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