.30.30.30.30.4
50 50 50 50 50
20 20 20 20 20
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 1616161610
SG2- Cut Flow00000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
108 111 114 121 124
60 50 45 35 20
1524 1270 1143 889 508
4-27
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Carbon Steel 70
Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Oxygen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21543, "D"
21543, "D"
P/N P/N
21543, "D"21543, "D"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-28
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.187 0.250 0.312 0.375 0.500 0.625
MM 4,7 6,4 7,9 9,5 12,7 12,9
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 606060606060
70 Amperes
Carbon Steel
PG
PG SG1
PGPG
O2 N2 O2
0 0 0 0.1 0.2 0.5
60 60 60 60 60
25 25 25 25 25 25
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 333333332020
SG2- Cut Flow000000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
108 110 114 113 135 140
110 100 70 60 30 25
2794 2413 1778 1524 762 635
4-29
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Carbon Steel 100
Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Oxygen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-30
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.312 0.375 0.500 0.625 0.750
MM 7,9 9,5 12,9 15,9 19,1
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 6060606060
100 Amperes
Carbon Steel
PG
PG SG1
PGPG
O2 N2 O2
0 0 0.1 0.1 0.1
80 80 80 80 80
30 30 30 30 30
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 3030303030
SG2- Cut Flow00000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
115 120 132 137 143
90 80 50 30 25
2290 2030 1270 760 630
4-31
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 30
Oxygen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Oxygen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21536 (3 holes)
21536 (3 holes)
21536 (3 holes
P/N P/N
21536
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21541, "B"
21541, "B"
P/N P/N
21541, "B"21541, "B"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
3 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-32
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 26GA 24GA 22GA 18GA 16GA
MM 0,40,60,71,21,6
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 4040404040
30 Amperes
Stainless Steel
PG
PG SG1
PGPG
O2 N2 O2
00000
45 45 45 45 45
18 18 18 18 18
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 2020202020
SG2- Cut Flow55555
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –LOW.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
105 105 107 109 111
250 200 190 140 100
6350 5080 4826 3556 2540
4-33
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a 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 Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21542, "C"
21542, "C"
P/N P/N
21542, "C"21542, "C"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-34
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.125 0.187 0.250 0.375
MM 3,2 4,7 6,4 9,5
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 45454545
50 Amperes
Stainless Steel
PG
PG SG1
PGPG
Air Air Air
0 0 01 0.2
60 60 60 60
95 95 95 95
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 35353535
SG2- Cut Flow0000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
134 140 145 155
90 60 40 18
2286 1524 1016 457
4-35
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a 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 Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21543, "D"
21543, "D"
P/N P/N
21543, "D"21543, "D"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-36
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.187 0.250 0.375 0.500
MM 4,7 6,4 9,5 12,7
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
70 Amperes
Stainless Steel
PG
PG SG1
PGPG
Air Air Air
0.3 0.4 0.5 0.6
70 70 70 70
95 95 95 95
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 40404040
SG2- Cut Flow0000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
131 152 158 162
100 50 28 20
2540 1270 711 609
4-37
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 100
Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-38
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.250 0.375 0.500 0.625
MM 6,4 9,5 12,7 15,9
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
100 Amperes
Stainless Steel
PG
PG SG1
SG1 SG2
PGPG
SG1SG1
Air Air Air
0.3 0.4 0.5 0.6
80 80 80 80
65 65 65 70
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 35353540
SG2- Cut Flow0000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
129 135 142 150
80 60 35 25
2030 1520 889 635
4-39
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 70
Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21543, "D"
21543, "D"
P/N P/N
21543, "D"21543, "D"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-40
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.125 0.187 0.250 0.387 0.500
MM 3,2 4,7 6,4 9,5 12,7
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 6060606060
70 Amperes
Stainless Steel
PG
PG SG1
PGPG
Air Air CH4
0.20.30.40.50.6
70 70 70 70 70
100 100 100 100 100
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 4040404040
SG2- Cut Flow 10 10 10 10 10
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
131 146 154 166 175
12080503024
3048 2032 1270 762 609
4-41
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 100
Air @ 125 PSI / 8.6 Bar Air @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-42
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.250 0.375 0.500 0.625
MM 6,4 9,5 12,7 15,9
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
100 Amperes
Stainless Steel
PG
PG SG1
PGPG
Air Air CH4
0.3 0.4 0.5 0.6
80 80 80 80
100 100 100 100
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 40404040
SG2- Cut Flow 7 10 10 10
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
140 150 159 170
80 60 35 25
2030 1524 889 635
4-43
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 50
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21542, "C"
21542, "C"
P/N P/N
21542, "C"21542, "C"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-44
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.125 0.187 0.250 0.375
MM 3,2 4,7 6,4 9,5
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 45454545
50 Amperes
Stainless Steel
PG
PG SG1
PGPG
N2 N2
0 0 0.1 0.2
60 60 60 60
85 85 85 85
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 35353535
SG2- Cut Flow0000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
128 133 144 155
90 60 40 22
2286 1524 1016 558
4-45
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 70
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21543, "D"
21543, "D"
P/N P/N
21543, "D"21543, "D"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-46
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.187 0.250 0.375 0.500
MM 4,7 6,4 9,5 12,7
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
70 Amperes
Stainless Steel
PG
PG SG1
PGPG
N2 N2
0.3 0.4 0.5 0.6
70 70 70 70
95 95 95 95
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 40404040
SG2- Cut Flow0000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
132 150 154 159
75 50 28 24
1905 1270 711 609
4-47
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 100
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-48
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.250 0.375 0.500 0.625
MM 6,4 9,5 12,7 15,9
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
100 Amperes
Stainless Steel
PG
PG SG1
PGPG
N2 N2
0.3 0.4 0.5 0.6
80 80 80 80
95 95 95 95
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 50353535
SG2- Cut Flow0000
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
135 145 153 157
80 60 35 25
2032 1520 889 635
4-49
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 70
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
 Swirl Baffle
Swirl Baffle
Swirl Baffle Swirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
 Nozzle
Nozzle
Nozzle Nozzle
P/N
P/N 21543, "D"
21543, "D"
P/N P/N
21543, "D"21543, "D"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
 Baffle and Nozzle
are the only two replaceable torch front-end parts that may vary with amperage
4-50
- Shield Retainer .
- Shield - Shield
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.187 0.250 0.375 0.500
MM 4,7 6,4 9,5 12,7
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 60606060
70 Amperes
Stainless Steel
PG
PG SG1
PGPG
N2 N2 CH4
0.3 0.4 0.5 0.6
75 75 75 75
85 85 85 85
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 43434343
SG2- Cut Flow5555
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
136 150 159 162
75 50 28 24
1905 1270 711 609
4-51
SECTION 4 OPERATION
(
)
)
PT-24 Torch
Material: Amperes: Plasm a Gas: Shield Gas: Shield Mix Gas:
Stainless Steel 100
Nitrogen @ 125 PSI / 8.6 Bar Nitrogen @ 125 PSI / 8.6 Bar Methane @ 100 PSI / 6.9 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
Nozzle
Nozzle
NozzleNozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-52
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Process Data
Material Thickness
IN 0.250 0.375 0.500 0.625
MM 6,4 9,5 12,7 5,9
Pierce Delay (SEC.)
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 50706042
100 Amperes
Stainless Steel
PG
PG SG1
PGPG
N2 N2 CH4
0.3 0.4 0.5 0.6
80 80 80 80
95 95 95 95
SG1 SG2
SG1SG1
SG2
SG2SG2
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 45454542
SG2- Cut Flow5557
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
138 150 162 170
80 60 35 25
2032 1524 889 635
4-53
SECTION 4 OPERATION
(
)
)
Plasma Marking “B” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
10
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N 21536 (3 Holes)
P/N 21536 (3 Holes)
P/N 21536 (3 Holes
P/N 21536
Nozzle
Nozzle
NozzleNozzle
P/N 21541 “B”
P/N 21541 “B”
P/N 21541 “B”P/N 21541 “B” Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
3 Holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-54
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Plasma Marking
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 35
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 35
SG2- Cu t Flow 0
“B” Nozzle
10 Amperes
35
35
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
77
200
5080
4-55
SECTION 4 OPERATION
Plasma Marking “B” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
15
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N 21536 3 holes
P/N 21536 3 holes
P/N 21536 3 holesP/N 21536 3 holes
Nozzle
Nozzle
NozzleNozzle
P/N 21541 “B”
P/N 21541 “B”
P/N 21541 “B”P/N 21541 “B” Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4-56
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Plasma Marking
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 35
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 35
SG2- Cu t Flow 0
“B” Nozzle
15 Amperes
35
35
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
77
300
7620
4-57
SECTION 4 OPERATION
(
)
)
Plasma Marking “C” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
10
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
Nozzle
Nozzle
NozzleNozzle
P/N 21542 “C”
P/N 21542 “C”
P/N 21542 “C”P/N 21542 “C” Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-58
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Plasma Marking
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 37
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 37
SG2- Cu t Flow 0
“C” Nozzle
10 Amperes
62
62
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
77
100
2540
4-59
SECTION 4 OPERATION
(
)
)
Plasma Marking “C” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
15
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
Nozzle
Nozzle
NozzleNozzle
P/N 21542 “C”
P/N 21542 “C”
P/N 21542 “C”P/N 21542 “C” Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-60
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Plasma Marking
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 35
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 35
SG2- Cu t Flow 0
“C” Nozzle
15 Amperes
62
62
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
77
200
5080
4-61
SECTION 4 OPERATION
(
)
)
Plasma Marking “D” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
10
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
Nozzle
Nozzle
NozzleNozzle
P/N 21543 “D”
P/N 21543 “D”
P/N 21543 “D”P/N 21543 “D” Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-62
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Plasma Marking
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 100
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 100
SG2- Cu t Flow 0
“D” Nozzle
10 Amperes
77
77
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
77
100
2540
4-63
SECTION 4 OPERATION
(
)
)
Plasma Marking “D” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
15
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
Nozzle
Nozzle
NozzleNozzle
P/N
P/N 21923, "E"
21923, "E"
P/N P/N
21923, "E"21923, "E"
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-64
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
SECTION 4 OPERATION
Plasma Marking
Process Data
Setup Parameters (see notes)
Plasma Start Gas 1 Plasma Cut Gas 1
SG1-Start 37
Shield Gas
(Flow Reading)
Flow Reading
SG1- Cut 37
SG2- Cu t Flow 0
“D” Nozzle
15 Amperes
62
62
Arc Voltage (standoff)
Travel Speed
IPM MM/MIN
Notes:
1. Pilot Arc –HIGH.
2. Cut and ALT gas mix in Flow Control.
3. Float – Center of Ball
77
300
7620
4-65
SECTION 4 OPERATION
(
)
)
Plasma Marking “D” Nozzle
PT-24 Torch
Amperes: Plasm a Gas: Shield Gas:
20
Argon @ 125 PSI / 8.6 Bar Air @ 125 PSI/ 8.6 Bar
Torch Body
Torch Body
Torch BodyTorch Body P/N 21758
P/N 21758
P/N 21758P/N 21758
Water Baffle
Water Baffle
Water BaffleWater Ba ff le P/N 21725
P/N 21725
P/N 21725P/N 21725 O-Ring
O-Ring
O-RingO-Ring P/N 638797
P/N 638797
P/N 638797P/N 638797 O-Ring
O-Ring
O-RingO-Ring P/N 86W62
P/N 86W62
P/N 86W62P/N 86W62 O-Ring
O-Ring
O-RingO-Ring P/N 950714
P/N 950714
P/N 950714P/N 950714 O-Ring
O-Ring
O-RingO-Ring P/N 98W18
P/N 98W18
P/N 98W18P/N 98W18 Electrode
Electrode
ElectrodeElectrode P/N 21539
P/N 21539
P/N 21539P/N 21539
Swirl Baffle
Swirl Baffle
Swirl BaffleSwirl Baffle
P/N
P/N 21692 (4 holes)
21692 (4 holes)
21692 (4 holes
P/N P/N
21692
Nozzle
Nozzle
NozzleNozzle
P/N 21543 “D”
P/N 21543 “D”
P/N 21543 “D”P/N 21543 “D” Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu ser
Nozzle Retainer/D if fu serNozzle Retainer/D if fu ser P/N 22007
P/N 22007
P/N 22007P/N 22007 Shield Cup Insulat or
Shield Cup Insulat or
Shield Cup Insulat orSh ield Cup Insu l a to r P/N 22010
P/N 22010
P/N 22010P/N 22010 Insulator Shield Reta in er
Insulator Shield Reta in er
Insulator Shield Reta in erInsulat or Sh ie ld Reta in er w/O-Ring P/N 21712
w/O-Ring P/N 21712
w/O-Ring P/N 21712w/O-Ring P/N 21712
4 holes
O-Ring
O-Ring - Shield
O-Ring O-Ring
(Ref. P/N 996528)
(Ref. P/N 996528)
(Ref. P/N 996528)(Ref. P/N 996528)
Cup shield w/Retainer
Cup shield w/Retainer
Cup shield w/RetainerCup shield w/Retainer P/N 22531
P/N 22531
P/N 22531P/N 22531
4-66
- Shield Retainer .
- Shield - Shield
 Baffle and Nozzle
are the only two
replaceable torch
front-end parts that
may vary with
amperage
Retainer .
Retainer .Retainer .
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