Tweco XTTM-300 User Manual
XTTM-300
LIQUID COOLED
PLASMA CUTTING TORCH
For Distributor Use With
Hypertherm
®
HD3070 System
Instruction Manual
Rev. AA.01 Date: December 20, 2006 Manual # 0-2912
Operating Features:
Coolant Flow
Minimum
0.9 gpm
Duty
Cycle
%
w WARNINGS
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Liquid Cooled Plasma Torch
RPT Model XT™-300 For Distributor Use With Hypertherm® HD3070 System
Instruction Manual No. 0-2912
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
© Copyright 2004, 2005, 2006 by
Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party
for any loss or damage caused by any error or omission in this Manual, whether
such error results from negligence, accident, or any other cause.
Printed in the United States of America
Publication Date: December 20, 2006
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date: ___________________________________
Power Supply Serial #: ___________________________________
Hypertherm
Torch Serial #: ___________________________________
®
is a registered trademark of Hypertherm, Inc.
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ............................................................................................... 1-1
1.01 Notes, Cautions and Warnings ..................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-3
Section 2: Torch Specifications ................................................................................................. 2-1
SECTION 3:
INSTALLATION ................................................................................................................. 3-1
3.01 Unpacking .................................................................................................... 3-1
3.02 Oxygen Plasma Pre-Charge Unit Installation ............................................... 3-1
3.03 Oxygen Plasma Pre-Charge Unit Switch Setting .......................................... 3-5
3.04 Connecting Torch ......................................................................................... 3-6
3.05 Consumables Selection ............................................................................... 3-8
3.06 Oxygen Plasma Pre-Charge Unit Installation Checks ................................ 3-11
3.07 Oxygen Plasma Pre-Charge Unit Operational Check ................................. 3-12
3.07 Pre-Charge Unit Checks ............................................................................ 3-12
SECTION 4-A:
OPERATION WITH MANUAL GAS CONSOLE ........................................................... 4A-1
Speed Charts for
Material Amperage Plasma Gas Shield Gas Page
30 O2 O2 - N2 4A-4
Mild Steel
Stainless Steel
Aluminum
50 O2 O2 - N2 4A-5
70 O2 O2 - N2 4A-6
100 O2 O2 - N2 4A-7
30 Air Air 4A-8
50 Air Air 4A-9
70 Air Air - CH4 4A-10
100 AR / H2 N2 4A-11
50 Air Air 4A-12
70 Air Air 4A-13
100 AR / H2 N2 4A-14
Manual
Gas Controls
TABLE OF CONTENTS (continued)
SECTION 4B:
OPERATION WITH 5-KNOB AUTOMATIC GAS CONSOLE ......................................... 4B-1
4B.01 Torch Parts Selection .............................................................................. 4B-1
4B.02 Pre-Setting Controls ................................................................................ 4B-1
4B.03 Recommended Cutting Speeds .............................................................. 4B-2
Speed Charts for
Material Amperage Plasma Gas Shield Gas Page
30 O2 O2 - N2 4B-4
Mild Steel
Stainless Steel
Aluminum
50 O2 O2 - N2 4B-5
70 O2 O2 - N2 4B-6
100 O2 O2 - N2 4B-7
30 Air Air 4B-8
50 Air Air 4B-9
70 Air Air - CH4 4B-10
50 Air Air 4A-11
70 Air Air 4A-12
5-Knob Automatic
SECTION 4C:
OPERATION WITH 6-KNOB AUTOMATIC GAS CONSOLE .......................................4C-1
4C.01 Torch Parts Selection ..............................................................................4C-1
4C.02 Pre-Setting Controls................................................................................4C-1
4C.03 Recommended Cutting Speeds .............................................................. 4C-2
Speed Charts for
Material Amperage Plasma Gas Shield Gas Page
30 O2 O2 - N2 4C-4
Mild Steel
Stainless Steel
Aluminum
50 O2 O2 - N2 4C-5
70 O2 O2 - N2 4C-6
100 O2 O2 - N2 4C-7
30 Air Air 4C-8
50 Air Air 4C-9
70 Air Air - CH4 4C-10
100 AR / H2 N2 4C-11
50 Air Air 4C-12
70 Air Air 4C-13
100 AR / H2 N2 4C-13
6-Knob Automatic
Gas Console
Gas Console
Section 5: General Maintenance .............................................................................................. 5-1
E. Coolant Leak Trouble-Shooting .................................................................... 5-5
TABLE OF CONTENTS
SECTION 6:
PARTS LIST ...................................................................................................................... 6-1
APPENDIX 1: ALTERNATE ARC VOLTAGE SETTINGS ........................................................... A-1
APPENDIX 2: WIRING DIAGRAM ............................................................................................ A-2
APPENDIX 3: PATENT INFORMATION .................................................................................... A-3
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.03, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove
all sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
Date: July 16, 2002 1-1 GENERAL INFORMATION
ELECTRIC SHOCK
NOISE
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area
where fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item
1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your
skin. The plasma arc process produces very bright ultra
violet and infra red light. These arc rays will damage
your eyes and burn your skin if you are not properly
protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
GENERAL INFORMATION 1-2 Date: July 16, 2002
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable from
the Superintendent of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
Date: July 16, 2002 1-3 GENERAL INFORMATION
GENERAL INFORMATION 1-4 Date: July 16, 2002
A. Torch Dimensions
Section 2: Torch Specifications
2" Diameter
3.25"
2.75"
6.00"
Art # A-04699
B. Torch Parts (Generic Parts Shown)
Art # A-04741
Shield Gas
Distributor
Shield Cap
Shield Cup
Tip
Plasma Gas
Distributor
Electrode
Cartridge
C. Parts - In - Place (PIP)
The torch is designed for use with a power supply which senses coolant return flow to confirm that torch
parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will
not provide power to the torch. Coolant leakage from the torch also indicates that torch parts are absent
or installed improperly.
D. Type of Cooling
Combination of gas stream through torch and liquid cooling.
Manual No. 0-2912 2-1 SPECIFICATIONS
E. XTTM-300 Torch Data (with Hypertherm HD3070 Power Supply)
p
TM
XT
-300 Torch Ratings
for use with Hypertherm HD3070 Power Supply
Ambient
Temperature
Duty Cycle 100% @ 100 Amps
Maximum Current 100 Amps
Voltage (V
)500V
eak
Arc Striking Voltage 10kV
Current
Minimum Coolant
Flow Requirements
TM
XT
-300 Torch Gas Specifications
Plasma Gases:
Shield Gases:
Operating Pres sure
Maximum Input Pressure 135 psi / 9.3 bar
Gas flow 10 - 300 scfh
104° F
40° C
Up to 100 Amps, DC,
Straight Polarity
0.9 gpm (3.4 lpm)
Compressed Air, Oxygen,
Nitrogen, H35, F5
Compressed Air, Oxygen,
Nitrogen, Water
125 psi ± 10 psi
8.6 bar ± 0.7 bar
Manual No. 0-2912 2-2 SPECIFICATIONS
SECTION 3:
INSTALLATION
3.01 Unpacking
The product is packaged and protected to prevent damage during shipping.
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify and account for each item.
3. Inspect each item for possible shipping damage. If damage is evident, contact your distributor and/or shipping
company before proceeding with system installation.
3.02 Oxygen Plasma Pre-Charge Unit Installation
The Oxygen Plasma Pre-Charge Unit is an addition to the Gas Control console on the HD-3070 Power Supply. The
pre-charge unit is used to increase the line pressure of the plasma gas (Oxygen) at the start of a cut cycle. The precharge unit is activated only during pre-flow when the gas selection switch is set to cut with Oxygen. This added
pressure provides improved consumable life during piercing. When cutting with any other plasma gas, the pre-charge
unit is not activated.
NOTE
The Thermal Dynamics Pre-Charge Unit is for use only with oxygen (O2)
gas.
Art # A-06722
Oxygen Plasma Pre-Charge Unit
A. Parts Supplied
The Pre-Charge Unit includes:
• Oxygen Plasma Pre-Charge Unit
• Oxygen Plasma Pre-Charge Supply Hose
• Oxygen Plasma Pre-Charge Outlet Hose
• Oxygen Plasma Outlet Tee Assembly
• Flashback Arrestor
Manual 0-2912 3-1 INSTALLATION
B. Connecting Oxygen Plasma Pre-Charge Unit
Refer to the connection diagrams and install the Pre-Charge Unit as follows:
1. Place the Unit on top of the existing Gas Console.
2. Disconnect the 3x1 Cable coming from the Plasma Power Supply from the existing Gas Console.
3. Connect the 3x1 Cable to the mating connector on the Oxygen Plasma Pre-Charge Unit.
4. Connect the end of the new 3x1 Cable supplied on the Pre-Charge Unit to the mating connector on the
existing Gas Console.
5. Disconnect the plasma gas line (blue) that goes to the torch from the existing Gas Console.
CAUTION
Do not use PTFE sealant with components carrying oxygen (O2). Do
not overtighten fittings or hose connections.
6. Install the Plasma Outlet Tee Assembly on the existing Gas Console. Angle the Plasma Outlet Tee Assembly
towards the Oxygen Plasma Pre-Charge Unit.
7. Connect the existing plasma gas line (blue) from the torch to the Plasma Outlet Tee Assembly.
8. Refer to the illustrations captioned 'after Pre-Charge Unit Installation'. Install the flash-back arrestor on the
pre-charge unit.
9. Connect the supplied hose between the flash-back arrestor and the Plasma Outlet Tee Assembly.
10.Connect the fitting on the hose from the Pre-Charge Unit to the O2A-1/8 NPT Straight Adapter on the Plasma
Outlet Tee Assembly.
11.Disconnect the oxygen (O2) supply line from the Gas Console.
12. Remove the existing oxygen (O2) supply line fitting from the Gas Console.
13. Connect the supplied Plasma Pre-Charge Supply Hose between the O2B fitting on the Oxygen Plasma PreCharge Unit tee and the existing Gas Console oxygen (O2) supply connection.
14. Remove the plug from the Tee Fitting of the Pre-Charge Unit.
CAUTION
Test all connections for leaks. Tighten connections as needed. Do not
overtighten.
15.Connect the oxygen (O2) supply line to the Oxygen Plasma Pre-Charge Unit tee.
16. Attach the ground wire from the ground stud on the Oxygen Plasma Pre-Charge Unit to the ground stud on
the Gas Console.
INSTALLATION 3-2 Manual 0-2912
Plasma Gas Line
To Torch
Ground Stud
Connection
Shield Gas Line
To Torch
Pre-Flow Gas Line
To Torch
Manual Gas Console
A-03785
Connection Diagram Of Original Manual Gas Console
3X1 Cable From
Power Supply
O2 Supply Line
N2 Supply Line
3X1 Cable From Power Supply
Original Plasma
Gas Line Fitting
Plasma Gas Line
To Torch
Shield Gas Line To Torch
Pre-Flow Gas Line To Torch
Green Light (Refer to Operation
Section of Torch Manual)
Flashback Arrestor
Plasma Outlet Tee Assembly
Manual Gas Console
Pre-Charge
Unit
Connect To Mating Connector
On Gas Console
O2 Supply Line
Tee Fitting
O2 Supply Hose
To Gas Console
N2 Supply Line
CAUTION
Do not interchange parts. Make sure the parts in the torch corre-
spond with the plasma and shield gas in use for the application.
Art # A-04449
Ground Stud Connection
Connection Diagram to Manual Gas Console After Pre-Charge Unit Installation
Manual 0-2912 3-3 INSTALLATION
Automated Gas Console
3X1 Cable From
Power Supply
Ground Stud
Connection
Art # A-03948
Plasma Gas Line
To Torch
Shield Gas Line
To Torch
Pre-Flow Gas Line
To Torch
O2 Supply Line
Connection Diagram for Original Automated Gas Console
Green Light (Refer to Operation
Section of Torch Manual)
3X1 Cable From Power Supply
Flashback Arrestor
Pre-Charge
Unit
Tee Fitting
Automated Gas Console
Shield Gas Line
To Torch
N2 Supply Line
Ground Stud Connection
O2 Supply Line
Connect To 3x1
Connector On
Gas Console
Plasma Gas Line
To Torch
Original Plasma
Gas Line Fitting
Plasma Outlet
Tee Assembly
Pre-Flow Gas Line
Connect to Plasma
Gas Line Fitting
To Torch
Connect to O
Supply Line Fitting
2
N2 Supply Line
O2 Supply Hose
To Gas Console
Connect to
Stud Connection
Art # A-04450
Connection Diagram for Automated Gas Console after pre-Charge Unit Installation.
INSTALLATION 3-4 Manual 0-2912
3.03 Oxygen Plasma Pre-Charge Unit Switch Setting
1. Turn the Oxygen Plasma Pre-Charge Unit upside down. The bottom of the assembly includes a label and a
cut-out. There is a toggle switch inside the cut-out.
2. Compare the label on the bottom of the Oxygen Plasma Pre-Charge Unit to the switches on the Gas Console.
For installations with Gas Consoles with switches as shown on the lower half of the label, set the toggle switch
on the Oxygen Plasma Pre-Charge Unit to position 'A'. For installations with Gas Consoles with switches as
shown on the upper half of the label, set the toggle switch on the Pre-Charge Unit to position 'B'. Use a pencil
or similar tool to set the switch. Do not open the Oxygen Plasma Pre-Charge Unit.
Cut-out
Art # A-04447
AUTO GAS BOX VERSION
PLASMA
AUX
2 N2
O
ALL MANUAL GAS BOXES
AUTO GAS BOX VERSION
A
PLASMA GAS SELECTOR
O
2 H35&N2
SHIELD
AIR
AUX
B
INCLUDES
B
A
INCLUDES
Toggle Switch (in 'A' Position)
View of Bottom of Pre-Charge Unit
3. Turn the Oxygen Plasma Pre-Charge Unit right side up. Set the unit securely on the Gas Control.
4. Turn on the oxygen (O2) gas supply and check all connections for leaks.
5. This completes the installation of the Oxygen Plasma Pre-Charge Unit.
Manual 0-2912 3-5 INSTALLATION
3.04 Connecting Torch
WARNINGS
Disconnect primary power at the source before disassembling the torch
or torch leads.
Use caution when removing the Pilot Return Lead from the existing Torch
as damage to the connection can result.
The Torch Head is a direct replacement for the Hypertherm Torch Head on the HD3070 System. Connect the Torch
Leads as follows:
1. Remove and set aside any consumables installed in the original torch. Release the torch positioning tube
from its support. Do not rotate the torch head or leads. Support the Torch Head and positioning tube manually.
2. Rotate the positioning tube to disconnect the Hypertherm Torch Head from the tube. Slide the tube back on
the leads to expose the torch leads connections to the torch head.
3. Disconnect the torch head from the leads. Set the torch head aside.
4. Connect the gas and coolant leads to the Torch Head.
a. Coolant supply and return connections to the Torch Head are of different lengths.
b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gas con-
nection is left-hand thread, the shield gas connection is right-hand thread.
Shield Gas
Heat Shrink
Pilot Lead (+)
Coolant Supply
Power Lead (-)
Coolant Return
Plasma Gas
(Left Hand Thread)
&
Art # A-04518
c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure the leads
to the Torch Head. Do not overtighten.
CAUTION
The gas and coolant leads include compression fittings. Do not use sealant on these connections.
Slowly apply pressure to the gas lines. Check for leaks at all connections
before continuing. If there are no leaks, shut off the gas supplies and
continue with installation.
INSTALLATION 3-6 Manual 0-2912
5. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread the
plastic lead cover/connector onto the mating Torch Head connector.
6. Press the Torch Head Assembly upward to connect to the Mounting Tube. Pull the leads back as needed to
ensure a proper fit to the Mounting Tube. Hold the Torch Head Assembly stationary; rotate the Mounting Tube
to thread it onto the Torch Head.
CAUTION
Ensure that the leads do not twist within the mounting tube. Leads must
lie as shown in the installation sketch.
Manual 0-2912 3-7 INSTALLATION
3.05 Consumables Selection
21-1020
Cartridge
Art # A-04031
30A Mild Steel, Precision
Electrode, 30A MS
Plasma
Tip, 30A MS
Shield
50A Mild Steel, Precision
21-1068
30A MS
21-1040
Gas Distributor,
21-1050
30A MS
21-1082
Gas Distributor,
21-1069
Electrode, 50A MS
21-1051
Tip, 50A MS
70A Mild Steel, Precision
21-1070
Electrode, 70A MS
Plasma
Gas Distributor
21-1052
Tip, 70A MS
Shield
Gas Distributor
100A Mild Steel, Precision
Electrode, 100A MS
21-1041
Tip, 100A MS
Swirl
21-1272
21-1071
21-1053
30A Stainless Steel, Precision
Electrode, 30A SS
Plasma
Tip, 30A SS
Shield
50A Stainless Steel / Aluminum, Precision
21-1077
Electrode, 50A SS/AL
21-1045
Gas Distributor
21-1059
No Swirl
Gas Distributor
Tip, 50A SS/AL
21-1274
70A Stainless Steel , Precision
21-1078
21-1060
100A Stainless Steel / Aluminum, Precision
21-1079
Electrode, 70A SS
Plasma
21-1041
Gas Distributor
21-1061
Tip, 70A SS
Shield
No Swirl
Gas Distributor
Electrode, 100A SS/AL
Tip, 100A SS/AL
21-1274
21-1080
21-1062
21-1024
Shield Cap, 30A MS
21-1025
Shield Cap, 50A MS
21-1026
Shield Cap, 70A MS
21-1027
Shield Cap, 100A MS
21-1033
Shield Cap, 30A SS
21-1016
Shield Cup
21-1034
Shield Cap, 50A SS/AL
21-1035
Shield Cap, 70A SS
21-1036
Shield Cap, 100A SS/AL
INSTALLATION 3-8 Manual 0-2912
Install Consumable Torch Parts
WARNINGS
Do not install consumables into the Cartridge
while the Cartridge is attached to the Torch Head.
Keep foreign materials out of the consumables and Cartridge.
Handle all parts carefully to avoid damage,
which may affect torch performance.
Art # A-03887
1. Check the appropriate cut chart for the right combination of parts for the cutting application.
2. Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are
seated correctly.
Electrode
Plasma Gas
Distributor
Tip
Shield Gas
Distributor
Shield Cap
3: Thread Shield Cup onto Cartridge
1: Stack Parts
Upper O-Ring
on Tip
2: Press Cartridge onto Stacked Parts
No Gaps
Between Parts
Cartridge Covers
Upper O-Ring
on Torch Tip
4: Check Shield Cap Protrusion
Shield Cup
Shield Cap
Shield Cap Protrudes
0.063-0.083" (1.6 - 2.1 mm)
Art # A-04716
Manual 0-2912 3-9 INSTALLATION
3. Use the removal tool to hold the cartridge assembly, while turning the shield cup onto the cartridge
assembly. When this group is fully assembled, the shield should protrude from the front of the shield cup
0.063" to 0.083" (1.6 - 2.1 mm). Without this protrusion the shield cup is not properly tightened onto the
cartridge assembly.
4. Take the removal tool off the cartridge. Fit the cartridge assembly onto the torch head. The cartridge should
seal to the large O-ring on the torch body as shown. If the cartridge does not seal on the O-ring, the cartridge
is not fully tightened.
CAUTION
Do not force the cartridge if it will not fully tighten. Remove the cartridge
and gently clean the threads on the torch head body with a wire brush.
Apply oxygen-compatible lubricant (supplied with the torch) to the threads.
Torch Head
0.063 - 0.083"
(1.6 - 2.1 mm)
Protrusion
Installing Assembled Cartridge Onto Torch Head
5. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.
Torch Head O-Ring
Art # A-07202
Ohmic Clip
A-03393
6. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.
7. Connect the wire lead from the height finder to the ohmic clip.
INSTALLATION 3-10 Manual 0-2912
3.06 Oxygen Plasma Pre-Charge Unit Installation Checks
ALWAYS verify proper function of the plasma pre-charge unit. Follow the steps below to verify the unit is installed
properly.
The pre-charge unit is used to increase the line pressure of the plasma gas (Oxygen) at the start of a cut cycle. The
pre-charge unit is activated only during pre-flow when the gas selection switch is set to cut with Oxygen. This added
pressure provides improved consumable life during piercing. When cutting with any other plasma gas, the pre-charge
unit is not activated.
To verify that the Oxygen Plasma Pre-Charge Unit is installed properly, check it as follows:
1. Be sure that O2 is being supplied to the pre-charge unit and to the gas box.
2. Be sure the gas outlet of the plasma pre-charge box is teed into the plasma lead.
3. Check the switch on the bottom of the pre-charge box to see if it is in the proper position (switch is changed
according to the type of gas box used.
4. Set the gas selection switch on the gas box to “O2/N2” cutting.
5. Turn on “Test Cut Flow” and observe the plasma outlet pressure of the gas box. This pressure will vary with
the consumables in the torch, but should generally be less than 60 psi. This is called the
pressure
6. Now turn the switch to “Test Pre-Flow”, and observe the outlet pressure of the plasma gas. It should climb to
120 PSI and the Green Light should be illuminated. This indicates that the plasma line (Oxygen) is correctly
being “pre-charged” to 120 PSI during pre-flow.
.
plasma cold flow
7. Now turn the switch back to “Test Cut-Flow”, and observe the outlet pressure of the plasma gas. It should drop
down to the plasma cold flow pressure.
Now verify that the plasma pre-charge unit is not energizing under the following conditions:
1. Set the Plasma Gas Selection switch off of Oxygen cutting (to H35 or Aux).
2. Turn on “Test Cut Flow” and observe the
3. Now turn the switch to “Test Pre-Flow”, and observe the outlet pressure of the plasma gas. It should remain at
the plasma cold flow pressure and the Green light should not be illuminated. This indicates that the plasma
pre-charge unit is not activating.
plasma cold flow pressure
.
Manual 0-2912 3-11 INSTALLATION
3.07 Oxygen Plasma Pre-Charge Unit Operational Check
THE PRE-CHARGE UNIT INCLUDES A GREEN LIGHT TO INDICATE THAT THE SYSTEM IS PRE-CHARGING
THE TORCH LEADS WITH OXYGEN. Follow the steps shown to confirm that switches on the gas console and on
the pre-charge unit are set properly. DO NOT OPERATE the system unless all gas control switches are set properly.
Compare to Gas Control Console Switches
HD3070 3-KNOB MANUAL BOX
PLASMA
(AUX A)
HD3070 6-KNOB AUTO BOX SWITCH SETTINGS
O
PLASMA GAS SELECTION
2
AIR
O
2
H35 & N2
HD3070 5-KNOB AUTO BOX SWITCH SETTINGS
PLASMA
O
2
AUX
A
SHIELD
N2
AUX
B
(AUX B)
Change Switch
to O2 position.
SHIELD
N
2
TEST
RUN
PREFLOW
PLASMA GAS SELECTION
AIR
2
H35&N
O
In Version A installations:
Is the Plasma Gas Selector switch
No
in the O2 position?
Check underside of Plasma Pre-Charge Unit
AUTO GAS BOX VERSION
PLASMA
AUX
O
2
PLASMA GAS SELECTOR
O
ALL MANUAL GAS BOXES
AUTO GAS BOX VERSION
A
2
H35&N
INCLUDES
SHIELD
AUX
N2
B
AIR
2
INCLUDES
Underside of Pre-Charge Unit
TEST
CUTFLOW
2
B
A
Version A
Yes
TEST
PREFLOW
(4, 5)
RUN
TEST
CUTFLOW
(1, 2, 3)
Version B
PLASMA
O
2
AUX
A
SHIELD
N2
AUX
B
In Version B installations:
Is the Plasma Gas Selector switch
Yes
in the O2 position?
No
Check underside of Plasma Pre-Charge Unit
AUTO GAS BOX VERSION
PLASMA
AUX
O
2
PLASMA GAS SELECTOR
O
ALL MANUAL GAS BOXES
AUTO GAS BOX VERSION
A
2
H35&N
INCLUDES
SHIELD
N2
AIR
B
AUX
B
A
2
INCLUDES
Underside of Pre-Charge Unit
Change Switch
to O2 position.
PLASMA GAS SELECTION
Change Switch
Art # A-06409
ALL MANUAL GAS BOXES
AUTO GAS BOX VERSION
Is the Pre-Charge Unit switch
No
to A position.
AIR
O
2
H35&N
in the A position?
2
INCLUDES
Yes
Is the green
light ON?
Yes
All switches are
set properly.
A
Green Light
AUTO GAS BOX VERSION
PLASMA
AUX
O
2
Is the Pre-Charge Unit switch
No
Change Switch
to B position.
SHIELD
N2
A
in the B position?
INCLUDES
AUX
B
Yes
Is the green
light ON?
Yes
All switches are
set properly.
B
Green Light
INSTALLATION 3-12 Manual 0-2912
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