ESAB PT-24 Precision Plasmarc System Series “B Installation manual / Instruction manual

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F15-800

Aug, 2008

Installation, Operation and Maintenance for the

PT-24 Precision Plasmarc System

Series “B”

411 South 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 F15800 .

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.

Printed in U.S.A.

Table of Contents

SECTION TITLE PAGE PARAGRAPH

SECTION 1

Safety ................................................................................................................................... 4

UNPACKING/HOISTING...................................................................................................... 18

1.1 Inspection ............................................................................................................................ 18

1.2 Hoisting................................................................................................................................ 18

SECTION 2 DESCRIPTION...................................................................................................................... 19

2.1 General................................................................................................................................. 19

2.2 Scope ................................................................................................................................... 19

2.3 Package Options Available ................................................................................................ 19

SECTION 3 INSTALLATION.................................................................................................................... 23

3.1 General................................................................................................................................. 23

3.2 Equipment Required........................................................................................................... 23

3.3 Location ............................................................................................................................... 23

3.4 Primary Electrical Input Connections............................................................................... 23

3.5 Interconnecting Lines......................................................................................................... 24

SECTION 4 OPERATION......................................................................................................................... 33

4.1 Power Source Controls/Indicators.................................................................................... 33

4.2 Operation ............................................................................................................................. 34

4.3 Sample Procedure for Setting O

4.4 Sample Procedure for Setting N

PROCESS DATA SHEETS .................................................................................................. 37

KERF .................................................................................................................................... 58

SECTION 5 CUTTING QUALITY ............................................................................................................. 71

5.1 Cut Angle ............................................................................................................................. 71

5.2 Voltage and Cut Quality ..................................................................................................... 72

5.3 Top Dross ............................................................................................................................ 74

5.4 Dross Formation ................................................................................................................. 74

5.5 Summary.............................................................................................................................. 75

SECTION 6 MAINTENANCE ................................................................................................................... 77

6.1 General................................................................................................................................. 77

6.2 Inspection and Cleaning .................................................................................................... 77

6.3 Torch Consumable Parts ................................................................................................... 77

6.4 Gas Pressure Switch .......................................................................................................... 77

6.5 PT-24 Torch Description and Maintenance...................................................................... 77

6.6 Torch Maintenance ............................................................................................................. 78

6.7 PT-24 Consumable Removal, Inspection and Installation.............................................. 78

SECTION 7 TROUBLESHOOTING ......................................................................................................... 81

7.1 Troubleshooting.................................................................................................................. 81

7.2 Process Troubleshooting................................................................................................... 81

7.3 Troubleshooting Procedures............................................................................................. 83

7.4 Schematics and Wiring ...................................................................................................... 88

SECTION 8 REPAIR PARTS ................................................................................................................... 97

8.1 General................................................................................................................................. 97

8.2 Ordering ............................................................................................................................... 97

REPLACEMENT PARTS LISTS .......................................................................................... 98

Gas Flow Rates on Flow Control Box ..................... 35

Gas Flow Rates on Flow Control Box ...................... 35

Table of Contents

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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.

1-1

SECTION 1 SAFETY

1.2 Safety Notations And Symbols

DANGER

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

ALERT or ATTENTION. Your safety is involved or potential equipment failure exists. Used with other symbols and information.

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

WARNING

CAUTION

NOTICE

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

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

Used to call attention to minor hazards to equipment.

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

1-2

SECTION 1 SAFETY

1.3 General Safety Information

Machinery often starts automatically.

WARNING

This equipment moves in various directions and speeds.

• Moving machinery can crush.

• Only qualified personnel should operate or

service this power source.

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

• 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 any equipment.

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.

1-3

SECTION 1 SAFETY

Failure to follow safety warning label

WARNING

1.4 Installation Precautions

instructions could result in death or serious injury.

Read and understand all safety warning labels on machine.

Refer to operator’s manual for additional safety information.

WARNING

Improperly Installed Equipment Can Cause Injury Or Death.

Follow these guidelines while installing machine:

• Contact your ESAB representative before

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

• Never attempt any machine modifications or

apparatus additions without first consulting a qualified ESAB representative.

• Observe machine clearance requirements

for proper operation and personnel safety.

• Always have qualified personnel perform

installation, troubleshooting and maintenance of this equipment.

• Provide a wall mounted disconnect switch

with proper fuse sizes close to the power supply.

1-4

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

1.6 Operating A Plasma Cutting Machine

Improper grounding can cause severe injury or death.

Machine must be properly grounded before put into service.

Flying debris and loud noise

WARNING

hazards.

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

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

• Noise from plasma arc can damage hearing.

Wear correct ear protection when cutting above water.

Burn hazard.

WARNING

Hot metal can burn.

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

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

1-5

SECTION 1 SAFETY

Hazardous voltages. Electric shock

WARNING

can kill.

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

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

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

• Do not touch live electrical parts.

• Keep all panels and covers in place when

machine is connected to power source.

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

• Keep gloves, shoes, clothing, work area,

and equipment dry.

• Replace worn or damaged cables.

Fume hazard.

WARNING

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

• Do NOT breathe fumes.

• Do not operate plasma torch without fume

removal system operating properly.

• Use additional ventilation to remove fumes if necessary.

• Use approved respirator if ventilation is not

adequate.

•

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

• Do not operate near degreasing and

spraying operations. Heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas and other irritant gases.

1-6

SECTION 1 SAFETY

Radiation hazard.

WARNING

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.

 Use special paint on walls to absorb

UV light.

 Install protective screens or curtains to

reduce ultraviolet transmission.

1-7

SECTION 1 SAFETY

Burn Hazard.

WARNING

Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible material.

• Do not have on your person any

combustibles (e.g. butane lighter).

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

• Wear correct eye and body protection.

• Wear gauntlet gloves, safety shoes and hat.

• Wear flame-retardant clothing covering all

exposed areas.

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

• Have fire extinguishing equipment available for use.

Explosion hazard.

WARNING

• Certain molten aluminum-lithium (Al-Li)

alloys can cause explosions when plasma cut OVER water.

 These alloys should only be dry cut on

a dry table.

 DO NOT dry cut over water.

 Contact your aluminum supplier for

additional safety information regarding hazards associated with these alloys

• Do not cut in atmospheres containing

explosive dust or vapors.

• Do not carry any combustibles on your

person (e.g. butane lighter)

• Do not cut containers that have held

combustibles.

1-8

SECTION 1 SAFETY

1.7 Service Precautions

Hazardous voltages. Electric shock

WARNING

can kill.

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

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

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

• Do not touch live electrical parts.

• Keep all panels and covers in place when

machine is connected to power source.

• Keep gloves, shoes, clothing, work area,

and equipment dry.

WARNING

• Inspect power and ground leads cables for

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

• Never bypass safety interlocks.

• Follow lock-out procedures.

Hot Torch can cause skin burns.

Allow torch to cool before servicing.

1-9

SECTION 1 SAFETY

Danger of Electric Shock.

DANGER

CAUTION

Torch may be electrically active.

Turn off Plasma Power Console before servicing.

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

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

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

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

1-10

SECTION 1 SAFETY

1.8 Safety References -- Regulations, Standards, Guidelines

1.8.1 USA

The following 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

1.8.2 International

Accident Prevention

VBG- Unfallverhütungsvorshriften

General Provisions

VBG 1

Allgemeine Unfallverhütungsvorshriften

Electrical Equipment and operating Equipment

VBG 4

Elektrische Anlagen

Welding, Cutting and related working methods

VBG 15

Schweißen un Schneiden un verwandte Verfahren

Shot Blasting Works

VBG 48

Strahlarbeiten

Gases

VBG 61

Gase

Oxygen

VBG 62

Sauerstoff

1-12

Operating liquid jet cutting machines

VBG 87

Arbeiten mit Flüssigkeitsstrahlem

VBG 93

Laser beams, accident prevention and Electrotechnology

Laserstrahlung, Unfallverhütungs-vorschriften für Feinmechnik und Elektrotechnik

Noise

VBG 121

Lärm

SECTION 1 SAFETY

VDE Regulations

VDE - Vorschriften

VDE 0100

Erection of power installations with normal voltages up to 1000 volts Bestimmungen für das Errichten von Stakstromanlagen mit Nennspannungen bis 1000 Volt

Electrical equipment of industrial machines

VDE0113

VDE 0837

VDE 0837-

Elektrishe Ausrüstung von Industriemaschinen

Radiation safety of laser products; users guide (DIN EN

60825) Strahlungssicherheit von Lasereinrichtungen und Benutzungsrichtlinen (DIN EN 60825)

Specification for laser guards

Anforderung an Lasershcutzwänden

TRAC Technical Rules for Acetylene and Carbide Stores TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager

Acetylene lines

TRAC-204

Azetylenleitungen

TRAC-206

TRAC-207

Acetylene cylinder battery systems

Azetylenflaschenbatterieanlagen

Safety devices

Sicherheitseinrichtungen

1-13

SECTION 1 SAFETY

TRG Technical Rules for Pressure gases TRG – Technische Regein für Druckgase

TRG 100

TRG 101

TRG 102

TRG 104

General regulations for pressure gases

Allgemeine Bestimmungen für Druckgase

Pressure gases

Druckgase

Technical gas mixtures

Technishe Gasgemische

Pressure gases; alterative use of compressed gas tanks

Druckgase, wahlweise Verwendung von Druckgasbehältem

1-14

SECTION 1 SAFETY

TRGS – Technische Richtlinien für Gefahrstoffe

TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe

DIN Standards

DIN-Normen

TRGS-402

TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)

TA TA-Luft un TA-Lärm (BLm SchV)

DIN 2310

Part 1

Teil 1

DIN 2310

Part 2

Teil 2

DIN 2310

Part 4

Teil 4

Ermittlung u. Beurteilung der Konzentration gefährlicher Stoffe in der Luft im Arbeitsbereich

Thermal cutting; terminology and nomenclature

Thermsiches Schneiden, Allgemeine Begriffe und Bennungen

Thermal cutting; determination of quality of cut faces

Thermsiches Schneiden, Ermittein der Güte von Schnittflächen

Thermal cutting; arc plasma cutting; process principles, quality, dimensional tolerances Thermsiches Schneiden, Plasmaschneiden, Verfahrensgrundlagen, Güte, Maßtoleranzen

DIN 2310

Part 5

Teil 5

DIN 2310

Part 6

Teil 6 Einführung, Verfahren

DIN 4844

Part 1

Teil 1 Sicherheitskennzeichen (Siehe EN 7287)

Thermal cutting; laser beam cutting of metallic materials; process principles Laserstrahlschneiden von metallischen Werkstoffen, Verfahrensgrundlagen, Güte, Maßtoleranzen

Thermal cutting; Classification, processes

Safety markings (DIN EN 7287)

1-15

SECTION 1 SAFETY

DIN EN ISO Harmonized Standards DIN EN ISO-Harmonisierte Normen

DIN EN

292/1 and 2

DIN EN 559

DIN EN 560

DIN EN 561

DIN EN

626-1

Safety of machinery

Sicherheit von Maschinen, Geräten und Anlagen

Hoses for welding, cutting and allied processes

Schläuche für Schweißen, Schneiden und verwandte Verfahren

Hose connections and hose couplings for equipment for welding, cutting and allied processes Schlauchanschlüsse und Schlauchverbindungen für Geräte zum Schweißen, Schneiden und verwandte Verfahren

Gas welding equipment hose couplings

Gasschweißgeräte, Kupplungen

Safety of machines, reduction of risks to health

Sichereit von Maschinen, Reduzierung des Gesundheitsrisikos

DIN EN

848-1

DIN EN

1829

DIN EN

9013

DIN EN

12584

DIN EN

12626

Single spindle vertical milling machines

Fräsmaschine für einseitige Bearbeitung mit drehendem Werkzeug

High pressure water jet machines

Hochdruckwasserstrahlschneidmaschine

Thermal cutting, oxygen cutting, process principles, dimensional tolerances Thermisches Schneiden, Autogenes Brennschneiden, Verfahrensgrundlagen, Güte, Maßtoleranzen

Imperfections in oxy/fuel flame cuts, laser beam cuts and plasma Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und Plasmaschnitten

Laser processing machines

Laserbearbeitungsmaschinen

1-16

SECTION 1 SAFETY

DIN EN

28206

DIN EN

31252

DIN EN

31553

DIN EN

60204-1

DIN EN

60825

Acceptance testing for oxygen cutting machines

Abnahmeprüfung für Brennschneidmaschinen

Laser Equipment

Lasergeräte

Laser and laser related equipment

Laser und Laseranlagen

Electrical equipment of machines

Elekrische Ausrüstung von Maschinen

Radiation safety of laser products

Strahlensicherheit von Laseranlagen

Arrangement of protection devices

DIN EN 999

Anordnung von Schutzeinrichtungen

VDI Guidelines

VDI 2906

Quality of cut faces on metallic workpieces; abrasive water jet cutting and arc plasma cutting Schnittflächenqualität beim Schneiden von Werkstücken aus Metall, Abrasiv- Wasserstrahischneiden und Plasmastrahischneiden

Room air; Technical systems for welding workshops

VDI 2084

Raumluft techn. Anlagen für Schweißwerkstätten

1-17

SECTION 1B UNPACKING/HOISTING

1.1 INSPECTION

A. The Precision Plasmarc System will be shipped in

four separate containers. The power source, the junction box, the flow control box and the PT-24 torch components will all have their own containers. Remove all packing material and inspect for evidence of concealed damage which may not have been apparent upon receipt of the four containers. All four components, the power source, flow control box, junction box and PT-24 torch are fully assembled. Immediately notify the carrier of any defects or damage.

B. Check each container for any loose parts prior to

disposing of shipping materials.

C. Check air louvers on the power source and junction

box and any other opening to ensure that any obstructions are removed.

1.2 HOISTING

The power source is equipped with one lifting eye that enables the unit to be hoisted.

SECTION 2 DESCRIPTION

2.1 GENERAL

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 power source also provides control voltage to the flow control box for precise control of the plasma gas and shield gas to the PT-24 torch.

Table 2-1. Available Package Options

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)deriuqer(xoBlortnoCwolF 61473N/P

)deriuqer(tinUFHhtiwxoBnoitcnuJ 00473N/P

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2.2 SCOPE

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

Table 2-1 lists Precision Plasmarc package options available through your ESAB dealer.

7853008550N/P

0641008550N/P 4781008550N/P

1641008550N/P

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)deriuqereno(eldnuBeniLsaG .tf01 .tf02 .tf03 .tf06

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)deriuqerowt(xoB .tf01 .tf02 .tf03 .tf06

.tf001

)deriuqerl51(sreniatnocl8.3tnalooChcroT 50F651N/P

tiKstraPerapS42-TP 90673N/P

50912N/P 60912N/P 70912N/P

20912N/P 30912N/P 40912N/P 43322N/P 53322N/P

71912N/P 81912N/P 91912N/P 02912N/P

12912N/P

NOTES: 1. 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.

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

SECTION 2 DESCRIPTION

Table 2-2. Technical Specifications

(Precision Plasma System)

Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz

Input Current 70/60/50/40/30/25 amps per phase

Power Factor 0.95

Output Current Range 15-100 amps dc

Output Load Voltage 215 V dc

Duty Cycle 100%

Open Circuit Voltage 315 V dc

PRECIS IO N P LASM A

POWER SUPPLY

O R

N O

42"

(1067mm)

WEIGHT = 560 lbs. (254 kg)

N E

R R

22" (559mm)

R E

W O

44"

(1118mm)

PRE CISION PLASMA

JUNCTION BOX

19.75"

(502mm)

WEIGHT = 26.5 lbs.(12 kg)

Flow Control

400 mm

6.75"

(171mm)

10.62"

(270mm)

275 mm

Figure 2-1. Precision Plasma System

275 mm

WEIGHT = 27 lbs. (12kg)

SECTION 2 DESCRIPTION

Table 2-3. Technical Specifications

(Plasma Gas)

Type O

, N2, Air

Pressure 125 psig (8.6 bar) Flow 100 cfh (47 I/min) max (varies with application) Purity Required O

-99.8%,N2-99.995%, Air-clean, dry, oil-free

Recommend Liquid Cylinder Oxygen: R-76-150-540LC (P/N 19777) Service Regulators Inert Gas: R-76-150-580LC (P/N 19977) Recommended Cylinder 2-Stage Oxygen: R-77-150-540 (P/N 998337) Regulators Hydrogen, Methane: R-77-150-350 (P/N 998342)

Nitrogen: R-77-150-580 (P/N 998344)

Industrial Air: R-77-150-590 (P/N 998348) Recommended Heavy-Duty Oxygen: R-76-150-024 (P/N 19151) Hi-FIow Station or Pipeline Regulators Recommended High-Capacity Non-Corrosive, Non-Toxic Industrial Gas: Station or Pipeline Regulators R-6703 (P/N 22236)

Table 2-4.Technical Specifications

(Starting Gas)

Type N

, Air

Pressure 125 psig (8.6 bar) Flow 60 cfh (28 I/min) max (varies with application) Purity Required 99.995%, Dry, clean, free of oil and matter

Table 2-5. Technical Specifications

(Secondary Gas)

Type N

H-35, Methane

2O2

Pressure 100 psig (6.9 bar) H-35, Methane 125 psig (8.6 bar) N

, O2, Air

Flow 60 cfh (28 I/min) max (varies with application) Purity Required N

-99.995%; O2-99.8%, H-35, Methane-99.8%

Table 2-6.Technical Specifications

(PT-24 Torch)

Type Water-Cooled, Dual Gas Rating 100 amps @ 100% duty cycle Dimensions: See Figure 8-9

Cooling Water PSI / Flow is 0.38 gpm (1.4 lpm) @ 115 psi (7.9 bar) measured at torch return hose of power supply.

SECTION 2 DESCRIPTION

SECTION 3 INSTALLATION

3.1 GENERAL

CAUTION

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

Be sure that the power source is properly configured for your input power supply. Do NOT connect a power source configured for 230 V to a 460 V input power supply. Damage to the machine may occur.

A. 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).

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

connecting workpiece to power source.

C. Primary Input Cable. See Section 3.4.

3.3 LOCATION

Adequate ventilation is necessary to provide proper cooling of the power source. Minimize the amount of dirt, dust, and excessive heat to which the equipment is exposed. There should be at least two feet of clearance between the power source and wall or any other obstruction to allow freedom of air movement through the power source.

Installing or placing any type of filtering device will restrict the volume of intake air, thereby subjecting the power source internal components to overheating. Use of any type of filter device voids the warranty.

3.4 PRIMARY ELECTRICAL INPUT CONNECTIONS (Figure 3-1)

WARNING

As shipped, the power source is configured for 575 V, 60 Hz input. If using 200, 230, 380, 415, or 460 V input, the jumper input power cables located on the auto transformer must be repositioned to the desired input voltage for safe operation. To gain access to the autotransformer, remove the right side panel. (See Figure 3-1.)

A line (wall) disconnect switch with fuses or circuit breakers should be provided at the main power panel (see Table 3-1 for fuse rating). The input power cable of the power source may be connected directly to the disconnect switch or a proper plug and receptacle may be purchased from a local electrical supplier. If using plug/receptacle combination, see Table 3-1 for recommended input conductors for connecting receptacle to line disconnect switch.

Table 3-1 Recommended Sizes For

Input Conductors and Lline Fuses

Input Requirements Input & Gnd Fuse Ratings/

Volts Phase Amps CU/AWG mm

200 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

*Sizes per National Electric Code for 75°C rated conductors @ 30°Cambient. Not more than three conductors in raceway or cable. Follow local codes if they specify sizes other than those listed above.

Conductor Phase, Amps

ELECTRIC SHOCK CAN KILL! Precautionary measures should be taken to provide maximum protection against electrical shock. Be sure that all power is off by opening the line (wall) disconnect switch and by unplugging the power cord to the unit before any connections are made inside of the power source.

The following procedure explains the proper installation steps for connecting primary electrical power to the power source. (See Figure 3-1.)

A. Remove right side panel.

B. Ensure input power cable is disconnected from all

electrical sources.

C. Route input power cable through the strain relief

located at the rear panel.

SECTION 3 INSTALLATION

D. Pull input power cable through the strain relief to allow

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

E. Connect input power cable ground wire to the ground

lug provided on the base of the power source.

F. Connect three power leads of the input power cable to

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

G. Connect jumper power cables from the bottom of the

main contactor to the proper input voltage marked on the auto transformer. The unit is factory set for 575 V.

CAUTION

Ensure each input power jumper cable is connected to the proper input voltage to be used on auto transformer.

H. Connect jumper wire to the proper input voltage

connector located on the 7-position terminal block. (See Figure 3-1.)

3.5 INTERCONNECTING LINES

(Refer to Figure 3-2)

A. All interconnecting service lines supplied are num-

bered on each end with corresponding numbers marked on the cabinets next to the connection to be made.

B. Connect all five lines in gas bundle (Figure 3-4) to Flow

Control Box and Junction Box (Figure 3-5).

C. Connect power and coolant lines in power bundle

(Figure 3-6) to junction box (Figure 3-7) and power source (Figure 3-2 or 3-3).

D. Remove panel from rear of console and attach the

pilot-arc, torch and work lead. See Figure 3-8 to replace panel.

TB1

TB2

200 230 380 415 460 575

Ground

Connection

PHASE 1

PHASE 2 PHASE 3

Input Power Cable

(customer supplied)

Main Contactor

7 Position Terminal Block

Auto Transformer

Factory wired for

575 volts

Figure 3-1. Power Source Primary Power Connection Diagram

(Shown factory connected in 575 V position)

SECTION 3 INSTALLATION

W/4 Gal. (1.5L)

Tank

COOLER

FLOW CONTROL BOX P/N-37416

Alternate Gas

Supplied by Customer

(Shield Addition)

POWER SOURCE

CONTROL LEAD - 14/19 Pin Connector

(Power Source to Flow Control Box)

CONTROL

AUTO TRANS.

POWER SOURCE P/N-37358

PRIMARY CABLE

(Customer Supplied)

19 pin

Control Lead P/N’s

30 ft. (9,1m) P/N-57002248

50 ft. (15,2m) P/N-57002249

75 ft. (22,9m) P/N-57002250

100 ft. (30,5m) P/N-57002251

WORK LEAD

(Customer Supplied)

2N2

14 pin

Alt

BACK

VIEW

See Fig. 3-7

PT-24 TORCH

4.5 ft. (1,4m) P/N 0558001460

12 ft. (3,7m) P/N 0558001874

17 ft. (5,2m) P/N 0558001461

CONTROL LEAD - 14 Pin Connector

(Supplied based on Customer Order)

160 ft. (48,8m) P/N-57002252

Note:

All service lines have identification

numbers stamped on connections

CONTROL LEAD

(Flow Control to

Junction Box)

7. Coolant to Torch

Power Bundle

#6. Coolant Return from Torch

JUNCTION BOX

with H.F. Unit

P/N-37400

CUTTING TABLE

(Customer Supplied)

HEIGHT CONTROL

(Customer Supplied)

Plasma

Start

ARC VOLTAGE REMOTE

(Customer Supplied)

CNC

#4. Shield Gas

Gas Bundle

Torch Power Cable

Pilot Arc Lead

#1. Cut Gas O

#5. Shield Gas, Preflow

#3. Plasma Gas N

#2. Cut Gas N

ARC VOLTAGE CONTROL

(Customer Supplied)

Figure 3-2. Precision Plasmarc Cutting Machine Interconnecting Diagram

Gas Bundle P/N’s

10 ft. (3m) P/N-21902

20 ft. (6m) P/N-21903

30 ft. (9m) P/N 21904

60 ft. (18m) P/N 22334

100 ft. (30m) P/N 22335

Power Bundle P/N’s

25 ft. (7.6m) P/N-21905

60 ft. (18m) P/N-21906

100 ft. (30m) P/N-21907

Control Lead P/N’s

10 ft. (3m) P/N-21917

20 ft. (6m) P/N-21918

30 ft. (9m) P/N-21919

60 ft. (18m) P/N-21920

100 ft. (30m) P/N-21921

SECTION 3 INSTALLATION

BUNDLE P/N #1 #2 #3 #4 #5 SHEATH

10 FT. (3m) 21902 21884 21875 21878 21887 21881 995832 20 FT. (6m) 21903 21885 21876 21879 21888 21882 995832 30 FT. (9m) 21904 21886 21877 21880 21889 21883 995826 60 FT. (18m) 22334 22337 22343 22345 22340 22347 995826 100 FT. (30m) 22335 22338 22344 22346 22341 22348 995826*

* 2 REQUIRED.

1 2 3 4 5

Junction Box with H.F. Unit

Figure 3-4. Gas Line Bundle

1 2 3 4 5

Flow Control

Box

Figure 3-5. Gas Bundle Installation

SECTION 3 INSTALLATION

No. 6 and No. 7 5/8-18 L.H.

(B-A/W) (B-A/W)

POWER CABLE#3 AWG

No. 6 and No. 7

5/8-18 L.H.

PILOT ARC #16 AWG(YELLOW)

POWER BUNDLE #6

25 FT. (7.6m) P/N-21905

60 FT. (18m) P/N-21906

100 FT. (30m) P/N-21907

(1) One 25 ft. piece Reqd. (2) Three 25 ft. pieces Reqd. (3) Four 25 ft. pieces Reqd.

Figure 3-6. Power Bundle

21911 21914

21912 21915

21913 21916

SHEATH

995832 (1)

995832 (2)

995832 (3)

Gas Tubing Bundle

Torch Assembly

Gas Tubing Bundle Connections:

Cut Gas (Yellow)

Shield Gas (Org. or Red)

Pre-Cut Gas (Black)

Start Gas (Blue)

Torch Pilot Arc

Torch Electrical (J2) Cable

Torch Negative

Power Cable

Hose No. 6

Power Bundle Assembly

Pilot Arc Cable

Hose No. 7

Figure 3-7. Power Bundle/Junction Box Connection

SECTION 3 INSTALLATION

E. Connect control lead (Figure 3-9) between the power

source and the flow control and from the flow control to the junction box. See Figure 3-2 or Figure 3-3 for the installation location.

CONTROL LEADS P/N'S

10 FT. (3m) P/N-21917 20 FT. (6m) P/N-21918 30 FT. (9m) P/N-21919

Figure 3-9. Available Control Lead

F. Torch Mounting Options.

1. The torch is normally mounted by the sleeve.

2. For more precise mounting, the torch can be mounted by the 1.812" (46 mm) dia collar shown (see Figure 3-10). This insulated collar and its shoulder are machined relative to the nozzle retainer thread on the torch body and is held concentric to the cutting nozzle within a total indicator reading of 0.010 inches (0.25 mm) or the nozzle bore is within 0.005 inches of any point on the 1.812 dia.

60 FT. (18m) P/N-21920 100 FT. (30m) P/N-21921

Figure 3-8. Power Bundle/Power Source Rear

Panel Connection

NOTE

When mounting, be sure not to cover the small vent hole in the side of the sleeve. This hole prevents coolant from building inside the sleeve should a leak occur in a service line.

1.812" (46mm)

Diameter Collar

2.0" (51mm)

Diameter Sleeve

Vent Hole

Figure 3-10. Torch Mounting Options

COOLA FILL CA

SECTION 3 INSTALLATION

G. Remove coolant fill cap at front of console and fill

coolant tank with 4 gallons (15 l) of plasma coolant. See Figure 3-11. Reinstall cap.

NOTE

Due to the high electrical conductivity, use of tap water or commercial antifreeze must NOT be used for torch cooling. A specially formulated torch coolant, P/N 156F05 (1 gallon (3.8 l) container) is available and recommended for torch cooling. The coolant also provides freeze protection down to -34° C.

NOTE

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

T O

L O

R R U

R E W

Flow Control Box

Alt.

XN2O

Alternate Gas (Shield Addition)

Figure 3-11. Filling Coolant

H. Make all connections to the CNC and height control.

See instructions provided with equipment supplied.

I. Connect gas supply to flow control. See gas require-

ments as listed in Tables 2-3, 2-4, and 2-5. (See Figure 3-12.)

J. With installation complete, check for gas and coolant

leaks with a standard soap solution as follows (see Figures 3-13 and 3-14):

Supplied by Customer

Figure 3-12. Gas Supply Connection

1. Close all valves on the gas flow control cabinet.

2. Set all inlet gas pressures to 125 psig (8.6 bar).

3. Turn the power source ON. The amber light to the left of the switch will glow, the console fan will operate and coolant will flow.

4. Coolant pump pressure should be 80 to 90 psi (5.5 to 6.2 bar). See coolant pump pressure gauge on front of console.

5. Check for leaks on connections No. 6 and 7 on the back of the console and in the junction box. Check the torch power cable and pilot arc cable connections in the junction box.

6. Check the vent hole in the side of the torch sleeve and the torch consumables.

7. With console ON, use a solution of soap and water. Check all gas connections for pressure tightness as per following:

SECTION 3 INSTALLATION

(a) Place the "plasma gas" select switch, SW-2,

in O2 position.

(b) Place the "shield gas" select switch, SW-3,

in O2 + N2 position.

position.

(d) Open valve NV-3 (start gas valve) and NV-6

(shield gas pre-flow valve) approximately two full turns.

(e) Check all gas connections on lines 2 and 5

and torch connections in junction box. Close valves NV-3 (start gas valve) and NV-6 (shield gas pre-flow valve).

(f) Place SW-1 in operate position to verify that

N2 output pressure on right side of control remains pressurized.

(g) Move switch SW-1 to CUT position.

(h) Open valves NV-1 (oxygen plasma gas valve)

and NV-5 (cut shield gas valve) approximately two full turns.

(i) Check all gas connections on line 1 and 4.

Recheck torch connections in junction box. Correct as needed.

(j) Close valves NV-1 (oxygen plasma gas

valve) and NV-5 (cut shield gas valve).

(k) Place SW-1 in operate position to verify that

O2 output pressure remains pressurized.

(l) Place plasma gas select switch SW-2 in N

position.

(m) Open valve NV-2 (nitrogen plasma gas) ap-

proximately two full turns.

(n) Check all gas connections on line 2 for leaks.

Correct as needed.

(o) Place SW-1 in operate position to verify that

N2 output pressure remains pressurized.

NV-6

SW-1

NV-1

NV-2

Front View

SW-2

SW-3

NV-3

O2 Pressure

Out

N2 Pressure

Out

Plasma Start

Press. Out

NV-5

NV-4

Figure 3-13. Flow Control Controls

PLASMA GAS

SHIELD GAS

N2+ALT

O2+N

Left Side View

SECTION 3 INSTALLATION

Flow Control Box

Alt. N

NOTE: The numbers in circles correspond with the steps

needed to check gas and coolant leaks.

Figure 3-14. Gas Coolant Leak Check

SECTION 3 INSTALLATION

SECTION 4 OPERATION

4.1 POWER SOURCE CONTROLS/ INDICATORS

Figure 4-1. Front Panel Controls

A. Main Power Switch - controls the input power to the

fan, water cooler, and the interface PCB. The amber light to the left of the switch indicates power is ON.

B. Output Current Dial - sets the cutting current when

current settings are made from the console front panel (remote/panel switch in PANEL position).

C. Remote/Panel Switch.

1. Panel Position - allows output current to be set by the output current dial as described above.

2. Remote Position - allows the output current to be set by the CNC with an analog dc signal.

0-10 V dc = 0 - 100 Adc

D. Cutting Current Meter - displays the actual cutting

current.

E. Cutting Voltage Meter - displays the actual cutting

voltage.

F. Pilot Arc High/Low Switch is used to select pilot arc

current.

G. Coolant Flow Fault Indicator - indicates low coolant

flow. The light will come on momentarily when the console is turned on and then go out.

H. Plasma Gas Pressure Fault Indicator - indicates low

plasma gas pressure.

I. Start Gas Pressure Fault Indicators - indicates low

start gas pressure.

J. P/S Temp Fault Indicator - indicates over tempera-

ture fault condition in the inverter power source.

K. P/S Fault Indicator - indicates fault in the plasma

control PCB in the inverter power source.

L. Over/Under Voltage Fault Indicator - indicates input

voltage is above or below the tolerances of the PCU console. Will latch until power is recycled by main power switch.

M. Emergency Stop Fault Indicator - indicates CNC

emergency condition.

SECTION 4 OPERATION

4.2 OPERATION

A. Check consumables in torch for damage and be sure

they are correct for the material to be cut and gas to be used (check against process data sheets starting on page 23).

B. Set N2, O2 and Air inlet gas pressures to 125 psig (8.6

bar) (flowing). Set H-35, methane inlet pressures to 100 psi.

C. Gas Flow Control (Figure 4-2).

1. Position PLASMA GAS select switch (SW-2) for plasma gas to be used.

2. Position SHIELD GAS select switch (SW-3) for shield gas or gases to be used.

3. Set SW-1 switch to start. Verify that N2 pressure is 125 psig (8.6 bars) while flowing.

4. Set SW-1 switch to CUT. Verify that O2 pressure is 125 psig (8.6 bars) while flowing.

5. Close any throttle valves not being used by turning them clockwise.

SW-2

PLASMA GAS

SHIELD GAS

O2+N

N2+ALT

3. If current is to be set from the cutting machine CNC, place the remote panel switch in REMOTE position. Consult the CNC instructions for setting currents.

Figure 4-3. Coolant Level Indicator

4. Check coolant level (see Figure 4-3). Coolant level must be checked with the console main power switch in the OFF position. The coolant level must fall within the SAFE OPERATING LEVEL indicated (See Section 3.5.G).

5. Place pilot arc high/low switch in the LOW position.

SW-3

Figure 4-2. Gas Flow Control

D. Console.

1. If current is to be set from console place the remote panel switch in the PANEL position.

2. Set the cutting current on the output current dial.

6. Turn on the power source by placing the main power switch in the ON position. The amber light to the left of the switch will come on.

7. Check coolant pressure. The pump pressure is factory set between 80-90 psig (5.5 to 6.2 bar).

8. Complete setting the gas flow rates by following the two examples on the next two pages.

E. Set the arc voltage from the suggested arc voltage

values given in the process data sheets.

NOTE

Arc voltage and piercing height will be set from the arc voltage control or from the CNC. Consult instructions supplied with your equipment.

SECTION 4 OPERATION

With the completion of the above settings the system is now ready for operation.

4.3 SAMPLE PROCEDURE FOR SETTING O2 GAS FLOW RATES ON FLOW CONTROL BOX (Figure 4-4)

NOTE

4.4 SAMPLE PROCEDURE FOR SETTING N2 GAS FLOW RATES ON FLOW CONTROL BOX (Figure 4-4)

NOTE

This is a sample procedure only and the operator must refer to the appropriate process data sheet.

SAMPLE SETUP:

Plasma - O2, Shield - N2 plus O2 Mix

A. Place PLASMA GAS select switch SW-2 in O

position.

B. Place SHIELD GAS select switch SW-3 in O2 + N

position. C. Place test switch SW-1 in START position. D. For setting plasma start gas adjust valve NV-3, read

flow on flowmeter FM-2. E. For setting shield preflow gas:

Adjust valve NV-6, read flow on flowmeter FM-3. F. Move test switch SW-1 to CUT position.

SAMPLE SETUP:

Plasma - N2 or Air, Shield - N2 or Air plus Alternate gas mix.

NOTE

To cut with air, connect the air source to the N2 inlet.

A. Place PLASMA GAS select switch SW-2 in N

position.

B. Place SHIELD GAS select switch SW-3 in N2 + ALT

position.

C. Place test switch SW-1 in START position.

D. For setting plasma start gas adjust valve NV-3, read

flow on flowmeter FM-2.

E. For setting shield preflow gas, adjust valve NV-6, read

flow on flowmeter FM-3.

G. For setting plasma cut gas adjust valve NV-1, read

flow on flowmeter FM-1.

H. For setting shield and mixing shield cut gas.

(1) Adjust valve NV-5 (N2), read flow on flowmeter

FM-3.

(2) Adjust valve NV-4 (O2), read flow on flowmeter

FM-4.

I. Move test switch SW-1 to OPERATE position. Flow

control is now set to operate.

F. Move test switch SW-1 to CUT position.

G. For setting plasma cut gas adjust valve NV-2, read

flow on flowmeter FM-2.

H. For setting shield and mixing shield cut gas.

(1 ) Adjust valve NV-5, read flow on flowmeter FM-3. (2 ) Adjust valve NV-4, read flow on flowmeter FM-4.

I. Move test switch SW-1 to OPERATE position. Flow

control is now set to operate.

SECTION 4 OPERATION

NV-1

NV-2

FM-1

FM-2

FM-3 FM-4

SW-2

SW-3

NV-3

NV-6

SW-1

NV-5

NV-4

Front View Left Side View

PLASMA GAS

SHIELD GAS

O2+N

N2+ALT

Figure 4-4. Flow Control Box

 grease P/N73585064. Wipe the

AL30

PROCESS DATA

11/30/99

ALUMINUM

AMPERAGE: 30

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

PT -24 TORCH

3 HOLE

P/N 21536

(SEE NOTES)

SWIRL BAFFLE

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

P/N 21541

NOZZLE "B"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

1. Assemble swirl baffle into nozzle first.

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES:

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

2 .075 0 0 40 55 4 5 20 10 152 3429 135

3 .125 0 0 40 55 4 5 20 10 158 1981 78

4 .187 0 0 40 55 4 5 20 10 170 76 2 30

1.5 .062 0 0 40 55 45 20 1 0 15 0 3810 150

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

2.2 .090 0 0 40 55 45 20 1 0 15 3 2667 105

6 .250 0 0 40 55 4 5 20 10 185 63 5 25

NOTES:

3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.

 grease P/N73585064. Wipe the

AL50

PROCESS DATA

11/30/99

ALUMINUM

AMPERAGE: 55

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

PT -24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21542

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

NOZZLE "C"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

3 .125 0 0 45 75 55 20 10 1 3 9 3302 130

4 .187 0 0 45 75 55 20 10 1 5 2 1981 78

1.5 .062 0 0 45 75 55 20 10 136 4318 170

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 0 0 45 75 55 20 10 1 6 2 1168 46

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

AL70

PROCESS DATA

11/30/99

ALUMINUM

AMPERAGE: 70

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21543

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

NOZZLE "D"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

4 .187 0 0 65 50 45 20 10 1 5 0 2032 80

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 0 0 65 50 45 20 10 1 5 7 1651 65

10 .375 .1 .1 65 60 45 20 10 168 1397 55

12 .500 .2 .1 65 60 45 20 10 178 762 30

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

AL100

PROCESS DATA

11/30/99

ALUMINUM

AMPERAGE: 100

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21923

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

NOZZLE "E"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

6 .250 0 0 80 100 6 0 3 1 1 0 1 5 0 2413 95

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

10 .375 0 0 80 100 60 3 1 10 162 2032 80

12 .500 .1 .1 80 100 60 3 1 10 166 1778 65

16 .625 .3 .1 80 100 60 3 1 10 176 1270 50

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

CB15

PROCESS DATA

11/30/99

AMPERAGE: 16

PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

ALT. GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

CARBON STEEL

PT-24 TORCH

2 HOLE

P/N 21852

(SEE NOTES)

SWIRL BAFFLE

P/N 21540

NOZZLE "A"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

1. Assemble swirl baffle into nozzle first.

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES:

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

0.9 20 GA 0 0 20 11 50 0 5 114 2540 100

1.3 18 GA 0 0 20 11 50 0 5 117 2159 85

1.5 16 GA 0 0 20 11 50 0 5 118 1778 70

1.9 14 GA .1 0 20 11 50 0 5 123 1270 50

2.7 12 GA .1 0 20 11 50 0 5 124 1016 40

3.4 10 GA .1 0 20 11 50 0 5 129 914 36

NOTES:

2 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.

 grease P/N73585064. Wipe the

CB30

PROCESS DATA

11/30/99

AMPERAGE: 35

PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

CARBON STEEL

PT -24 TORCH

3 HOLE

P/N 21536

(SEE NOTES)

SWIRL BAFFLE

P/N 21541

NOZZLE "B"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

ELECTRODE

P/N 21539

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

3 .125 0 0 38 15 50 0 10 119 1397 55

4 .187 .1 .1 38 15 5 0 0 10 122 1016 40

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

1.9 14 GA 0 0 38 15 50 0 5 113 2032 80

6 .250 .2 .1 38 15 5 0 0 10 124 889 35

3.2 .135 0 0 38 15 50 0 10 120 1320 52

NOTES:

3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.

 grease P/N73585064. Wipe the

CB50

PROCESS DATA

11/30/99

AMPERAGE: 45

PLASMA GAS: OXYGEN PRESSURE:125PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125PSI/8.6 BAR

SHIELD MIX GAS: OXYGEN PRESSURE:125PSI/8.6 BAR

CARBON STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21542

NOZZLE "C"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

1. Assemble swirl baffle into nozzle first.

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES:

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

3 .125 0 0 50 20 50 10 0 119 1524 60

4 .187 .1 .1 50 20 5 0 1 0 0 127 1143 45

6 .250 .2 .1 50 20 5 0 1 0 0 130 8 8 9 3 5

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

3.2 .135 0 0 50 20 50 1 0 0 121 1270 50

10 .375 .3 .1 50 20 5 0 1 0 0 136 50 8 2 0

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

CB70

PROCESS DATA

11/30/99

AMPERAGE: 70

PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

CARBON STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21543

NOZZLE "D"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

4 .187 0 0 60 25 60 20 0 118 3048 120

6 .250 0 0 60 25 60 20 0 121 2540 100

8 .312 0 0 60 25 60 20 0 122 2032 80

10 .375 .1 .1 60 25 60 20 0 126 1651 65

11 .500 .2 .1 60 25 60 20 0 133 762 30

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

19 .625 .3 .1 60 25 60 20 0 144 635 25

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

CB100

PROCESS DATA

11/30/99

AMPERAGE: 100

PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

CARBON STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21923

NOZZLE "E"

ðððððð ð

1. Assemble swirl baffle into nozzle first.

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES:

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

8 .312 0 0 80 30 60 30 0 132 2290 90

10 .375 0 0 80 30 60 30 0 137 2030 80

12 .500 .1 .1 80 30 6 0 3 0 0 140 1270 50

16 .625 .2 .1 80 30 6 0 3 0 0 143 76 0 3 0

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

19 .750 .3 .1 80 30 6 0 3 0 0 146 63 0 2 5

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS30A

PROCESS DATA

11/30/99

AMPERAGE: 30

PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

STAINLESS STEEL

PT-24 TORCH

3 HOLE

P/N 21536

(SEE NOTES)

SWIRL BAFFLE

P/N 21541

NOZZLE "B"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

0.4 26 GA 0 0 45 18 40 20 5 101 6350 250

0.6 24 GA 0 0 45 18 40 20 5 102 5080 200

0.8 22 GA 0 0 45 18 40 20 5 103 4826 190

1.2 18 GA 0 0 45 18 40 20 5 105 3556 140

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

1.5 16 GA 0 0 45 18 40 20 5 107 2540 100

NOTES:

3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.

 grease P/N73585064. Wipe the

SS50A

PROCESS DATA

11/30/99

AMPERAGE: 50

PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: AIR PRESSURE:125 PSI/8.6 BAR

STAINLESS STEEL

PT-24 TORCH

3 HOLE

P/N 21536

(SEE NOTES)

SWIRL BAFFLE

P/N 21542

NOZZLE "C"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

3 .125 0 0 60 95 45 55 0 134 2286 90

4 .187 0 0 60 95 45 35 0 140 1524 60

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .1 .1 60 95 4 5 35 0 14 5 1016 40

10 .375 .2 .1 60 95 4 5 3 5 0 155 55 8 2 2

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS70A

PROCESS DATA

11/30/99

AMPERAGE: 70

PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: AIR PRESSURE:125 PSI/8.6 BAR

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21543

NOZZLE "D"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

4 .187 .3 .1 70 95 6 0 40 0 13 1 2540 100

6 .250 .4 .1 70 95 6 0 40 0 15 4 1270 50

10 .375 .5 .1 70 95 6 0 4 0 0 159 71 1 2 8

13 .500 .6 .1 70 95 6 0 4 0 0 162 60 9 2 4

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS100A

PROCESS DATA

11/30/99

AMPERAGE: 100

PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: AIR PRESSURE:125 PSI/8.6 BAR

STAINLESS STEEL

PT -24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21923

NOZZLE "E"

ðððððð ð

1. Assemble swirl baffle into nozzle first.

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES:

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .3 .1 80 65 6 0 3 5 0 138 2030 80

10 .375 .4 .1 80 65 6 0 3 5 0 142 1520 60

12 .500 .5 .1 80 65 6 0 3 5 0 150 88 9 3 5

16 .625 .6 .1 80 65 6 0 3 5 0 157 63 5 2 5

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

PROCESS DATA

 grease P/N73585064. Wipe the

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

nozzle, electrode and water baffle.

SS50A4

(MM/MIN) (IPM)

11/30/99

AMPERAGE: 50

PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

STAINLESS STEEL

4 HOLE

P/N 21692 PT -24 TORCH

(SEE NOTES)

SWIRL BAFFLE

P/N 21542

NOZZLE "C"

P/N 22010

INSULA T OR

SHIELD CUP

ðððððð ð

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

†

ALT

†

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

3 .125 0 0 60 95 45 40 7 135 2286 90

4 .187 0 0 60 95 45 40 7 146 1524 60

6 .250 .1 .1 60 95 4 5 4 0 7 157 1041 41

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

10 .375 .2 .1 60 95 4 5 4 0 7 175 55 8 2 2

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS70A4

PROCESS DATA

11/30/99

AMPERAGE: 70

PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21543

NOZZLE "D"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

2 .125 .2 .1 70 100 60 5 0 15 135 3048 120

4 .187 .3 .1 70 100 60 4 0 10 147 2032 80

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .4 .1 70 100 60 4 0 10 159 1270 50

10 .375 .5 .1 70 1 0 0 60 40 10 1 7 1 7 6 2 3 0

12 .500 .6 .1 70 1 0 0 60 40 10 1 7 6 6 0 9 2 4

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS100A4

PROCESS DATA

11/30/99

AMPERAGE: 100

PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21923

NOZZLE "E"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .3 .1 80 65 6 0 4 0 7 140 2030 80

10 .375 .4 .1 80 65 6 0 4 0 1 0 1 5 1 1524 60

12 .500 .5 .1 80 65 6 0 4 0 1 0 1 5 9 889 35

16 .625 .6 .1 80 65 6 0 4 0 1 0 1 6 6 635 25

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS50N

PROCESS DATA

11/30/99

AMPERAGE: 50

PLASMA GAS: NITROGEN PRESSURE:125PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125PSI/8.6 BAR

SHIELD MIX GAS:

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21542

NOZZLE "C"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

3 .125 0 0 60 85 45 45 0 128 2286 90

4 .187 0 0 60 85 45 45 0 133 1524 60

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .1 .1 60 85 4 5 4 5 0 144 1016 40

10 .375 .2 .1 60 85 45 35 0 1 5 5 55 8 2 2

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS70N

PROCESS DATA

11/30/99

AMPERAGE: 70

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS:

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21543

NOZZLE "D"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

4 .187 .3 .1 70 95 6 0 40 0 1 3 2 1905 75

6 .250 .4 .1 70 95 6 0 40 0 1 5 0 1270 50

10 .375 .5 .1 70 95 6 0 40 0 15 9 7 1 1 28

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

13 .500 .6 .1 70 95 6 0 40 0 1 6 2 60 9 2 4

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS100N

PROCESS DATA

11/30/99

AMPERAGE: 100

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS:

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21923

NOZZLE "E"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

6 .250 .3 .1 80 95 6 0 5 0 0 138 2032 80

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

10 .375 .4 .1 80 95 6 0 3 5 0 145 1520 60

12 .500 .5 .1 80 95 6 0 3 5 0 153 88 9 3 5

16 .625 .6 .1 80 95 6 0 35 0 157 635 2 5

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

SS70NM

PROCESS DATA

11/30/99

AMPERAGE: 70

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21543

NOZZLE "D"

ðððððð ð

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

(SEE NOTES)

NOZZLE RET AINER/

nozzle, electrode and water baffle.

P/N 22007

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

4 .187 .3 .1 70 100 60 6 5 5 138 1778 70

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .4 .1 70 100 60 6 5 5 150 1143 45

10 .375 .5 .1 70 1 0 0 60 65 5 170 76 2 3 0

13 .500 .6 .1 70 1 0 0 60 70 5 179 60 9 2 4

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.

 grease P/N73585064. Wipe the

PROCESS DATA

11/30/99

AMPERAGE: 100

PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR

SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

STAINLESS STEEL

PT-24 TORCH

4 HOLE

P/N 21692

(SEE NOTES)

SWIRL BAFFLE

P/N 21923

NOZZLE "E"

ðððððð ð

2. To prevent leakage between the nozzle and nozzle retainer,

moisten the corner of a clean, dry, lint-free cloth with a very

small amount of Krytox

inner surface of the nozzle retainer that comes in contact with

the nozzle. Use care to apply a very thin film to ensure a

proper seal.

3. Use tool (P/N 21765) supplied with torch to remove or install

nozzle, electrode and water baffle.

NOTES: 1. Assemble swirl baffle into nozzle first.

P/N 21539

ELECTRODE

DIFFUSER

P/N 22007

(SEE NOTES)

NOZZLE RET AINER/

(MM/MIN) (IPM)

†

ALT

†

P/N 22010

INSULA T OR

SHIELD CUP

INSULATOR SHIELD

RETAINER w/O-RING

CUP SHIELD

w/RETAINER

P/N 21712

P/N 22531

DELAY PIERCE START CUT (FLOW READING) VOLTAGE

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC

(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT

6 .250 .3 .1 80 95 6 0 50 5 1 3 3 1778 70

10 .375 .4 .1 80 95 6 0 70 5 1 5 8 1524 60

12 .500 .5 .1 80 95 6 0 60 5 1 7 0 96 5 3 8

16 .625 .6 .1 80 95 6 0 60 5 1 7 7 66 0 2 6

NOTES:

4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. SS100NM

SECTION 4 OPERATION

Aluminum Kerf Values N2/N2/CH4

Aluminum N2/N2/CH4 30 Amperes

Material Thickness (mm)

1.575 1.905 2.286 3.175 4.750 6.350

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.210

0.087

1.524

1.2701.270

1.270

1.651

0.065

0.060

0.050

0.062 0.075 0.090 0.125 0.187 0.250

0.050

Material Thickness (inches)

Aluminum N2/N2/CH4 50 Amperes

Material Thickness (mm)

1.575 3.175 4.775 6.350

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.362

1.524

1.651

2.032

0.080

0.093

0.065

0.060

0.062 0.125 0.188 0.250

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

0.190

0.170

0.150

0.130

0.110

Kerf (inches)

0.090

0.070

0.050

Aluminum N2/N2/CH4 70 Amperes

Material Thickness (mm)

4.750 6.350 9.525 12. 700

3.048

2.845

2.540

0.112

0.100

0.187 0.250 0.375 0.500

2.540

0.100

0.120

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

0.190

0.170

0.150

0.130

0.110

Kerf (inches)

0.090

0.070

Material Thickness (inches)

Aluminum N

/CH4 100 Amperes

2/N2

Material Thickness (mm)

6.350 9.525 12.700 15.875

3.302

2.540

0.100

2.667

0.105

2.921

0.115

0.130

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

0.050

0.250 0.375 0.500 0.625

1.270

Material Thickness (inches)

SECTION 4 OPERATION

Carbon Steel Kerf Values O2/N2/O2

Carbon Steel O2/N2/O2 16 Amperes

Material Thickness (mm)

1.219 3.404

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

1.473

1.118

0.058

0.044

0.048 0.134

Material Thickness (inches)

Carbon Steel O2/N2/O2 35 Amperes

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

Material Thickness (mm)

1.524 3.175 6.350

1.499

1.168

1.321

0.059

0.052

0.046

0.060 0.125 0.250

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

Carbon Steel O2/N2/O2 45 Amperes

Material Thickness (mm)

3.175 6.350 9.525

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.413

0.095

1.626

1.930

0.076

0.064

0.125 0.250 0.375

Material Thickness (inches)

Carbon Steel O2/N2/O2 70 Amperes

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

Material Thickness (mm)

3.429 6.350 9.525 12 .700

2.540

0.100

1.575

1.778

2.032

0.080

0.070

0.062

0.135 0.250 0.375 0.500

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

Carbon Steel O2/N2/O2 100 Amperes

Material Thickness (mm)

9.525 12.700 19.050

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

3.048

0.120

2.540

2.337

0.100

0.092

0.375 0.500 0.750

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

Stainless Steel Kerf Values O2/N2/O2

Stainless Steel O2/N2/O2 30 Amperes

Material Thickness (mm)

0.457 0.584 0.7 26 1.207 1.588

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

1.143

0.889

0.035

26GA 24GA 22GA 18GA 16GA

0.889

0.035

0.8890.889

0.035

0.045

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

Stainless Steel Kerf Values Air/Air/CH4

Stainless Steel Air/Air/CH4 70 Amperes

Material Thickness (mm)

3.175 4.775 6.35 0 9.525 12.700

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.921

0.115

1.778

2.032

0.080

2.540

2.286

0.100

0.090

0.070

0.125 0.188 0.25 0 0.375 0.500

Material Thickness (inches)

Stainless Steel Air/Air/CH4 100 Amperes

Material Thickness (mm)

6.350 9.525 12 .700 15.875

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.190

0.170

0.150

0.130

0.110

Kerf (inches)

0.090

0.070

0.050

3.556

3.048

0.140

0.120

2.540

2.286

0.100

0.090

0.250 0.375 0.500 0.625

Material Thickness (inches)

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

SECTION 4 OPERATION

Stainless Steel Kerf Values N2/N2/CH4

Stainless Steel N2/N2/CH4 70 Amperes

Material Thickness (mm)

4.750 6.350 9.525 1 2.700

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.921

2.032

2.413

0.095

2.667

0.105

0.115

0.080

0.187 0.250 0.375 0.500

Material Thickness (inches)

Stainless Steel N2/N2/CH4 100 Amperes

Material Thickness (mm)

6.350 9.525 12.700 15.875

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.190

0.170

0.150

0.130

0.110

Kerf (inches)

0.090

0.070

0.050

3.810

3.302

0.150

0.130

2.794

2.540

0.110

0.100

0.250 0.375 0.500 0.625

Material Thickness (inches)

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

SECTION 4 OPERATION

Stainless Steel Kerf Values N2/N2

Stainless Steel N2/N2 50 Amperes

Material Thickness (mm)

3.175 4.750 6.350 9.525

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.032

1.778

0.080

0.070

1.524

1.651

0.065

0.060

0.125 0.187 0.250 0.375

Material Thickness (inches)

Stainless Steel N2/N2 70 Amperes

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

Material Thickness (mm)

4.750 6.350 9.525 1 2.700

2.540

2.286

0.100

1.778

0.090

0.070

0.187 0.250 0.375 0.500

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

Stainless Steel N2/N2 100 Amperes

Material Thickness (mm)

6.350 9.525 12.700 15.875

0.190

0.170

0.150

0.130

0.110

Kerf (inches)

0.090

0.070

0.050

3.556

0.140

2.540

2.794

0.110

3.048

0.120

0.100

0.250 0.375 0.500 0.625

Material Thickness (inches)

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

SECTION 4 OPERATION

Stainless Steel Kerf Values Air/Air

Stainless Steel Air/Air 50 Amperes

Material Thickness (mm)

3.175 4.750 6.350 9.525

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.413

1.524

1.651

2.032

0.080

0.095

0.065

0.060

0.125 0.187 0.250 0.375

Material Thickness (inches)

Stainless Steel Air/Air 70 Amperes

Material Thickness (mm)

4.750 6.350 9.525 12. 700

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

0.140

0.120

0.100

0.080

0.060

Kerf (inches)

0.040

0.020

0.000

2.9212.921

0.115

1.905

2.794

0.110

0.115

0.075

0.187 0.250 0.375 0.500

Material Thickness (inches)

3.556

3.048

2.540

2.032

1.524

Kerf (mm)

1.016

0.508

0.000

SECTION 4 OPERATION

0.190

0.170

0.150

0.130

0.110

Kerf (inches)

0.090

0.070

0.050

Stainless Steel Air/Air 100 Amperes

Material Thickness (mm)

6.350 9.525 12.700 15.875

4.064

3.556

2.921

3.302

0.130

0.140

0.115

0.250 0.375 0.500 0.625

0.160

4.826

4.318

3.810

3.302

2.794

Kerf (mm)

2.286

1.778

1.270

Material Thickness (inches)

SECTION 4 OPERATION

Page intentionally left blank.

SECTION 5 CUTTING QUALITY

5.1 CUT ANGLE

Cut squareness is always a concern when using nitrogen gas. The cut angle is referred to as either being positive or negative (Figure 5-1). With a positive cut angle, the top dimension of the part is slightly less than the bottom dimension. With a negative cut angle, the top dimension is slightly greater than the bottom dimension. The cut angle is controlled by standoff (arc voltage), cutting speed, and cutting amperage. If the cutting speed and amperage are correct and the part has an excessive positive angle, the standoff is too high. Begin lowering the arc voltage in increments of 5 volts, observing cut squareness. There will always be slight top edge rounding of the part when using nitrogen.

The optimum torch height is just before the part begins to develop a negative cut angle. To expand upon the other two variables, if the torch standoff is correct, too fast of a cutting speed will result in a positive cut angle; too slow of a travel speed will result in a negative cut angle. Too high or too low of current also produces a positive cut angle.

Oxygen plasma will also produce the same positive or negative cut angle as nitrogen. The cut angle is controlled by the torch standoff (arc voltage) cutting speed, and cutting amperage. The major difference is the sharp top edge of the part. The positive angle changes but the sharp top edge remains. If speeds and currents are correct, lower the arc voltage in increments of 5 volts until the cut angle begins to go negative or the cut face is under cut. At this point, increase voltage until positive angle reappears. This is the optimum cut squareness for these conditions.

POSITIVE (+) CUT ANGLE

Bottom dimension "A" is greater than dimension "B"

NEGATIVE (-) CUT ANGLE

Bottom dimension "A" is

Figure 5-1. Cut Angle

less than dimension "B"

SECTION 5 CUTTING QUALITY

ARC VOLTAGE/STANDOFF

Standoff and arc voltage are proportional. The higher the torch above the plate (standoff), the higher the operating voltage and vice versa.

Standoff Arc Voltage

LAG LINES

These lines appear on the cut surface. They are used to determine if your process parameters are correct.

Figure 5-2. Cut Quality

5.2 VOLTAGE AND CUT QUALITY.

Standoff (arc voltage) has a direct influence on cut quality and squareness. It is recommended that prior to cutting, all cutting parameters are set to the manufacturer's suggested conditions. A sample cut should be made followed by a close examination of the part.

Arc Voltage

End View

(+) Cut Angle

If it has an excessive bevel or rounded top edge, it may be the standoff (arc voltage) is set too high (Figure 5-3). Lower the voltage until the excessive bevel or rounded top edge disappears. On material thickness 1/4 inch (6 mm) and greater, a standoff too close may result in a negative cut angle (Figure 5-5).

ARC VOLTAGE TOO HIGH

Correct Cutting Speed Positive Cut Angle Rounded Top Edge More Dross Top Dross Cut Face Smooth "S" Shaped Lag Lines

Cut Face

Figure 5-3. Cut Quality (Arc Voltage Too High)

SECTION 5 CUTTING QUALITY

ARC VOLTAGE CORRECT

Correct Cutting Speed Square Top Edge No Top Dross Little or No Bottom Dross Cut Face Smooth Uniform Lag Lines

End View

Arc Voltage

Optimum

Cut Angle

Cut Face

End View

Figure 5-4. Cut Quality (Arc Voltage Correct)

ARC VOLTAGE TOO LOW

Correct Cutting Speed Under Cut Top Edge Negative Cut Angle Dross

Arc Voltage

(-) Cut Angle

Cut Face Rough Vertical Serrated Lag Lines

Cut Face

Figure 5-5. Cut Quality (Arc Voltage To Low With a Negative Cut Angle)

SECTION 5 CUTTING QUALITY

ARC VOLTAGE TOO LOW

Arc Voltage

Under Cut

End View

Cut Face

Figure 5-6. Cut Quality (Arc Voltage Too Low With An Under Cut Top Edge)

Top Edge

-/+ Cut Angle

5.3 TOP DROSS.

Top dross usually appears as splatter near the top edge of the kerf. This is a result of torch standoff (arc voltage) set too high or a cutting speed set too fast. Use the parameter charts for recommended speed. The most common problem is torch standoff or arc voltage control. Simply lower the voltage settings in increments of 5 volts until the top dross disappears. If an arc voltage control is not being used, simply lower the torch manually until the top dross disappears (Figure 5-7).

Correct Cutting Speed Under Cut Top Edge Negative Cut Angle Dross Cut Face Rough Vertical Serrated Lag Lines

5.4 DROSS FORMATION.

The correct cutting arc voltage also has an influence on dross formation. If the arc voltage is set too high, the cut angle becomes positive. In addition, dross forms on the bottom edge of the part. This occurs because we are now trying to cut the part with the feather tip of the plasma arc. This dross is usually very tenacious and requires chipping and grinding for removal. Too low of a cutting voltage results in an undercutting of the parts or negative cut angle. Dross formation usually occurs but in most cases removes easily (Figure 5-6)

SECTION 5 CUTTING QUALITY

TOP DROSS

Splatter appears on the top edge of both pieces of the plate. Lower the voltage in increments 5 V dc (maximum ) until top dross disappears.

Figure 5-7. Top Dross

HIGH SPEED DROSS

Fine roll over dross that welds to bot tom of edge. Cleaning requires chipping or grinding.

Figure 5-8. High Speed Dross

LOW SPEED DROSS

Globular dross that forms in large deposits. Comes off very easily.

Figure 5-9. Low Speed Dross

5.5 SUMMARY.

Arc voltage is not an independent variable. It is dependent upon cutting amperage, nozzle size, torch standoff, cut gas flow rate and cutting speed. An increase in arc voltage can result from a decrease in cutting speed, an increase in cutting amperage, a decrease in nozzle size,

an increase in gas flow, an increase in cut water flow or an increase in torch standoff. Assuming that all of the variables are set to the manufacturer's settings, torch standoff becomes the most influential variable to the process. Good and accurate height control is a necessity in producing excellent cut quality.

SECTION 5 CUTTING QUALITY

SECTION 6 MAINTENANCE

6.1 GENERAL

If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do NOT permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts.

WARNING

Be sure that the wall disconnect switch or wall circuit breaker is open before attempting any inspection or work inside of the Power Source, the junction box, the flow control box or the PT-24 torch.

6.2 INSPECTION AND CLEANING

Frequent inspection and cleaning of the Precision Plasmarc System is recommended for safety and proper operation. Some suggestions for inspecting and cleaning are as follows:

A. Check work cable to workpiece connection.

B. Check safety earth ground at workpiece and at power

source chassis.

C. Check heat shield on torch. It should be replaced if

damaged.

D. Check the torch electrode and cutting nozzle for wear

on a daily basis. Remove spatter, resharpen point, or

replace if necessary.

E. Make sure cable and hoses are not damaged or

kinked.

F. Make sure all plugs, fittings, and ground connections

are tight.

CAUTION

Water or oil occasionally accumulates in compressed air lines. Be sure to direct the first blast of air away from the equipment to avoid damage to the junction box or flow control box.

G. With all input power disconnected, and with proper eye

and face protection on, blow out the inside of the power source, the flow control, and the junction box using low-pressure dry compressed air.

6.3 TORCH CONSUMABLE PARTS

WARNING

Make sure power switch on the Power Source is in OFF position before working on the torch.

Spare parts kit P/N37609 is available for maintaining the PT-24 torch. For contents and recommended uses, see Figure 6-1 and Process Data Sheets.

6.4 GAS PRESSURE SWITCH

The pressure switches are factory set to provide precise control of the cooling gas and plasma gas pressure. The two switches are located in the junction box. The pressure adjustment wheels on the pressure switches should not be touched. Consult your ESAB representative if you have determined that the pressure switches are not

functioning properly.

6.5 PT-24 TORCH DESCRIPTION

See Table 2-6 for overall size and general configuration.

A. Mounting. The torch can be mounted by the sleeve

or by the 1.812 inches (46 mm) dia machined surface shown (see Figure 3-10). This insulated surface and its shoulder are machined relative to the nozzle retainer thread on the torch body and is held concentric to the cutting nozzle within a total indicator reading of 0.010 inches (0.25 mm) or the nozzle bore is within

0.005 inches of any point on the 1.812 dia. When mounting be sure not to cover the small vent hole in the side of the sleeve. This hole prevents coolant from building inside the sleeve should a leak occur in a service line.

B. Service Lines. Both the 4.5 and 17 ft (1.4 m and

5.2 m) long lines are shielded and connect to the junction box by a friction fit grounded connection.

SECTION 6 MAINTENANCE

C. Water Cooling. Coolant enters the torch through the

power cable (-), circulates through the torch body and the electrode, crosses over to the nozzle (+) section of the torch body through nonconductive bypass tubes, travels back through the body and circulates between the nozzle retainer and the nozzle, then back through the torch body to the junction box via the pilot arc cable.

D. Plasma Cut and Start Gas. These gases enter the

torch through connections that house check valves within the torch body. The valves acting in conjunction with solenoid valves control the back and forth switching of start and cut gases. See Figure 6-2 for further explanation of this system.

E. Shield Gas. Shield preflow, cut shield and postflow

enter the torch through one connection, pass through the torch body, through the shield gas diffuser and then out of the orifice in the shield cap that surrounds the plasma jet.

F. Power and Pilot Arc Lines. Coolant IN to the torch

is through the power cable (-). Coolant OUT from the torch is through the pilot arc (+) line.

6.6 TORCH MAINTENANCE

WARNING

B. Water leaks, moisture, or coolant dripping from the

vent hole in the sleeve indicates service line damage. If service lines have to be replaced always use two wrenches to avoid twisting the metal tubes.

C. The torch sleeve P/N 21757 is threaded onto the torch

body. If the sleeve is too tight to be readily removed by hand, use a large adjustable wrench on the flats located on the body or lightly tighten these flats in a vise. With the body secured in this manner, the use of two hands on the sleeve may break the sleeve free, if not, use a strap wrench. Always check service line connections for leaks before replacing the sleeve.

D. Be especially careful not to get dirt or foreign matter

in the check valve fittings where the plasma cut and start gases are attached. If however dirt or other foreign matter gets into the check valves, they can be dismantled, then cleaned and replaced.

CAUTION

The seat, ball and spring must not be damaged when handling. Also, Do NOT substitute any other spring or ball. If they are dropped, lost, or damaged they must be replaced with genuine ESAB replacement parts. Changes, substitutions or damaged parts will affect set pressures and cause poor starting and piercing.

Make sure power switch on the console is in the OFF position and primary input power is disconnected.

A. Always check the three O-rings on the torch body

before each day's operation and replace if any damage or wear is noted. Apply a thin coat of silicone grease to O-rings before assembling to torch. The O-ring P/ N 638797 inside the torch body that seals the nozzle is especially critical. Because of its location, damage or wear is not readily apparent. Replacing this ring on a daily basis is recommended. Be careful not to scratch or damage the inside surface of the torch. A toothpick works well for removing the O-ring. The ring can be replaced without removing the water baffle P/ N 21725, if however the baffle is to be removed, always use a 3/16 inch (5 mm) hex wrench or nut driver.

6.7 PT-24 CONSUMABLE REMOVAL, INSPECTION AND INSTALLATION

WARNING

Make sure power switch on the console is in the OFF position and primary input power is disconnected.

NOTE

When changing consumables, if the nozzle retainer/ diffuser seems especially stubborn and difficult to remove, the console is probably still on. With the console on, the pump will be running and coolant pressure behind the retainer will prevent it from turning freely. Check the console before making further attempts to remove the nut. Notice also that a small amount of coolant will be lost each time consumables are removed. This is normal and eventually the coolant will have to be replaced. Check the coolant before each operation.

A. Removal and Inspection

SECTION 6 MAINTENANCE

passages for blockage. Clear blockages with an

1. Unscrew the shield cup retainer. The cup may come free with the retainer or stay on the torch. If on the torch, pluck it free with your thumbnail. Inspect the cup for damage around the orifice, if the edge of the orifice is damaged, it must be replaced. Straight cuts cannot be produced if this orifice is distorted.

air stream, if blockages cannot be cleared, replace the baffle. Do NOT insert anything in these holes in an effort to clear them. Distortion of these holes will impair cutting performance.

6. Unscrew the electrode with the aid of the tool provided.

2. The shield cup insulator is sandwiched between the insulator shield retainer and the nozzle retainer/diffuser and may stay attached to nozzle retainer because of the very close fit-up between these members.

3. Unscrew the nozzle retainer/diffuser. Inspect for any damage especially where the retainer contacts the nozzle. The innerface between the retainer and the nozzle creates a metal to metal seal for the coolant. Any damage to this sealing surface will cause a leak and poor cutting will result. Replace as necessary, do not attempt to repair. Check the small gas passages for blockages. Clear blockages with an air stream.

4. The nozzle is removed with the aid of the tool provided. Place the slot around the groove in the nozzle and pull the nozzle free.

5. Remove the swirl baffle from the nozzle. If the baffle remains in the torch, it will come free with the removal of the electrode. Check the small gas

B. Installation

1. Electrode - Apply a thin film of silicone grease to the O-ring, just enough to produce a shiny surface, thread the electrode in place and snug tight with the tool provided. Do NOT overtighten.

2. Nozzle & Swirl Baffle - Place the swirl baffle into the nozzle being careful not to get anything in the small gas passages. Push this assembly into the torch.

3. Nozzle Retainer/Diffuser - To prevent leakage between the nozzle and nozzle retainer, moisten the corner of a clean, dry, lint-free cloth with a very small smount of Krytox grease P/N 73585064. Wipe the inner surface of the nozzle retainer that comes in contact with the nozzle. Use care to apply a very thin film to ensure a proper seal. Thread the nozzle retainer onto torch and hand tighten.

4. Shield Cup Insulator - Push the shield cup insulator on the nozzle retainer.

CUP SHIELD w/ RETAINER 22531

INSULATOR SHIELD RETAINER W/ O-RING C-21712

NOZZLE RETAINER/ DIFFUSER - D-22007

SHIELD CUP INSULATOR 22010

For removing and replacing water baffler

ELECTRODE & NOZZLE TOOL C-21765

NOZZLE "A" (15A) - 21540 "B" (30A) - 21541 "C" (50A) - 21542 "D" (70A) - 21543 "E" (100A) - 21923

Slot for removing nozzle

Assemble swirl ring into nozzle first

5. Shield Cup and Retainer - Screw this assembly onto the torch and hand tighten.

SWIRL BAFFLE 21852 (15A) - 2 HOLES 21536 (30A) - 3 HOLES 21692 (50/70/100A) - 4 HOLES

O-RING 98W18

ELECTRODE (15/30/50/70A) 21539

Hex for installing electrode

Figure 6-1. Front End Parts, PT-24 Torch

O-RING 638797

WATER BAFFLE C-21725

O-RING 86W62

O-RING 950715

TORCH ASSEMBLY D-21530

SECTION 6 MAINTENANCE

C-22388-A

Figure 6-2. Schematic Gas Flow

SECTION 7 TROUBLESHOOTING

7.1 TROUBLESHOOTING

The signal exchange between the PLC and external devices are both time and condition dependent. If a required signal is not received in the proper sequence, the PLC will discontinue the process and

WARNING

ELECTRIC SHOCK CAN KILL! Be sure that all primary power to the machine has been externally disconnected. Open the line (wall) disconnect switch or circuit breaker before attempting inspection or work inside the power source.

WARNING

Capacitors can store high voltages even when power is disconnected or unit is deenergized. Ensure power supply capacitors are grounded prior to performing maintenance.

generate a fault signal to the CNC.

7.2 PROCESS TROUBLESHOOTING

A. Programmable Logic Controller (PLC).

The PLC is located in the Precision Plasma Power Source. It is a device capable of providing predefined outputs depending on state of the inputs. The precise conditions are programmed and permanently stored in the PLC. The PLC is visible through the plexiglass window on the left side panel of the power source.

The PLC will provide predefined outputs in response to input signals from external devices. This exchange of signals can be confirmed by observing the LEDs on the top of the PLC while troubleshooting. These indications are useful in isolating a system failure to the most likely device.

The LEDs are divided into two groups; Input (0-15) and Output (0-11). Input LEDs light when the corresponding signal is detected by the PLC. Output LEDs light when the PLC issues a signal to an external device.

LEDs are highly reliable indicators. It is not likely that one will "burn out". However, if the technician is not confident that the LEDs are working, the presence of a signal can be confirmed by using a meter and taking a measurement on the appropriate pin. Refer to the schematic and wiring diagrams.

SECTION 7 TROUBLESHOOTING

PA202

AC100

-240V INPUT

L2/N

23 4

1 2

omron SYSMAC CJ1M PROGRAMMABLE

POWER

CONTROLLER CPU12

OPEN

MCPWR BUSY

RUN

ERR/ALM

PRPHL

COMM

BKUP

SW SETTING

BATTERY

PERIPHERAL

PORT

INH

IA111

0 8

COM

AC100V 7mA 50H z 8mA 60H z

109114512 13

1514

OC201

AC250 V 2A

DC24V 2A

423 56

321

OC201

AC250 V 2A DC24V 2A

23 654 7

701

1. Power Supply

2. CPU

3. AC Input Module

4. Relay Output Module

5. Flash Memory

Figure 7-1 Programmable Logic Controller (PLC)

Table 7-1 PLC Input/Output LEDs

INPUT OUTPUT

LED Function LED Function

0 Start/Stop 1-0 Travel 1 Preflow 1-1 Hi-Frequency 2 Arc-On 1-2 Pilot Arc Relay 3O2 Pressure 1-3 Power Source 4N2 Pressure 1-4 Start Pressure Switch Fault 5 Reserved 1-5 Cut Gas Pressure Switch Fault 6 Fault 1-6 Fault Output 7 ---8 2-0 Start Gas On

2-1 Cut Gas On 2-3 Full Shield 2-4 Regulated Shield

SECTION 7 TROUBLESHOOTING

7.3 TROUBLESHOOTING PROCEDURES

Check the problem against the symptoms in the following troubleshooting guide. The remedy may be quite simple. If the cause cannot be quickly located, shut off the input power, open up the appropriate component, and perform a simple visual inspection of all the components and wiring. Check for secure terminal connections, loose or burned wiring or components, bulged or leaking capacitors, or any other sign of damage or discoloration.

The cause of control malfunctions can be found by referring to the sequence of operations (Figure 7-1) and electrical schematic diagram (Figures 7-2, 7-3, 7-5 and 7-

8) and checking the various components. A voltohmmeter will be necessary for some of these checks.

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WARNING

Voltages in plasma cutting equipment are high enough to cause serious injury or possibly death. Be particularly careful around equipment when the covers are removed.

NOTE

Before checking voltages in the circuit, disconnect the power from the high frequency generator to avoid damaging your voltmeter.

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SECTION 7 TROUBLESHOOTING

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SECTION 7 TROUBLESHOOTING

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SECTION 7 TROUBLESHOOTING

Table 7-2 . Troublesho otin g Gu ide

PROBLEM POSSIBLE CAUSE ACTION

7. Torch fails to fire S tart gas Cooling water flow

Faulty cooling water flow

switc h C W FS Obstruction in torch

limiting cooling water flow

Nozzle life extremely

short

9. Short electrode life Insufficient cooling

10. Short electrode/nozzle

life

Pilot arc h i g h /lo w sw it c h is in high position

Nozzle pitting/arcing inside bore

Start gas flow too low

Start gas quality

Cut gas quality

Water leak on torch front end

Lower start gas flow. Pump pressure too low; should be 80/90 PSI

7.9 bars).

( Replace CWFS switch.

Cooling Water PSI / Flow is 0.38 gpm (1.4 lpm) @ 115 psi (7.9 bar) measured at torch return hose of power

Coolant flow through torch should be greater than

0.5 gal/min.

supply.

Place switch in low position.

Nitrogen quality too low, requires 99.995% pure

for longest nozzle life. Check cutting parameters.

Check pump for 115 PSI (7.9 bars) output pressure.

Gas quality needs to be 99.995% minimum. Oxygen gas needs to be 99.8% minimum.

Check nozzle retainer for tightening.

115

11. Positive cut angle Arc voltage too high Cutting speed too fast Cutting current too high

Cutting current too low

12. Negative cut angle Arc voltage too low Cutting speed too slow

Lower arc voltage in small increments If cutting speed is too fast, simply lower speed

Wrong nozzle being used or lower current into correct operating range

Raise current if nozzle is designed for it.

Raise the arc voltage in small increments.

Slowly increase cutting speed.

SECTION 7 TROUBLESHOOTING

Table 7-3. PT-24 Torch Leak Procedure

Front end of torch leaking

Remove: shield cup

insulator shield retainer insulator ring nozzle retaining cup nozzle swirl baffle

electrode

Visually inspect nozzle sealing o-ring and electrode o-ring

Are o-rings damaged?

Visually inspect nozzle and retaining cup metal-to-metal seat

Are seats damaged?

Reassemble electrode, swirl baffle, nozzle and retaining cup

Turn on coolant flow and check for leaks

Still

Leaking?

yes

Replace o-ring

Replace

parts

Replace nozzle

Leaking?

Let’s cut!

Still

yes

Replace Retaining cup

SECTION 7 TROUBLESHOOTING

D-37414

Figure 7-2. Flow Control Schematic

SECTION 7 TROUBLESHOOTING

D-37399-E

Junction Box Schematic and Wiring Diagram

SECTION 7 TROUBLESHOOTING

D-37413

Figure 7-4. Flow Control Wiring Diagram

SECTION 7 TROUBLESHOOTING

C2-1 (YEL)

TB5-PA (YEL)

WHT

T1T2T3

ZD2

L1L3L2BA

WHT

PLC1 P2-9 (VIO)

C1-1 (BLU)

R12

R11

R14-1 (GRY)

TB3

R15

C2-2 (WHT)

PLC1 P2-10 (RED)

L1-H1 (BLU)

S2-2 (BLU )

SH1

K2-T1(YEL)

K2-T3(WHT)

R14

D1(-) GRY

PCB2

TB7

omron

RUN

PA202

POWER

AC100

-240V INPUT

BLU

MOD1 SH 1-1 (GRY)

BLU

111

R10

R9R7R8

222

BLU

S2-3 (BLK)

S2-6 (ORN)

BLU

TB5

L2/N

K8 K4

3 3

OC201IA111 OC201

SYSMAC

ERR/ALM

CJ1M

INH

01234

0765

1324

760

OPEN

SW SETTING BATTERY

MCPWR

BUSY

PERIPHERAL

PORT

PRPHL COMM BKUP

COM

AC100V 7mA 50Hz 8mA 60Hz

PLC1

3214567

111089 12

131415

C6C6

AC250V 2A

DC24V 2A DC24V 2A

PROGRAMMABLE CONTROLLER CPU12

TB8

1 4

31313

A B

TB4

SEE CHART

SEE DETAIL

TB6

PLC MOD

12345678

SEE DETAIL

K2-L3 (BLU)

TB6-2(RED) TB5-TORCH(BLK) R15-2 (RED)

MOD1

R13

MOD1 TB3-1 (RED)

3 6

7 A B BA

PLC TB4-4(BRN)

PLC TB7-16( BLU)

PLC J1

PLC TB7-2 (WHT)

PS-L2

PLC TB8-14 (GRN)

PS-LG

PLC TB8-14 (GRN)PS-GR

PLC TB7-7 (VIO )

OUT1-0

PLC TB7-8 (VIO )

OUT1-C0

PLC TB7-9 (BRN)OUT1-1 PLC TB7-12 (BLK)

OUT1-C1

PLC TB7-11 ( RED)

OUT1-2

PLC TB7-12 (BLK)

OUT1-C2

PLC TB7-14 (ORN)

OUT1-3 OUT1-C3 PLC TB7-13 (ORN)

PLC TB7-15 ( YEL)

OUT1-4

PLC TB4-6 (GRY)

OUT1-C4

PLC TB7-19 (VIO)

OUT1-5

PLC TB4-8 (GRY)

OUT1-C5

PLC TB7-16 (BLU)

OUT1-6

PLC TB4-8 (GRY)

OUT1-C6

PLC TB7-20 (VIO)

OUT2-0 OUT2-C0

PLC TB7-17 (GRY)

OUT2-1

PLC TB7-21 ( BRN)

OUT2-C1

PLC TB4-8 (GRY)

OUT2-2

PLC TB7-22 ( RED)

OUT2-C2

PLC TB4-6 (GRY) PLC TB7-23 (ORN)

OUT2-3

PLC TB4-6 (GRY)

OUT2-C3

IN1-0 PLC TB8-1 (WHT)

PLC TB8-2 (BRN)

IN1-1

PLC TB8-4 (RED)IN1-2 PLC TB8-5 (ORN)

IN1-3 IN1-4

PLC TB8-6 (YEL ) IN1-5 IN1-6

PLC TB8-8 (BLU) IN1-7 IN1-8 IN1-9 IN1-10 IN1-11 IN1-12 IN1-13 IN1-14

PLC TB8-23 (BLK)

IN1-15

PLC TB8-18 (BLK)

IN1-COM IN1-COM

TB3-21 ( GRY)

TB3-20 ( BLU)

PLC1 MODULE

1PLC TB7-10 (BLK)PS-L1 1PLC TB7-14(ORN)

PLC TB7-13(ORN)

PLC TB7-2(WHT)3

PLC TB8-4(RED)4 TB3-5 (BLK)

TB3-6(VIO)

PLC TB8-8(BLU)8

PLC TB8-2(BRN)

TB3-23 ( BLK)

PCB2 - P1

TB5-WORK(RED)P1-1

P1-2

TB3-13(ORN) TB3-14(BRN)

P1-3

TB5-TORCH(BLK)

P1-6

4 7

ZD3

3 6 9

5 6

7 8 9

TB3-22 ( WHT)

PLC TB4-2(WHT)

PLC CB3-1(BLK)

PLC TB7-2(WHT)

PLC TB7-24(GRY)3

J1-C(ORN) TB5-WORK(RED)

J1-N(GRY)

PLC TB7-11(RED)

K3-6(WHT)

K3-9(ORN)

K4-9(GRY)

K4-6(YEL)

TB4-4(BRN)15

3 6

4 7

AB AB

PLC TB4-4(BRN)

PLC TB8-6(YEL )

PLC TB4-1(WHT)

J1-K (YEL)

1P4-10(VIO)

PLC1 P2-7 (VIO)

2P4-9(VIO)

PLC1 P2-9 (VIO)

P4-2(BLU)

4 P4-1 (BLU)

5 PCB1 P7- 1(BLK)

7 PLC1 P2-1 (VIO)

PLC1 P2-2 (VIO)

K2-A (VIO)

10 K2-B(RED)

11 PCB1 P1-7(WHT)

PCB1 P1-8(ORN)12

13 PCB1 P1-9(GRY) 14 PCB1 P1- 10(YEL)

15 PLC1 P2- 4(BLU)

PCB1 P2-15(YEL)1

2 PCB1 P2-16(YEL )

PCB1 P2-8(GRY)3

PCB1 P2-9(RED)

PCB1 P2-10(GRY)5

PCB1 P10-4(WHT)6

7 PCB1 P10-3(BLK)

PCB1 P10-5(WHT)8

3 6

4 7

J1-G (BLK)

PLC TB4-1(WHT)

PLC TB8-5(ORN)

PLC TB 7-19(VIO)

PLC TB4-4(BRN)

PLC1 MODULE

P2 P1

PCB1 P4-1(BRN)1

2 PCB1 P4-2(GRY)

PCB1 P4-7(YEL)3

PCB1 P4-9(YEL)

PCB1 P4-10(WHT)

PCB1 P5-1 (BLK)5 6PLC1 P2-15(BLU) PCB1 P5-2(VIO)

PCB1 P4-8(ORN)8

3 6

4 7

PLC TB4-4(BRN)

PLC1 J2-13(GRY)

PCB1 P7-3(RED) MOD1-TB3-1 (RED)

K3K4

3 6

ABAB

PLC1 J2-11(WH T)

PLC TB4-4(BRN)

PLC1 J2-12(ORN)

PLC TB 7-15(YEL)

PLC1 J2-14(YEL)

PCB1 P1-15(BLU)22

PCB1 P3-13(WHT)44

PCB1 P1-13(BLK)5

PCB1 P3-18(BLU)77

PCB-TB P1-1(YEL)8

R2-1(ORN)

12 13

PCB1 P9-1(RED)14

PCB1 P9-3(BLK)15

TB6 6532147

MOD1 P3-6(GRY)

S3-6(GRY) S3-3(ORN)

MOD1 P3-5(BRN)

POWER MOD1

11 PCB1 P1 -16(VIO)

33 PCB1 P3-12(ORN)

8S3-4(BLU)

NOT USED

3421 765 8

PLC TB4 (SEE DETAIL-SHT 4)

1 PCB1 P4-3(RED)

PCB1 P4-4(YEL)

3 PCB1 P4-15(BLU)

PCB1 P4-16(ORN)4

TB6-6(BRN)5

TB6-8(GRY)PCB1 P1-14(RED)

PCB1 P4-11(RED)7

8 PCB1 P4-12(BLK)

PCB1 P4-13(VIO)9

PCB1 P4-14(YEL)10

TB5-PA(YEL)

FRONT VIEW WITH FRONT PANEL REMOVED

PCB1 P2-14(BLU)1

PLC1 P2-4(BLU) PCB1 P2-13(BLU)2

R10-1 (GRY)

TB5-WORK(BLK)

SH1

PCB2

3 PCB1 P2-12(BRN)

13 PCB1 P1-3(RED)

MOD1 SH1-2(BLK)

MOD1 TB3-1(BLK)

PLC1 P2-3(BLU)

PCB1 P2-11(BRN)4

PCB1 P2-5(ORN)

PCB1 P2-4(ORN)

PCB1 P2-2(VIO)9

PLC1 P2-2(VIO) PCB1 P2-1(VIO)10

PLC1 P2-1(VIO)

PCB1 P3-1(GRY)11

PCB1 P3-2(BLU)12

PCB1 P1-2(BRN)14

TB5

WORK

TORCH

PCB2-PA(YEL)

K2-T1 (YEL)

PLC1 J2-5(RED)

PCB2 P1-1 (RED)

PCB2 P1-6 (BLK)

VIEW F-F

VIEW E-E

0558003589

SHEET 3 OF 4

SECTION 7 TROUBLESHOOTING

TB4

1 K5-6 (WHT)

K6-6 (WHT) PLC TB4-2 (WHT) PLC TB7-2 (WHT)

TB3-2 (WHT)

K7-6 (WHT) PLC TB8-24 (WHT) TB4-1 (WHT)

K3-B(BRN)

K4-B(BRN)

K5-B(BRN) K6-B(BRN) K8-B(BRN) PLC J2-15(BRN)

PLC OUT2-C3 (GRY)

PLC OUT1-C4 (GRY) PLC TB4-7 (GRY) PLC OUT2-C2 (GRY)

PLC TB7-24 (GRY) PLC TB4-8 (GRY) J1-D (GRY) PLC TB4-6 (GRY)

PLC TB4-7 (GRY)

PLC OUT2-C1 (GRY) PLC OUT1-C6 (GRY) PLC OUT1-C5 (GRY)

PLC

TB7

PLC CB3-2 (BLK)1 PLC TB7-10 (BLK)

PLC J2-2 (WHT) PLC PS-L2 (WHT) PLC J1-3 (WHT) PLC TB4-1 (WHT)

TB3-4 (VIO) PLC OUT1-0 (VIO)

TB3-3 (VIO) PLC OUT1-C0 (VIO)

J1-M (BRN) PLC OUT1-1 (BRN)

PLC TB7-18 (BLK)10 PLC PS-L1 (BLK) PLC J1-2 (ORN) PLC TB7-1(BLK)

PLC J2-10 (RED)11 PLC OUT1-2 (RED)

PLC OUT1-C1 (BLK) PLC OUT1-C2 (BLK)

PLC TB7-1(BLK)

PLC J1-2 (ORN)

PLC OUT1-C3 (ORN)

PLC J1-1 (ORN)

PLC OUT1-3 (ORN) K3-A (YEL)

PLC OUT1-4 (YEL)

K8-A (BLU) PLC OUT1-6 (BLU)

PLC OUT2-C0 (GRY)

PLC TB7-24 (GRY)

PLC IN1-COM (BLK)

PLC TB7-10 (BLK)

PLC OUT1-5 (VIO) PLC TB7-24 (GRN) K4-A (VIO)

J1-B (VIO) PLC OUT2-0 (VIO)

J1-F (BRN)

PLC OUT2-1 (BRN)

PLC OUT2-2 (RED) J1-J (RED)

PLC OUT2-3 (ORN) J1-L (ORN)

PLC J2-3 (GRY) PLC TB4-7 (GRY) PLC TB7-17 (GRY)

TB8

1 PLC CB1-2 (BLK)

TB3-1 (WHT) PLC IN1-0 (WHT)PLC TB7-12 (BLK)

2 K7-4 (BRN)

PLC IN1-1 (BRN)

PLC J1-4 (RED) PLC IN1-2 (RED)

K5-9 (ORN) PLC IN1-3 (ORN)

K6-9 (YEL) PLC IN1-4 (YEL)

PLC IN1-6 (BLU)

PLC J1-8 (BLU)

PLC PS-LG (GRN)

PLC PS-GR (GRN) GND1 (GRN)

PLC IN1-15 (BLK)

PLC TB7-18 (BLK) PLC TB4-2 (WHT)

PLC J2-1 (BLK)

PLC CB3

0558003589

SHEET 4 OF 4

PLC TB7-1 (BLK)

SECTION 7 TROUBLESHOOTING

0558003591

MAX

10K 8W

R11

40 39

38 37

36 35

34 33

31 30

26 25 24 23

22 21

19 18 17

13 12 11 10

9 8 7 6 5 4

3 2 1

J2P2

CB3

2 3

PUMP MOTOR

CB2

575V

460V

415V

380V

230V

200V

TB2

15A

2156

FNT PNL

ON/OFF

ØC

ØB

ØA

ZD1,220

120VAC

X13 X12 X11 X16

X15

X14

4 5

X10

13 14

15 16

J4 P4

MOV2

610V

MOV3

610V

MOV1

610V

FS1

575V

460V

415V

380V

230V

200V

575V

460V

415V

380V

230V

200V

575V

460V

415V

380V

230V

200V

P3J3

18VAC

6 5

18VAC

3 2

24VAC

12VAC

120VAC

CB1

TB1

P10-5 P10-3 P10-4 P2-10 P2-9 P2-8 P2-16 P2-15 P2-14 P2-13 P2-12 P2-11 P2-7 P2-6 P2-5 P2-4 P2-2 P2-1

P3-1

P3-2

P1-3 P1-2

-P8-

AM1

AMMETER

CH7

CH8

CH6

CH5

CH4

CH3

CH2

CH1

BH7

BH8

BH6

BH5

BH4

BH3

BH2

BH1

AH7

AH8

AH6

AH5

AH4

AH3

AH2

AH1

PCB1

ISOLATION AMPLIFIER AND

FAULT SIGNAL PCB

38103

LED4

LED1

LED2

LED3

AUTO XFMR

LED7

P7-1 P7-3

LED8

LED5

LED9

P1-5

NOT USED ON

PLASMA GAS

P1-10

P1-7

P1-8

START GAS

P1-9

P1-6

P4-9 P4-1 P4-2 P4-7

P4-8 P4-10

P5-1

P1-12

P5-2

P1-11 P1-18

P1-17

P4-14 P4-13 P4-12 P4-11 P10-1 P10-2 P4-16 P4-15 P4-4

P4-3 P3-18(-)

P3-17(+)

P9-3

P9-1

P1-14

P1-13

P3-13

P3-12

P1-15

P1-16

MOD1 POWER MODULE #1

LED6

VOLTMETER

PRECISION PLASMA CONSOLE

12345678 82143657 1 325476 89 10111213141516 910

TB2-2 TB2-1 BR1-A BR1-B BR1-C

5 6

J1P1

7 9

1 2 3

8 4 5

A B

PCB TRIM POT

838193

TB4-1

TB4-4

TB4-2

EFC SEL

TB8-23TB8-24

PLC1 PLC MODULE #1

ZD2 220VAC

120VAC RELAY

FRONT PNL LOCAL

CURRENT SETTING POT

TB6-7

TB6-6

4.99K4.99K

321

LOCAL/REMOTE

7 6 5

4 3

2 1

SH1-2 SH1-1

TB3-1

20uf 400V

10K

MIN

TB6-8

FRONT PNL

CURRENT

SETTING

DPDT S3

ESAB PT-24 Precision Plasmarc System Series “B Installation manual / Instruction manual

Specifications and Main Features

Frequently Asked Questions

User Manual