Tweco XT 301 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; 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 0-4806 Rev. AF

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 0-4806 Rev. AF

Mild Steel, 55A

2

2

Plasma / Air Shield

O

2

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 (PSI) (PSI) Volts

Cut Flow Pr essures

Plasma

(O

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

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

@ Rec.

Speed

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

Material

Thickness

(mm)

1
2
3
4
5
6

Cut Flow Pr essures

Plasma

(O

(Bar) (Bar) Volts

Shield

)

(Air)

Voltage

Arc

Torch

Working

Height

(mm)

±0.1

Travel

Speed

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

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

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

Torch Data 8-3 Manual 0-4806 Rev. AF

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 (PSI) (PSI) Volts

Cut Flow Pr essures

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

(mm)

1
2
3
4
5
6

Cut Flow Pr essures

Plasma

(Air)

(Bar) (Bar) Volts

Shield

(Air)

Arc

Voltage

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

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 8-4 Manual 0-4806 Rev. AF

Mild Steel

100A

Plasma / Air Shield

O

2

Gas Distributor

/Air)

2

(in)

Plasma

Electrode

35-1041

Travel

Speed

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

35-1071

Initial

Piercing

Height

Cartridge

35-1020

Art # A-04863

Pierce

Delay

Ker f Width

@ Rec.

Speed

Shield Cup

35-1016

Shield Cap

35-1027

Shield

Gas Distributor

35-1272

100A Mild Steel (O

Material

Thickness

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

Cut FlowPressures

Plasma

(O

2

Shield

)

(Air)

Arc

Voltage

Tip

35-1053

Torch

Working

Height

±0.005

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 0.350 0.6 0.138

1 1.000 94 49 164 0.200 10 0.140

Edge Start

Material

Thickness

(mm)

2
3
4
5
6

8
10
12
15
20
25

Cut Flow Pressures

Plasma

(O

2

(Bar) (Bar) Volts

Shield

)

(Air)

Voltage

Arc

Torch

Working

Height

(mm)

±0.1

Travel

Speed

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

Initial

Piercing

Height

Pierce

Delay

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 9.5 0.6 3.5

6.5 3.4 163 5.0 280 3.6

Edge Start

Ker f Width

@ Rec.

Speed

Torch Data 8-5 Manual 0-4806 Rev. AF

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-04863

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 1.00 90 45 180 0.200 20 0.112

Edge Start

Material

Thickness

(mm)

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 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

Edge Start

Torch Data 8-6 Manual 0-4806 Rev. AF

Mild Steel

200A

Air Plasma / Air Shield

Shield

Retainer
35-1019

Shield Cup

35-1018

Shield

Cap

35-1028

Shield Gas

Distributor

35-1280

Tip

35-1055

Plasma Gas

Distributor

35-1041

Electrode

35-1085

Cartridge

35-1020

Art # A-06988

200A Mild Steel (Air/Air)

Material

Thickness

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Arc

Voltage

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

Torch

Working

Height

(in)

±0.005

Tr avel

Speed

Initial

Piercing

Height

Pierce

Delay

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

1/4 0.250 90 60 163 0.140 185 0.300 0 0 .096
3/8 0.375 90 60 160 0.140 130 0.300 0.1 0.131
1/2 0.500 90 60 162 0.140 100 0.300 0.3 0.150
5/8 0.625 90 60 164 0.140 75 0.300 0.4 0.158
3/4 0.750 90 60 168 0.180 60 0.350 0.5 0.176

1 1.000 90 60 177 0.200 35 0.500 1.5 0.189
1-1/4 1.250 90 60 185 0.250 20 0.209
1-1/2 1.500 90 60 189 0.250 15 0.225

2 2.000 90 60 204 0.300 10 0.270

Edge Start
Edge Start
Edge Start

Ker f Width

@ Rec.

Speed

Material

Thickness

(mm)

6

8

10
12
15
20
25
32
38
44
50

Cut Flow Pressures

Plasma

(Air)

Shield

(Air)

Voltage

(Bar) (Bar) Volts

Arc

Torch

Working

Height

(mm)

±0.1

6.2 4.1 163 3.6 4700 7.6 0 2.4

6.2 4.1 161 3.6 3970 7.6 0.1 2.9

6.2 4.1 160 3.6 3190 7.6 0.1 3.4

6.2 4.1 162 3.6 2710 7.6 0.3 3.7

6.2 4.1 163 3.6 2080 7.6 0.4 4.0

6.2 4.1 169 4.6 1430 9.5 0.6 4.5

6.2 4.1 176 5.0 920 12.5 1.4 4.8

6.2 4.1 185 6.4 500 5.3

6.2 4.1 189 6.4 380 5.7

6.2 4.1 196 6.9 320 6.2

6.2 4.1 203 7.5 260 6.8

Tr avel

Speed

Initial

Piercing

Height

Pierce

Delay

Ker f Width

@ Rec.

Speed

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

Edge Start
Edge Start
Edge Start
Edge Start

Torch Data 8-7 Manual 0-4806 Rev. AF

Mild Steel

200A

Plasma / Air Shield

O

2

Shield Retainer

35-1019

Material

Thickness

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

1/4 0.250 90 58 154 0.140 190 0.300 0.1 0.153
3/8 0.375 90 58 156 0.140 140 0.300 0.3 0.159
1/2 0.500 90 58 158 0.140 100 0.350 0.4 0.168
5/8 0.625 90 58 161 0.140 70 0.350 0.5 0.183
3/4 0.750 90 58 168 0.160 60 0.400 0.6 0.192

1 1.000 90 58 170 0.180 40 0.500 0.9 0.207

1 1/4 1.250

1 1/ 2 1.500

22.000

Shield Cup

35-1018

Shield Cap

35-1029

Cut Flow

Plasma

(O

90 58 175 0.200 30 0.500 2 0.216

90 58 178 0.200 20 0.237
90 58 203 0.250 10 0.268

Shield

)

2

Shield Gas

Distributor

35-1281

200A Mild S t e el O

Arc

(Air)

Voltage

Tip

35-1056

/Air

2

Torch

Working

Height

(in)

±0.005

Art # A-07612

Pierce

Delay

Cartridge

35-1020

Kerf Width

@ Rec.

Speed

Plasma Gas

Distributor

35-1041

Travel

Speed

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

Electrode

35-1085

Initial

Piercing

Height

Edge Start
Edge Start

200A Mild Steel O2/Air

Material

Thickness

(mm)

6

8
10
12
15
20
25

32

38 Edge Start
44 Edge Start
50 Edge Start

Bold type

indicates maximum piercing parameters.

Cut Flow

Plasma

(O

(Bar) (Bar) Volts

6.2 4.0 154 3.6 4830 7.6 0.1 3.9

6.2 4.0 155 3.6 4170 7.6 0.2 4.0

6.2 4.0 156 3.6 3400 7.8 0.3 4.1

6.2 4.0 158 3.6 2760 8.6 0.4 4.2

6.2 4.0 160 3.6 1990 8.9 0.5 4.5

6.2 4.0 168 4.1 1450 12.7 0.6 4.9

6.2 4.0 170 4.5 1050 12.7 0.9 5.2

6.2 4.0 175 5.1 750 12.7 2.1 5.5

6.2 4.0 178 5.1 510 6.0

6.2 4.0 190 5.7 390 6.4

6.2 4.0 201 6.3 270 6.8

Shield

)

(Air)

2

Arc

Voltage

Torch

Working

Height

(mm)

±0.1

Bold italic

Travel

Speed

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

indicates edge star ts only.

Initial

Piercing

Height

Pierce

Delay

Kerf Width

@ Rec.

Speed

Torch Data 8-8 Manual 0-4806 Rev. AF

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

(mm)

0.8
1

1.5
2
3
4
5
6

Cut Flow Pressures

Plasma

(Air)

(Bar) (Bar) Volts

Shield

(Air)

Arc

Voltage

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

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 8-9 Manual 0-4806 Rev. AF