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

F-15-480-E

July, 2007

Installation, Operation and Maintenance Manual for the

PRECISION PLASMARC SYSTEM

with Electronic Flow Control

CUTTING SYSTEMS

411 s. Ebenezer Road
Florence, SC 29501-0545

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

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

ESAB Cutting Systems first priority is total
customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.

This manual is ESAB Part Number F15480

March-01 date reflects added cable part nos. in
Sect 2. Corrected Pressure in Section 6.
Dec.-01 Replacement parts section updated

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

© ESAB Cutting Systems, 2001

Printed in U.S.A.

Precision Plasma Electronic Flow Control Table of Contents

Page
Section 1 Safety

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

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

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

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

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

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

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

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

Section 2 Description

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

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

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

2.4 Technical Specifications .................................................................................

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

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

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

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

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

Section 3 Installation

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

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

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

3.4 Primary Electrical Input Connections.............................................................. 2

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

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

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

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

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

3.9 Replacement of EPROM in the Plasmarc Power Source Programmable

Logic Controller (PLC) ...........................................................................................

12

i

Precision Plasma Electronic Flow Control Table of Contents

Section 4 Operation

4.1 Power Supply Controls

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

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

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

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

4.1.5 Current Control Switch............................................................................. 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/O2............................................. 81

4.4.3.4 Stainless Steel Kerf Values Air/Air/CH4.......................................... 82

4.4.3.5 Stainless Steel Kerf Values N2/N2/CH4........................................... 83

4.4.3.6 Stainless Steel Kerf Values N2/N2................................................... 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 and DEF.TEC .......... 24

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

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

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

6.12.8 Solenoid/Proportional Valve Requirements and
Gas Error Monitoring

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

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

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

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

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

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

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

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

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

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

Section 7 Replacement Parts

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

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

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

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

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

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

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

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

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

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

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

7.12 Interface Cables and Hoses .......................................................................... 44

Customer/Technical Information Resource Back Manual Cover

iv

SECTION 1 SAFETY

1.1 Introduction

The process of cutting metals with plasma equipment

1.2 Safety Notations And Symbols

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

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

ALERT or ATTENTION. Your safety is involved

!

DANGER

!

WARNING

!

CAUTION

!

CAUTION

NOTICE

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

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

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

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

Used to call attention to minor hazards to
equipment.

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

1-1

SECTION 1 SAFETY

1.3 General Safety Information

WARNING

!

Machine starts automatically.

This equipment moves in various directions and
speeds.

• Moving machinery can crush.

• Only qualified personnel should operate or

service equipment.

WARNING

!

• Keep all personnel, materials, and equipment

not involved in production process clear of
entire system area.

• Keep gear racks and rails clear of debris or

obstructions, such as tools or clothing.

• Fence off entire work cell to prevent

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

• Post appropriate WARNING signs at every

work cell entrance.

• Follow lockout procedure before servicing.

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

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

• Read entire procedure before operating or

performing any system maintenance.

• Special attention must be given to all

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

• All safety precautions relevant to electrical

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

• Read all safety publications made available

by your company.

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 machine.

Refer to operator’s manual for additional
safety information.

WARNING

!

Improperly installed equipment can cause
injury or death.

Follow these guidelines while installing machine:
Do not connect a cylinder directly to machine

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

Contact your ESAB representative before
installation. He can suggest certain precautions
regarding piping installation and machine lifting,
etc. to ensure maximum security.

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

Observe machine clearance requirements for
proper operation and personnel safety.

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

WARNING

!

death.
Machine must be properly grounded before put

into service.

Improper grounding can damage machine
and electrical components.

• Machine must be properly grounded before

put into service.

• Cutting table must be properly grounded to a

good Earth ground rod.

1.6 Operating A Plasma Cutting Machine

WARNING

!

WARNING

!

Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. Wear

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

• Chipped slag may be hot and fly far.

Bystanders should also wear goggles and
safety glasses.

• From plasma arc can damage hearing. Wear

correct ear protection when cutting above
water.

Burn hazard.

Hot metal can burn.

• Do not touch metal plate or parts immediately

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

Do not touch plasma torch immediately after

1-4

SECTION 1 SAFETY

cutting. Allow torch time to cool.

1-5

SECTION 1 SAFETY

WARNING

!

Hazardous voltages. Electric shock
can kill.

• Do NOT touch plasma torch, cutting table or

cable connections during plasma cutting
process.

• Always turn power off to plasma power

supplies before touching or servicing plasma
torch.

• Always turn power off to plasma power

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

• Do not touch live electrical parts.

• Keep all panels and covers in place when

machine is connected to power source.

• Insulate yourself from workpiece and

electrical ground: wear insulating gloves,
shoes and clothing.

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

equipment dry.

WARNING

!

Pinch hazard.

Moving vertical slides can crush or pinch.
Keep hands clear of torch and slide during

operation.

Fume hazard.

WARNING

!

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

• Do NOT breathe fumes.

• Do not operate plasma torch without fume

removal system operating properly.

• Use additional ventilation to remove fumes if

necessary.

• Use approved respirator if ventilation is not

1-6

SECTION 1 SAFETY

adequate.

1-7

SECTION 1 SAFETY

WARNING

!

Radiation hazard.

Arc rays can injure eyes and burn skin.

• Wear correct eye and body protection.

• Wear dark safety glasses or goggles with side

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

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

• Replace glasses/goggles when lenses are

pitted or broken

• Warn others in area not to look directly at the

arc unless wearing appropriate safety
glasses.

• Prepare cutting area to reduce reflection and

transmission of ultraviolet light.

• Paint walls and other surfaces with dark

colors to reduce reflections.

• Install protective screens or curtains to

reduce ultraviolet transmission.

WARNING

!

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can rupture and
violently release gas.

• Avoid rough handling of cylinders.

• Keep cylinder valves closed when not in use.

• Maintain hoses and fittings in good condition.

• Always secure cylinders in an upright

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

• Locate cylinders away from heat, sparks and

flames. Never strike an arc on a cylinder.

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

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

1-8

SECTION 1 SAFETY

WARNING

!

CAUTION

Spark hazard.

Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

• Do not cut containers that have held

combustibles.

• Do not have on your person any combustibles

(e.g. butane lighter).

• Pilot arc can cause burns. Keep torch nozzle

away from yourself and others when
activating plasma process.

• Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.

• Wear flame-retardant clothing that covers all

exposed areas.

• Wear cuffless trousers to prevent entry of

sparks and slag.

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:

• reduced consumable life

• degradation of cut quality

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

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

1-9

SECTION 1 SAFETY

WARNING

!

Explosion hazard.

Certain molten aluminum-lithium (Al-Li) alloys
can cause explosions when plasma cut OVER
water.

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

Alithlite (Alcoa) X8192 (Alcoa)
Alithally (Alcoa) Navalite (US Navy)
2090 Alloy (Alcoa) Lockalite (Lockheed)
X8090A (Alcoa) Kalite (Kaiser)
X8092 (Alcoa) 8091 (Alcan)

• These alloys should only be dry cut on a dry

table.

• DO NOT dry cut over water.

• Contact your aluminum supplier for additional

safety information regarding hazards
associated with these alloys

1.7 Service Precautions

.

CAUTION

CAUTION

!

Establish and adhere to preventive maintenance.
A composite program can be established from
recommended schedules in the instruction
literature.

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

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

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

Never plug or unplug a printed circuit board
while machine power is on. Instantaneous
surges of voltage and current can damage
electronic components.

1-10

SECTION 1 SAFETY

1.8 Safety References

The following nationally recognized publications on safety in welding

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

• “Precautions and Safe Practices in Welding and Cutting with

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

• “Precautions and Safe Practices for Electric Welding and

Cutting,” Form 52-529. ESAB Cutting Systems.

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

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

• “Recommended Safe Practices for Shielded Gases for Welding

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

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

American Welding Society.

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

Welding Society.

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

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

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

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

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

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

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

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

ESAB Cutting Systems.

• “Precautions for Safe Handling of Compressed Gases in

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

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

1-11

SECTION 1 SAFETY

This page intentionally left blank.

1-12

SECTION 2 DESCRIPTION

2.1 General

2.2 Scope

2.3 Package Options Available

Precision Plasmarc package options available through your ESAB dealer

Precision Plasmarc Power Source (

(required)

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

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

Power Bundle (one required)

Gas Line Bundle (one required)

10 ft. (3 m) P/N 21917

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

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

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

P/N 37357

4.5 ft. (1.4 m) P/N 0558001463
12 ft. (4.4 m) P/N 0558001877
17 ft. (5.2 m) P/N 0558001464
12 ft. (3.6 m) P/N 22428
25 ft. (7.6 m) P/N 21905
40 ft. (12.2 m) P/N 22504
60 ft. (18 m) P/N 21906
80 ft. (24.4 m) P/N 22505
100 ft. (30 m) P/N 21907
10 ft. (3 m) P/N 37533
20 ft. (6 m) P/N 37534
30 ft. (9 m) P/N 37535
60 ft. (18 m) P/N 37536
100 ft. (30 m) P/N 37537

20 ft. (6 m) P/N 21918

Standard Cable 30 ft. (9 m) P/N 21919

60 ft. (18 m) P/N 21920

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

Flex cable (recommended

for power track applications)

2-1

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

SECTION 2 DESCRIPTION

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

Control Lead – Power Source to Cutting Machine I/O

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

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

NOTES:

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

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

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

2.4 Precision Plasma Technical Specifications

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

2.4.1 System

Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz
Input Current 65/60/50/40/30/25 amps per phase
Power Factor 0.95
Output Current Range 15-100 amps dc
Output Load Voltage 120 V dc
Duty Cycle 100%
Open Circuit Voltage 315 V dc

2-2

SECTION 2 DESCRIPTION

42" (1067mm)

POWER SUPPLY

O

L

I

P

R

L

O

R

T

N

O

C

T

N

E

R

R

U

C

N

O

I

S

I

C

E

R

22" (559mm)

WEIGHT = 560 lbs. (254 kg)

A

C

R

A

M

S

A

L

P

T
C

R

E

W

O

P

19.75" (502mm)

44" (1118mm)

ELEC TR O NI C FLOW CO NTROL BO X

12.25" (311mm)

JUNCTION BOX

10.62" (270mm)

WEIGHT = 26.5 lbs.(12 kg)

2

O

2

N

R

I

A

S

A

G

A

M

S

A

L

P

2

.

S

O

A

N

G

A

M

S

A

L

P

N

1

.

E

G

O

Y

N

X

O

N

E
G
O

R

T
I
N

I

R
A

N

O
G
R

A

12" (305mm)

WEIGHT = 51 lbs. (23 kg)

6.75" (171mm)

14.5" (1118mm)

H

T

E

M

5

3

-

H

2

N

2

N

2

O

R

I

A

S

A

G

D

L

E

I

H

S

2

.

S

O

A

N

G

D

L

I

E

H

S

N

1

E

.

G

O

O

N

R
T
I

N

N
E
G

O

R
T
I
N

E
N
A

H
T
E

M

N
E
G

Y
X
O

N

E
G
O

R

D
Y
H

I

R

A

2-3

SECTION 2 DESCRIPTION

2.4.2 Plasma Gas Technical Specifications

Type O
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

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

2.4.3 Start Gas Technical Specifications

, N2, Air

2

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

-99.995%

O

2

N

-99.995%

2

Air-clean, dry and oil free
Oxygen: R-76-150-540LC (P/N 19777)
Inert gas: R-76-150-580LC (P/N 19977)
Oxygen: R-77-150-540 (P/N 998337
Hydrogen/Methane:R-77-150-350 (P/N

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

998348)
Oxygen: R-76-150-024 (P/N 19151)

R-6703 (P/N 22236)

Type N

, Air

2

Pressure 125 psig (8.6 bar)
Flow

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

Minimum Purity Required 99.995%

2.4.4 Secondary Gas Technical Specifications

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

100 psig (6.6 bar) H-35,

Pressure

Flow

Methane; 125 psig (8.6 bar) N2,
O

, Air

2

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

Minimum Purity Required 99.995%

2.4.5 Pt-24 Torch Technical Specifications

Type Water-Cooled, Dual Gas
Rating 100 amps @ 100 % duty cycle
Dimensions See Package Options (2.3)

2-4

SECTION 3 INSTALLATION

3.1 General

NOTICE

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

3.2 Equipment Required

3.3 Location

• Gas Supply and Hoses. Gas supply may be from

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

• Work Lead. No. 4 AWG cable is recommended

for connecting workpiece to power source.

• Primary Input Cable.

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

the supply side for the EFC to function properly.

• Ventilation is necessary to provide proper cooling

of the power supply.

• Minimize dirt, dust and exposure to external heat

sources.

• Allow a minimum of two feet clearance around

the power supply for free air movement.

Do Not Restrict Air Flow

CAUTION

!

Restricting intake air with any type of filter on or

around 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.

WARNING

!

Input Power Configuration

Machine must be properly configured for your
input power.

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

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

Recommended Sizes For Input Conductors And Line Fuses

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

Input Power Connection At Wall

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

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

Input requirements

Volts Phase Amps

Input & ground

conductor,

cu/awg/mm

2

Fuse ratings /

phase, amps

3-2

SECTION 3 INSTALLATION

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

1. Remove right side panel.

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

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

Ground Connection

TB2

TB1

200
230
380
415
460
575

200
230
380
415
460
575

200
230
380

415
460
575

200
230
380
415
460
575

K1

PHASE 1

PHASE 2

PHASE 3

Input Power Cable
(Customer supplied)

Main
Contactor

7 Position
Terminal Block

Auto
Transformer

Factory Wired
for 575 volts

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

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

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

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

CAUTION

!

Input Power Jumper Connection

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

Factory wired for 575 V.

8. Connect jumper wire to the proper input voltage

connector located on the 7-position terminal block.
TB2

3-3

SECTION 3 INSTALLATION

3.5 Interconnecting Lines

Black
Red/Orange
Yellow
Blue

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

Mounting Plate

Gas Line Bundle

Gas Bundle
Installation

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

Power supply and EFC Connections to J-Box

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

Torch Bundle

Torch Hose/Power
Cable Connection

Torch
Solenoid
Electrical
Connection

Torch Pilot Arc
Connection

Junction Box to Torch

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

3-6

SECTION 3 INSTALLATION

Precision Plasmarc Component Interconnecting Diagram

CNC

ASIOB

Control Lead

EFC/Junction

Box

High

Frequency

120VAC

Junction
Box

EFC

High Frequency 120VAC

Gas Line Bundle

Power Bundle

25 micron Filters

N

2

O

2

4

AirCH

Ar

Ground Rod

Torch

Cutting Table

Work Lead

Control Lead

Power Supply to CNC

Primary Power Cable

3-7

SECTION 3 INSTALLATION

Gas Line Contamination Will Damage

CAUTION

!

Proportional Valves

Purge Gas Lines

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

1/4 NPT

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 Filter

25μ Filters

N

O

2

2

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

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
# 7 Connection

CONTROL LEAD

3-9

SECTION 3 INSTALLATION

3.6 Torch Mounting

CAUTION

Do Not Cover Vent Hole.

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

Torch Mounting Options.

1.812" (46mm)

Diameter Collar

2.0" (51mm)

Diameter Sleeve

Vent Hole

• The torch is normally mounted by the 2.0 inch
diameter (51mm) sleeve. Do not cover vent hole.

• For custom alternative mounting, the torch can
be mounted by the 1.812" (46 mm) dia collar
shown. This insulated collar and its shoulder are
machined relative to the nozzle retainer thread on
the torch body.

• Use only specified mounting surfaces

3-10

SECTION 3 INSTALLATION

3.7 Torch Coolant

PILOT

CONTROL

CURRENT

RECISION PLASMARC

ARC

POWER

• Remove coolant fill cap at front of console and fill
coolant tank with 4 gallons (15 liters) of plasma
coolant, P/N 156F05 (one gallon).

Coolant
Fill Cap

CAUTION

!

3.8 Inspection of Gas and Coolant Lines

• Do not fill above maximum level

• Reinstall Cap.

Commercial Antifreeze Will Cause Torch To
Malfunction

Use Special Torch Coolant! P/N156F05

Due to high electrical conductivity, DO NOT use
tap water or commercial antifreeze for torch
cooling. A specially formulated torch coolant is
REQUIRED. This coolant also protects for
freezing to –34° C.

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

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

• Gas lines, use a standard soap solution.
Pressurize the system from the control (SDP file)

• Coolant- check connections for signs of moisture at
connections

3-11

SECTION 3 INSTALLATION

3.9 Replacement of EPROM in the Plasmarc Power Source Programmable Logic

Controller (PLC)

CAUTION

!

CAUTION

!

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
Damaged System Components

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

Mishandling Can Damage Electronic
Components.

Handle electronic components with care.

• Do not drop

• Do not bend pins

• Do not touch circuit components- handle

along edges when possible

Electronic Components Are Subject To

CAUTION

!

WARNING

!

Electro-Static-Discharge (ESD) Damage

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

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

Wear a protective ground strap when handling

sensitive electronic components.

Electric shock Can Kill!

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

3-12

SECTION 3 INSTALLATION

T
O
L

I
P

C
R

A

R
E

W

O

P

C

R

A

M

S

A

L

P

N

O

I

S

I

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

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

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

PLC

Left Side Panel

L

O
R
T

N
O

C

T
N
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

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.

EPROM Locked In Place

EPROM Lock Released

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

5. Remove the EFC EPROM from the packaging.

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

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

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

EPPESA= Series “A” EPROM, manual flow
control
P/N 99513607

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

3-14

SECTION 4 OPERATION

LOW

4.1 Power Supply Controls

4.1.1 Main Power Switch

EMERGENCY

STOP

DO NOT S WIT CH

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.

WHIL E CUTTING

4.1.2 Pilot Arc Switch

EMERGENC Y

STOP

POWER

ON

WARNING

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.

Adjusting Pilot Arc While in Operation Could
Damage Torch.

Do not adjust pilot arc switch while in operation.
Adjust before torch starts.

Precision Plasma with Electronic Flow Control -

4-1

SECTION 4 OPERATION

4.1.3 Fault Indicator Lights

4.1.4 Meters

Fault Indicator Lights

• Coolant flow will show low coolant flow. When
unit is turned on, the light will briefly show a fault
and then go out.

• Plasma Gas Pressure fault indicator -- low
Plasma Gas Pressure. Torch will not fire when
indicated. Not used for the EFC.

• Start Gas Pressure fault indicator -- low start
gas pressure. Torch will not fire when indicated.

Not used for the EFC.

• 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.

• Cutting Current Meter (A) -- Displays actual

cutting current in amperes.

• Cutting Voltage Meter (V) -- Displays actual

cutting voltage.

4-2

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

4.1.5 Current Control Switch

Control Remote/Panel Switch

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

• Output Current Dial – sets the cutting current
when current setting is made from the console
front panel. Dial reads 0 to 99.9 amps. 70.0
amps shown.

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

0-10 Vdc = 0-100 Adc

Precision Plasma with Electronic Flow Control -

4-3

SECTION 4 OPERATION

4.2 Cut Quality

4.2.1 Introduction

NOTICE

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

 4.2.2 Cut Angle, negative or positive
 4.2.3 Cut not flat, rounded or undercut
 4.2.4 Surface roughness
 4.2.5 Dross

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

• Make small incremental adjustments when

making corrections.

• Adjust Arc Voltage in 5 volt increments, up or

down as required.

• Adjust cutting speed 5% or less as required

until conditions improve.

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

4-4

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

4.2.2 Cut Angle

Negative Cut Angle

Part

Top dimension is greater than the bottom.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• Standoff low (arc voltage)

• Cutting speed slow (machine travel rate)

Drop Part

Part

Drop Part

Positive Cut Angle

Top dimension is less than the bottom dimension.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• High standoff High (arc voltage)

• Cutting speed fast

• Current high or low. (See Process Data for

recommended current level for specific nozzles).

Precision Plasma with Electronic Flow Control -

4-5

SECTION 4 OPERATION

4.2.3 Cut Flatness

Drop

Part

Top And Bottom Rounded

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

• High current for given material thickness (See

Process Data for proper settings).

Top Edge Undercut

• Standoff low (Arc Voltage)

Drop Part

4-6

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

4.2.4 Surface Finish

Process Induced Roughness

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

• Incorrect Shield Gas mixture (See Process Data)

Top View

Machine Induced

or

Process Induced

Roughness

Roughness

• Worn or damaged consumables

Machine Induced Roughness

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

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

(Refer to Maintenance Section in machine
owners manual).

• Carriage wheel adjustment

Precision Plasma with Electronic Flow Control -

4-7

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

Lag Lines

Cut Face

Roll over

setup. Refer to Process Data.

High Speed Dross

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

• Standoff high (arc voltage)

Side view

Lag Lines Cut Face

Globules

• Cutting speed fast

Slow Speed Dross

Forms as globules on bottom along kerf. Removes
easily.

• Cutting speed slow

4-8

Side View

Precision Plasma with Electronic Flow Control -

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

Precision Plasma with Electronic Flow Control -

4-9

SECTION 4 OPERATION

4.2.6 Dimensional Accuracy

NOTICE

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

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

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

NOTICE

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

4-10

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

4.3 Influence of Gas Options on Cut Quality

4.3.1 Introduction

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

NOTICE

4.3.2 Aluminum

Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material

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

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

• Smooth cut face

• Virtually no dross

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

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

Precision Plasma with Electronic Flow Control -

4-11

SECTION 4 OPERATION

Refer to Cutting Process Data in the PT24

NOTICE

Manual for recommended flow/pressure
settings.

4.3.3 Carbon Steel

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

• Smooth cut face

• Virtually no dross

Oxygen
Oxygen/Nitrogen

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

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

• Smooth cut face

• Virtually no dross

Oxygen
Nitrogen

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

4-12

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Refer to Cutting Process Data in the PT24

NOTICE

4.3.4 Stainless Steel

Manual for recommended flow/pressure
settings.

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

• Positive cut angle

• Excellent dross performance

• Shiny cut surface.

Nitrogen
Nitrogen/Methane

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

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

• Dark cut face

• Virtually dross free

• Improved cut squareness

Oxygen
Oxygen/Nitrogen

Low amperage cutting/slower speeds produce squarer cuts in thin
materials. The oxygen allows for a lower arc voltage, improving cut
squareness. The “B” nozzle is used at 30 amps

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

• Cut edge dark

• good dross performance

• Good cut angle

Air
Air

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

Precision Plasma with Electronic Flow Control -

4-13

SECTION 4 OPERATION

NOTICE

Stainless Steel

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

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

• Matted cut edge appearance

• Light gray color

• Much smoother finish

• Possible slight increase in cut angle

Air
Air/Methane

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

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

• Dark cut face similar to air

• Excellent dross performance

• Good cut angle

Nitrogen
Nitrogen

Shield and plasma gases combine, the volume/pressure of shield gas
can negatively affect cut squareness. Higher shield volume produces
a negative cut angle. A lower volume, produces a positive angle.

4-14

Material Thickness:

Cut Qualities:

Plasma Gas:

Shield Gas:

Discussion:

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

• Shiny cut face

• Lip formation at the bottom

• Dross formation can be extensive and difficult to remove

Nitrogen
Nitrogen/Methane
Because methane is a fuel gas, flow/pressure rates can affect the cut

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

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

2

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

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

4.4 Process Data

4.4.1 Introduction

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

• cutting aluminum, carbon and stainless steel

• arc voltage (standoff)

• cutting speed

• current (amperes)

• gas flow rates for all plasma/shield gas

combinations

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

Also included is information on consumable part

numbers for current being used.

Precision Plasma with Electronic Flow Control -

4-15

SECTION 4 OPERATION

4.4.2 Process Data

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
30

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21536 (3 holes)

! Nozzle
P/N 21541, "B"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-16

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.062 0.075 0.090 0.125 0.187 0.250

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45 45 45

SG1- Cut 20 20 20 20 20 20

30 Amperes

Aluminum

PG SG1 SG2

N

2

0 0 0 0 0 0

40 40 40 40 40 40

55 55 55 55 55 55

N

CH

2

4

SG2- Cut Flow 10 10 10 10 10 10

Flow Reading

Arc Voltage (standoff)

150 152 153 158 170 189

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

150 135 105 78 30 25

3810 3429 2667 1981 762 635

Precision Plasma with Electronic Flow Control -

4-17

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
55

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21542, "C"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-18

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

55 Amperes

Aluminum Aluminum

PG SG1 SG2

N

Material Thickness

IN 0.062 0.125 0.187 0.250

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

Pierce Delay (SEC.)

2

0 0 0 0

N

CH

2

4

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 55 55 55 55

SG1- Cut 20 20 20 20

45 45 45 45

75 75 75 85

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

136 139 152 168

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

170 130 78 46

4318 3302 1981 1168

Precision Plasma with Electronic Flow Control -

4-19

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
70

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21543, "D"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-20

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45

SG1- Cut 20 20 20 20

70 Amperes

Aluminum

PG SG1 SG2

N

2

0 0 0.1 0.2

65 65 65 65

100 100 100 100

N

CH

2

4

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

150 157 168 178

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 65 55 30

2032 1651 1397 762

Precision Plasma with Electronic Flow Control -

4-21

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Aluminum
100

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21923, "E"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-22

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 31 31 31 31

100 Amperes

Aluminum

PG SG1 SG2

N

2

0 0 0.1 0.1

80 80 80 80

100 100 100 100

N

CH

2

4

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

155 160 166 174

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

95 80 65 50

2413 2032 1778 1270

Precision Plasma with Electronic Flow Control -

4-23

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
16

Oxygen (O2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21852 (2 holes)

! Nozzle
P/N 21540, "A"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-24

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

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

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 20 20 20 20 20 20

SG1- Cut 0 0 0 0 0 0

16 Amperes

Carbon Steel

PG SG1 SG2

O

2

0 0 0 0.1 0.5 0.5

20 20 20 20 20 20

11 11 11 11 11 11

N

2

O

2

SG2- Cut Flow 6 6 6 6 6 7

Flow Reading

Arc Voltage (standoff)

103 105 115 118 116 117

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

100 85 80 60 50 36

2540 2159 2032 1524 1270 914

4-25

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
35

Oxygen (O2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21536 (3 holes)

! Nozzle
P/N 21541, "B"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-26

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 14GA 0.125 0.135 0.187 0.250

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 50 50 50 50 50

SG1- Cut 0 0 0 0 0

35 Amperes

Carbon Steel

PG SG1 SG2

O

2

0 0 0 0 0

38 38 38 38 38

15 15 15 15 15

N

2

O

2

SG2- Cut Flow 6 6 6 6 6

Flow Reading

Arc Voltage (standoff)

113 119 120 122 124

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

80 55 52 40 30

3032 1397 1320 1016 762

4-27

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
45

Oxygen (O2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21542, "C"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-28

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.135 0.187 0.250 0.375

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 50 50 50 50 50

SG1- Cut 18 18 18 18 10

45 Amperes

Carbon Steel

PG SG1 SG2

O

2

0.3 0.3 0.3 0.3 0.4

50 50 50 50 50

20 20 20 20 20

N

2

O

2

SG2- Cut Flow 0 0 0 0 0

Flow Reading

Arc Voltage (standoff)

108 111 114 121 124

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

60 50 45 35 20

1524 1270 1143 889 508

4-29

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
70

Oxygen (O2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21543, "D"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-30

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.312 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60 60 60

SG1- Cut 33 33 33 33 20 20

70 Amperes

Carbon Steel

PG SG1 SG2

O

2

0.3 0.3 0.3 0.4 0.5 0.5

60 60 60 60 60 60

25 25 25 25 25 25

N

2

O

2

SG2- Cut Flow 0 0 0 0 0 0

Flow Reading

Arc Voltage (standoff)

108 110 114 113 135 140

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

110 95 70 60 30 25

2794 2413 1778 1524 762 635

4-31

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Carbon Steel
100

Oxygen (O2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21923, "E"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-32

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.312 0.375 0.500 0.625 0.750

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60 60

SG1- Cut 30 30 30 30 30

100 Amperes

Carbon Steel

PG SG1 SG2

O

2

0.3 0.3 0.4 0.5 0.5

80 80 80 80 80

30 30 30 30 30

N

2

O

2

SG2- Cut Flow 0 0 0 0 0

Flow Reading

Arc Voltage (standoff)

115 120 132 137 143

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

90 80 50 30 25

2290 2030 1270 760 630

Precision Plasma with Electronic Flow Control -

4-33

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
30

Oxygen (O2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Oxygen (O2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21536 (3 holes)

! Nozzle
P/N 21541, "B"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-34

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 26GA 24GA 22GA 18GA 16GA

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 40 40 40 40 40

SG1- Cut 20 20 20 20 20

30 Amperes

Stainless Steel

PG SG1 SG2

O

2

0 0 0 0 0

45 45 45 45 45

18 18 18 18 18

N

2

O

2

SG2- Cut Flow 5 5 5 5 5

Flow Reading

Arc Voltage (standoff)

105 105 107 109 111

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –LOW.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

250 200 190 140 100

6350 5080 4826 3556 2540

4-35

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
50

Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21542, "C"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-36

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.375

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45

SG1- Cut 35 35 35 35

50 Amperes

Stainless Steel

PG SG1 SG2

Air Air Air

0 0 0.1 0.2

60 60 60 60

95 95 95 95

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

134 140 145 157

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

90 60 40 22

2286 1524 1016 559

4-37

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21543, "D"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-38

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 40 40 40 40

70 Amperes

Stainless Steel

PG SG1 SG2

Air Air Air

0.3 0.4 0.5 0.6

70 70 70 70

95 95 95 95

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

131 152 158 162

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

100 50 28 24

2540 1270 711 609

4-39

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)
Air @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21923, "E"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-40

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 35 35 35 40

100 Amperes

Stainless Steel

PG SG1 SG2

Air Air Air

0.3 0.4 0.5 0.6

80 80 80 80

65 65 65 70

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

129 135 142 150

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

80 60 35 25

2030 1520 889 635

4-41

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21543, "D"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-42

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.387 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60 60

SG1- Cut 40 40 40 40 40

70 Amperes

Stainless Steel

PG SG1 SG2

Air Air CH

0.2 0.3 0.4 0.5 0.6

70 70 70 70 70

100 100 100 100 100

4

SG2- Cut Flow 10 10 10 10 10

Flow Reading

Arc Voltage (standoff)

131 146 154 166 175

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

120 80 50 30 24

3048 2032 1270 762 609

4-43

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Air @ 125 psi (8.6 bar)
Air @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21923, "E"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-44

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 40 40 40 40

100 Amperes

Stainless Steel

PG SG1 SG2

Air Air CH

0.3 0.4 0.5 0.6

80 80 80 80

100 100 100 100

4

SG2- Cut Flow 10 10 10 10

Flow Reading

Arc Voltage (standoff)

140 150 159 170

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

80 60 35 25

2030 1524 889 635

4-45

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
50

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21542, "C"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-46

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.125 0.187 0.250 0.375

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 45 45 45 45

SG1- Cut 35 35 35 35

50 Amperes

Stainless Steel

PG SG1 SG2

N

2

0 0 0.1 0.2

60 60 60 60

85 85 85 85

N

2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

128 133 144 155

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

90 60 40 22

2286 1524 1016 558

4-47

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21543, "D"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-48

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 40 40 40 40

70 Amperes

Stainless Steel

PG SG1 SG2

N

2

0.3 0.4 0.5 0.6

70 70 70 70

95 95 95 95

N

2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

132 150 154 159

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

75 50 28 24

1905 1270 711 609

4-49

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21923, "E"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-50

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 50 35 35 35

100 Amperes

Stainless Steel

PG SG1 SG2

N

2

0.3 0.4 0.5 0.6

80 80 80 80

95 95 95 95

N

2

SG2- Cut Flow 0 0 0 0

Flow Reading

Arc Voltage (standoff)

135 145 153 157

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

80 60 35 25

2032 1520 889 635

4-51

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
70

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

! Swirl Baffle
P/N 21692 (4 holes)

! Nozzle
P/N 21543, "D"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-52

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are
the only two
replaceable torch
front-end parts that
may vary with
amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.187 0.250 0.375 0.500

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 43 43 43 43

70 Amperes

Stainless Steel

PG SG1 SG2

N

2

0.3 0.4 0.5 0.6

75 75 75 75

85 85 85 85

N

CH

2

4

SG2- Cut Flow 5 5 5 5

Flow Reading

Arc Voltage (standoff)

136 150 159 162

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

70 50 28 24

1778 1270 711 609

4-53

SECTION 4 OPERATION

RECISION
LASMARC

PT-24 Torch

Material:

Amperes:

Plasma Gas:

Shield Gas:

Shield Mix Gas:

Stainless Steel
100

Nitrogen (N2) @ 125 psi (8.6 bar)
Nitrogen (N2) @ 125 psi (8.6 bar)
Methane (CH4) @ 100 psi (6.9 bar)

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

!Swirl Baffle
P/N 21692 (4 holes)

!Nozzle
P/N 21923, "E"

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-54

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are

the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Process Data

Material Thickness

IN 0.250 0.375 0.500 0.625

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

Pierce Delay (SEC.)

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

SG1-Start 60 60 60 60

SG1- Cut 45 45 45 45

100 Amperes

Stainless Steel

PG SG1 SG2

N

2

0.3 0.4 0.5 0.6

80 80 80 80

95 95 95 95

N

CH

2

4

SG2- Cut Flow 5 5 5 7

Flow Reading

Arc Voltage (standoff)

138 150 162 170

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

80 60 35 25

2032 1524 889 635

Precision Plasma with Electronic Flow Control -

4-55

SECTION 4 OPERATION

Plasma Marking “B” Nozzle

RECISION
LASMARC

PT-24 Torch

Amperes:

10

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

!Swirl Baffle
P/N 21536 (3 Holes)

!Nozzle
P/N 21541 “B”

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-56

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are

the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 35

SG1- Cut 35

SG2- Cut Flow 0

“B” Nozzle

10 Amperes

35

35

Arc Voltage (standoff)

77

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

Precision Plasma with Electronic Flow Control -

200

5080

4-57

SECTION 4 OPERATION

Plasma Marking “B” Nozzle

RECISION
LASMARC

PT-24 Torch

Amperes:

15

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

!Swirl Baffle
P/N 21536 3 holes

!Nozzle
P/N 21541 “B”

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-58

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are

the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 35

SG1- Cut 35

SG2- Cut Flow 0

“B” Nozzle

15 Amperes

35

35

Arc Voltage (standoff)

77

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

300

7620

Precision Plasma with Electronic Flow Control -

4-59

SECTION 4 OPERATION

Plasma Marking “C” Nozzle

RECISION
LASMARC

PT-24 Torch

Amperes:

10

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

!Swirl Baffle
P/N 21692 (4 holes)

!Nozzle
P/N 21542 “C”

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-60

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are

the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 37

SG1- Cut 37

SG2- Cut Flow 0

“C” Nozzle

10 Amperes

62

62

Arc Voltage (standoff)

77

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

100

2540

Precision Plasma with Electronic Flow Control -

4-61

SECTION 4 OPERATION

Plasma Marking “C” Nozzle

RECISION
LASMARC

PT-24 Torch

Amperes:

15

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

!Swirl Baffle
P/N 21692 (4 holes)

!Nozzle
P/N 21542 “C”

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-62

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are

the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -

SECTION 4 OPERATION

Plasma Marking

Process Data

Setup Parameters (see notes)

Plasma Start Gas 1
Plasma Cut Gas 1

Shield Gas

(Flow Reading)

Flow Reading

SG1-Start 35

SG1- Cut 35

SG2- Cut Flow 0

“C” Nozzle

15 Amperes

62

62

Arc Voltage (standoff)

77

Travel Speed

IPM
MM/MIN

Notes:

1. Pilot Arc –HIGH.

2. Cut and ALT gas mix in Flow Control.

3. Float – Center of Ball

200

5080

Precision Plasma with Electronic Flow Control -

4-63

SECTION 4 OPERATION

Plasma Marking “D” Nozzle

RECISION
LASMARC

PT-24 Torch

Amperes:

10

Plasma Gas: Argon @ 125 PSI / 8.6 Bar

Shield Gas: Air @ 125 PSI/ 8.6 Bar

Torch Body
P/N 21758

Water Baffle
P/N 21725

O-Ring
P/N 638797

O-Ring
P/N 86W62

O-Ring
P/N 950714

O-Ring
P/N 98W18

Electrode
P/N 21539

!Swirl Baffle
P/N 21692 (4 holes)

!Nozzle
P/N 21543 “D”

Nozzle
Retainer/Diffuser

Shield Cup Insulator
P/N 22010

Insulator Shield
Retainer w/O-Ring

4-64

O-Ring - Shield Retainer

. (Ref. P/N 996528)

Cup shield w/Retainer
P/N 22531

! Baffle and Nozzle are

the only two

replaceable torch

front-end parts that

may vary with

amperage

Precision Plasma with Electronic Flow Control -