Tweco Auto-Cut 100 User Manual

8. TORCH OPERATION

Torch Parts Selection

The application will determine which torch parts must be used. Refer to the cut charts for the proper torch parts to
install for a selected application.

CAUTION

Do not interchange parts. Make sure all torch parts correspond with the
plasma and shield gases in use for the application.

Pre-Setting Power Supply Controls

Set the Power Supply controls prior to operating the system as described in the power supply Operating Manual.
Refer to the cutting charts for the proper cutting parameters for the application.

Recommended Cutting Speeds

Cutting speed depends on material and thickness. The following factors may affect system performance:

• Torch parts wear; gas quality and mass flow / pressure (mass flow); operator experience; torch standoff
height; proper work cable connection; alloying contents of material; cutting table capabilities & accuracy.

NOTE

This information represents realistic expectations using recommended
practices and well-maintained systems. Actual speeds may vary from
those shown in the charts depending on the alloy content of the selected
material. Voltage ratings may vary depending on the CNC, cutting table,
or height controller.

For complete cutting speed chart data refer to the following pages.

Consumables Notes

Always assemble the consumable parts properly. Improper assembly may damage the parts or the torch head.
Ensure that parts are seated together correctly.

Always check the shield gas distributor for charring when changing parts. Do not use the distributor if it is charred.
Replace the shield gas distributor regularly to ensure proper performance.

Operational Notes

Always purge the torch after changing consumables or if the power supply has been shut off. The power supply's
built-in purge function may not be enough to properly purge the torch. Manually flow gas with the 'Test Cut Flow' and
'Test Pre-Flow' functions to help remove any remaining coolant from the lines.

Slightly increasing the preflow pressure may increase piercing ability on thicker materials. However, increasing the
preflow pressure too much may affect plasma starting reliability (misfiring).

Decreasing preflow pressure may improve piloting. Preflow pressure can be reduced without affecting cut perfor­mance as long as the pilot arc still transfers to the plate well. Decreasing preflow pressure too much will affect the
ability to transfer the arc to the plate and may cause damage to the tip.

Notes on Chart Measurements

Pressure measurements in the charts are in psi(g), not psi(a). 0 psi(g) = 14.7 psi(a) (1 atmosphere).

Ball settings are at the center of the guage ball.

Torch Data 8-1 Manual 0-4733 Rev. AD

Ohmic Sensing

Ohmic sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic
sensing circuit.

Direction of Cut

The plasma gas stream swirls as it leaves the torch to maintain a stable arc column. This swirl effect results in one
side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more
square than the left.

Left Side

Cut Angle

Right Side

Cut Angle

A-00512

Clockwise

Scrap

Counter-

Clockwise

Scrap

Workpiece

Art # A-04182

Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, move the torch counterclockwise around the circle.
To keep the square edge along an outside diameter cut, move the torch in a clockwise direction.

Underwater Cutting

Cutting on a water table either underwater or with the water touching the plate or with a water muffler system is not
recommended. If a water table is used the water level must be a minimum of 4 inches / 100 mm from the bottom of the
plate. Failure to follow this recommendation could result in poor cut quality and short consumable parts life.

Torch Data 8-2 Manual 0-4733 Rev. AD

Mild Steel

55A

O2 Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1025

Shield Gas Distributor

35-1272

Tip

35-1051

Plasma Gas Distributor

35-1041

Electrode

35-1069

Cartridge

35-1020

Art # A-04940

55A Mild Steel (O2/Air)

Material

Thickness

(ga) (in) inch ps i psi Volts

Cut Flow Pressures

Plasma

(O2)

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

(ipm) (in) (s ec) (in)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

21 0.033 70 20 120 0.125 600 0.200 0.0 0.073
16 0.060 70 20 120 0.125 400 0.200 0.0 0.071
10 0.135 80 20 126 0.125 180 0.200 0.2 0.083

3/16 0.188 80 20 127 0.125 120 0.200 0.2 0.081

1/4 0.250 80 20 128 0.125 85 0.200 0.3 0.086

Material

Thickness

(m m)

1
2
3
4
5
6

Cut Flow Pressures

Plasma

(O2)

bar bar Volts

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

4.8 1.4 120 3.2 14040 5.1 0.0 1.8

4.8 1.4 121 3.2 8760 5.1 0.0 1.9

5.5 1.4 125 3.2 5830 5.1 0.2 2.0

5.5 1.4 126 3.2 3930 5.1 0.2 2.1

5.5 1.4 127 3.2 2920 5.1 0.2 2.1

5.5 1.4 128 3.2 2360 5.1 0.3 2.2

Ker f Width

@ Rec.

Speed

Torch Data 8-3 Manual 0-4733 Rev. AD

Mild Steel

55A

Air Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1025

Shield Gas

Distributor

35-1272

Tip
35-1051

Plasma Gas Distributor

35-1041

Electrode

35-1069

Cartridge

35-1020

Art # A-04941

55A Mild Steel (Air/Air)

Material

Thickness

(ga) (in) inch ps i psi Volts

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

(ipm) (in) (s ec) (in)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

21 0.033 70 20 152 0.188 500 0.200 0.1 0.079
16 0.060 70 20 154 0.188 300 0.200 0.1 0.086
10 0.135 92 80 166 0.188 190 0.200 0.2 0.079

3/16 0.188 92 80 166 0.188 130 0.250 0.3 0.089

1/4 0.250 92 80 170 0.188 95 0.250 0.3 0.090

Material

Thickness

(m m)

1
2
3
4
5
6

Cut Flow Pressures

Plasma

(Air)

bar bar Volts

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

4.8 1.4 152 4.8 11500 5.1 0.1 2.0

4.8 1.4 157 4.8 6920 5.1 0.1 2.1

6.3 5.5 163 4.8 5460 5.1 0.2 2.0

6.3 5.5 166 4.8 4180 5.6 0.2 2.1

6.3 5.5 167 4.8 3180 6.4 0.3 2.3

6.3 5.5 169 4.8 2610 6.4 0.3 2.3

Ker f Width

@ Rec.

Speed

Torch Data 8-4 Manual 0-4733 Rev. AD

Mild Steel

100A

Plasma / Air Shield

O

2

Shield Cup

35-1016

Shield Cap

35-1027

Shield

Gas Distributor

35-1272

Tip

35-1053

Plasma

Gas Distributor

35-1041

Electrode

35-1071

Cartridge

35-1020

Art # A-04863

100A Mild Steel (O2/Air)

Material

Thickness

Cut Flow P res sures

Plasma

(O2)

Shield

(Air)

Arc

Voltage

(ga) (in) inch psi psi Volts

Torch

Working

Height

(in)

±0.005

Travel

Speed

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

(ipm) (in) (sec) (in)

16 0.060 94 49 127 0.110 500 0.250 0.1 0.071
10 0.135 94 49 134 0.110 240 0.250 0.2 0.081

3/16 0.188 94 49 128 0.120 185 0.250 0.3 0.073

1/4 0.250 94 49 130 0.120 130 0.300 0.3 0.095
3/8 0.375 94 49 138 0.130 80 0.300 0.3 0.113
1/2 0.500 94 49 138 0.140 57 0.300 0.3 0.113
5/8 0.625 94 49 144 0.140 45 0.350 0.5 0.111
3/4 0.750 94 49 150 0.150 25 NR NR 0.138

1 1.000 94 49 164 0.200 10 NR NR 0.140

Material

Thickness

(mm)

2
3
4
5
6

8
10
12
15
20
25

Cut Flow P res sures

Plasma

(O2)

Shield

(Air)

bar bar Volts

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

6.5 3.4 129 2.8 11050 6.4 0.1 1.9

6.5 3.4 132 2.8 7580 6.4 0.2 2.0

6.5 3.4 131 2.9 5500 6.4 0.2 2.0

6.5 3.4 128 3.1 4500 6.5 0.3 1.9

6.5 3.4 130 3.1 3610 7.3 0.3 2.3

6.5 3.4 134 3.2 2640 7.6 0.3 2.7

6.5 3.4 138 3.3 1950 7.6 0.3 2.9

6.5 3.4 138 3.5 1580 7.6 0.3 2.9

6.5 3.4 142 3.6 1230 8.5 0.4 2.8

6.5 3.4 152 4.0 580 NR NR 3.5

6.5 3.4 163 5.0 280 NR NR 3.6

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

Torch Data 8-5 Manual 0-4733 Rev. AD

Mild Steel

100A

Air Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1027

Shield

Gas Distributor

35-1272

Tip

35-1053

Plasma

Gas Distributor

35-1041

Electrode

35-1071

Cartridge

35-1020

Art # A-07173

100A Mild Steel (Air/Air)

Material

Thickness

(ga) (in) inch psi psi Volts

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

(ipm)(in)(sec)(in)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

16 0.060 90 45 149 0.110 600 0.250 0.1 0.072
10 0.135 90 45 145 0.110 300 0.250 0.2 0.065

3/16 0.188 90 45 149 0.110 210 0.250 0.3 0.073

1/4 0.250 90 45 152 0.120 150 0.300 0.3 0.078
3/8 0.375 90 45 152 0.130 85 0.300 0.3 0.091
1/2 0.500 90 45 159 0.140 75 0.300 0.3 0.095
5/8 0.625 90 45 153 0.140 55 0.350 0.5 0.099
3/4 0.750 90 45 163 0.150 30 0.350 0.6 0.120

1 1.000 90 45 180 0.200 20 NR NR 0.112

Material

Thickness

(m m)

2
3
4
5
6

8
10
12
15
20
25

Cut Flow Pressures

Plasma

(Air)

bar bar Volts

Shield

(Air)

Arc

Voltage

6.2 3.1 148 2.8 13340 6.4 0.1 1.8

6.2 3.1 146 2.8 9340 6.4 0.2 1.7

6.2 3.1 147 2.8 6650 6.4 0.2 1.7

6.2 3.1 149 2.8 5120 6.5 0.3 1.9

6.2 3.1 151 3.0 4150 7.3 0.3 2.0

6.2 3.1 152 3.2 2950 7.6 0.3 2.2

6.2 3.1 153 3.3 2120 7.6 0.3 2.3

6.2 3.1 157 3.5 1960 7.6 0.3 2.4

6.2 3.1 155 3.6 1540 8.5 0.4 2.5

6.2 3.1 166 4.0 720 9.5 0.6 3.0

6.2 3.1 179 5.0 520 NR NR 2.9

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

Torch Data 8-6 Manual 0-4733 Rev. AD

Stainless Steel

55A

Air Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1034

Shield Gas Distributor

35-1272

Tip

35-1060

Plasma Gas Distributor

35-1041

Electrode

35-1078

Cartridge

35-1020

Art # A-04942

55A Stainless Steel (Air/Air)

Material

Thickness

(ga) (in) inch psi psi Volts

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

(ipm)(in)(sec)(in)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

21 0.034 70 20 104 0.125 600 0.200 0.0 0.067
16 0.063 70 50 105 0.150 350 0.200 0.0 0.068
10 0.141 70 50 110 0.150 100 0.200 0.1 0.086

3/16 0.188 70 50 112 0.150 60 0.200 0.1 0.086

1/4 0.250 70 50 112 0.150 40 0.200 0.2 0.088

Material

Thickness

(m m)

0.8
1

1.5
2
3
4
5
6

Cut Flow Pressures

Plasma

(Air)

bar bar Volts

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

4.8 1.4 104 3.2 15240 5.1 0.0 1.7

4.8 1.4 104 3.3 14060 5.1 0.0 1.7

4.8 3.4 105 3.7 9750 5.1 0.0 1.7

4.8 3.4 106 3.8 7610 5.1 0.0 1.8

4.8 3.4 109 3.8 4400 5.1 0.1 2.1

4.8 3.4 111 3.8 2180 5.1 0.1 2.2

4.8 3.4 112 3.8 1450 5.1 0.1 2.2

4.8 3.4 112 3.8 1130 5.1 0.2 2.2

Ker f Width

@ Rec.

Speed

Torch Data 8-7 Manual 0-4733 Rev. AD

Stainless Steel

100A

Air Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1027

Shield

Gas Distributor

35-1272

Tip

35-1053

Plasma

Gas Distributor

35-1041

Electrode

35-1071

Cartridge

35-1020

Art # A-07173

100A Stainless Steel (Air/Air)

Material

Thickness

Cut Flow P res sures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

(ga) (in) inch psi psi Volts

Torch

Working

Height

(in)

±0.005

Travel

Speed

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

(ipm) (in) (sec) (in)

16 0.063 85 42 144 0.080 500 0.200 0.0 0.099
10 0.141 85 42 150 0.100 225 0.325 0.0 0.102

3/16 0.188 85 42 153 0.140 175 0.325 0.1 0.105

1/4 0.250 85 42 155 0.140 100 0.325 0.1 0.105
3/8 0.375 85 42 160 0.140 65 0.325 0.2 0.110
1/2 0.500 85 42 166 0.160 45 0.325 0.4 0.112

5/8 0.625 85 42 165 0.160 35 0.350 1.0 0.114

Material

Thickness

(mm)

1.5
2
3
4
5
6
8

10
12
15

Cut Flow P res sures

Plasma

(Air)

Shield

(Air)

bar bar Volts

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

5.7 2.9 144 2.0 12700 5.1 0.0 2.4

5.7 2.9 145 2.1 11290 5.7 0.0 2.5

5.7 2.9 149 2.0 6330 8.3 0.0 2.6

5.7 2.9 151 3.6 5270 8.3 0.1 2.7

5.7 2.9 153 3.6 4170 8.3 0.1 2.7

5.7 2.9 155 3.6 3020 8.3 0.1 2.7

5.7 2.9 158 3.6 2080 8.3 0.2 2.7

5.7 2.9 161 3.6 1580 8.3 0.2 2.8

5.7 2.9 165 4.0 1260 8.3 0.4 2.8

5.7 2.9 165 4.1 960 8.7 0.8 2.9

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

Torch Data 8-8 Manual 0-4733 Rev. AD

Stainless Steel

100A

H35 Plasma / N2 Shield

Shield Cup

35-1016

Shield Cap

35-1034

Shield

Gas Distributor

35-1272

Tip

35-1062

100A Sta i n l ess Stee l (H35/N2)

Cut Flow P res sures

Material

Thickness

Plasma

(H35)

Shield

(N2)

Arc

Voltage

(ga) (in) inch psi psi Volts

3/8 0.375 100 80 145 0.130 50 0.250 0.3 0.090
1/2 0.500 100 80 148 0.130 37 0.250 0.5 0.100
5/8 0.625 100 90 155 0.140 26 0.250 0.6 0.115

Plasma

Gas Distributor

35-1041

Torch

Working

Height

(in)

±0.005

Electrode
35-1080

Travel

Speed

Cartridge

35-1020

Art # A-04938

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

(ipm) (in) (sec) (in)

Material

Thickness

(mm)

10
12
15

Cut Flow P res sures

Plasma

(H35)

Shield

(N2)

bar bar Volts

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

6.9 5.5 145 3.3 1220 6.4 0.3 2.3

6.9 5.5 147 3.3 1010 6.4 0.5 2.5

6.9 6.2 151 3.5 740 6.4 0.6 2.8

Ker f Width

@ Rec.

Speed

Torch Data 8-9 Manual 0-4733 Rev. AD

Stainless Steel

r

100A

N2 Plasma / H20 Shield

Shield Cup

35-1016

Shield Cap

35-1034

Shield Gas Distributor

35-1272

Tip

35-1053

Plasma Gas Distributor*

35-1041

Electrode

35-1089

Cartridge

35-1020

Art # A-07089

100A Stainless Steel (N2/H2O)

Cut Flow Pressures

Material

Thickness

Plasma

(N2)

Shield

(H2O)

Arc

Voltage

(ga) (in) inc h ps i B all * Vol ts

Torch

Working

Height

(in)

±0.005

Travel

Speed

Initial

Piercing

Height

Pierce

Delay

(ipm) (in) (sec) (in)

Kerf

Width

@ Rec.

Speed

10 0.141 100 5 160 0.125 160 0.200 0.000 0.074

3/16 0.188 100 5 157 0.125 100 0.250 0.300 0.080

1/4 0.250 100 5 155 0.125 60 0.250 0.300 0.086
3/8 0.375 100 5 159 0.125 50 0.250 0.300 0.087
1/2 0.500 100 5 169 0.130 35 0.300 0.500 0.100
5/8 0.625 100 5 175 0.140 30 0.300 0.600 0.110
3/4 0.750 100 5 177 0.150 25 NR NR N/A

Kerf

Width

@ Rec.

Speed

Material

Thickness

(mm)

3
4
5
6
8

10
12
15
20

Cut Flow Pressures

Plasma

(N2)

Shield

(H2O)

bar Ball * Vol t s

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

6.9 5 161 3.2 4810 4.5 0 1.8

6.9 5 159 3.2 3530 5.5 0.1 1.9

6.9 5 157 3.2 2400 6.4 0.3 2.1

6.9 5 155 3.2 1750 6.4 0.3 2.2

6.9 5 157 3.2 1390 6.4 0.3 2.2

6.9 5 160 3.2 1210 6.5 0.3 2.3

6.9 5 167 3.3 970 7.3 0.5 2.5

6.9 5 173 3.5 800 7.6 0.6 2.7

6.9 5 178 3.9 600 NR NR N/A

* Bal l set t i ng for shiel d water i s set using a li ne pressure of 55 psi / 3.8 ba

: Ohm ic height sens i ng is not rec om m ended wit h wat er s hi eld.

NOTE

Water on the plate int erferes electrical ly wit h t he ohm ic s ensing c i rc ui t .

Torch Data 8-10 Manual 0-4733 Rev. AD

Aluminum

55A

Air Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1034

Shield Gas Distributor

35-1272

Tip

35-1060

Plasma Gas Distributor

35-1041

Electrode

35-1078

Cartridge

35-1020

Art # A-04942

55A Aluminum (Air/Air)

Material

Thickness

(ga) (in) inch ps i psi Volts

23

0.031 70 50 100 0.100 600 0.150 0.0 0.066

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

(ipm)(in)(sec)(in)

Initial

Piercing

Height

Pierce

Delay

Kerf Width

@ Rec.

Speed

16 0.064 70 50 105 0.100 400 0.200 0.0 0.070

0.135 70 50 115 0.150 140 0.200 0.0 0.084

3/16 0.188 70 50 120 0.150 100 0.200 0.0 0.084

1/4 0.250 70 50 122 0.150 50 0.200 0.1 0.089

Material

Thickness

(m m)

1
2
3
4
5
6

Cut Flow Pressures

Plasma

(Air)

bar bar Volts

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

4.8 3.4 101 2.5 13950 4.1 0.0 1.7

4.8 3.4 107 2.8 8790 5.1 0.0 1.9

4.8 3.4 113 3.5 5130 5.1 0.0 2.0

4.8 3.4 117 3.8 3130 5.1 0.0 2.1

4.8 3.4 120 3.8 2360 5.1 0.0 2.2

4.8 3.4 122 3.8 1550 5.1 0.1 2.2

Kerf Width

@ Rec.

Speed

Torch Data 8-11 Manual 0-4733 Rev. AD

Aluminum

100A

Air Plasma / Air Shield

Shield Cup

35-1016

Shield Cap

35-1027

Shield

Gas Distributor

35-1272

Tip

35-1053

Plasma

Gas Distributor

35-1041

Electrode

35-1071

Cartridge

35-1020

Art # A-07173

100A Aluminum (Air/Air)

Material

Thickness

(ga) (in) inch ps i psi Volts

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

(ipm) (in) (s ec) (in)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

16 0.064 85 42 154 0.130 500 0.200 0.0 0.103
10 0.135 85 42 157 0.130 260 0.200 0.0 0.106

3/16 0.188 85 42 156 0.130 120 0.325 0.1 0.100

1/4 0.250 85 42 158 0.140 100 0.325 0.2 0.104
3/8 0.375 85 42 162 0.140 75 0.325 0.2 0.107
1/2 0.500 85 42 168 0.140 45 0.325 0.3 0.109
5/8 0.625 85 42 175 0.140 35 0.325 0.4 0.112
3/4 0.750 85 42 180 0.180 35 0.350 0.9 0.121

Material

Thickness

(m m)

2
3
4
5
6

8
10
12
15
20

Cut Flow Pressures

Plasma

(Air)

bar bar Volts

Shield

(Air)

Arc

Voltage

5.9 2.9 155 3.3 11430 5.1 0.0 2.6

5.9 2.9 156 3.3 8050 5.1 0.0 2.7

5.9 2.9 157 3.3 5100 6.4 0.0 2.6

5.9 2.9 156 3.3 2980 8.3 0.1 2.6

5.9 2.9 158 3.5 2650 8.3 0.2 2.6

5.9 2.9 160 3.6 2210 8.3 0.2 2.7

5.9 2.9 163 3.6 1790 8.3 0.2 2.7

5.9 2.9 167 3.6 1310 8.3 0.3 2.8

5.9 2.9 173 3.6 960 8.3 0.4 2.8

5.9 2.9 181 4.9 890 9.9 1.0 3.1

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

Torch Data 8-12 Manual 0-4733 Rev. AD

Aluminum

100A

H35 Plasma / N2 Shield

Shield Cup

35-1016

Shield Cap

35-1034

Shield

Gas Distributor

35-1272

35-1062

100A Aluminum (H35/N2)

Material

Thickness

(ga) (in) inch psi psi Volts

Cut Flow Pressures

Plasma

(H35)

Shield

(N2)

Arc

Voltage

3/8 0.375 120 50 150 0.188 60 0.350 0.1 0.100
1/2 0.500 120 50 156 0.188 40 0.350 0.4 0.110
5/8 0.625 120 50 160 0.188 30 0.350 0.5 0.113
3/4 0.750 120 50 171 0.250 20 0.350 0.6 0.130

Tip

Plasma

Gas Distributor

35-1041

Torch

Working

Height

(in)

±0.005

Electrode
35-1080

Travel

Speed

(ipm)(in)(sec)(in)

Initial

Piercing

Height

Cartridge

35-1020

Art # A-04938

Pierce

Delay

Kerf Width

@ Rec.

Speed

Material

Thickness

(m m)

10
12
15
20

Cut Flow Pressures

Plasma

(H35)

bar bar Volts

Shield

(N2)

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min) (mm) (sec) (mm)

Initial

Piercing

Height

Pierce

Delay

8.3 3.4 151 4.8 1450 8.9 0.1 2.6

8.3 3.4 155 4.8 1130 8.9 0.3 2.7

8.3 3.4 159 4.8 830 8.9 0.5 2.8

8.3 3.4 174 6.8 430 8.9 0.6 3.4

Kerf Width

@ Rec.

Speed

Torch Data 8-13 Manual 0-4733 Rev. AD

Aluminum

100A

N2 Plasma / H20 Shield

Shield Cup

35-1016

Shield Cap

35-1034

Shield

Gas Distributor

35-1272

Tip

35-1053

Plasma

Gas Distributor

35-1041

Electrode

35-1089

Cartridge

35-1020

Art # A-07174

100A Aluminum (N2/H2O)

Material

Thickness

Plasma

(N2)

Shield

(H2O)

Arc

Voltage

(ga) (in) inc h psi Ball * V ol t s

Cut Flow P res sures

Torch

Working

Height

(in)

±0.005

Tr avel

Speed

Initial

Piercing

Height

Pierce

Delay

(ipm) (in) (sec) (in)

Kerf

Width

@ Rec.

Speed

10 0.135 100 5 148 0.125 170 0.200 0.0 0.072

3/16 0.188 100 5 158 0.125 80 0.250 0.3 0.080

1/4 0.250 100 5 158 0.125 60 0.250 0.3 0.085
3/8 0.375 100 5 161 0.125 50 0.250 0.3 0.086
1/2 0.500 100 5 170 0.130 35 0.300 0.6 0.091
5/8 0.625 100 5 180 0.140 20 0.300 0.8 0.120

Material

Thickness

(mm)

4
5
6

8
10
12
15

Cut Flow P res sures

Arc

Plasma

(N2)

Shield

(H2O)

Voltage

bar Ball * V ol t s

6.9 5 152 3.2 3350 5.6 0.1 1.9

6.9 5 158 3.2 1960 6.4 0.3 2.1

6.9 5 158 3.2 1640 6.4 0.3 2.1

6.9 5 160 3.2 1390 6.4 0.3 2.2

6.9 5 162 3.2 1210 6.5 0.3 2.2

6.9 5 168 3.3 970 7.3 0.5 2.3

6.9 5 177 3.5 610 7.6 0.7 2.8

Torch

Working

Height

(mm)

±0.1

Tr avel

Speed

Initial

Piercing

Height

Pierce

Delay

(mm/min) (mm) (sec) (mm)

* Bal l set t i ng for shiel d water i s set using a li ne pressure of 55 psi / 3. 8 bar.

Kerf

Width

@ Rec.

Speed

: Ohm ic height sens i ng is not recom m ended wit h wat er s hiel d.

NOTE

Water on the plate int erferes electricall y wit h t he ohmi c s ensing c i rc ui t .

Torch Data 8-14 Manual 0-4733 Rev. AD

TORCH REPLACEMENT PARTS

Returns

If a product must be returned for service, contact your authorized distributor. Materials returned without proper autho­rization will not be accepted.

Ordering Information

Order replacement parts by catalog number and complete description of the part or assembly. Also include the
model and serial number of the machine or torch.

Refer to parts diagrams within the body of the manual for consumable parts and replacement O-Ring catalog num­bers.

Qty. Description Catalog Number

1 XT-301 Torch w/ 25' / 7.6 m Leads 2-7000

1 XT-301 Torch w/ 35' / 10.6 m Leads 2-7001

1 XT-301 Torch w/ 50' / 15.2 mLeads 2-7002

1 XT-301 Torch w/ 75' / 22.9 m Leads 2-7003

1 XT-301 Torch w/ 100' / 30.5 m Leads 2-7004

1 O-Ring Lubricant (Christo-Lube MCG-129) 9-4893

1 Coolant Check Valve Kit 9-4846

1 Water Shield Regulator 8-6118

1 Torch Cartridge (includes Cartridge Tool) 35-1020

1 Cartridge Tool 9-9431

1 Shield Cup 35-1016

Inner O-Ring (Cat. No. 8-0545)
Location (Under Locking Ring)

Cartridge Retaining

Ring 9-9489

Snap Ring

O-Rings

Cat. No. 9-9041

O-Ring, Cat. No. 8-0544

O-Ring, Cat. No. 8-0540

Cat. No. 8-0539

Cartridge Assembly

Cat. No. 8-3487

Cat. No. 8-0530

Art # A-07087

Coolant Tube Kit
9-9429

Torch Head

Art # A-07088

Torch Data 8-15 Manual 0-4733 Rev. AD

Qty. Description Catalog Number

1 XT-301Torch Head Kit 35-1002

1 Torch Clamp Assembly 9-9336

1 Torch Positioning Tube (includes Hardware Kit ) 9-4700

1 Positioning Tube Hardware Kit (includes O-Ring) 9-4847

1 Coolant Tube Kit 9-9429

1 Ohmic Clip (not shown) 9-9414

Torch Head

Coolant Tube Assembly

Torch Clamp

Coolant Return

Check Valve

and Connector

End Cap

O-Ring (included
in Hardware Kit)

R

G

Positioning Tube

Torch Leads

Leads Clamp

Art # A-06980

To GCM-1000

Torch Data 8-16 Manual 0-4733 Rev. AD

Consumables Selection Chart

8-0545

(Behind Ring)

'O' Rings

8-0544

8-0540

35-1020

Cartridge

35-1069

35-1020

35-1020

35-107135-1053

35-1069

35-1020

35-1071

35-1020

35-1020

35-1078

35-1071

35-1020

35-1020

35-1089

35-1080

35-104135-127235-1025

Distributor

Plasma GasShield Gas

35-1051

Distributor

Shield CapShield Cup ElectrodeTip

35-1016

35-104135-127235-1025

35-104135-127235-1027

35-1051

35-1016

35-1016

35-104135-127235-1027

35-1053

35-1016

35-104135-127235-1034

35-104135-127235-1027

35-1053

35-1060

35-1016

35-1016

35-104135-127235-1034

35-1041

35-1062

35-1053

35-127235-1034

35-1016

35-1016

9-9414

Ohmic Sensor

Plasma/Shield GasAmps

Air Plasma / Air Shield

55A

XT-301™ Conventional Plasma Torch

Auto-Cut™ 55-100 Amps

Art # A-07806

Air Plasma / Air Shield

O2 Plasma / Air Shield

100A

Mild Steel

O2 Plasma / Air Shield

Air Plasma / Air Shield

Air Plasma / Air Shield

55A

Stainless Steel

N2 Plasma / H2O Shield

H35 Plasma / N2 Shield

100A

Aluminum

Torch Data 8-17 Manual 0-4733 Rev. AD

Consumables O-Ring Locations and Catalog Numbers

Consumables O-Ring Locations and Catalog Numbers

Shield Cap

O-Ring 9-9039

35-1034

Tips

B

A

35-1051

A - O-Ring 9-9038

B - O-Ring 9-9060

35-1053

A - O-Ring 9-9038

B - O-Ring 9-9060

O-Ring 9-9035

35-1069
35-1071

O-Ring 9-9035

35-1078

Electrodes

O-Ring 9-9035

35-1080
35-1089

35-1060

A - O-Ring 9-9038

B - O-Ring 9-9060

35-1062

A - O-Ring 9-9038

B - O-Ring 9-9060

Art # A-07165

Torch Data 8-18 Manual 0-4733 Rev. AD

PATENT INFORMATION

XTTM-301 Plasma Cutting Torch Patents

The following parts are covered under U.S. and Foreign Patents as follows:

Catalog # Description Patent(s)

35-1020 Cartridge US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1022 Cartridge US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1068 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517577 Other Pat(s) Pending
35-1069 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517576 Other Pat(s) Pending
35-1070 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517576 Other Pat(s) Pending
35-1071 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517576 Other Pat(s) Pending
35-1072 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517576 Other Pat(s) Pending
35-1077 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566 Other Pat(s) Pending
35-1078 Electrode US Pat No(s) 6946616; 6919526; D505963; 6989505; 6998566 Other Pat(s) Pending
35-1079 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566 Other Pat(s) Pending
35-1080 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517577 Other Pat(s) Pending
35-1085 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566 Other Pat(s) Pending
35-1086 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517576 Other Pat(s) Pending
35-1087 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517577 Other Pat(s) Pending
35-1088 Electrode US Pat No(s) 6946616; 6919526; 6989505; 6998566; D517576 Other Pat(s) Pending
35-1040 Plasma Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1041 Plasma Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1043 Plasma Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1044 Plasma Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1046 Plasma Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1024 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1025 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1026 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1027 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1034 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1028 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1029 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1030 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1031 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1032 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1033 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1035 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1036 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1037 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1275 Shield Cap US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1016 Shield Cup US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1018 Shield Cup US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1082 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1272 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1273 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1274 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1280 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1281 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1282 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1283 Shield Gas Distributor US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1019 Shield Retainer US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1021 Shield Retainer US Pat No(s) 6946616; 6919526; 6989505 Other Pat(s) Pending
35-1050 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s) Pending

35-1051 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s)Pending

35-1052 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s) Pending

35-1053 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s)Pending

Torch Data 8-19 Manual 0-4733 Rev. AD

XTTM-301 Plasma Cutting Torch Patents

The following parts are covered under U.S. and Foreign Patents as follows:

Catalog # Description Patent(s)

35-1054 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s) Pending

35-1058 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s)Pending

35-1060 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; Other

Pat(s) Pending

35-1061 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s) Pending

35-1062 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600; D519135; D524,336 Other

Pat(s)Pending
35-1055 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600 Other Pat(s) Pending
35-1056 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600 Other Pat(s) Pending
35-1057 Tip US Pat No(s) 6946616; 6919526; 6989505; 7005600 Other Pat(s) Pending
35-1001 Torch Head US Pat No(s) 6946616; 6919526; 6852944; 6989505; 7071443 Other Pat(s) Pending

The following parts are licensed under U.S. Patent No. 5,120,930 and 5,132,512:

Catalog # Description

35-1027 Shield Cap
35-1028 Shield Cap
35-1029 Shield Cap
35-1030 Shield Cap
35-1032 Shield Cap

NOTE

This manual may refer to some or all of the parts listed.

Torch Data 8-20 Manual 0-4733 Rev. AD