Tweco Torch Data 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; operator experience; torch standoff height; proper
work cable connection; alloy content of material; cutting table capabilities & accuracy.

NOTE

This information represents realistic expectations using recommended practices and well­maintained 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 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 gauge ball.

Ohmic Sensing

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

Manual 0-4730 Rev. AF 8-1 TORCH DATA

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.

Manual 0-4730 Rev. AF 8-2 TORCH DATA

Mild Steel

30A

Plasma / O2 Shield

O

2

Shield Cup

21-1016

Shield Cap

21-1024

Shield

Gas Distributor

21-1082

Tip

21-1050

Plasma

Gas Distributor

21-1040

Electrode

21-1068

Cartridge

21-1020

Art # A-06768

30A Mild Steel (O2/O2)

Material

Thickness

Pre Flow

Pressure

(Air)

Cut Flow Rates / Pressures

Plasma (O2) Shield (O2)

Arc

Voltage

(ga) (in) inch (PSI) Ball (PSI) Ball (PSI) Volts

Torch

Working

Height

(in)

±0.005

Travel

Speed

Initial

Piercing

Height

Pierce

Delay

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

Kerf

Width

@ Rec.

Speed

20 0.036 60 22 120 21 120 128 0.050 130 0.120 0.2 0.058
16 0.060 60 22 120 21 120 143 0.050 60 0.120 0.3 0.070
14 0.075 60 22 120 21 120 145 0.070 45 0.120 0.3 0.072
12 0.105 60 22 120 21 120 148 0.110 40 0.150 0.3 0.074
10 0.135 80 22 120 21 120 154 0.130 30 0.150 0.3 0.085

3/16 0.188 80 22 120 21 120 154 0.120 25 0.150 0.4 0.075

Kerf

Width

@ Rec.

Speed

Material

Thickness

(mm)

1
2
3
4
5

Pre Flow

Pressure

(Air)

Cut Flow Rates / Pressures

Plasma (O2) Shield (O2)

Voltage

(Bar) Ball (Bar) Ball (Bar) Volts

Arc

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min)

Initial

Piercing

Height

Pierce

Delay

(mm) (sec) (mm)

4.1 22 8.3 21 8.3 130 1.3 3050 3.0 0.2 1.5

4.1 22 8.3 21 8.3 145 1.9 1130 3.1 0.3 1.8

4.1 22 8.3 21 8.3 150 3.0 910 3.8 0.3 2.0

5.5 22 8.3 21 8.3 154 3.2 710 3.8 0.3 2.1

5.5 22 8.3 21 8.3 155 3.0 640 3.8 0.4 1.9

Marking (with 30A Mild Stee l Pa rts)

15A Arc Current

Burn-through may

occur on

thicknesses

< 1/16" (0.063") /

1.6 mm

Pre Flow

Pres sure

)

(N

2

20psi

1.4 bar

Cut Flow Rates / Pressures

Plasma

Pressure (N

Ball Press Ball P ress Volts

20

)

2

40 psi

2.8 bar

Shield

Pres sure N2)

80 psi

70

5.5 bar

Arc

Voltage

145

Torch

Working

Height

In ± 0. 005 /

mm ± 0 .1

0.1

2.5

Travel

Speed

ipm /

mm/min

300

7600

Initial

Piercing

Height

In ± 0. 005 /

mm ± 0 .1

0.1

2.5

Pierce

Delay

(sec)

0

Marking

Quality

Degrades

as

Thickness

Decreases.

Manual 0-4730 Rev. AF 8-3 TORCH DATA

Mild Steel

Kerf

50A

Plasma / Air Shield

O

2

Shield Cup

21-1016

Shield Cap

21-1025

Material

Thickness

Pre Flow
Pressure

(Air)

(ga) (in) inch (psi) Ball (psi) Ball (psi) Volts

Shield

Gas Distributor

21-1272

Tip

21-1051

50A Mild Steel (O

Cut Flow Rates / Pressures

Plasma (O2) Shield (Air)

Plasma

Gas Distributor

21-1041

/Air)

2

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Cartridge

21-1020Electrode

21-1069

Art # A-06085

Travel

Speed

Initial

Piercing

Height

Pierce

Delay

Width

@ Rec.

Speed

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

14 0.075 70 28 120 20 120 130 0.060 320 0.100 0.0 0.040

12 0.105 70 28 120 20 120 130 0.060 270 0.100 0.0 0.052

10 0.135 70 28 120 20 120 126 0.040 160 0.100 0.4 0.044

3/16 0.188 70 28 120 40 120 130 0.060 100 0.110 0.4 0.054

1/4 0.250 70 28 120 40 120 132 0.060 90 0.110 0.4 0.062

l

Kerf

Width

@ Rec.

Speed

Material

Thickness

(mm)

Pre Flow
Pressure

(Air)

Cut Flow Rates / Pressures

Plasma (O2)

Shield ( Air)

Voltage

(bar) Ball (bar) Ball (bar) Volts

Arc

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min)

Initial

Piercing

Height

Pierce

Delay

(mm) (sec) (mm)

2
3
4
5
6

4.8 28 8.3 20 8.3 130 1.5 7970 2.5 0.0 1.1

4.8 28 8.3 20 8.3 128 1.3 5640 2.5 0.2 1.2

4.8 28 8.3 20 8.3 128 1.2 3420 2.7 0.4 1.2

4.8 28 8.3 40 8.3 130 1.5 2500 2.8 0.4 1.4

4.8 28 8.3 40 8.3 132 1.5 2340 2.8 0.4 1.5

Marking (with 50A Mild Stee l Pa rts)

18A Arc Curren t

Burn-through

may happen for

thicknesses < 1/16"

(0.063") / 1. 6 m m

Pre Flow
Pressure

(

)

N

2

20 psi

1.4 bar

Cut Flow Rates / Pressures

Plasma

Pressure (

)

N

2

Shield

P re ssure (

N

)

2

Arc

Voltage

Ball Press Ball Press Volts

40

40 ps i

2.8 bar

75

80 psi

5.5 bar

160

Torch

Working

Height

in ±0. 005 /

mm ±0.1

Travel

Speed

ipm /

mm/min

0.12 3 300
7600

Initial

Piercing

Height

in ±0. 005 /

mm ±0.1

0.12
3

Pierce

Delay

sec

0

Marking

quality

degrades

as

thickness

decreases.

Manual 0-4730 Rev. AF 8-4 TORCH DATA

Mild Steel

70A

Plasma / Air Shield With XTL Torch Valve Assembly*

O

2

Shield Cup

21-1016

Shield Cap

21-1026

Shield

Gas Distributor

21-1272

Tip

21-1152

Plasma

Gas Distributor

21-1041

Cartridge

21-1020Electrode

21-1170

Art # A-07662

70A Mild Steel XTL (O2/Air)

Material

Thickness

(ga) (in) inch (PSI) Ball (PSI) Ball (PSI) Volts

Pre Flow

Pressure

(Air)

Cut Flow Rates / Pressures

Plasma (O2) 5Shield (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 0.060 46 35 120 41 120 138 0.070 300 0.100 0.1 0.073
14 0.075 46 35 120 41 120 138 0.070 300 0.100 0.1 0.072
12 0.105 46 55 120 60 120 142 0.080 270 0.120 0.2 0.078
10 0.135 46 55 120 60 120 142 0.080 180 0.150 0.2 0.071

3/16 0.188 46 55 120 60 120 148 0.100 130 0.200 0.4 0.077

1/4 0.250 46 55 120 60 120 148 0.100 100 0.200 0.5 0.083

Material

Thickness

(mm)

1.5
2
3
4

6

16A Arc Curren t

Burn-through

may occur

on thick nes ses

< 1/ 16" (0. 063" ) /

1.6 mm .

*XTL (eXTreme Life) Torch Valve Assembly increases the life of consumables over the original
Torch Valve Assembly. Requires Firmware version 3.2 or higher and XTL consumables.

Pre Flow

Pressure

(Air)

(Bar) Ball (Bar) Ball (Bar) Volts

Cut Flow Rates / Pressures

Plasma (O2)

Shield (Air)

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Travel

Speed

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

Initial

Piercing

Height

Pierce

Delay

3.2 35 8.3 41 8.3 138 1 .8 7620 2.5 0.1 1.9

3.2 35 8.3 41 8.3 138 1.8 7530 2.6 0.1 1.9

3.2 55 8.3 60 8.3 142 2.0 5860 3.4 0.2 1.9

3.2 55 8.3 60 8.3 145 2.3 4030 4.4 0.3 1.9

3.2 55 8.3 60 8.3 148 2.5 3190 5.1 0.4 2.0

3.2 55 8.3 60 8.3 148 2.5 2710 5.1 0.5

Marking (with 70A Mild Stee l Pa rts)

Pre Flow

Pressure

(

)

N

2

20 ps i

1.4 bar

Cut Flow Rates / Pressures

)

Pressure (

Shield

Plasma

Pressure (

N

2

Ball Press Ball Press

50

40 psi

2.8 bar

80

80 ps i

5.5 bar

Arc

Voltage

)

N

2

Volts

155

Torch

Working

Height

in ±0. 005 /

mm ± 0 .1

0.12
3

Travel

Speed

ipm /

mm/min

300

7600

Initial

Piercing

Height

in ±0.005 /

mm ±0.1

0.12
3

Pierce

Delay

sec

0

Kerf

Width

@ Rec.

Speed

2.1

Marking

quality

degrades

as

thickness

decreases.

Manual 0-4730 Rev. AF 8-5 TORCH DATA

Mild Steel

Kerf

p

85A

Air Plasma / Air Shield

Shield Cup

21-1016

Shield Cap

21-1027

Shield

Gas Distributor

21-1272

Tip

21-1153

Plasma

Gas Distributor

21-1041

Electrode

21-1071

Cartridge

21-1020

Art # A-04028

85A Mild Steel Air/Air

Material

Thickness

(ga) (in) inch (psi) Ball (psi) Ball (psi) Volts

Pre Flow

Pressure

(Air)

Cut Flow Rates / Pressures

Plasma (A ir) Shield (A ir)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

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

Initial

Piercing

Height

Pierce

Delay

Width

@ Rec.

S

eed

10 0.135 74 55 120 80 120 160 0.070 240 0.200 0.0 0.062

3/16 0.188 74 55 120 80 120 161 0.090 174 0.200 0.1 0.065
1/4 0.250 74 55 120 80 120 164 0.090 140 0.200 0.2 0.065

3/8 0.375 74 55 120 80 120 175 0.170 75 0.250 0.3 0.085
1/2 0.500 74 55 120 80 120 169 0.120 64 0.300 0.3 0.081
5/8 0.625 74 55 120 80 120 178 0.140 30 0.350 0.8 0.095
3/4 0.750 74 55 120 80 120 186 0.150 25 NR NR 0.098

Material

Thickness

(mm)

4
5
6

8
10
12
15
20

Pre Flow

Pressure

(Air)

(bar) Ball (bar) Ball (bar) Volts

Cut Flow Rates / Pressures

Plasma (A ir) Shield (A ir)

Voltage

Arc

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min)

5.1 55 8.3 80 8.3 160 2.0 5310 5.1 0.0 1.6

5.1 55 8.3 80 8.3 162 2.3 4240 5.1 0.1 1.7

5.1 55 8.3 80 8.3 163 2.3 3730 5.1 0.2 0.2

5.1 55 8.3 80 8.3 170 3.3 2700 5.7 0.3 1.9

5.1 55 8.3 80 8.3 174 4.1 1860 6.5 0.3 2.2

5.1 55 8.3 80 8.3 170 3.3 1690 7.3 0.3 2.1

5.1 55 8.3 80 8.3 176 3.4 1000 8.5 0.7 2.3

5.1 55 8.3 80 8.3 188 3.9 600 NR NR 2.5

Initial

Piercing

Height

(mm) (sec) (mm)

Pierce

Delay

Kerf

Width

@ Rec.

Speed

Manual 0-4730 Rev. AF 8-6 TORCH DATA

Mild Steel

100A

Plasma / Air Shield With XTL Torch Valve Assembly*

O

2

Shield Cup

21-1016

Shield Cap

21-1027

Material

Thickness

(ga) (in) inch (PSI) Ball (PSI) Ball (PSI) V olts

10 0.135 40 55 120 80 120 138 0.070 280 0.200 0.2 0.065

3/16 0.188 40 55 120 80 120 140 0.090 190 0.200 0.2 0.070
1/4 0.250 40 55 120 80 120 141 0.100 150 0.200 0.3 0.078

3/8 0.375 40 55 120 80 120 143 0.110 95 0.250 0.4 0.085
1/2 0.500 40 55 120 80 120 147 0.120 64 0.300 0.6 0.097
5/8 0.625 40 55 120 80 120 148 0.120 50 0.350 0.8 0.100
3/4 0.750 40 55 120 80 120 157 0.150 25 0.125

Material

Thickness

Pre Flow

Pressure

(Air)

Pre Flow

Pressure

(Air)

Shield

Gas Distributor

21-1272

Cut Flow Rates / Pressures

) Shield (Air)

2

Cut Flow Rates / Pressures

Plasma (O

) Shield (Air)

2

21-1153

100A Mild Steel XTL O

Tip

Plasma

Gas Distributor

21-1041

/Air

2

Arc

Voltage

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Torch

Working

Height

Electrode

21-1171

Travel

SpeedPlasma (O

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

Travel

Speed

Piercing

Piercing

Cartridge

21-1020

Art # A-07665

Initial

Height

Edge start Only

Initial

Height

Pierce

Delay

Pierce

Delay

Kerf Width

@ Rec.

Speed

Kerf Width

@ Rec.

Speed

(mm)

4
5
6

8
10
12
15
20

15A Arc Current

Burn-through

may occur

for thick nesses

< 1/16" (0.063") / 1.6 mm.

*XTL (eXTreme Life) Torch Valve Assembly increases the life of consumables over the original
Torch Valve Assembly. Requires Firmware version 3.2 or higher and XTL consumables.

(Bar) Ball (Bar) Ball (Bar) Volts

2.8 55 8.3 80 8.3 139 2.0 6120 5.1 0.2 1.7

2.8 55 8.3 80 8.3 140 2.3 4670 5.1 0.2 1.8

2.8 55 8.3 80 8.3 141 2.5 4030 5.1 0.3 1.9

2.8 55 8.3 80 8.3 142 2.7 3080 5.7 0.4 2.1

2.8 55 8.3 80 8.3 144 2.8 2300 6.5 0.4 2.2

2.8 55 8.3 80 8.3 146 3.0 1800 7.3 0.6 2.4

2.8 55 8.3 80 8.3 148 3.1 1370 8.5 0.7 2.5

2.8 55 8.3 80 8.3 157 3.8 640 3.2

Marking (with 100A Mild Steel Parts)

Pre Flow

Pressure

)

(

N

2

20 psi

1.4 bar

Cut Flow Rates / Pressures

Plasma

Pres sure (

Ball Press Ball P ress Volts

50

N

2

40 psi

2.8 bar

)

Shield

Pres sure (

100

N

80 psi

5.5 bar

2

)

Arc

Voltage

190

(mm)

±0.1

Torch

Working

Height

in ±0.005 /

mm ±0.1

0.12
3

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

Edge Start Only

Travel

Speed

ipm /

mm/min

300

7600

Initial

Piercing

Height

in ±0.005 /

mm ±0.1

0.12
3

Pierce

Delay

(sec)

0

Marking

quality

degrades

as

thickness

decreases

Manual 0-4730 Rev. AF 8-7 TORCH DATA

Stainless Steel

30A

Air Plasma / Air Shield

Shield Cup

21-1016

Shield Cap

21-1033

Shield

Gas Distributor

21-1274

Tip

21-1059

Plasma

Gas Distributor

21-1045

Cartridge

21-1020Electrode

21-1077

Art # A-04498

30A Stainless Steel (Air/Air)

Material

Thickness

(ga) (in) inch (psi) Ball (psi) Ball (psi) Volts

Pre Flow

Pressure

(Air)

Cut Flow Rates / Pressures

Plasma (A ir) Shield (A ir)

Arc

Voltage

Torch

Working

Height

(in)

±0.005

Travel

Speed

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

Initial

Piercing

Height

Pierce

Delay

Kerf

Width

@ Rec.

Speed

26 0.019 60 64 120 20 120 87 0.020 350 0.040 0.0 0.029
24 0.025 60 64 120 20 120 85 0.020 320 0.040 0.0 0.028
22 0.031 60 64 120 20 120 80 0.020 310 0.040 0.0 0.034
20 0.038 60 64 120 20 120 75 0.020 300 0.060 0.1 0.025
18 0.050 60 64 120 20 120 78 0.020 150 0.080 0.2 0.032
16 0.063 60 64 120 20 120 76 0.020 110 0.080 0.2 0.030

Kerf

Width

@ Rec.

Speed

Material

Thickness

(mm)

0.6

0.8
1

1.5
2

Pre Flow

Pressure

(Air)

(bar) Ball (bar) Ball (bar) Volts

Cut Flow Rates / Pressures

Plasma (A ir) Shield (A ir)

Voltage

Arc

Torch

Working

Height

(mm)

±0.1

Travel

Speed

(mm/min)

Initial

Piercing

Height

(mm) (sec) (mm)

Pierce

Delay

4.1 64 8.3 20 8.3 85 0.5 13580 1.0 0.0 0.7

4.1 64 8.3 20 8.3 80 0.5 11580 1.1 0.0 0.9

4.1 64 8.3 20 8.3 75 0.5 9780 1.6 0.1 0.7

4.1 64 8.3 20 8.3 77 0.5 5970 2.0 0.2 0.8

4.1 64 8.3 20 8.3 74 0.5 4050 2.0 0.2 0.7

Manual 0-4730 Rev. AF 8-8 TORCH DATA

Stainless Steel

30A

Plasma / H2O Shield

N

2

Shield Cup

21-1016

Shield Cap

21-1033

Cut Flow Rates / Pressures

Material

Thickness

Pre Flow

Pressure

(N

)

2

Plasma (N

(ga) (in) (in) (psi) Ball (psi) Ball (psi) (v olts)

Shield

Gas Distributor

21-1274

30A Stainless Steel N

) S hi eld (H2O)

2

Tip

21-1059

Plasma

Gas Distributor

21-1045

O

2/H2

** A r c

Voltage

Torch

Working

Height

±0.005

(in)

Cartridge

21-1020Electrode

21-1077

Art # A-04498

Kerf

Width

@ Rec.

Speed

Travel

Speed

Initial

Piercing

Height

Pierce

Delay

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

26 0.019 90 75 120 4 55 91 0.020 600 0.040 0.0 0.047

24 0.025 90 64 120 4 55 97 0.020 440 0.040 0.0 0.045
22 0.031 90 50 120 4 55 95 0.020 420 0.040 0.0 0.045
20 0.038 90 60 120 5 55 105 0.020 300 0.050 0.1 0.044
18 0.050 90 60 120 5 55 78 0.030 250 0.050 0.1 0.035
16 0.063 90 60 120 5 55 85 0.050 205 0.060 0.2 0.044

Material

Thickness

(mm)

0.6

0.8

1.0

1.5

2.0

Pre Flow

Pressure

(N

Cut Flow Rates / Pressures

)

2

Plasma (N

) S hi eld (H2O)

2

** Arc

Voltage

Torch

Working

Height

(bar) Ball (bar) Ball (bar) (volts) (mm)

Travel

Speed

(mm/min)

Initial

Piercing

Height

Pierce

Delay

(mm) (sec) (mm)

6.2 75 8.3 4 3.8 96 0.5 12110 1.0 0.0 1.2

6.2 64 8.3 4 3.8 96 0.5 10450 1.0 0.0 1.1

6.2 50 8.3 4 3.8 102 0.5 7470 1.3 0.1 1.1

6.2 60 8.3 5 3.8 83 1.0 5550 1.4 0.2 1.0

6.2 60 8.3 5 3.8 93 2.0 3820 1.8 0.3 1.4

Kerf

Width

@ Rec.

Speed

Pres s ure of the wat er s upply li ne s houl d be regulated by c ust omer-s uppl ied pres sure regulator.

NOTE 1

: Ohmic height sensing is not recommended with water shield.

W at er on t he plat e i nt erferes elect ricall y wi t h t he ohm i c sens i ng c i rc ui t .

NOTE 2

: Wat er s ourc e used for H

O Wat er Shi el d m ust be demine ral i zed.

2

Manual 0-4730 Rev. AF 8-9 TORCH DATA