F15-800

November, 2003

Installation, Operation and Maintenance for the

PT-24 Precision Plasmarc System

Series “B”

411 South Ebenezer Road

Florence, SC 29501-0545
The equipment described in this manual is
potentially hazardous. Use caution when installing,
operating and maintaining this equipment.

Purchaser is solely responsible for the safe

operation and use of all products purchased,
including compliance with OSHA and other
government standards. ESAB Cutting
Systems has no liability for personal injury or
other damage arising out of the use of any
product manufactured or sold be ESAB. See
standard ESAB terms and conditions of sale
for a specific statement of ESAB’s
responsibilities and limitations on its liability.

ESAB Cutting Systems first priority is total

customer satisfaction. We constantly look for
ways to improve our products, service and
documentation. As a result, we make
enhancements and/or design changes as
required. ESAB makes every possible effort to
ensure our documentation is current. We
cannot guarantee that each piece of
documentation received by our customers
reflects the latest design enhancements.
Therefore, the information contained in this
document is subject to change without notice.

This manual is ESAB Part Number F15800

.

This manual is for the convenience and use of the

cutting machine purchaser. It is not a contract or
other obligation on the part of ESAB Cutting
Systems.

© ESAB Cutting Systems, 2003

Printed in U.S.A.
Table of Contents
SECTION TITLE PAGE
PARAGRAPH

SECTION 1
Safety ................................................................................................................................... 4
UNPACKING/HOISTING...................................................................................................... 18
1.1 Inspection ............................................................................................................................ 18
1.2 Hoisting................................................................................................................................ 18
SECTION 2 DESCRIPTION...................................................................................................................... 19
2.1 General................................................................................................................................. 19
2.2 Scope ................................................................................................................................... 19
2.3 Package Options Available ................................................................................................ 19
SECTION 3 INSTALLATION.................................................................................................................... 23
3.1 General................................................................................................................................. 23
3.2 Equipment Required........................................................................................................... 23
3.3 Location ............................................................................................................................... 23
3.4 Primary Electrical Input Connections............................................................................... 23
3.5 Interconnecting Lines......................................................................................................... 24
SECTION 4 OPERATION......................................................................................................................... 33
4.1 Power Source Controls/Indicators.................................................................................... 33
4.2 Operation ............................................................................................................................. 34
4.3 Sample Procedure for Setting O2 Gas Flow Rates on Flow Control Box ..................... 35
4.4 Sample Procedure for Setting N2 Gas Flow Rates on Flow Control Box ...................... 35
PROCESS DATA SHEETS .................................................................................................. 37
KERF .................................................................................................................................... 58
SECTION 5 CUTTING QUALITY ............................................................................................................. 71
5.1 Cut Angle ............................................................................................................................. 71
5.2 Voltage and Cut Quality ..................................................................................................... 72
5.3 Top Dross ............................................................................................................................ 74
5.4 Dross Formation ................................................................................................................. 74
5.5 Summary.............................................................................................................................. 75
SECTION 6 MAINTENANCE ................................................................................................................... 77
6.1 General................................................................................................................................. 77
6.2 Inspection and Cleaning .................................................................................................... 77
6.3 Torch Consumable Parts ................................................................................................... 77
6.4 Gas Pressure Switch .......................................................................................................... 77
6.5 PT-24 Torch Description and Maintenance ...................................................................... 77
6.6 Torch Maintenance ............................................................................................................. 78
6.7 PT-24 Consumable Removal, Inspection and Installation.............................................. 78
SECTION 7 TROUBLESHOOTING ......................................................................................................... 81
7.1 Troubleshooting.................................................................................................................. 81
7.2 Process Troubleshooting................................................................................................... 81
7.3 Troubleshooting Procedures............................................................................................. 83
7.4 Schematics and Wiring ...................................................................................................... 88
SECTION 8 REPAIR PARTS ................................................................................................................... 97
8.1 General................................................................................................................................. 97
8.2 Ordering ............................................................................................................................... 97
REPLACEMENT PARTS LISTS .......................................................................................... 98

1
Table of Contents
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2
SECTION 1 SAFETY
1.1 Introduction
The process of cutting metals with plasma
equipment provides industry with a valuable and
versatile tool. ESAB cutting machines are
designed to provide both operation safety and
efficiency. However, as with any machine tool,
sensible attention to operating procedures,
precautions, and safe practices is necessary to
achieve a full measure of usefulness. Whether an
individual is involved with operation, servicing, or
as an observer, compliance with established
precautions and safe practices must be
accomplished. Failure to observe certain
precautions could result in serious personnel injury
or severe equipment damage. The following
precautions are general guidelines applicable when
working with cutting machines. More explicit
precautions pertaining to the basic machine and
accessories are found in the instruction literature.
For a wide scope of safety information on the field
of cutting and welding apparatus, obtain and read
the publications listed in the Recommended
References.

1-1
SECTION 1 SAFETY
1.2 Safety Notations And Symbols The following words and symbols are used
throughout this manual. They indicate different
levels of required safety involvement.
ALERT or ATTENTION. Your safety is
! involved or potential equipment failure exists.
Used with other symbols and information.

Used to call attention to immediate hazards

! DANGER which, if not avoided, will result in serious
personal injury or loss of life.

Used to call attention to potential hazards that

! WARNING could result in personal injury or loss of life.

Used to call attention to hazards that could

! CAUTION result in minor personal injury or equipment
damage.

Used to call attention to minor hazards to

CAUTION equipment.

Used to call attention to important

installation, operation or maintenance
NOTICE information not directly related to safety
hazards.

1-2
SECTION 1 SAFETY
1.3 General Safety Information
Machinery often starts automatically.
! WARNING This equipment moves in various directions and
speeds.
• Moving machinery can crush.
• Only qualified personnel should operate or
service this power source.
• Keep all personnel, materials, and
equipment not involved in production
process clear of entire system area.
• Fence off entire work cell to prevent
personnel from passing through area or
standing in the working envelope of the
equipment.
• Post appropriate WARNING signs at every
work cell entrance.
• Follow lockout procedure before servicing
any equipment.

Failure to follow operating instructions

! WARNING could result in death or serious injury.
Read and understand this operator’s manual
before using machine.
• Read entire procedure before operating or
performing any system maintenance.
• Special attention must be given to all hazard
warnings that provide essential information
regarding personnel safety and/or possible
equipment damage.
• All safety precautions relevant to electrical
equipment and process operations must be
strictly observed by all having system
responsibility or access.
• Read all safety publications made available
by your company.

1-3
SECTION 1 SAFETY
Failure to follow safety warning label
! WARNING instructions could result in death or
serious injury.
Read and understand all safety warning labels
on machine.
Refer to operator’s manual for additional safety
information.

1.4 Installation Precautions

Improperly Installed Equipment Can
! WARNING Cause Injury Or Death.
Follow these guidelines while installing machine:
• Contact your ESAB representative before
installation. He can suggest certain
precautions regarding piping installation and
machine lifting, etc. to ensure maximum
security.
• Never attempt any machine modifications or
apparatus additions without first consulting
a qualified ESAB representative.
• Observe machine clearance requirements
for proper operation and personnel safety.
• Always have qualified personnel perform
installation, troubleshooting and
maintenance of this equipment.
• Provide a wall mounted disconnect switch
with proper fuse sizes close to the power
supply.

1-4
SECTION 1 SAFETY
1.5 Electrical Grounding
Electrical grounding is imperative for proper
machine operation and SAFETY. Refer to this
manual’s Installation section for detailed grounding
instructions.

Electric shock hazard.

! WARNING Improper grounding can cause severe injury or
death.
Machine must be properly grounded before put
into service.

1.6 Operating A Plasma Cutting Machine

Flying debris and loud noise
! WARNING hazards.
• Hot spatter can burn and injure eyes. Wear
goggles to protect eyes from burns and
flying debris generated during operation.
• Chipped slag may be hot and fly far.
Bystanders should also wear goggles and
safety glasses.
• Noise from plasma arc can damage hearing.
Wear correct ear protection when cutting
above water.

Burn hazard.
! WARNING Hot metal can burn.
• Do not touch metal plate or parts
immediately after cutting. Allow metal time
to cool, or douse with water.
• Do not touch plasma torch immediately after
cutting. Allow torch time to cool.

1-5
SECTION 1 SAFETY

Hazardous voltages. Electric shock

! WARNING can kill.
• Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
• Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
• Always turn power off to plasma power
supplies before servicing any system
component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Wear insulating gloves, shoes and clothing
to insulate yourself from workpiece and
electrical ground.
• Keep gloves, shoes, clothing, work area,
and equipment dry.
• Replace worn or damaged cables.

Fume hazard.
! WARNING Fumes and gases generated by the plasma
cutting process can be hazardous to your
health.
• Do NOT breathe fumes.
• Do not operate plasma torch without fume
removal system operating properly.
• Use additional ventilation to remove fumes if
necessary.
• Use approved respirator if ventilation is not
adequate.
• Provide positive mechanical ventilation when
cutting galvanized steel, stainless steel, copper,
zinc, beryllium, or cadmium. Do not breathe
these fumes.
• Do not operate near degreasing and
spraying operations. Heat or arc rays can react
with chlorinated hydrocarbon vapors to form
phosgene, a highly toxic gas and other irritant
gases.

1-6
SECTION 1 SAFETY

Radiation hazard.
! WARNING Arc rays can injure eyes and burn skin.
• Wear correct eye and body protection.
• Wear dark safety glasses or goggles with
side shields. Refer to following chart for
recommended lens shades for plasma cutting:
Arc Current Lens Shade
Up to 100 Amps Shade No. 8
100-200 Amps Shade No. 10
200-400 Amps Shade No. 12
Over 400 Amps Shade No. 14
• Replace glasses/goggles when lenses are
pitted or broken
• Warn others in area not to look directly at
the arc unless wearing appropriate safety
glasses.
• Prepare cutting area to reduce reflection
and transmission of ultraviolet light.
Use special paint on walls to absorb
UV light.
Install protective screens or curtains to
reduce ultraviolet transmission.

1-7
SECTION 1 SAFETY

Burn Hazard.
! WARNING Heat, spatter, and sparks cause fire and burns.
• Do not cut near combustible material.
• Do not have on your person any
combustibles (e.g. butane lighter).
• Pilot arc can cause burns. Keep torch
nozzle away from yourself and others when
activating plasma process.
• Wear correct eye and body protection.
• Wear gauntlet gloves, safety shoes and hat.
• Wear flame-retardant clothing covering all
exposed areas.
• Wear cuffless trousers to prevent entry of
sparks and slag.
• Have fire extinguishing equipment available
for use.

Explosion hazard.
! WARNING
• Certain molten aluminum-lithium (Al-Li)
alloys can cause explosions when plasma cut
OVER water.
These alloys should only be dry cut on
a dry table.
DO NOT dry cut over water.
Contact your aluminum supplier for
additional safety information regarding
hazards associated with these alloys.
• Do not cut in atmospheres containing
explosive dust or vapors.
• Do not carry any combustibles on your
person (e.g. butane lighter)
• Do not cut containers that have held
combustibles.

1-8
SECTION 1 SAFETY
1.7 Service Precautions

Hazardous voltages. Electric shock

! WARNING can kill.
• Do NOT touch plasma torch, cutting table or
cable connections during plasma cutting
process.
• Always turn power off to plasma power
supplies before touching or servicing plasma
torch.
• Always turn power off to plasma power
supplies before removing covers or panels to
service any system component.
• Do not touch live electrical parts.
• Keep all panels and covers in place when
machine is connected to power source.
• Keep gloves, shoes, clothing, work area,
and equipment dry.
• Inspect power and ground leads cables for
wear or cracking. Replace worn or damaged
cables. Do not use if damaged.
• Never bypass safety interlocks.
• Follow lock-out procedures.

Hot Torch can cause skin burns.

! WARNING
Allow torch to cool before servicing.

1-9
SECTION 1 SAFETY

Danger of Electric Shock.

! DANGER Torch may be electrically active.

Turn off Plasma Power Console before

servicing.

Establish and adhere to preventive

CAUTION maintenance. A composite program can be
established from recommended schedules.
Avoid leaving test equipment or hand tools on
machine. Severe electrical or mechanical
damage could occur to equipment or machine.

Extreme caution should be used when probing

! CAUTION circuitry with an oscilloscope or voltmeter.
Integrated circuits are susceptible to over
voltage damage. Power off before using test
probes to prevent accidental shorting of
components.
All circuit boards securely seated in sockets, all
cables properly connected, all cabinets closed
and locked, all guards and covers replaced
before power is turned on.

1-10
SECTION 1 SAFETY
1.8 Safety References -- Regulations, Standards, Guidelines

The following recognized publications on safety in welding and cutting

operations are recommended. These publications have been prepared
to protect persons from injury or illness and to protect property from
damage, which could result from unsafe practices. Although some of
these publications are not related specifically to this type of industrial
cutting apparatus, the principles of safety apply equally.
1.8.1 USA
• “Precautions and Safe Practices in Welding and Cutting with
Oxygen-Fuel Gas Equipment,” Form 2035. ESAB Cutting
Systems.
• “Precautions and Safe Practices for Electric Welding and Cutting,”
Form 52-529. ESAB Cutting Systems.
• “Safety in Welding and Cutting” - ANSI Z 49.1, American Welding
Society, 2501 NW 7th Street, Miami, Florida, 33125.
• “Recommended Safe Practices for Shielded Gases for Welding and
Plasma Arc Cutting” - AWS C5.10-94, American Welding Society.
• “Recommended Practices for Plasma Arc Welding” - AWS C5.1,
American Welding Society.
• “Recommended Practices for Arc Cutting” - AWS C5.2, American
Welding Society.
• “Safe Practices” - AWS SP, American Welding Society.
• “Standard for Fire Protection in Use of Cutting and Welding
Procedures” - NFPA 51B, National Fire Protection Association, 60
Batterymarch Street, Boston, Massachusetts, 02110.
• “Standard for Installation and Operation of Oxygen - Fuel Gas
Systems for Welding and Cutting” - NFPA 51, National Fire
Protection Association.
• “Safety Precautions for Oxygen, Nitrogen, Argon, Helium, Carbon
Dioxide, Hydrogen, and Acetylene,” Form 3499. ESAB Cutting
Systems. Obtainable through your ESAB representative or local
distributor.
• "Design and Installation of Oxygen Piping Systems," Form 5110.
ESAB Cutting Systems.
• “Precautions for Safe Handling of Compressed Gases in
Cylinders”, CGA Standard P-1, Compressed Gas Association.
Literature applicable to safe practices in welding and cutting with
gaseous materials is also available from the Compressed Gas
Association, Inc., 500 Fifth Ave., New York, NY 10036.

1-11
SECTION 1 SAFETY
1.8.2 International

Accident Prevention
VBG- Unfallverhütungsvorshriften

General Provisions
VBG 1
Allgemeine Unfallverhütungsvorshriften

Electrical Equipment and operating Equipment

VBG 4
Elektrische Anlagen

Welding, Cutting and related working methods

VBG 15
Schweißen un Schneiden un verwandte Verfahren

Shot Blasting Works

VBG 48
Strahlarbeiten

Gases
VBG 61
Gase

Oxygen
VBG 62
Sauerstoff

Operating liquid jet cutting machines

VBG 87
Arbeiten mit Flüssigkeitsstrahlem

Laser beams, accident prevention and Electro-

technology
VBG 93
Laserstrahlung, Unfallverhütungs-vorschriften für
Feinmechnik und Elektrotechnik

Noise
VBG 121
Lärm

1-12
SECTION 1 SAFETY
VDE Regulations
VDE - Vorschriften

Erection of power installations with normal voltages up to

1000 volts
VDE 0100
Bestimmungen für das Errichten von Stakstromanlagen
mit Nennspannungen bis 1000 Volt

Electrical equipment of industrial machines

VDE0113
Elektrishe Ausrüstung von Industriemaschinen

Radiation safety of laser products; users guide (DIN EN

60825)
VDE 0837
Strahlungssicherheit von Lasereinrichtungen und
Benutzungsrichtlinen (DIN EN 60825)

VDE 0837- Specification for laser guards

50
Anforderung an Lasershcutzwänden

TRAC Technical Rules for Acetylene and Carbide Stores

TRAC- Techische Regein für Azetylenanlagen und Calciumcargidlager

Acetylene lines
TRAC-204
Azetylenleitungen

Acetylene cylinder battery systems

TRAC-206
Azetylenflaschenbatterieanlagen

Safety devices
TRAC-207
Sicherheitseinrichtungen

1-13
SECTION 1 SAFETY
TRG Technical Rules for Pressure gases
TRG – Technische Regein für Druckgase

General regulations for pressure gases

TRG 100
Allgemeine Bestimmungen für Druckgase

Pressure gases
TRG 101
Druckgase

Technical gas mixtures

TRG 102
Technishe Gasgemische

Pressure gases; alterative use of compressed gas tanks

TRG 104
Druckgase, wahlweise Verwendung von
Druckgasbehältem

1-14
SECTION 1 SAFETY

TRGS – Technische Richtlinien für Gefahrstoffe

TRGS-102 Techn. Richtkonzentration (TRK) für gefährliche Stoffe

Ermittlung u. Beurteilung der Konzentration gefährlicher

TRGS-402
Stoffe in der Luft im Arbeitsbereich

TRGS-900 Grenzwerte in der Luft am Arbeitsplatz (Luftgrenzwerte)

TA TA-Luft un TA-Lärm (BLm SchV)

DIN Standards
DIN-Normen

DIN 2310
Thermal cutting; terminology and nomenclature
Part 1
Thermsiches Schneiden, Allgemeine Begriffe und
Teil 1
Bennungen

DIN 2310
Thermal cutting; determination of quality of cut faces
Part 2
Thermsiches Schneiden, Ermittein der Güte von
Teil 2
Schnittflächen

DIN 2310 Thermal cutting; arc plasma cutting; process principles,

Part 4 quality, dimensional tolerances
Thermsiches Schneiden, Plasmaschneiden,
Teil 4
Verfahrensgrundlagen, Güte, Maßtoleranzen

DIN 2310 Thermal cutting; laser beam cutting of metallic materials;

Part 5 process principles
Laserstrahlschneiden von metallischen Werkstoffen,
Teil 5
Verfahrensgrundlagen, Güte, Maßtoleranzen

DIN 2310
Thermal cutting; Classification, processes
Part 6
Teil 6 Einführung, Verfahren

DIN 4844
Safety markings (DIN EN 7287)
Part 1
Teil 1 Sicherheitskennzeichen (Siehe EN 7287)

1-15
SECTION 1 SAFETY
DIN EN ISO Harmonized Standards
DIN EN ISO-Harmonisierte Normen

DIN EN Safety of machinery

292/1 and 2
Sicherheit von Maschinen, Geräten und Anlagen

Hoses for welding, cutting and allied processes

DIN EN 559
Schläuche für Schweißen, Schneiden und verwandte
Verfahren

Hose connections and hose couplings for equipment for

welding, cutting and allied processes
DIN EN 560 Schlauchanschlüsse und Schlauchverbindungen für
Geräte zum Schweißen, Schneiden und verwandte
Verfahren

Gas welding equipment hose couplings

DIN EN 561
Gasschweißgeräte, Kupplungen

Safety of machines, reduction of risks to health

DIN EN
626-1 Sichereit von Maschinen, Reduzierung des
Gesundheitsrisikos

Single spindle vertical milling machines

DIN EN
848-1 Fräsmaschine für einseitige Bearbeitung mit drehendem
Werkzeug

DIN EN High pressure water jet machines

1829
Hochdruckwasserstrahlschneidmaschine

Thermal cutting, oxygen cutting, process principles,

DIN EN dimensional tolerances
9013 Thermisches Schneiden, Autogenes Brennschneiden,
Verfahrensgrundlagen, Güte, Maßtoleranzen

Imperfections in oxy/fuel flame cuts, laser beam cuts and

DIN EN plasma
12584 Unregeimäßigkeiten an Brennschnitten, Laserstrahl- und
Plasmaschnitten

DIN EN Laser processing machines

12626
Laserbearbeitungsmaschinen

1-16
SECTION 1 SAFETY

DIN EN Acceptance testing for oxygen cutting machines

28206
Abnahmeprüfung für Brennschneidmaschinen

DIN EN Laser Equipment

31252 Lasergeräte

DIN EN Laser and laser related equipment

31553 Laser und Laseranlagen

DIN EN Electrical equipment of machines

60204-1 Elekrische Ausrüstung von Maschinen

DIN EN Radiation safety of laser products

60825 Strahlensicherheit von Laseranlagen

Arrangement of protection devices

DIN EN 999
Anordnung von Schutzeinrichtungen
VDI Guidelines

Quality of cut faces on metallic workpieces; abrasive

water jet cutting and arc plasma cutting
VDI 2906 Schnittflächenqualität beim Schneiden von Werkstücken
aus Metall, Abrasiv- Wasserstrahischneiden und
Plasmastrahischneiden

Room air; Technical systems for welding workshops

VDI 2084
Raumluft techn. Anlagen für Schweißwerkstätten

1-17
SECTION 1B UNPACKING/HOISTING

1.1 INSPECTION B. Check each container for any loose parts prior to
disposing of shipping materials.
A. The Precision Plasmarc System will be shipped in
four separate containers. The power source, the C. Check air louvers on the power source and junction
junction box, the flow control box and the PT-24 torch box and any other opening to ensure that any obstruc-
components will all have their own containers. Re- tions are removed.
move all packing material and inspect for evidence of
concealed damage which may not have been appar- 1.2 HOISTING
ent upon receipt of the four containers. All four
components, the power source, flow control box, The power source is equipped with one lifting eye that
junction box and PT-24 torch are fully assembled. enables the unit to be hoisted.
Immediately notify the carrier of any defects or dam-
age.

18
SECTION 2 DESCRIPTION

2.1 GENERAL 2.2 SCOPE

The Precision Plasmarc System consists of four separate The purpose of this manual is to provide the operator with
components. The power source, the junction box, the all the information required to install and operate the
flow control box, and the PT-24 torch. The power source Precision Plasmarc System. Technical reference mate-
provides power and coolant to the PT-24 torch via the rial is also provided to assist in troubleshooting the cutting
junction box. The power source also provides control package.
voltage to the flow control box for precise control of the
plasma gas and shield gas to the PT-24 torch. 2.3 PACKAGE OPTIONS AVAILABLE

Table 2-1 lists Precision Plasmarc package options avail-

able through your ESAB dealer.

Table 2-1. Available Package Options

Precision Plasmarc Power Source (200/230/380/415/460/575) 3-phase 50/60 P/N 0558003587

Hz (required)

Flow Control Box (required) P/N 37416

Junction Box with HF Unit (required) P/N 37400

Pt-24 Torch (one required)

4.6 ft. P/N 0558001460
12 ft. P/N 0558001874
17 ft. P/N 0558001461

Power Bundle (one required)

25 ft. P/N 21905
60 ft. P/N 21906
100 ft. P/N 21907

Gas Line Bundle (one required)

10 ft. P/N 21902
20 ft. P/N 21903
30 ft. P/N 21904
60 ft. P/N 22334
100 ft. P/N 22335

Control Lead-Flow Control to Junction Box and Power Source to Flow Control
Box (two required)
10 ft. P/N 21917
20 ft. P/N 21918
30 ft. P/N 21919
60 ft. P/N 21920
100 ft. P/N 21921

Torch Coolant 3.8 l containers (15 l required) P/N 156F05

PT-24 Spare Par ts Kit P/N 37609

NOTES: 1. Control lead from the power source to customer CNC is supplied based on customer order.
Gas supply, hoses, work lead and input primary cable are all supplied by the customer.

2. See Process Data Sheets for a list of torch consumable parts.

19
SECTION 2 DESCRIPTION

Table 2-2. Technical Specifications

(Precision Plasma System)
Input Voltage 200/230/380/415/460/575 V 3 phase 50/60 Hz

Input Current 70/60/50/40/30/25 amps per phase

Power Factor 0.95

Output Current Range 15-100 amps dc

Output Load Voltage 215 V dc

Duty Cycle 100%

Open Circuit Voltage 315 V dc

PRECISION PLASMA
PRECISION PLASMA
JUNCTION BOX
POWER SUPPLY

PILO T
AR C

6.75"
C ON TRO L

P OWER

CU RR ENT

(171mm)
PL ASM ARC
REC I SI ON

44" 19.75" 10.62"

(1118mm) (502mm) (270mm)

WEIGHT = 26.5 lbs.(12 kg)

42"
(1067mm)

22" (559mm) Flow Control

WEIGHT = 560 lbs. (254 kg)

400 mm

275 mm

275 mm

WEIGHT = 27 lbs. (12kg)

Figure 2-1. Precision Plasma System

20
SECTION 2 DESCRIPTION
Table 2-3. Technical Specifications
(Plasma Gas)

Type O2, N2, Air

Pressure 125 psig (8.6 bar)
Flow 100 cfh (47 I/min) max (varies with application)
Purity Required O2-99.8%,N2-99.995%, Air-clean, dry, oil-free
Recommend Liquid Cylinder Oxygen: R-76-150-540LC (P/N 19777)
Service Regulators Inert Gas: R-76-150-580LC (P/N 19977)
Recommended Cylinder 2-Stage Oxygen: R-77-150-540 (P/N 998337)
Regulators Hydrogen, Methane: R-77-150-350 (P/N 998342)
Nitrogen: R-77-150-580 (P/N 998344)
Industrial Air: R-77-150-590 (P/N 998348)
Recommended Heavy-Duty Oxygen: R-76-150-024 (P/N 19151)
Hi-FIow Station or Pipeline
Regulators
Recommended High-Capacity Non-Corrosive, Non-Toxic Industrial Gas:
Station or Pipeline Regulators R-6703 (P/N 22236)

Table 2-4.Technical Specifications

(Starting Gas)

Type N2, Air

Pressure 125 psig (8.6 bar)
Flow 60 cfh (28 I/min) max (varies with application)
Purity Required 99.995%, Dry, clean, free of oil and matter

Table 2-5. Technical Specifications

(Secondary Gas)

Type N2O2 H-35, Methane

Pressure 100 psig (6.9 bar) H-35, Methane
125 psig (8.6 bar) N2, O2, Air
Flow 60 cfh (28 I/min) max (varies with application)
Purity Required N2-99.995%; O2-99.8%, H-35, Methane-99.8%

Table 2-6.Technical Specifications

(PT-24 Torch)

Type Water-Cooled, Dual Gas

Rating 100 amps @ 100% duty cycle

Dimensions: See Figure 8-9

21
SECTION 2 DESCRIPTION

22
SECTION 3 INSTALLATION

3.1 GENERAL

Proper installation can contribute materially to the satis- ! CAUTION

factory and trouble-free operation of the Precision Plasmarc
System. It is suggested that each step in this section be Be sure that the power source is properly configured
studied and carefully followed. for your input power supply. Do NOT connect a power
source configured for 230 V to a 460 V input power
3.2 EQUIPMENT REQUIRED supply. Damage to the machine may occur.

A. Gas Supply and Hoses. Gas supply may be from a As shipped, the power source is configured for 575 V, 60
bulk source or from a bank of manifold cylinders and Hz input. If using 200, 230, 380, 415, or 460 V input, the
regulated to supply 125 psig (8.6 bar) to the Flow jumper input power cables located on the auto trans-
Control (gas flowing). former must be repositioned to the desired input voltage
for safe operation. To gain access to the autotransformer,
B. Work Lead. No. 4 AWG cable is recommended for remove the right side panel. (See Figure 3-1.)
connecting workpiece to power source.
A line (wall) disconnect switch with fuses or circuit break-
C. Primary Input Cable. See Section 3.4. ers should be provided at the main power panel (see Table
3-1 for fuse rating). The input power cable of the power
source may be connected directly to the disconnect
3.3 LOCATION switch or a proper plug and receptacle may be purchased
from a local electrical supplier. If using plug/receptacle
Adequate ventilation is necessary to provide proper cool- combination, see Table 3-1 for recommended input con-
ing of the power source. Minimize the amount of dirt, dust, ductors for connecting receptacle to line disconnect switch.
and excessive heat to which the equipment is exposed.
There should be at least two feet of clearance between the
power source and wall or any other obstruction to allow Table 3-1 Recommended Sizes For
freedom of air movement through the power source. Input Conductors and Lline Fuses

Input Requirements Input & Gnd Fuse Ratings/

Installing or placing any type of filtering device will restrict Conductor Phase, Amps
the volume of intake air, thereby subjecting the power
Volts Phase Amps CU/AWG mm 2
source internal components to overheating. Use of any
type of filter device voids the warranty. 200 3 70 No. 4 25 100
230 3 60 No. 6 16 80
380 3 50 No. 8 10 80
3.4 PRIMARY ELECTRICAL INPUT 415 3 40 No. 10 6 60
CONNECTIONS (Figure 3-1) 460 3 30 No. 10 6 50
575 3 25 No. 10 6 40
*Sizes per National Electric Code for 75°C rated conductors @ 30°Cambient. Not
more than three conductors in raceway or cable. Follow local codes if they specify

! WARNING sizes other than those listed above.

ELECTRIC SHOCK CAN KILL! Precautionary mea- The following procedure explains the proper installation
sures should be taken to provide maximum protec- steps for connecting primary electrical power to the power
tion against electrical shock. Be sure that all power is source. (See Figure 3-1.)
off by opening the line (wall) disconnect switch and
by unplugging the power cord to the unit before any A. Remove right side panel.
connections are made inside of the power source.
B. Ensure input power cable is disconnected from all
electrical sources.

C. Route input power cable through the strain relief

located at the rear panel.

23
SECTION 3 INSTALLATION

D. Pull input power cable through the strain relief to allow H. Connect jumper wire to the proper input voltage
cable wires sufficient length to connect to the main connector located on the 7-position terminal block.
contactor. Tighten strain relief to ensure input power (See Figure 3-1.)
cable is secured.
3.5 INTERCONNECTING LINES
E. Connect input power cable ground wire to the ground (Refer to Figure 3-2)
lug provided on the base of the power source.
A. All interconnecting service lines supplied are num-
F. Connect three power leads of the input power cable to bered on each end with corresponding numbers marked
the terminals located atop the main contactor. Secure on the cabinets next to the connection to be made.
the leads by tightening each screw.
B. Connect all five lines in gas bundle (Figure 3-4) to Flow
G. Connect jumper power cables from the bottom of the Control Box and Junction Box (Figure 3-5).
main contactor to the proper input voltage marked on
the auto transformer. The unit is factory set for 575 V. C. Connect power and coolant lines in power bundle
(Figure 3-6) to junction box (Figure 3-7) and power
source (Figure 3-2 or 3-3).

! CAUTION D. Remove panel from rear of console and attach the

pilot-arc, torch and work lead. See Figure 3-8 to
replace panel.
Ensure each input power jumper cable is connected to
the proper input voltage to be used on auto trans-
former.

Ground Input Power Cable

Connection (customer supplied)

TB2
K1
200
230 Main Contactor
380
415
460
575

7 Position Terminal Block

200
PHASE 1

TB1
230
380
415 Auto Transformer
460
575
200
PHASE 2

230
380
415
460
575
200
PHASE 3

230
380
415
460 Factory wired for
575 575 volts

Figure 3-1. Power Source Primary Power Connection Diagram

(Shown factory connected in 575 V position)
24
 SECTION 3
Note:
All service lines have identification
numbers stamped on connections

CONTROL LEAD
(Flow Control to
FLOW CONTROL BOX P/N-37416
Junction Box)

Power Bundle
1
#6. Coolant to Torch
#7. Coolant Return from Torch 2
3 O2
Torch Power Cable
Figure 3-2. Precision Plasmarc Cutting Machine Interconnecting Diagram

4 N2
Pilot Arc Lead
Alt
5

BACK 14 pin
Gas Bundle VIEW
#1. Cut Gas O2 Plasma
X
#2. Cut Gas N2 Plasma N2 O2
#3. Plasma Gas N2 Start
#4. Shield Gas
#5. Shield Gas, Preflow
Alternate Gas
(Shield Addition)
ARC VOLTAGE CONTROL
(Customer Supplied) See Fig. 3-7
Supplied by Customer
1 2 3 4 5

JUNCTION BOX 6 7
25

with H.F. Unit CONTROL LEAD - 14/19 Pin Connector

CNC P/N-37400 (Power Source to Flow Control Box)

19 pin
PT-24 TORCH POWER SOURCE
ARC VOLTAGE REMOTE
4.5 ft. (1,4m) P/N 0558001460
(Customer Supplied)
12 ft. (3,7m) P/N 0558001874
17 ft. (5,2m) P/N 0558001461
HEIGHT CONTROL CONTROL
(Customer Supplied) COOLER
W/4 Gal. (1.5L)
Tank

CUTTING TABLE
(Customer Supplied) WORK LEAD

INSTALLATION
(Customer Supplied) AUTO TRANS.

CONTROL LEAD - 14 Pin Connector

(Supplied based on Customer Order) POWER SOURCE P/N-37358
Control Lead P/N’s Power Bundle P/N’s
10 ft. (3m) P/N-21917 25 ft. (7.6m) P/N-21905 Gas Bundle P/N’s Control Lead P/N’s
20 ft. (6m) P/N-21918 60 ft. (18m) P/N-21906 10 ft. (3m) P/N-21902 30 ft. (9,1m) P/N-57002248
30 ft. (9m) P/N-21919 100 ft. (30m) P/N-21907 20 ft. (6m) P/N-21903 50 ft. (15,2m) P/N-57002249
60 ft. (18m) P/N-21920 30 ft. (9m) P/N 21904 75 ft. (22,9m) P/N-57002250
100 ft. (30m) P/N-21921 60 ft. (18m) P/N 22334 100 ft. (30,5m) P/N-57002251 PRIMARY CABLE
100 ft. (30m) P/N 22335 160 ft. (48,8m) P/N-57002252 (Customer Supplied)
SECTION 3 INSTALLATION

BUNDLE P/N #1 #2 #3 #4 #5 SHEATH

10 FT. (3m) 21902 21884 21875 21878 21887 21881 995832
20 FT. (6m) 21903 21885 21876 21879 21888 21882 995832
30 FT. (9m) 21904 21886 21877 21880 21889 21883 995826
60 FT. (18m) 22334 22337 22343 22345 22340 22347 995826
100 FT. (30m) 22335 22338 22344 22346 22341 22348 995826*
* 2 REQUIRED.

Figure 3-4. Gas Line Bundle

1
2
3
4
5

1 2 3 4 5
Flow Control
Box
Junction Box
with H.F. Unit

Figure 3-5. Gas Bundle Installation

26
SECTION 3 INSTALLATION

No. 6 and No. 7 No. 6 and No. 7

5/8-18 L.H. 5/8-18 L.H.
7 (B-A/W) (B-A/W)

7
6

6
PILOT ARC #16 AWG(YELLOW)
POWER CABLE#3 AWG
POWER BUNDLE #6 #7 SHEATH
25 FT. (7.6m) P/N-21905 21911 21914 995832 (1)
60 FT. (18m) P/N-21906 21912 21915 995832 (2)
100 FT. (30m) P/N-21907 21913 21916 995832 (3)
(1) One 25 ft. piece Reqd.
(2) Three 25 ft. pieces Reqd.
(3) Four 25 ft. pieces Reqd.

Figure 3-6. Power Bundle

Gas Tubing Bundle Connections:

Cut Gas (Yellow)
Shield Gas (Org. or Red)
Pre-Cut Gas (Black) Pilot Arc Cable
Gas Tubing Start Gas (Blue) Power Hose No. 7
Bundle Cable

Torch Pilot Arc

Torch Electrical Hose No. 6
(J2) Cable
Torch Assembly Torch Negative Power Bundle Assembly

Figure 3-7. Power Bundle/Junction Box Connection

27
SECTION 3 INSTALLATION

E. Connect control lead (Figure 3-9) between the power

source and the flow control and from the flow control
to the junction box. See Figure 3-2 or Figure 3-3 for the
installation location.

CONTROL LEADS P/N'S

10 FT. (3m) P/N-21917 60 FT. (18m) P/N-21920
20 FT. (6m) P/N-21918 100 FT. (30m) P/N-21921
30 FT. (9m) P/N-21919

Figure 3-9. Available Control Lead

F. Torch Mounting Options.

1. The torch is normally mounted by the sleeve.

2. For more precise mounting, the torch can be

mounted by the 1.812" (46 mm) dia collar shown
(see Figure 3-10). This insulated collar and its
shoulder are machined relative to the nozzle
retainer thread on the torch body and is held
concentric to the cutting nozzle within a total
indicator reading of 0.010 inches (0.25 mm) or the
nozzle bore is within 0.005 inches of any point on
the 1.812 dia.

NOTE
COOLA
FILL CA
When mounting, be sure not to cover the small vent hole
in the side of the sleeve. This hole prevents coolant from
building inside the sleeve should a leak occur in a service
line.
1.812" (46mm) 2.0" (51mm)
Diameter Collar Diameter Sleeve

Vent Hole

Figure 3-10. Torch Mounting Options

Figure 3-8. Power Bundle/Power Source Rear

Panel Connection

28
 SECTION 3 INSTALLATION

G. Remove coolant fill cap at front of console and fill Flow Control Box
coolant tank with 4 gallons (15 l) of plasma coolant.
See Figure 3-11. Reinstall cap.
O2
N2
NOTE Alt.

Due to the high electrical conductivity, use of tap water or

commercial antifreeze must NOT be used for torch cool-
ing. A specially formulated torch coolant, P/N 156F05 (1
gallon (3.8 l) container) is available and recommended for
torch cooling. The coolant also provides freeze protection
down to -34° C.

NOTE

Operating the unit without coolant will cause permanent

damage to coolant pump.

X N2 O2
PI LOT
ARC
CONTR OL

POWER

CURRE NT

PL AS M A RC
RE CIS ION
Alternate Gas
(Shield Addition)

Supplied by Customer

ANT
AP Figure 3-12. Gas Supply Connection

1. Close all valves on the gas flow control cabinet.

2. Set all inlet gas pressures to 125 psig (8.6 bar).

3. Turn the power source ON. The amber light to the

left of the switch will glow, the console fan will
operate and coolant will flow.

Figure 3-11. Filling Coolant 4. Coolant pump pressure should be 80 to 90 psi (5.5
to 6.2 bar). See coolant pump pressure gauge on
front of console.
H. Make all connections to the CNC and height control.
See instructions provided with equipment supplied. 5. Check for leaks on connections No. 6 and 7 on the
back of the console and in the junction box.
I. Connect gas supply to flow control. See gas require- Check the torch power cable and pilot arc cable
ments as listed in Tables 2-3, 2-4, and 2-5. (See connections in the junction box.
Figure 3-12.)
6. Check the vent hole in the side of the torch sleeve
and the torch consumables.
J. With installation complete, check for gas and coolant
leaks with a standard soap solution as follows (see 7. With console ON, use a solution of soap and
Figures 3-13 and 3-14): water. Check all gas connections for pressure
tightness as per following:

29
SECTION 3 INSTALLATION

(a) Place the "plasma gas" select switch, SW-2, (h) Open valves NV-1 (oxygen plasma gas valve)
in O2 position. and NV-5 (cut shield gas valve) approxi-
mately two full turns.
(b) Place the "shield gas" select switch, SW-3,
in O2 + N2 position. (i) Check all gas connections on line 1 and 4.
Recheck torch connections in junction box.
(c) Place the "test switch" SW-1 in START Correct as needed.
position.
(d) Open valve NV-3 (start gas valve) and NV-6 (j) Close valves NV-1 (oxygen plasma gas
(shield gas pre-flow valve) approximately valve) and NV-5 (cut shield gas valve).
two full turns.
(k) Place SW-1 in operate position to verify that
(e) Check all gas connections on lines 2 and 5 O2 output pressure remains pressurized.
and torch connections in junction box. Close
valves NV-3 (start gas valve) and NV-6 (l) Place plasma gas select switch SW-2 in N2
(shield gas pre-flow valve). position.

(f) Place SW-1 in operate position to verify that (m) Open valve NV-2 (nitrogen plasma gas) ap-
N2 output pressure on right side of control proximately two full turns.
remains pressurized.
(n) Check all gas connections on line 2 for leaks.
(g) Move switch SW-1 to CUT position. Correct as needed.

(o) Place SW-1 in operate position to verify that

N2 output pressure remains pressurized.

SW-2
SW-3

NV-3 PLASMA GAS

O2 Pressure O2 N2

Out SHIELD GAS

O2+N2 N2+ALT
N2 Pressure
NV-6 Out

Plasma Start
SW-1 Press. Out

NV-1
NV-5

NV-4

NV-2

Front View Left Side View

Figure 3-13. Flow Control Controls

30
SECTION 3 INSTALLATION

Flow Control Box

2

7 7
1
Alt. N2 O2

7
6
7

3
5
6
6 7

NOTE: The numbers in circles correspond with the steps

needed to check gas and coolant leaks.

Figure 3-14. Gas Coolant Leak Check

31
SECTION 3 INSTALLATION

32
SECTION 4 OPERATION

4.1 POWER SOURCE CONTROLS/

INDICATORS
C
D
E

G I J L K M A
H
B
Figure 4-1. Front Panel Controls

A. Main Power Switch - controls the input power to the F. Pilot Arc High/Low Switch is used to select pilot arc
fan, water cooler, and the interface PCB. The amber current.
light to the left of the switch indicates power is ON.
G. Coolant Flow Fault Indicator - indicates low coolant
B. Output Current Dial - sets the cutting current when flow. The light will come on momentarily when the
current settings are made from the console front panel console is turned on and then go out.
(remote/panel switch in PANEL position).
H. Plasma Gas Pressure Fault Indicator - indicates low
C. Remote/Panel Switch. plasma gas pressure.

1. Panel Position - allows output current to be set by I. Start Gas Pressure Fault Indicators - indicates low
the output current dial as described above. start gas pressure.

2. Remote Position - allows the output current to be J. P/S Temp Fault Indicator - indicates over tempera-
set by the CNC with an analog dc signal. ture fault condition in the inverter power source.

0-10 V dc = 0 - 100 Adc K. P/S Fault Indicator - indicates fault in the plasma
control PCB in the inverter power source.
D. Cutting Current Meter - displays the actual cutting
current. L. Over/Under Voltage Fault Indicator - indicates input
voltage is above or below the tolerances of the PCU
E. Cutting Voltage Meter - displays the actual cutting console. Will latch until power is recycled by main
voltage. power switch.

M. Emergency Stop Fault Indicator - indicates CNC

emergency condition.

33
SECTION 4 OPERATION

4.2 OPERATION 3. If current is to be set from the cutting machine

CNC, place the remote panel switch in REMOTE
A. Check consumables in torch for damage and be sure position. Consult the CNC instructions for setting
they are correct for the material to be cut and gas to currents.
be used (check against process data sheets starting
on page 23).

B. Set N2, O2 and Air inlet gas pressures to 125 psig (8.6
bar) (flowing). Set H-35, methane inlet pressures to
100 psi.

C. Gas Flow Control (Figure 4-2).

1. Position PLASMA GAS select switch (SW-2) for

plasma gas to be used.

2. Position SHIELD GAS select switch (SW-3) for

shield gas or gases to be used.

3. Set SW-1 switch to start. Verify that N2 pressure

is 125 psig (8.6 bars) while flowing.

4. Set SW-1 switch to CUT. Verify that O2 pressure

is 125 psig (8.6 bars) while flowing.
Figure 4-3. Coolant Level Indicator
5. Close any throttle valves not being used by
turning them clockwise. 4. Check coolant level (see Figure 4-3). Coolant
level must be checked with the console main
PLASMA GAS
power switch in the OFF position. The coolant
SW-2 level must fall within the SAFE OPERATING
O2 N2
LEVEL indicated (See Section 3.5.G).
SHIELD GAS

O2+N2 N2+ALT 5. Place pilot arc high/low switch in the LOW posi-
tion.

6. Turn on the power source by placing the main

power switch in the ON position. The amber light
SW-3
to the left of the switch will come on.

7. Check coolant pressure. The pump pressure is

factory set between 80-90 psig (5.5 to 6.2 bar).

8. Complete setting the gas flow rates by following

the two examples on the next two pages.

E. Set the arc voltage from the suggested arc voltage

Figure 4-2. Gas Flow Control values given in the process data sheets.

D. Console. NOTE

1. If current is to be set from console place the Arc voltage and piercing height will be set from the arc
remote panel switch in the PANEL position. voltage control or from the CNC. Consult instructions
supplied with your equipment.
2. Set the cutting current on the output current dial.

34
SECTION 4 OPERATION
With the completion of the above settings the system is
now ready for operation. 4.4 SAMPLE PROCEDURE FOR
SETTING N2 GAS FLOW RATES ON
FLOW CONTROL BOX (Figure 4-4)
4.3 SAMPLE PROCEDURE FOR
SETTING O2 GAS FLOW RATES ON NOTE
FLOW CONTROL BOX (Figure 4-4)
This is a sample procedure only and the operator must
refer to the appropriate process data sheet.
NOTE
SAMPLE SETUP:
This is a sample procedure only and the operator must
refer to the appropriate process data sheet.
Plasma - N2 or Air, Shield - N2 or Air plus Alternate
gas mix.
SAMPLE SETUP:
NOTE
Plasma - O2, Shield - N2 plus O2 Mix
To cut with air, connect the air source to the N2 inlet.
A. Place PLASMA GAS select switch SW-2 in O2
position.
A. Place PLASMA GAS select switch SW-2 in N2
position.
B. Place SHIELD GAS select switch SW-3 in O2 + N2
position.
B. Place SHIELD GAS select switch SW-3 in N2 + ALT
position.
C. Place test switch SW-1 in START position.
C. Place test switch SW-1 in START position.
D. For setting plasma start gas adjust valve NV-3, read
flow on flowmeter FM-2.
D. For setting plasma start gas adjust valve NV-3, read
E. For setting shield preflow gas:
flow on flowmeter FM-2.
Adjust valve NV-6, read flow on flowmeter FM-3.
E. For setting shield preflow gas, adjust valve NV-6, read
flow on flowmeter FM-3.
F. Move test switch SW-1 to CUT position.
F. Move test switch SW-1 to CUT position.
G. For setting plasma cut gas adjust valve NV-1, read
flow on flowmeter FM-1.

H. For setting shield and mixing shield cut gas.

G. For setting plasma cut gas adjust valve NV-2, read
flow on flowmeter FM-2.
(1) Adjust valve NV-5 (N2), read flow on flowmeter
FM-3.
H. For setting shield and mixing shield cut gas.
(2) Adjust valve NV-4 (O2), read flow on flowmeter
(1) Adjust valve NV-5, read flow on flowmeter FM-3.
FM-4.
(2) Adjust valve NV-4, read flow on flowmeter FM-4.
I. Move test switch SW-1 to OPERATE position. Flow
control is now set to operate.
I. Move test switch SW-1 to OPERATE position. Flow
control is now set to operate.

35
SECTION 4 OPERATION

FM-1 FM-2 FM-3 FM-4

SW-2
SW-3 PLASMA GAS

NV-3 O2 N2

NV-6 SHIELD GAS

O2+N2 N2+ALT

SW-1

NV-5

NV-1

NV-2 NV-4

Front View Left Side View

Figure 4-4. Flow Control Box

36
 ALUMINUM
11/30/99
PROCESS DATA
AMPERAGE: 30
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "B" 3 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21541 P/N 21536 PT-24 TORCH

ð ð ð ð ð ð ð ð
37

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

1.5 .062 0 0 40 55 45 20 10 150 3810 150

2 .075 0 0 40 55 45 20 10 152 3429 135
2.2 .090 0 0 40 55 45 20 10 153 2667 105
3 .125 0 0 40 55 45 20 10 158 1981 78
4 .187 0 0 40 55 45 20 10 170 762 30
6 .250 0 0 40 55 45 20 10 185 635 25
NOTES:
3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
AL30
 ALUMINUM
11/30/99
PROCESS DATA
AMPERAGE: 55
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "C" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21542 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
38

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

1.5 .062 0 0 45 75 55 20 10 136 4318 170

3 .125 0 0 45 75 55 20 10 139 3302 130
4 .187 0 0 45 75 55 20 10 152 1981 78
6 .250 0 0 45 75 55 20 10 162 1168 46

NOTES: AL50
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 ALUMINUM
11/30/99
PROCESS DATA
AMPERAGE: 70
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "D" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21543 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
39

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
P/N 21539 moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

4 .187 0 0 65 50 45 20 10 150 2032 80

6 .250 0 0 65 50 45 20 10 157 1651 65
10 .375 .1 .1 65 60 45 20 10 168 1397 55
12 .500 .2 .1 65 60 45 20 10 178 762 30

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. AL70
 ALUMINUM
11/30/99
PROCESS DATA
AMPERAGE: 100
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "E" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21923 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
40

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER 2. To prevent leakage between the nozzle and nozzle retainer,
RETAINER w/O-RING DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

6 .250 0 0 80 100 60 31 10 150 2413 95

10 .375 0 0 80 100 60 31 10 162 2032 80
12 .500 .1 .1 80 100 60 31 10 166 1778 65
16 .625 .3 .1 80 100 60 31 10 176 1270 50

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. AL100
 CARBON STEEL
11/30/99
PROCESS DATA

AMPERAGE: 16
PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
ALT. GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "A" 2 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21540 P/N 21852 PT-24 TORCH

ð ð ð ð ð ð ð ð
41

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER 2. To prevent leakage between the nozzle and nozzle retainer,
RETAINER w/O-RING DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

0.9 20 GA 0 0 20 11 50 0 5 114 2540 100

1.3 18 GA 0 0 20 11 50 0 5 117 2159 85
1.5 16 GA 0 0 20 11 50 0 5 118 1778 70
1.9 14 GA .1 0 20 11 50 0 5 123 1270 50
2.7 12 GA .1 0 20 11 50 0 5 124 1016 40
3.4 10 GA .1 0 20 11 50 0 5 129 914 36

NOTES:
2 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball. CB15
 CARBON STEEL
11/30/99
PROCESS DATA
AMPERAGE: 35
PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "B" 3 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21541 P/N 21536 PT-24 TORCH

ð ð ð ð ð ð ð ð
42

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER 2. To prevent leakage between the nozzle and nozzle retainer,
RETAINER w/O-RING DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

1.9 14 GA 0 0 38 15 50 0 5 113 2032 80

3 .125 0 0 38 15 50 0 10 119 1397 55
3.2 .135 0 0 38 15 50 0 10 120 1320 52
4 .187 .1 .1 38 15 50 0 10 122 1016 40
6 .250 .2 .1 38 15 50 0 10 124 889 35

NOTES: CB30
3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball.
 CARBON STEEL
11/30/99
PROCESS DATA
AMPERAGE: 45
PLASMA GAS: OXYGEN PRESSURE:125PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125PSI/8.6 BAR
SHIELD MIX GAS: OXYGEN PRESSURE:125PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "C" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21542 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
43

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

3 .125 0 0 50 20 50 10 0 119 1524 60

3.2 .135 0 0 50 20 50 10 0 121 1270 50
4 .187 .1 .1 50 20 50 10 0 127 1143 45
6 .250 .2 .1 50 20 50 10 0 130 889 35
10 .375 .3 .1 50 20 50 10 0 136 508 20

NOTES: CB50
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 CARBON STEEL
11/30/99
PROCESS DATA
AMPERAGE: 70
PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "D" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21543 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
44

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER 2. To prevent leakage between the nozzle and nozzle retainer,
RETAINER w/O-RING DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

4 .187 0 0 60 25 60 20 0 118 3048 120

6 .250 0 0 60 25 60 20 0 121 2540 100
8 .312 0 0 60 25 60 20 0 122 2032 80
10 .375 .1 .1 60 25 60 20 0 126 1651 65
11 .500 .2 .1 60 25 60 20 0 133 762 30
19 .625 .3 .1 60 25 60 20 0 144 635 25
NOTES: CB70
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 CARBON STEEL
11/30/99
PROCESS DATA
AMPERAGE: 100
PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "E" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21923 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
45

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING 2. To prevent leakage between the nozzle and nozzle retainer,
DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

8 .312 0 0 80 30 60 30 0 132 2290 90

10 .375 0 0 80 30 60 30 0 137 2030 80
12 .500 .1 .1 80 30 60 30 0 140 1270 50
16 .625 .2 .1 80 30 60 30 0 143 760 30
19 .750 .3 .1 80 30 60 30 0 146 630 25

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. CB100
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 30
PLASMA GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: OXYGEN PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "B" 3 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21541 P/N 21536 PT-24 TORCH

ð ð ð ð ð ð ð ð
46

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING 2. To prevent leakage between the nozzle and nozzle retainer,
DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

0.4 26 GA 0 0 45 18 40 20 5 101 6350 250

0.6 24 GA 0 0 45 18 40 20 5 102 5080 200
0.8 22 GA 0 0 45 18 40 20 5 103 4826 190
1.2 18 GA 0 0 45 18 40 20 5 105 3556 140
1.5 16 GA 0 0 45 18 40 20 5 107 2540 100

NOTES:
3 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - low. Float - center of ball. SS30A
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 50
PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: AIR PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "C" 3 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21542 P/N 21536 PT-24 TORCH

ð ð ð ð ð ð ð ð
47

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
P/N 21539 moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

3 .125 0 0 60 95 45 55 0 134 2286 90

4 .187 0 0 60 95 45 35 0 140 1524 60
6 .250 .1 .1 60 95 45 35 0 145 1016 40
10 .375 .2 .1 60 95 45 35 0 155 558 22

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. SS50A
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 70
PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: AIR PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "D" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21543 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
48

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
P/N 21539 moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

4 .187 .3 .1 70 95 60 40 0 131 2540 100

6 .250 .4 .1 70 95 60 40 0 154 1270 50
10 .375 .5 .1 70 95 60 40 0 159 711 28
13 .500 .6 .1 70 95 60 40 0 162 609 24

NOTES: SS70A
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 100
PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: AIR PRESSURE:125 PSI/8.6 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "E" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21923 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
49

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING 2. To prevent leakage between the nozzle and nozzle retainer,
DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

6 .250 .3 .1 80 65 60 35 0 138 2030 80

10 .375 .4 .1 80 65 60 35 0 142 1520 60
12 .500 .5 .1 80 65 60 35 0 150 889 35
16 .625 .6 .1 80 65 60 35 0 157 635 25

NOTES: SS100A
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 50
PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "C" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21542 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
50

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING 2. To prevent leakage between the nozzle and nozzle retainer,
DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

3 .125 0 0 60 95 45 40 7 135 2286 90

4 .187 0 0 60 95 45 40 7 146 1524 60
6 .250 .1 .1 60 95 45 40 7 157 1041 41
10 .375 .2 .1 60 95 45 40 7 175 558 22

NOTES: SS50A4
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 70
PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "D" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21543 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
51

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING 2. To prevent leakage between the nozzle and nozzle retainer,
DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

2 .125 .2 .1 70 100 60 50 15 135 3048 120

4 .187 .3 .1 70 100 60 40 10 147 2032 80
6 .250 .4 .1 70 100 60 40 10 159 1270 50
10 .375 .5 .1 70 100 60 40 10 171 762 30
12 .500 .6 .1 70 100 60 40 10 176 609 24

NOTES: SS70A4
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 100
PLASMA GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: AIR PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "E" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21923 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
52

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

6 .250 .3 .1 80 65 60 40 7 140 2030 80

10 .375 .4 .1 80 65 60 40 10 151 1524 60
12 .500 .5 .1 80 65 60 40 10 159 889 35
16 .625 .6 .1 80 65 60 40 10 166 635 25

NOTES: SS100A4
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 50
PLASMA GAS: NITROGEN PRESSURE:125PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125PSI/8.6 BAR
SHIELD MIX GAS:

SWIRL BAFFLE
SHIELD CUP NOZZLE "C" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21542 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
53

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING 2. To prevent leakage between the nozzle and nozzle retainer,
DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

3 .125 0 0 60 85 45 45 0 128 2286 90

4 .187 0 0 60 85 45 45 0 133 1524 60
6 .250 .1 .1 60 85 45 45 0 144 1016 40
10 .375 .2 .1 60 85 45 35 0 155 558 22

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. SS50N
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 70
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS:

SWIRL BAFFLE
SHIELD CUP NOZZLE "D" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21543 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
54

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER 2. To prevent leakage between the nozzle and nozzle retainer,
RETAINER w/O-RING DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539 small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

4 .187 .3 .1 70 95 60 40 0 132 1905 75

6 .250 .4 .1 70 95 60 40 0 150 1270 50
10 .375 .5 .1 70 95 60 40 0 159 711 28
13 .500 .6 .1 70 95 60 40 0 162 609 24

NOTES: SS70N
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 100
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS:

SWIRL BAFFLE
SHIELD CUP NOZZLE "E" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21923 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
55

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER 2. To prevent leakage between the nozzle and nozzle retainer,
RETAINER w/O-RING DIFFUSER moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) P/N 21539
small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

6 .250 .3 .1 80 95 60 50 0 138 2032 80

10 .375 .4 .1 80 95 60 35 0 145 1520 60
12 .500 .5 .1 80 95 60 35 0 153 889 35
16 .625 .6 .1 80 95 60 35 0 157 635 25

NOTES: SS100N
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball.
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 70
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "D" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21543 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
56

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
(SEE NOTES) P/N 21539 moisten the corner of a clean, dry, lint-free cloth with a very
P/N 22531 small amount of Krytox grease P/N73585064. Wipe the
P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

4 .187 .3 .1 70 100 60 65 5 138 1778 70

6 .250 .4 .1 70 100 60 65 5 150 1143 45
10 .375 .5 .1 70 100 60 65 5 170 762 30
13 .500 .6 .1 70 100 60 70 5 179 609 24

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. SS70NM
 STAINLESS STEEL
11/30/99
PROCESS DATA
AMPERAGE: 100
PLASMA GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD GAS: NITROGEN PRESSURE:125 PSI/8.6 BAR
SHIELD MIX GAS: METHANE PRESSURE:100 PSI/6.9 BAR

SWIRL BAFFLE
SHIELD CUP NOZZLE "E" 4 HOLE
INSULATOR (SEE NOTES)
P/N 22010 P/N 21923 P/N 21692 PT-24 TORCH

ð ð ð ð ð ð ð ð
57

CUP SHIELD INSULATOR SHIELD NOZZLE RETAINER/ ELECTRODE NOTES: 1. Assemble swirl baffle into nozzle first.
w/RETAINER RETAINER w/O-RING DIFFUSER 2. To prevent leakage between the nozzle and nozzle retainer,
P/N 21539 moisten the corner of a clean, dry, lint-free cloth with a very
(SEE NOTES) small amount of Krytox grease P/N73585064. Wipe the
P/N 22531 P/N 21712 P/N 22007 inner surface of the nozzle retainer that comes in contact with
the nozzle. Use care to apply a very thin film to ensure a
proper seal.
3. Use tool (P/N 21765) supplied with torch to remove or install
nozzle, electrode and water baffle.

MATERIAL RISE SET-UP PARAMETERS* TRAVEL SPEED

THICKNESS PIERCE ON PLASMA PLASMA SHIELD ARC
DELAY PIERCE START CUT (FLOW READING) VOLTAGE
† †
(MM) (IN) (Sec.) (Sec.) (FLOW READING) (FLOW READING) PRE CUT ALT (MM/MIN) (IPM)

6 .250 .3 .1 80 95 60 50 5 133 1778 70

10 .375 .4 .1 80 95 60 70 5 158 1524 60
12 .500 .5 .1 80 95 60 60 5 170 965 38
16 .625 .6 .1 80 95 60 60 5 177 660 26

NOTES:
4 Hole Baffle - *Set flow reading with valves. † CUT & ALT mix in flow control. Pilot Arc - high. Float - center of ball. SS100NM
SECTION 4 OPERATION
Aluminum Kerf Values N2/N2/CH4

Aluminum N2/N2/CH4 30 Amperes

Material Thickness (mm)
1.575 1.905 2.286 3.175 4.750 6.350

0.140 3.556

0.120 3.048

0.100 2.540
2.210
Kerf (inches)

0.080 0.087 2.032

Kerf (mm)
1.651
1.524
0.060 0.065 1.524
1.270 1.270 1.270
0.060
0.040
0.050 0.050 0.050 1.016

0.020 0.508

0.000 0.000
0.062 0.075 0.090 0.125 0.187 0.250

Material Thickness (inches)

Aluminum N2/N2/CH4 50 Amperes

Material Thickness (mm)
1.575 3.175 4.775 6.350

0.140 3.556

0.120 3.048

0.100 2.362 2.540

2.032
0.093
Kerf (inches)

0.080 2.032
Kerf (mm)

1.651 0.080
1.524
0.060 0.065 1.524
0.060

0.040 1.016

0.020 0.508

0.000 0.000
0.062 0.125 0.188 0.250

Material Thickness (inches)

58
SECTION 4 OPERATION

Aluminum N2/N2/CH4 70 Amperes

Material Thickness (mm)
4.750 6.350 9.525 12.700

0.190 4.826

0.170 4.318

0.150 3.810
Kerf (inches)

0.130 3.302
3.048

Kerf (mm)
2.845
0.110 0.120 2.794
2.540 2.540
0.112

0.090
0.100 0.100 2.286

0.070 1.778

0.050 1.270
0.187 0.250 0.375 0.500

Material Thickness (inches)

Aluminum N2/N2/CH4 100 Amperes

Material Thickness (mm)
6.350 9.525 12.700 15.875

0.190 4.826

0.170 4.318

0.150 3.810

3.302
Kerf (inches)

0.130 3.302
Kerf (mm)

2.921 0.130
0.110 2.667 2.794
2.540 0.115
0.105
0.090
0.100 2.286

0.070 1.778

0.050 1.270
0.250 0.375 0.500 0.625

Material Thickness (inches)

59
SECTION 4 OPERATION

Carbon Steel Kerf Values O2/N2/O2

Carbon Steel O2/N2/O2 16 Amperes

Material Thickness (mm)
1.219 3.404

0.140 3.556

0.120 3.048

0.100 2.540
Kerf (inches)

0.080 2.032

Kerf (mm)
1.473
0.060 1.524
1.118 0.058
0.040 1.016
0.044

0.020 0.508

0.000 0.000
0.048 0.134

Material Thickness (inches)

Carbon Steel O2/N2/O2 35 Amperes

Material Thickness (mm)
1.524 3.175 6.350

0.140 3.556

0.120 3.048

0.100 2.540
Kerf (inches)

0.080 2.032
Kerf (mm)

1.499
0.060 1.321 1.524
1.168
0.059
0.052
0.040 0.046 1.016

0.020 0.508

0.000 0.000
0.060 0.125 0.250

Material Thickness (inches)

60
SECTION 4 OPERATION

Carbon Steel O2/N2/O2 45 Amperes

Material Thickness (mm)
3.175 6.350 9.525

0.140 3.556

0.120 3.048

0.100 2.413 2.540

0.095
1.930
Kerf (inches)

0.080 2.032

Kerf (mm)
1.626
0.076
0.060 1.524
0.064

0.040 1.016

0.020 0.508

0.000 0.000
0.125 0.250 0.375

Material Thickness (inches)

Carbon Steel O2/N2/O2 70 Amperes

Material Thickness (mm)
3.429 6.350 9.525 12.700

0.140 3.556

0.120 3.048

2.540
0.100 2.540
0.100
2.032
Kerf (inches)

0.080 2.032
Kerf (mm)

1.778
1.575
0.080

0.060
0.070 1.524
0.062

0.040 1.016

0.020 0.508

0.000 0.000
0.135 0.250 0.375 0.500

Material Thickness (inches)

61
SECTION 4 OPERATION

Carbon Steel O2/N2/O2 100 Amperes

Material Thickness (mm)
9.525 12.700 19.050

0.140 3.556

3.048
0.120 3.048
0.120
2.540
0.100 2.337 2.540
0.100
0.092
Kerf (inches)

0.080 2.032

Kerf (mm)
0.060 1.524

0.040 1.016

0.020 0.508

0.000 0.000
0.375 0.500 0.750

Material Thickness (inches)

62
SECTION 4 OPERATION

Stainless Steel Kerf Values O2/N2/O2

Stainless Steel O2/N2/O2 30 Amperes

Material Thickness (mm)
0.457 0.584 0.726 1.207 1.588

0.140 3.556

0.120 3.048

0.100 2.540
Kerf (inches)

0.080 2.032

Kerf (mm)
0.060 1.524
1.143
0.889 0.889 0.889 0.889
0.040 0.045 1.016

0.035 0.035 0.035 0.035

0.020 0.508

0.000 0.000
26GA 24GA 22GA 18GA 16GA

Material Thickness (inches)

63
SECTION 4 OPERATION

Stainless Steel Kerf Values Air/Air/CH4

Stainless Steel Air/Air/CH4 70 Amperes

Material Thickness (mm)
3.175 4.775 6.350 9.525 12.700

0.140 3.556

0.120 2.921 3.048

2.540 0.115
0.100 2.540
2.286
0.100
2.032
0.090
Kerf (inches)

0.080 1.778 2.032

Kerf (mm)
0.080

0.060
0.070 1.524

0.040 1.016

0.020 0.508

0.000 0.000
0.125 0.188 0.250 0.375 0.500

Material Thickness (inches)

Stainless Steel Air/Air/CH4 100 Amperes

Material Thickness (mm)
6.350 9.525 12.700 15.875

0.190 4.826

0.170 4.318

0.150 3.810
3.556
Kerf (inches)

0.130 0.140 3.302

Kerf (mm)

3.048

0.110
0.120 2.794
2.540
2.286
0.090
0.100 2.286
0.090

0.070 1.778

0.050 1.270
0.250 0.375 0.500 0.625

Material Thickness (inches)

64
SECTION 4 OPERATION

Stainless Steel Kerf Values N2/N2/CH4

Stainless Steel N2/N2/CH4 70 Amperes

Material Thickness (mm)
4.750 6.350 9.525 12.700

0.140 3.556

0.120 2.921 3.048

2.667
0.115
0.100 2.413 2.540
0.105
2.032 0.095
Kerf (inches)

0.080 2.032

Kerf (mm)
0.080

0.060 1.524

0.040 1.016

0.020 0.508

0.000 0.000
0.187 0.250 0.375 0.500

Material Thickness (inches)

Stainless Steel N2/N2/CH4 100 Amperes

Material Thickness (mm)
6.350 9.525 12.700 15.875

0.190 4.826

0.170 4.318

3.810
0.150 3.810
0.150
3.302
Kerf (inches)

0.130 3.302
Kerf (mm)

0.130
2.794
0.110 2.540 2.794
0.110

0.090
0.100 2.286

0.070 1.778

0.050 1.270
0.250 0.375 0.500 0.625

Material Thickness (inches)

65
SECTION 4 OPERATION

Stainless Steel Kerf Values N2/N2

Stainless Steel N2/N2 50 Amperes

Material Thickness (mm)
3.175 4.750 6.350 9.525

0.140 3.556

0.120 3.048

0.100 2.540

2.032
Kerf (inches)

0.080 2.032

Kerf (mm)
1.778
1.651 0.080
1.524
0.060
0.070 1.524
0.065
0.060

0.040 1.016

0.020 0.508

0.000 0.000
0.125 0.187 0.250 0.375

Material Thickness (inches)

Stainless Steel N2/N2 70 Amperes

Material Thickness (mm)
4.750 6.350 9.525 12.700

0.140 3.556

0.120 3.048

2.540
0.100 2.540
2.286 2.286
0.100
0.090 0.090
Kerf (inches)

0.080 1.778 2.032

Kerf (mm)

0.060
0.070 1.524

0.040 1.016

0.020 0.508

0.000 0.000
0.187 0.250 0.375 0.500

Material Thickness (inches)

66
SECTION 4 OPERATION

Stainless Steel N2/N2 100 Amperes

Material Thickness (mm)
6.350 9.525 12.700 15.875

0.190 4.826

0.170 4.318

0.150 3.810
3.556
Kerf (inches)

0.130 0.140 3.302

Kerf (mm)
3.048

2.794
0.110
0.120 2.794
2.540
0.110

0.090
0.100 2.286

0.070 1.778

0.050 1.270
0.250 0.375 0.500 0.625

Material Thickness (inches)

67
SECTION 4 OPERATION
Stainless Steel Kerf Values Air/Air

Stainless Steel Air/Air 50 Amperes

Material Thickness (mm)
3.175 4.750 6.350 9.525

0.140 3.556

0.120 3.048

0.100 2.413 2.540

2.032 0.095
Kerf (inches)

0.080 2.032

Kerf (mm)
1.651 0.080
1.524
0.060 0.065 1.524
0.060

0.040 1.016

0.020 0.508

0.000 0.000
0.125 0.187 0.250 0.375

Material Thickness (inches)

Stainless Steel Air/Air 70 Amperes

Material Thickness (mm)
4.750 6.350 9.525 12.700

0.140 3.556

0.120 2.921 2.921 3.048

2.794
0.115 0.115
0.100
0.110 2.540

1.905
Kerf (inches)

0.080 2.032
Kerf (mm)

0.075
0.060 1.524

0.040 1.016

0.020 0.508

0.000 0.000
0.187 0.250 0.375 0.500

Material Thickness (inches)

68
SECTION 4 OPERATION

Stainless Steel Air/Air 100 Amperes

Material Thickness (mm)
6.350 9.525 12.700 15.875

0.190 4.826

0.170 4.318
4.064

0.150 0.160 3.810

3.556

3.302
0.140
Kerf (inches)

0.130 3.302

Kerf (mm)
2.921 0.130

0.110 2.794
0.115

0.090 2.286

0.070 1.778

0.050 1.270
0.250 0.375 0.500 0.625

Material Thickness (inches)

69
SECTION 4 OPERATION
Page intentionally left blank.

70
SECTION 5 CUTTING QUALITY

5.1 CUT ANGLE The optimum torch height is just before the part begins to
develop a negative cut angle. To expand upon the other
Cut squareness is always a concern when using nitrogen two variables, if the torch standoff is correct, too fast of a
gas. The cut angle is referred to as either being positive cutting speed will result in a positive cut angle; too slow of
or negative (Figure 5-1). With a positive cut angle, the top a travel speed will result in a negative cut angle. Too high
dimension of the part is slightly less than the bottom or too low of current also produces a positive cut angle.
dimension. With a negative cut angle, the top dimension
is slightly greater than the bottom dimension. The cut Oxygen plasma will also produce the same positive or
angle is controlled by standoff (arc voltage), cutting negative cut angle as nitrogen. The cut angle is controlled
speed, and cutting amperage. If the cutting speed and by the torch standoff (arc voltage) cutting speed, and
amperage are correct and the part has an excessive cutting amperage. The major difference is the sharp top
positive angle, the standoff is too high. Begin lowering the edge of the part. The positive angle changes but the sharp
arc voltage in increments of 5 volts, observing cut top edge remains. If speeds and currents are correct,
squareness. There will always be slight top edge round- lower the arc voltage in increments of 5 volts until the cut
ing of the part when using nitrogen. angle begins to go negative or the cut face is under cut.
At this point, increase voltage until positive angle reap-
pears. This is the optimum cut squareness for these
conditions.

B
POSITIVE (+) CUT ANGLE
Bottom dimension "A" is
greater than dimension "B"
A

B
NEGATIVE (-) CUT ANGLE
Bottom dimension "A" is
less than dimension "B"
A

Figure 5-1. Cut Angle

71
SECTION 5 CUTTING QUALITY

ARC VOLTAGE/STANDOFF
Standoff and arc voltage are proportional.
The higher the torch above the plate
(standoff), the higher the operating voltage
and vice versa.
Standoff Arc Voltage

LAG LINES
These lines appear on the cut surface.
They are used to determine if your
process parameters are correct.

Figure 5-2. Cut Quality

5.2 VOLTAGE AND CUT QUALITY. If it has an excessive bevel or rounded top edge, it may be
the standoff (arc voltage) is set too high (Figure 5-3).
Standoff (arc voltage) has a direct influence on cut quality Lower the voltage until the excessive bevel or rounded
and squareness. It is recommended that prior to cutting, top edge disappears. On material thickness 1/4 inch (6
all cutting parameters are set to the manufacturer's sug- mm) and greater, a standoff too close may result in a
gested conditions. A sample cut should be made fol- negative cut angle (Figure 5-5).
lowed by a close examination of the part.

ARC VOLTAGE TOO HIGH

Correct Cutting Speed
Positive Cut Angle
Rounded Top Edge
More Dross
Arc Voltage Top Dross
Cut Face Smooth
End View (+) Cut Angle "S" Shaped Lag Lines

Cut Face

Figure 5-3. Cut Quality (Arc Voltage Too High)

72
SECTION 5 CUTTING QUALITY

ARC VOLTAGE CORRECT

Correct Cutting Speed
Square Top Edge
No Top Dross
Little or No Bottom Dross
Arc Voltage Cut Face Smooth
Uniform Lag Lines
End View Optimum
Cut Angle

Cut Face

Figure 5-4. Cut Quality (Arc Voltage Correct)

ARC VOLTAGE TOO LOW

Correct Cutting Speed
Under Cut Top Edge
Negative Cut Angle
Dross
Arc Voltage Cut Face Rough
Vertical Serrated Lag Lines
End View (-) Cut Angle

Cut Face

Figure 5-5. Cut Quality (Arc Voltage To Low With a Negative Cut Angle)

73
SECTION 5 CUTTING QUALITY

ARC VOLTAGE TOO LOW

Arc Voltage Correct Cutting Speed

Under Cut Top Edge
Negative Cut Angle
Under Cut
End View Top Edge Dross
-/+ Cut Angle Cut Face Rough
Vertical Serrated Lag Lines

Cut Face

Figure 5-6. Cut Quality (Arc Voltage Too Low With An Under Cut Top Edge)

5.3 TOP DROSS. 5.4 DROSS FORMATION.

Top dross usually appears as splatter near the top edge The correct cutting arc voltage also has an influence on
of the kerf. This is a result of torch standoff (arc voltage) dross formation. If the arc voltage is set too high, the cut
set too high or a cutting speed set too fast. Use the angle becomes positive. In addition, dross forms on the
parameter charts for recommended speed. The most bottom edge of the part. This occurs because we are now
common problem is torch standoff or arc voltage control. trying to cut the part with the feather tip of the plasma arc.
Simply lower the voltage settings in increments of 5 volts This dross is usually very tenacious and requires chipping
until the top dross disappears. If an arc voltage control is and grinding for removal. Too low of a cutting voltage
not being used, simply lower the torch manually until the results in an undercutting of the parts or negative cut
top dross disappears (Figure 5-7). angle. Dross formation usually occurs but in most cases
removes easily (Figure 5-6)

74
SECTION 5 CUTTING QUALITY

TOP DROSS
Splatter appears on the top edge of both
pieces of the plate. Lower the voltage in
increments 5 V dc (maximum ) until top
dross disappears.

Figure 5-7. Top Dross

HIGH SPEED DROSS

Fine roll over dross that welds to
bot tom of edge. Cleaning requires
chipping or grinding.

Figure 5-8. High Speed Dross

LOW SPEED DROSS

Globular dross that forms in large
deposits. Comes off very easily.

Figure 5-9. Low Speed Dross

5.5 SUMMARY. an increase in gas flow, an increase in cut water flow or an

increase in torch standoff. Assuming that all of the
Arc voltage is not an independent variable. It is depen- variables are set to the manufacturer's settings, torch
dent upon cutting amperage, nozzle size, torch standoff, standoff becomes the most influential variable to the
cut gas flow rate and cutting speed. An increase in arc process. Good and accurate height control is a necessity
voltage can result from a decrease in cutting speed, an in producing excellent cut quality.
increase in cutting amperage, a decrease in nozzle size,

75
SECTION 5 CUTTING QUALITY

76
SECTION 6 MAINTENANCE

6.1 GENERAL G. With all input power disconnected, and with proper eye
and face protection on, blow out the inside of the power
If this equipment does not operate properly, stop work source, the flow control, and the junction box using
immediately and investigate the cause of the malfunction. low-pressure dry compressed air.
Maintenance work must be performed by an experienced
person, and electrical work by a trained electrician. Do
NOT permit untrained persons to inspect, clean, or repair 6.3 TORCH CONSUMABLE PARTS
this equipment. Use only recommended replacement
parts.

! WARNING
! WARNING Make sure power switch on the Power Source is in OFF
position before working on the torch.
Be sure that the wall disconnect switch or wall circuit
breaker is open before attempting any inspection or Spare parts kit P/N37609 is available for maintaining the
work inside of the Power Source, the junction box, PT-24 torch. For contents and recommended uses, see
the flow control box or the PT-24 torch. Figure 6-1 and Process Data Sheets.

6.2 INSPECTION AND CLEANING 6.4 GAS PRESSURE SWITCH

Frequent inspection and cleaning of the Precision The pressure switches are factory set to provide precise
Plasmarc System is recommended for safety and proper control of the cooling gas and plasma gas pressure. The
operation. Some suggestions for inspecting and cleaning two switches are located in the junction box. The pressure
are as follows: adjustment wheels on the pressure switches should not
be touched. Consult your ESAB representative if you
A. Check work cable to workpiece connection. have determined that the pressure switches are not
functioning properly.
B. Check safety earth ground at workpiece and at power
source chassis.
6.5 PT-24 TORCH DESCRIPTION
C. Check heat shield on torch. It should be replaced if
damaged.
See Table 2-6 for overall size and general configuration.
D. Check the torch electrode and cutting nozzle for wear
on a daily basis. Remove spatter, resharpen point, or A. Mounting. The torch can be mounted by the sleeve
replace if necessary. or by the 1.812 inches (46 mm) dia machined surface
shown (see Figure 3-10). This insulated surface and
E. Make sure cable and hoses are not damaged or its shoulder are machined relative to the nozzle
kinked. retainer thread on the torch body and is held concen-
tric to the cutting nozzle within a total indicator reading
F. Make sure all plugs, fittings, and ground connections of 0.010 inches (0.25 mm) or the nozzle bore is within
are tight. 0.005 inches of any point on the 1.812 dia. When
mounting be sure not to cover the small vent hole in
the side of the sleeve. This hole prevents coolant from
! CAUTION building inside the sleeve should a leak occur in a
service line.
Water or oil occasionally accumulates in compressed
air lines. Be sure to direct the first blast of air away B. Service Lines. Both the 4.5 and 17 ft (1.4 m and
from the equipment to avoid damage to the junction 5.2 m) long lines are shielded and connect to the
box or flow control box. junction box by a friction fit grounded connection.

77
SECTION 6 MAINTENANCE

C. Water Cooling. Coolant enters the torch through the B. Water leaks, moisture, or coolant dripping from the
power cable (-), circulates through the torch body and vent hole in the sleeve indicates service line damage.
the electrode, crosses over to the nozzle (+) section If service lines have to be replaced always use two
of the torch body through nonconductive bypass wrenches to avoid twisting the metal tubes.
tubes, travels back through the body and circulates
between the nozzle retainer and the nozzle, then back C. The torch sleeve P/N 21757 is threaded onto the torch
through the torch body to the junction box via the pilot body. If the sleeve is too tight to be readily removed
arc cable. by hand, use a large adjustable wrench on the flats
located on the body or lightly tighten these flats in a
D. Plasma Cut and Start Gas. These gases enter the vise. With the body secured in this manner, the use
torch through connections that house check valves of two hands on the sleeve may break the sleeve free,
within the torch body. The valves acting in conjunc- if not, use a strap wrench. Always check service line
tion with solenoid valves control the back and forth connections for leaks before replacing the sleeve.
switching of start and cut gases. See Figure 6-2 for
further explanation of this system. D. Be especially careful not to get dirt or foreign matter
in the check valve fittings where the plasma cut and
E. Shield Gas. Shield preflow, cut shield and postflow start gases are attached. If however dirt or other
enter the torch through one connection, pass through foreign matter gets into the check valves, they can be
the torch body, through the shield gas diffuser and dismantled, then cleaned and replaced.
then out of the orifice in the shield cap that surrounds
the plasma jet.

F. Power and Pilot Arc Lines. Coolant IN to the torch ! CAUTION

is through the power cable (-). Coolant OUT from the
torch is through the pilot arc (+) line. The seat, ball and spring must not be damaged when
handling. Also, Do NOT substitute any other spring
6.6 TORCH MAINTENANCE or ball. If they are dropped, lost, or damaged they
must be replaced with genuine ESAB replacement
parts. Changes, substitutions or damaged parts will
affect set pressures and cause poor starting and
! WARNING piercing.

Make sure power switch on the console is in the OFF 6.7 PT-24 CONSUMABLE REMOVAL,
position and primary input power is disconnected. INSPECTION AND INSTALLATION

A. Always check the three O-rings on the torch body

before each day's operation and replace if any damage
or wear is noted. Apply a thin coat of silicone grease
! WARNING
to O-rings before assembling to torch. The O-ring P/ Make sure power switch on the console is in the OFF
N 638797 inside the torch body that seals the nozzle position and primary input power is disconnected.
is especially critical. Because of its location, damage
or wear is not readily apparent. Replacing this ring on NOTE
a daily basis is recommended. Be careful not to
scratch or damage the inside surface of the torch. A When changing consumables, if the nozzle retainer/
toothpick works well for removing the O-ring. The ring diffuser seems especially stubborn and difficult to re-
can be replaced without removing the water baffle P/ move, the console is probably still on. With the console
N 21725, if however the baffle is to be removed, on, the pump will be running and coolant pressure behind
always use a 3/16 inch (5 mm) hex wrench or nut the retainer will prevent it from turning freely. Check the
driver. console before making further attempts to remove the
nut. Notice also that a small amount of coolant will be lost
each time consumables are removed. This is normal and
eventually the coolant will have to be replaced. Check the
coolant before each operation.
A. Removal and Inspection

78
SECTION 6 MAINTENANCE
passages for blockage. Clear blockages with an
1. Unscrew the shield cup retainer. The cup may air stream, if blockages cannot be cleared, re-
come free with the retainer or stay on the torch. If place the baffle. Do NOT insert anything in these
on the torch, pluck it free with your thumbnail. holes in an effort to clear them. Distortion of these
Inspect the cup for damage around the orifice, if holes will impair cutting performance.
the edge of the orifice is damaged, it must be
replaced. Straight cuts cannot be produced if this 6. Unscrew the electrode with the aid of the tool
orifice is distorted. provided.

2. The shield cup insulator is sandwiched between B. Installation

the insulator shield retainer and the nozzle re-
tainer/diffuser and may stay attached to nozzle 1. Electrode - Apply a thin film of silicone grease to
retainer because of the very close fit-up between the O-ring, just enough to produce a shiny sur-
these members. face, thread the electrode in place and snug tight
with the tool provided. Do NOT overtighten.
3. Unscrew the nozzle retainer/diffuser. Inspect for
any damage especially where the retainer con- 2. Nozzle & Swirl Baffle - Place the swirl baffle into
tacts the nozzle. The innerface between the the nozzle being careful not to get anything in the
retainer and the nozzle creates a metal to metal small gas passages. Push this assembly into the
seal for the coolant. Any damage to this sealing torch.
surface will cause a leak and poor cutting will
result. Replace as necessary, do not attempt to 3. Nozzle Retainer/Diffuser - To prevent leakage
repair. Check the small gas passages for block- between the nozzle and nozzle retainer, moisten
ages. Clear blockages with an air stream. the corner of a clean, dry, lint-free cloth with a very
small smount of Krytox grease P/N 73585064.
4. The nozzle is removed with the aid of the tool Wipe the inner surface of the nozzle retainer that
provided. Place the slot around the groove in the comes in contact with the nozzle. Use care to
nozzle and pull the nozzle free. apply a very thin film to ensure a proper seal.
Thread the nozzle retainer onto torch and hand
5. Remove the swirl baffle from the nozzle. If the tighten.
baffle remains in the torch, it will come free with
the removal of the electrode. Check the small gas 4. Shield Cup Insulator - Push the shield cup insula-
tor on the nozzle retainer.

CUP SHIELD SHIELD CUP NOZZLE 5. Shield Cup and Retainer - Screw this assembly
w/ RETAINER INSULATOR "A" (15A) - 21540
22531 22010 "B" (30A) - 21541 onto the torch and hand tighten.
"C" (50A) - 21542
"D" (70A) - 21543
"E" (100A) - 21923

SWIRL BAFFLE
21852 (15A) - 2 HOLES O-RING
21536 (30A) - 3 HOLES 86W62
21692 (50/70/100A) - 4 HOLES

O-RING O-RING O-RING

98W18 638797 950715

INSULATOR SHIELD
RETAINER W/ O-RING
C-21712
Slot for Assemble
NOZZLE RETAINER/ removing swirl ring
DIFFUSER - D-22007 nozzle into nozzle
first

For removing ELECTRODE WATER

and replacing (15/30/50/70A) BAFFLE
water baffler 21539 C-21725

ELECTRODE & Hex for TORCH ASSEMBLY

NOZZLE TOOL installing D-21530
C-21765 electrode

Figure 6-1. Front End Parts, PT-24 Torch

79
SECTION 6 MAINTENANCE
C-22388-A

Figure 6-2. Schematic Gas Flow

80
SECTION 7 TROUBLESHOOTING

7.1 TROUBLESHOOTING
The signal exchange between the PLC and external
devices are both time and condition dependent. If
a required signal is not received in the proper
sequence, the PLC will discontinue the process and
! WARNING generate a fault signal to the CNC.

ELECTRIC SHOCK CAN KILL! Be sure that all primary

power to the machine has been externally discon-
nected. Open the line (wall) disconnect switch or
circuit breaker before attempting inspection or work
inside the power source.

! WARNING
Capacitors can store high voltages even when power
is disconnected or unit is deenergized. Ensure
power supply capacitors are grounded prior to per-
forming maintenance.

7.2 PROCESS TROUBLESHOOTING

A. Programmable Logic Controller (PLC).

The PLC is located in the Precision Plasma Power

Source. It is a device capable of providing pre-
defined outputs depending on state of the inputs.
The precise conditions are programmed and per-
manently stored in the PLC. The PLC is visible
through the plexiglass window on the left side panel
of the power source.

The PLC will provide predefined outputs in re-

sponse to input signals from external devices. This
exchange of signals can be confirmed by observing
the LEDs on the top of the PLC while troubleshoot-
ing. These indications are useful in isolating a
system failure to the most likely device.

The LEDs are divided into two groups; Input (0-15)

and Output (0-11). Input LEDs light when the
corresponding signal is detected by the PLC. Out-
put LEDs light when the PLC issues a signal to an
external device.

LEDs are highly reliable indicators. It is not likely

that one will "burn out". However, if the technician
is not confident that the LEDs are working, the
presence of a signal can be confirmed by using a
meter and taking a measurement on the appropri-
ate pin. Refer to the schematic and wiring dia-
grams.

81
SECTION 7 TROUBLESHOOTING

1 2 3 4

1 2
omron RUN
PA202 SYSMAC ERR/ALM IA111 OC201 OC201
CJ1M INH
PROGRAMMABLE PRPHL 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
POWER CONTROLLER COMM 8 9 10 11 12 13 14 15
CPU12 BKUP
0 0 0
L L
1 CO CO
OPEN SW SETTING 2 1 1
BATTERY
3 C1 C1
L1 MCPWR
4 2 2
AC100 BUSY
-240V 5 C2 C2
INPUT 6 3 3
L2/N
7 C3 C3
8 4 4

9 C4 C4
PERIPHERAL 10 5 5

11 C5 C5
12 6 6

13 C6 C6
14 7 7
NC
15 C7 C7

COM NC NC

NC COM NC NC

AC100V
7mA 50Hz AC250V 2A AC250V 2A
PORT 8mA 60Hz DC24V 2A DC24V 2A

1. Power Supply
5 2. CPU
3. AC Input Module
4. Relay Output Module
5. Flash Memory
Figure 7-1 Programmable Logic Controller (PLC)

Table 7-1 PLC Input/Output LEDs

INPUT OUTPUT

LED Function LED Function

0 Start/Stop 1-0 Travel

1 Preflow 1-1 Hi-Frequency
2 Arc-On 1-2 Pilot Arc Relay
3 O2 Pressure 1-3 Power Source
4 N2 Pressure 1-4 Start Pressure Switch Fault
5 Reserved 1-5 Cut Gas Pressure Switch Fault
6 Fault 1-6 Fault Output
7 ----
8 2-0 Start Gas On
2-1 Cut Gas On
2-3 Full Shield
2-4 Regulated Shield

82
SECTION 7 TROUBLESHOOTING

7.3 TROUBLESHOOTING PROCEDURES

Check the problem against the symptoms in the follow-

ing troubleshooting guide. The remedy may be quite ! WARNING
simple. If the cause cannot be quickly located, shut off
the input power, open up the appropriate component, Voltages in plasma cutting equipment are high enough
and perform a simple visual inspection of all the compo- to cause serious injury or possibly death. Be particu-
nents and wiring. Check for secure terminal connec- larly careful around equipment when the covers are
tions, loose or burned wiring or components, bulged or removed.
leaking capacitors, or any other sign of damage or
discoloration. NOTE

The cause of control malfunctions can be found by Before checking voltages in the circuit, disconnect the
referring to the sequence of operations (Figure 7-1) and power from the high frequency generator to avoid dam-
electrical schematic diagram (Figures 7-2, 7-3, 7-5 and 7- aging your voltmeter.
8) and checking the various components. A volt-
ohmmeter will be necessary for some of these checks.

Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e

PROB L EM POSSIB L E CAUSE ACTION

1. Reduced consumable Skeleton cutting Cutting skeletons to facilitate their removal

(electrode) life from the table can adversely affect electrode
life by:

1. Causing the torch to run off the work.

2. Continuous Pilot Arc edge star ts.

3. Greatly increasing the frequency of star ts

T h i s i s m a i n l y a p r o b l e m fo r O 2 c u t t i n g
and can be alleviated by choosing a path
with a minimum number of star ts.

4. Increased likelihood that the plate will

spring up against the nozzle causing a
double arc. This can be mitigated by
careful operator attention and by
increasing standoff and reducing cutting
speeds.

Height control problems See crashing/diving in Item 2 below.

Piercing standoff too low Increase piercing standoff.

Star ting on edges with Position torch more carefully or use a waster
continuous pilot arc plate to star t on.

83
SECTION 7 TROUBLESHOOTING

Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e
PROB L EM POSSIB L E CAUSE ACTION
2. Reduced nozzle life Contacting work Diving is usually caused by a change in arc
diving voltage when an automatic height control is in
use. Diving can damage the nozzle. Usually
the voltage change is the result of a change of
direction or speed to negotiate a corner or as
a result of plate falling away from the arc.
These problems can be dealt with by disabling
the height control in such situations and by
extinguishing the arc earlier when finishing the
cut on falling plate.

Diving may also be caused by a problem with

the height control or the signals fed to it.

Work flipping The nozzle may sometimes be damaged if the

torch hits a flipped up par t. This is difficult to
avoid entirely but careful par t programming
can minimize the problem.

Catching on piece This refers to crashes or nozzle damage

caused by the front end of the torch catching
on top spatter after a pierce. Hold the torch at
a high standoff or star t with a longer lead-in to
avoid this problem.

Excessive speed Reduce speed to prevent rooster tailing during

cut. Reduce speed around corners if rooster
tailing occurs only coming out of corners.

Process factors Same as for electrode above.

Inadequate initial delay. Increases delay time.

Pierce not complete before
star ting

3. Poor cut quality Gas selection O2 carbon steel - best cut quality minimal
dross.
N2/Air -Stainless steel best cut quality when
used with CH4 or H-35 alternate gas.
N2/Aluminum - best cut quality when using
CH4 alternate gas.

Torch alignment to work Verify and correct torch alignment (ver tical).

Incorrect current Verify correct current. Refer to perimeter

tables.

Cutting over slats Cutting over slats will cause some bottom
dross. If the cut runs along the slat, it can
produce other cut quality problems. The only
solution is to avoid running along the slats.

84
SECTION 7 TROUBLESHOOTING

Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e

PROB L EM POSSIB L E CAUSE ACTION

3. Poor cut quality (cont.) Cutting machine or torch Make sure brackets and height control are rigid and
vibrates properly adjusted.

Bevel angle Same as dross and cut surface above except varying
characteristics of material being cut and cutting
machine or torch vibrations. Standoff and speed have
considerable effect on bevel angle.

Wrong travel direction (good With standard swirl par ts the most square side of the
angle on scrap side) cut is on the right side of the direction of travel.

Plate shifting while being cut Small, thin or lightweight plates can shift while cutting.
Clamp them down.

Slag buildup on cut table Clean slag from cut table.

4. No pilot arc Contaminated electrode Clean or replace electrode.

Insufficient spark gap setting (in Set spark gap to 0.040 IN (1.0 mm).
plumbing box

Pilot Arc Contactor (PAC) Replace contactor.

malfunctioning

Blown pilot arc fuses Replace fuses.

Pressure switches N2 pressure switch, switch faulty or not adjusted

properly.

5. No arc transfer Cutting current setting may be Raise cutting current (see Process Data).
too low

Torch may be too high above Lower the torch standoff slightly.
the workpiece

Work lead may be dis- Make sure work lead is firmly connected to workpiece
connected from cutting table or cutting table.

N2 or O2 check valve in torch Unscrew torch sleeve. Then disassemble two copper
body may be stuck open adapters from torch body and remove debris. Do not
lose ball and string.

6. No preflow No star t signal Check input O LED on PLC. Should be lit. This
verifies a star t commend has been given.

Emergency stop signal open Check for continuity between TB3-18 and TB3-19.
(Also see NOTE in Schematic Diagram, Fig 7-6).

Shor ted, closed or jumpered out Check cooling water LED on front panel. Should be lit.
CWFS

No cooling water Check reservoir. Add coolant until full.

N2 pressure switch not activated With gas supply on, check LED 4 on PLC. Should be
lit when switch is positioned in START GAS TEST or
START condition.

85
SECTION 7 TROUBLESHOOTING

Tab l e 7-2. Tr o u b l es h o o t i n g Gu i d e

PROB L EM POSSIB L E CAUSE ACTION

7. Torch fails to fire Star t gas Lower star t gas flow.

Cooling water flow Pump pressure too low; should be 80/90 PSI
(5.5/6.2 bars).
Faulty cooling water flow
switch CWFS Replace CWFS switch.

Obstruction in torch
limiting cooling water flow Coolant flow through torch should be greater than
0.5 gal/min.

8. Nozzle life extremely Pilot arc high/low switch is Place switch in low position.
shor t in high position

Nozzle pitting/arcing Nitrogen quality too low, requires 99.995% pure

inside bore for longest nozzle life.

Star t gas flow too low Check cutting parameters.

9. Shor t electrode life Insufficient cooling Check pump for 80/90 PSI (5.5/6.2 bars) output
pressure.

Star t gas quality Gas quality needs to be 99.995% minimum.

Cut gas quality Oxygen gas needs to be 99.8% minimum.

10. Shor t electrode/nozzle Water leak on torch front Check nozzle retainer for tightening.
life end

11. Positive cut angle Arc voltage too high Lower arc voltage in small increments

Cutting speed too fast If cutting speed is too fast, simply lower speed

Cutting current too high Wrong nozzle being used or lower current into
correct operating range

Cutting current too low Raise current if nozzle is designed for it.

12. Negative cut angle Arc voltage too low Raise the arc voltage in small increments.

Cutting speed too slow Slowly increase cutting speed.

86
SECTION 7 TROUBLESHOOTING

Table 7-3. PT-24 Torch Leak Procedure

Front end of torch leaking

Remove: shield cup

insulator shield retainer
insulator ring
nozzle retaining cup
nozzle
swirl baffle
electrode

Visually inspect nozzle sealing o-ring and electrode o-ring

Are o-rings yes Replace

damaged? o-ring

no
Visually inspect nozzle and retaining cup metal-to-metal seat

Are seats yes Replace

damaged? parts

no
Reassemble electrode, swirl baffle, nozzle and retaining cup

Turn on coolant flow and check for leaks

Still
yes
Leaking? Replace nozzle

Still
no yes
Leaking? Replace Retaining cup

no
Let’s cut!

87
 SECTION 7
D-37414
88

TROUBLESHOOTING
Figure 7-2. Flow Control Schematic
 SECTION 7
D-37399-D

D
89

TROUBLESHOOTING
Figure 7-3. Junction Box Schematic and Wiring Diagram
 SECTION 7
D-37413
90

TROUBLESHOOTING
Figure 7-4. Flow Control Wiring Diagram
SECTION 7 TROUBLESHOOTING

92
SECTION 7 TROUBLESHOOTING

93
SECTION 7 TROUBLESHOOTING

TB5-PA (YEL)
C2-1 (YEL)

C2-2 (WHT)
MOD1 WHT
P1

T1
T2
T3
E 8 P1
1
K2
J1 ZD2
1

L1
L2
L3
A

B
TB7
SEE CHART

PLC1 P2-10 (RED)

PCB2 WHT

PLC1 P2-9 (VIO)

16

L1-H1 (BLU)
TB6
omr on
PA 202 S YS MAC RUN IA 111 OC201 OC 201

1 2 3 4 5 6 7 8
E RR/ALM
CJ1M INH 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
P ROGRAMMABLE P RP HL
CONTROLLE R COMM 8 9 10 11 12 13 14 15
P OW E R CPU12 BKUP

0 0 0
L L
1 CO CO

C1-1 (BLU)
MOD1 SH1-1 (GRY)

S2-2 (BLU)
OP E N
S W S E TTING
2 1 1
BATTE RY
3 C1 C1
L1 MCP W R
4 2 2
A C 100 BUS Y

E
-240V 5 C2 C2
IN PUT 6 3 3

SEE DETAIL
L2/N
7 C3 C3
8 4 4
9 C4 C4
PER IPHER A L 10 5 5
11 C5 C5
12 6 6

P3
13 C6 C6
14 7 7
NC
15 C7 C7
COM NC NC

COM NC NC
NC

1
AC100V
7m A 50Hz AC250V 2A AC250V 2A

F
8m A 60Hz DC24V 2A DC24V 2A
POR T
S2-6 (ORN)

S2-3 (BLK)

PLC1
K2-L3 (BLU)
BLU C2
BLU TB8 P2 10 1 1 SH1

R12
R11
TB5 J2 16 C1 K2-T1(YEL)
2 2
2 2 2 2 2 K2-T3(WHT)

R13
SEE CHART 1
BLU TB6-2(RED) R14-1 (GRY)
BLU
1
BLU
1
F 1 TB5-TORCH(BLK) D1
K8 K7 K6 K5 K4 K3 8
1 1 1 1 3 1 3 1 3 1 3 1 3 1 3
TB4 SEE DETAIL R15-2 (RED) 1 P2
4 6 4 6 4 6 4 6 4 6 4 6

R10 R7 7
A
9
B
7
A
9
B
7
A
9
B
7
A
9
B
7
A
9
B
7
A
9
B
PLC MOD
R9 R8 R1 P3 TB3
1 8
1
P4

16
R15 2
MOD1 TB3-1 (RED)2 D1(-) GRY
1 R14 1
T2

K8 K7 K6 K5 K4 K3
1 3 1 3 1 3 1 3 1 3 1 3
4 6 4 6 4 6 4 6 4 6 4 6
7 9
A B
7 9
A B
7 9
A B
7 9
A B
7 9
A B
7 9
A B
FRONT VIEW
PLC TB4-1(WHT)
PLC TB4-2(WHT)
PLC TB4-4(BRN)

PLC TB8-2(BRN)

PLC TB4-4(BRN)
PLC TB7-16(BLU)

PLC TB8-6(YEL)

PLC TB4-1(WHT)

WITH FRONT
PLC TB8-5(ORN)

PLC TB7-19(VIO)

PLC1 J2-11(WHT)
PLC TB4-4(BRN)

PLC1 J2-12(ORN)
PLC TB7-15(YEL)
PLC1 J2-13(GRY)

PLC TB4-4(BRN)
PLC1 J2-14(YEL)
PLC TB4-4(BRN)
TB3-22 (WHT)
TB3-21 (GRY)
TB3-20 (BLU)

TB3-23 (BLK)

PANEL REMOVED
ZD3
J1-G (BLK)
J1-K (YEL)

1 2 3 4 5 6 7 8

PLC TB4 (SEE DETAIL-SHT 4) P4

PLC1 MODULE PLC1 MODULE
1 PCB1 P2-14(BLU)
PLC J1 J2 P2 P1
PLC1 P2-4(BLU)
PS-L1 PLC TB7-10 (BLK) 1 PLC TB7-14(ORN) 1 PLC CB3-1(BLK) 1 P4-10(VIO) 1 PCB1 P4-1(BRN)
PS-L2 PLC TB7-2 (WHT) 2 PCB1 P2-13(BLU)
PLC1 P2-7 (VIO) 2 PCB1 P4-2(GRY) POWER MOD1
PS-LG PLC TB8-14 (GRN) PLC1 P2-3(BLU)
PS-GR PLC TB8-14 (GRN) 2 PLC TB7-13(ORN) 2 PLC TB7-2(WHT) 2 P4-9(VIO) 3 PCB1 P4-7(YEL) P1 P2 P3 SH1
3 PCB1 P2-12(BRN)
3 PLC TB7-2(WHT) PLC1 P2-9 (VIO) PCB1 P4-9(YEL) 1 PCB1 P1-16(VIO) 1 1 PCB1 P4-3(RED) 1 R10-1 (GRY)
4 PCB1 P2-11(BRN)
4 PLC TB8-4(RED) 3 PLC TB7-24(GRY) 3 P4-2(BLU) 4 PCB1 P4-10(WHT) 2 PCB1 P1-15(BLU) 2 2 PCB1 P4-4(YEL) 2 TB5-WORK(BLK)
5
OUT1-0 PLC TB7-7 (VIO) 5 TB3-5 (BLK) 4 J1-C(ORN) 4 P4-1(BLU) 5 PCB1 P5-1 (BLK) 3 PCB1 P3-12(ORN) 3 3 PCB1 P4-15(BLU)
OUT1-C0 PLC TB7-8 (VIO) 6
5 TB5-WORK(RED) PLC1 P2-15(BLU) 6 PCB1 P5-2(VIO) 4 PCB1 P3-13(WHT) 4 4 PCB1 P4-16(ORN)
OUT1-1 PLC TB7-9 (BRN) 6 TB3-6(VIO) 7 PCB1 P2-5(ORN)
6 5 PCB1 P7-1(BLK) 7 5 PCB1 P1-13(BLK) 5 5 TB6-6(BRN)
OUT1-C1 PLC TB7-12 (BLK) 7
7 8 PCB1 P2-4(ORN)
OUT1-2 PLC TB7-11 (RED) 8 PLC TB8-8(BLU) 6 8 PCB1 P4-8(ORN) 6 PCB1 P1-14(RED) 6 6 TB6-8(GRY)
8 9 PCB1 P2-2(VIO)
OUT1-C2 PLC TB7-12 (BLK) 9 7 PLC1 P2-1 (VIO) 9 7 PCB1 P3-18(BLU) 7 NOT USED 7 PCB1 P4-11(RED)
OUT1-3 PLC TB7-14 (ORN) 9 J1-N(GRY) PLC1 P2-2(VIO)
10 8 10 S3-4(BLU) 8 8 PCB1 P4-12(BLK)
OUT1-C3 PLC TB7-13 (ORN) 10 PLC TB7-11(RED) 10 PCB1 P2-1(VIO)
9 PLC1 P2-2 (VIO) 8 PCB-TB P1-1(YEL) 9 PCB1 P4-13(VIO)
OUT1-4 PLC TB7-15 (YEL) PLC1 P2-1(VIO)
OUT1-C4 PLC TB4-6 (GRY) K2-A (VIO) 9 R2-1(ORN) 10 PCB1 P4-14(YEL)
11 PCB1 P3-1(GRY)
OUT1-5 PLC TB7-19 (VIO) 11 K3-6(WHT) 10 K2-B(RED) 10
OUT1-C5 PLC TB4-8 (GRY) 12 PCB1 P3-2(BLU)
12 K3-9(ORN) 11 PCB1 P1-7(WHT) 11
OUT1-6 PLC TB7-16 (BLU) 13 PCB1 P1-3(RED)
OUT1-C6 PLC TB4-8 (GRY) 13 K4-9(GRY) 12 PCB1 P1-8(ORN) 12
14 PCB1 P1-2(BRN)
OUT2-0 PLC TB7-20 (VIO) 14 K4-6(YEL) 13 PCB1 P1-9(GRY) 13
15
OUT2-C0 PLC TB7-17 (GRY) 15 TB4-4(BRN) 14 PCB1 P1-10(YEL) 14 PCB1 P9-1(RED)
OUT2-1 PLC TB7-21 (BRN) 16
16 15 PLC1 P2-4(BLU) 15 PCB1 P9-3(BLK)
OUT2-C1 PLC TB4-8 (GRY)
16 16
OUT2-2 PLC TB7-22 (RED)
OUT2-C2 PLC TB4-6 (GRY)
OUT2-3 PLC TB7-23 (ORN)
PCB2 TB5
OUT2-C3 PLC TB4-6 (GRY)
P3
1 PCB1 P2-15(YEL) PCB2-PA(YEL)
IN1-0 PLC TB8-1 (WHT) 2 PCB1 P2-16(YEL) K2-T1 (YEL)
R3
IN1-1 PLC TB8-2 (BRN) PCB1 P7-3(RED) PA
3 PCB1 P2-8(GRY) MOD1 SH1-2(BLK) PLC1 J2-5(RED)
IN1-2 PLC TB8-4 (RED) MOD1-TB3-1 (RED) R4
IN1-3 PLC TB8-5 (ORN) 4 PCB1 P2-9(RED) PCB2 P1-1 (RED)
WORK
IN1-4 PLC TB8-6 (YEL) 5 PCB1 P2-10(GRY) TB6 1 2 3 4 5 6 7 8 PCB2 P1-6 (BLK)
IN1-5
6 PCB1 P10-4(WHT) MOD1 TB3-1(BLK)
IN1-6 PLC TB8-8 (BLU) MOD1 P3-6(GRY) TORCH
7 PCB1 P10-3(BLK) TB5-PA(YEL)
IN1-7 R5 S3-6(GRY)
IN1-8 8 PCB1 P10-5(WHT) S3-3(ORN)
R6 VIEW F-F
IN1-9 MOD1 P3-5(BRN)
IN1-10 PCB2 - P1
IN1-11
IN1-12 P1-1 TB5-WORK(RED)
IN1-13 P1-2 TB3-13(ORN)
IN1-14 P1-3 TB3-14(BRN) VIEW E-E
PLC TB8-23 (BLK) P1-6 TB5-TORCH(BLK)
IN1-15
IN1-COM PLC TB8-18 (BLK)
0558003589
IN1-COM SHEET 3 OF 4

94
SECTION 7 TROUBLESHOOTING

PLC

PLC TB7-1 (BLK)

TB4 TB7 TB8

PLC J2-1 (BLK)

1 K5-6 (WHT) 1 PLC CB3-2 (BLK) 1 PLC CB1-2 (BLK)
K6-6 (WHT) PLC TB7-10 (BLK) TB3-1 (WHT)
PLC TB4-2 (WHT) PLC TB7-12 (BLK) PLC IN1-0 (WHT)
PLC TB7-2 (WHT)
2 PLC J2-2 (WHT) 2 K7-4 (BRN)
2 TB3-2 (WHT)
K7-6 (WHT) PLC PS-L2 (WHT) PLC IN1-1 (BRN)
PLC TB8-24 (WHT) PLC J1-3 (WHT)
TB4-1 (WHT) PLC TB4-1 (WHT)
3 3 2
3 1

4 K3-B(BRN) 4 4 PLC J1-4 (RED) PLC CB3

K4-B(BRN) PLC IN1-2 (RED)
K5-B(BRN)
K6-B(BRN)
K8-B(BRN)
PLC J2-15(BRN)
5 5 5 K5-9 (ORN)
PLC IN1-3 (ORN)
6 PLC OUT2-C3 (GRY)
PLC OUT1-C4 (GRY) 6 6 K6-9 (YEL)
PLC TB4-7 (GRY) PLC IN1-4 (YEL)
PLC OUT2-C2 (GRY)
7 TB3-4 (VIO) 7
7 PLC TB7-24 (GRY) PLC OUT1-0 (VIO)
PLC TB4-8 (GRY)
J1-D (GRY)
PLC TB4-6 (GRY)
8 TB3-3 (VIO) 8 PLC IN1-6 (BLU)
8 PLC TB4-7 (GRY) PLC OUT1-C0 (VIO) PLC J1-8 (BLU)
PLC OUT2-C1 (GRY)
9 J1-M (BRN) 9
PLC OUT1-C6 (GRY)
PLC OUT1-C5 (GRY) PLC OUT1-1 (BRN)

10 PLC TB7-18 (BLK)

PLC PS-L1 (BLK)
PLC J1-2 (ORN) 10
PLC TB7-1(BLK)
11 PLC J2-10 (RED)
PLC OUT1-2 (RED)
11
12 PLC OUT1-C1 (BLK)
PLC OUT1-C2 (BLK)
PLC TB7-1(BLK) 12

13 PLC J1-2 (ORN)

PLC OUT1-C3 (ORN) 13
14 PLC J1-1 (ORN) 14PLC PS-LG (GRN)
PLC OUT1-3 (ORN) PLC PS-GR (GRN)
15 K3-A (YEL) GND1 (GRN)
PLC OUT1-4 (YEL)
16 K8-A (BLU)
PLC OUT1-6 (BLU) 15
17 PLC OUT2-C0 (GRY)
PLC TB7-24 (GRY) 16
17
18 PLC IN1-COM (BLK)
PLC TB7-10 (BLK) 18

19 PLC OUT1-5 (VIO) 19

PLC TB7-24 (GRN)
K4-A (VIO) 20

20 J1-B (VIO)
21
PLC OUT2-0 (VIO)
21 J1-F (BRN) 22
PLC OUT2-1 (BRN)
22 PLC OUT2-2 (RED)
23 PLC IN1-15 (BLK)
J1-J (RED)

23 PLC OUT2-3 (ORN)

24 PLC TB7-18 (BLK)
J1-L (ORN)
24 PLC J2-3 (GRY)
PLC TB4-2 (WHT) 0558003589
PLC TB4-7 (GRY) SHEET 4 OF 4
PLC TB7-17 (GRY)

95
 SECTION 7 TROUBLESHOOTING

0558003591

41
P2 J2 CB3
1 2
1 3A 40
2 39
TB4-1 38
3
PUMP
4 37
MOTOR 15 TB4-4
M2 7 36
4 1 T1 J3 P3
X13
PCB1 9 35
8 P10-5 ISOLATION AMPLIFIER AND
2

X12 18VAC FAULT SIGNAL PCB 8

7 P10-3
X11 18VAC 34
CB2

6 P10-4 38103 10
7A

X16
T3 5 P2-10 33
X15 18VAC
4 P2-9
H7 H7 X14 18VAC 32
1

7 3 P2-8 LED1 LED4 LED7

575V X6
2 P2-16
1 6
460V
H6 H6 X5
X8
1
24VAC
P2-15 P7-1 5
1 P2-14 31
H5 H5 X7 24VAC P7-3 6
5 2 P2-13 LED2 LED5 LED8 30
415V X4
3 P2-12
H4 H4 X3 24VAC
4 4 P2-11 29
380V
5 P2-7
H3 H3
3 6 P2-6 TB4-2 28
230V X10 PLASMA GAS
7 P2-5 LED3 LED6 LED9
H2 H2 X9 12VAC P1-10 14
2 8 P2-4
200V X2 P1-7 11
9 P2-2
H1 H1 X1 120VAC
1 10 P2-1 9 6
P1-8 12
TB2 11 P3-1 START GAS A B
2 12 P3-2
K3
EFC
27
SEL
13 P1-3 9 6 TB8-24 TB8-23
1 F4 2

P1-9 13
14 P1-2 A B
15A

K4
15
16
P8

P6

P1-5
P1-6

J4 P4 9 6
NC C A B
K5
NO FS1
+

+
-
-

-
-

2 6 9 6
3 AM1
AMMETER
V1
VOLTMETER P1 J1 A B
FNT PNL S1 K6
ON/OFF 7
1 5 ZD1,220 2 1
CB1 9 26
3A 2 P4-9 10 25
M1 24
1 P4-1 1
120VAC P4-2 2 23
T2
CH7 P4-7 3 22
A K1 B 21
4 ØC
CH8 9 6 20
L3 T3 575V CH6 A B
18 K8
P4-8 8 PLC1
460V
17
CH5 P4-10 4 PLC MODULE #1 19
P5-1 5 18
415V CH4 P1-12
16 P5-2 6 17
P1-11 16
380V CH3
15 P1-18
MOV2
230V CH2 P1-17
14
610V 200V CH1 ZD2 220VAC
13
P4-14
MOV3 BH7 A B
5 P4-13
P4-12 L1
K2
T1
610V BH8 P4-11 15
L2 T2
P10-1
ØB L2 T2 575V BH6 P10-2 L3 T3 C2 R11
12
P4-16 20uf
AUTO XFMR

120VAC RELAY 10K

460V BH5 P4-15 400V 8W
11
P4-4
415V BH4 P4-3
14
10 FRONT PNL LOCAL
P3-18(-) CURRENT SETTING POT

TB6-7
380V BH3 R2
TB6-6
9 P3-17(+) 10K

TB6-8
MIN MAX
230V BH2 P9-3 1 3
8
P9-1 2
R3 R4
200V BH1 P1-14 4.99K 4.99K
7
P1-13
AH7 P3-13
MOV1 P3-12 6
AH8 P1-15 3 1 6 4
PCB TRIM POT FRONT PNL
ØA L1 T1 610V P1-16 1 838193 CURRENT
575V AH6 SETTING
6 LOCAL/REMOTE
2 5 DPDT S3
460V AH5 NOT USED ON
5
PRECISION PLASMA CONSOLE
415V AH4 J2 P1 P3
6 380V
4
AH3
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10
P4
3
10 13
230V AH2
2 9 12
200V
1
AH1 8 11
TB1 TB2-2 7 10
TB2-1
MOD1
6 9
BR1-A 5 8
POWER MODULE #1
BR1-B
BR1-C 4 7
3 6
2 5
1 4

SH1-2 3
SH1-1 2
TB3-1 1

96
SECTION 7 TROUBLESHOOTING

0558003591

41
40
39
38
37
36 J1
35 A
B
34 C
33 D
32 E
CNC START

CONTROL BOX
0 L2 F
CNC PREFLOW
POWER SUPPLY

1 L1
ARC ON TO CNC
MODULE

2 LG G

TO FLOW
31 O2 PS
3 GR H
30 N2 PS
4 NC J
5 NC

J1
29 FAULT K
MODULE

6 0
INPUT

TRAVEL
7 C0 L
28 8 1
FC HF M
9 C1
OUTPUT MODULE

10 2 N
PAC
11 C2 P
#1

12 3 R
13 START
C3
START GAS FLT S
14 4
CUT GAS FLT
27 15 5
FAULT TO CNC
T
COM 6 U
ZD3
220 VAC COM C4
C6 C5 V
START GAS ON, NITROGEN
C0 0
A B CUT GAS ON, OXYGEN
C1 OUTPUT 1
K7 C2 MODULE
2
FULL SHIELD
#2
4 REGULATED SHIELD TB3 J2
3
6
PLC C3 1 N START SIGNAL FROM
COMMON TB4 7&8
2 M CNC TO P.S., RELAY CLOSING
120VAC RELAY
3 I ARC ON SIGNAL FROM P.S.
4 G TO CNC, RELAY CLOSING
26 5 ARC ON SIGNAL
25 6
FROM P.S. TO CNC,
24 TRANSISTOR
23 7 START SIGNAL FROM
22 8 CNC TO P.S., 120VAC
21 9 START SIGNAL FROM
CNC TO P.S., 24VAC
20 10
11 L +10VDC REMOTE CURRENT
PLC1 12 J SETTING FROM CNC TO P.S.
19 PLC MODULE #1
13 C VOLTAGE DIVIDER, (+)
18
14 H VOLTAGE DIVIDER, (-)
17 1 F3 2 15
16 1A
16
17
18 E EMERGENCY STOP FROM CNC TO P.S.
RELAY/CONTACTOR NORMALLY CLOSED
19 F OPEN IN CASE OF EMERGENCY
TB6-5 20 A FAULT SIGNAL FROM P.S. TO CNC
R6 21 B RELAY CLOSING, DRY CONTACT
15 39K
2W TB6-4 22 K 120VAC PREFLOW SIGNAL
R5 23 D FROM CNC TO P.S.
39K
2W TB6-2 24
14

TO CUTTING MACHINE CNC

H2 FRONT PNL CONNECTOR CHASSIS GND SUPPLIED
PILOT ARC BY CUTTING MACHINE GROUP
SELECTOR
L1 S2 6
5 HI
H1 4 R7
20 OHM 20 OHM 300W
300W
3 R1 R8
2
LO 20 OHM 300W R10
1
R7 R9 3.1 OHM
C1 10K 300W

TO JUNCTION BOX J1
OHM 20 OHM 300W
20uf WORK
400V 8W
D1 R7
10K P1-2 P1-1
13 OHM
START UP
8W
P1-6

12 P1-3 PCB2
PA
PILOT ARC
R14 838131
11 20 OHM
10 50W TORCH
9
8 R15
20 OHM
7 50W
6
5
4

3
2
1

97
SECTION 8 REPLACEMENT PARTS
8.1 General
Always provide the serial number of the unit on
which the parts will be used. The serial number is
stamped on the unit nameplate.

8.2 Ordering
To ensure proper operation, it is recommended that
only genuine ESAB parts and products be used
with this equipment. The use of non-ESAB parts
may void your warranty.

Replacement parts may be ordered from your

ESAB Distributor or from:

ESAB Welding and Cutting Products

ATTN: Customer Service Department
PO Box 100545 Ebenezer Road
Florence, SC USA 29501-0545
Phone (843) 664-4405
(800) ESAB-123 (372-3123)

ESAB Cutting Systems - Canada

6010 Tomken Road
Mississauga, Ontario, Canada L5T 1X9
Phone (905) 670-0220
Fax (905) 670-4879

ESAB Cutting Systems GMBH

Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Phone 011-49-6039-400
Fax 011-49-6039-403-02
http://www.esab.de

Be sure to indicate any special shipping instructions

when ordering replacement parts.

Refer to the Communications Guide located on the

last page of this manual for a list of customer
service phone numbers.

99
SECTION 8 REPLACEMENT PARTS
8.3 Plasmarc Power Source-Exterior Components

2 1
3

4
6 8

OUTPUTS
START-STOP 0 1-0 TRAVEL
PREFLOW 1 1-1 HI FREQUENCY
ARC-ON 2
O2 PRESSURE 3
N2 PRESSURE 4
PILOT 5
FAULT 6
7
1-2
1-3
1-4
1-5
1-6
1-7
PILOT ARC RELAY
POWER SOURCE
START GAS PRESS SWI FAULT
CUT GAS PRESS SWI FAULT
OUTPUT FAULT
5
8 2-0 START GAS ON N2
2-1 CUT GAS ON O2
INPUTS 2-2 FULL SHIELD
2-3 REGULATED SHIELD

100
SECTION 8 REPLACEMENT PARTS

Item Part Number Symbol Description

Number (Elec-Ay)
1 35925YL Cover-Top

2 995227 Label Warning-Exposed High Volt

3 2091514 Label Warning

4 34941 Lens Clear

5 13734588 Logo ESAB Clear

6 35924YL Panel Right Side

7 32403Y Panel Left Side

8 61328087 Screw, HMH ¼-20 X .50 L

101
SECTION 8 REPLACEMENT PARTS

5 4 3 2
6
1
7

11

10

See
"TEE"
Detail
Page 7-12

102
SECTION 8 REPLACEMENT PARTS

Item Part Number Symbol Description

Number (Elec-Ay)
1 672508 S1 Switch Toggle 2PST 2 Pos 15A
2 634518 S2,3 Switch Toggle DPDT 2 Pos 15A
3 951061 AM1,VM1 Meter LED 5VDC
4 951061 AM1,VM1 Meter LED 5VDC
5 634518 S2,3 Switch Toggle DPDT 2 Pos 15A
6 2234589 R2 POT 10K 10 Turn
7 954751 Overlay Precision Plasma
8 32286GY Panel Front
9 See Below Gauge 200 PSI
10 952182 Spout Remote Filler w/Cap
11 36346GY BRKT, Remote Filler

Refer to Console Serial Number to determine

NOTICE which gauge to order. Gauges require
different hole sizes in front panel and are not
interchangeable.
• Console with serial number in PxxJ348xx
format require gauge P/N 0558004488
• All others use P/N 598481

P/N 598481 P/N 0558004488

103
SECTION 8 REPLACEMENT PARTS

11

2
10

13

9
3

12
4
8

104
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 35928GY Door Access Rear

2 952209 J1 Conn Box Recpt 19 FS SH

3 952210 J2 Conn Box Recpt 14 FS SH

4 97W6 3 Strain Relief

5 23610197 Plug Hole .875 Dia. .125 CT Nyl BK

6 952571 F4 Fuse 7A 600 VAC Fast Acting

7 32202GY Panel Rear

8 58V75 Adaptor B/A-W F ¼ NPTM BKHD

9 954599 Label Rating Precision Plasma

10 950829 CB1 Circuit Breaker 3 AMP

11 950937 Strain Relief

12 13730763 Plate, Serial

13 950874 CB2 Circuit Breaker 7 AMP

105
SECTION 8 REPLACEMENT PARTS
8.4 Plasmarc Power Source-Internal Components
18
17
Reference: PCB1
Isolation Amp

Reference:
Meter LED
AM1,VM1

4
20
3
5
3

7
19

8 PA202

POWER
omron
SYSMAC
CJ1M
PROGRAMMABLE
CONTROLLER
CPU12
RUN
ERR/ALM
INH
PRPHL
COMM
BKUP
IA111
0
8
1 2 3 4 5 6 7
9
10 11 12 13 14 15
OC201
0 1 2 3 4 5 6 7
OC201
0 1 2 3 4 5 6 7
15
0 0 0
L L
CO CO
1
OPEN
SW SETTING 2 1 1
BATTERY C1 C1
AC100 3
L1 MCPWR
-240V 4 2 2
BUSY
INPUT C2 C2
5
L2/N 6 3 3
C3 C3
7
8 4 4
C4 C4
PERIPHERAL 9
10
5 5
11 C5 C5
12
6 6
13 C6 C6
14
NC 7 7
15 C7 C7
COM NC NC
NC COM NC NC

AC100V
7mA 50Hz AC250V 2A AC250V 2A
PORT 8mA 60Hz DC24V 2A DC24V 2A

10

12 13
14
11

106
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 35920GY Base, Precision Plasma

2 635686 TB4 Term Block 8 pos

3 838103 PCB1 PCB Isolation AMP

950096 PCB1 P9,7 Housing Contact, Crimp 3 pin
952053 Standoff #6-32 X .88 L
952034 PCB1 P10 Plug 5 Pos
952030 PCB1 P1,3,4 Plug 18 Pos
952032 PCB1 P2 Plug 16 Pos
952205 PCB1 P5 Receptacle P/C 4 Pos

4 0558003595G Box PLC

5 0558003578 PLC PLC Controller

6 38131 PCB2 Board, PC Startup

7 950760 K3-6,8 Relay Enclosed DPDT 24VAC

8 17300020 R1,7,8,9 Resistor 300W 20ohm 10%

10 13735308 K7 Relay Enclose DPDT 120VAC 20A

11 952012 Caster Fixed

12 35682 T2 XFMR Auto

13 952179 Tank, Water

14 952013 Caster Swivel

15 639533 Bushing, Snap .88 I.D. X 1.09 MH X .45 L

16 17300931 Resistor, 300W 3.1ohm 10%

17 952095 Spacer, LED

18 71200732 Adhesive, SIRBR Clr

19 950829 CB3 Circuit Breaker, 3 AMP

20 0558003577 TB7, TB8 Terminal Block, 24 POS, 300V

107
SECTION 8 REPLACEMENT PARTS

4 3

14
11

5 13
6 12 7

10
7

9
8

108
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 952026 TB2 Terminal Block

2 673502 K1 Contactor 3 Pole 75A

3 672002GY Shroud, Fan

4 2062334 M1 Motor, Fan

5 36417GY Shroud, Fan

6 951215 M2 Motor, Carb 1/3 Hp

7 951347 Pump, Carb w/Strainer

8 950179 Tee, Pipe Branch ¼ Brs

9 10Z30 Adaptor, B/A-W M ¼ NPTM

10 182W82 Elbow 90 DEG. ¼ NPT

11 37348 Kit, Wire Primary

12 33551 BRKT, Water Tank

13 37805 T3 Auto XFMR

14 32203GY BRKT, Auto XFMR

109
SECTION 8 REPLACEMENT PARTS

5
8 6 9

7 1 2
3
9
8 2 7
9 3 7

12
13

11

“TEE” Detail
10 X5

110
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 36538 Hose, Assy Pump Outlet- Torch out

2 950001 FS1 Switch, Flow .25 GPM SPSTB

3 21124 Valve, Check Assy

4 36539 Hose, Assy Flowswitch To Core

5 90858009 TBG, Nylobrade 3/8 I.D X .625 O.D.

6 36418 Hose Assy Tank Bottom- Pump Inlet

7 58V75 Adaptor, B/A-W F ¼ NPTM BKHD

8 182W82 Elbow 90 Deg. ¼ NPT

9 10Z30 Adaptor, B/A-W M ¼ NPTM

10 994471 Clamp, Hose W/D .50 Dia X 1.06 SS

11 952179 Tank, Water

12 952182 Spout, Remote Filler w/Cap

13 952181 Tee, Plastic Pipe

111
SECTION 8 REPLACEMENT PARTS

10 6

2
9

7 1

112
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 13735961 Heat Exchanger

2 950823 Bushing, Snap

3 950167 Grommet, Rub 1.12 I.D. X 1.50 O.D. X .06 W

4 995103 TB3 Terminal Block 24 POS 15A

5 36919 TB5 Board, Terminal Output

6 96W10 Holder, Fuse

7 92W57 Grommet, Rub .63 I.D. X .88 O.D. X .06 W

8 639533 Bushing, Snap .88 I.D. X 1.09 MH X .45 L

9 35930GY BRKT, Heat Exchanger

10 2234891 Plug, 10 Pos

113
SECTION 8 REPLACEMENT PARTS

6
13

8
4

3
10

2
11

12

114
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 950823 Bushing, Snap

2 17750020 R11,12 Res 20 ohm 50W

3 36527GY Cover, Terminal Board

4 951161 C1,2 Cap, Metpoly 20uf 400VDC

5 673458 K2 Contactor, Pilot Arc 3P 40A

6 2234521 P4,MOD1 Plug, 16 Pos

P1,PLC1 P2

7 2234891 MOD1 P3, 4, Plug, 10 Pos

PLC1 P1

8 2234518 J3 Receptacle, 8 Pos

9 2234521 P1,PLC1 P2 Plug, 16 Pos

10 2234519 J4, PLC1 J2 Receptacle, 16 Pos

11 635686 TB6 Terminal Strip, 8 Pos

12 647065L1 Choke Signal #Ch12

13 38193 PCB-TB Printed Circuit Board Trim Pot

115
SECTION 8 REPLACEMENT PARTS
8.5 PLC Precision Plasma CJIM P/N 0558003578

1 2 3 4

1 2
omron RUN
PA202 SYSMAC ERR/ALM IA111 OC201 OC201
CJ1M INH
PROGRAMMABLE PRPHL 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7 0 1 2 3 4 5 6 7
POWER CONTROLLER COMM 8 9 10 11 12 13 14 15
CPU12 BKUP
0 0 0
L L

1 CO CO
OPEN SW SETTING 2 1 1
BATTERY
3 C1 C1
L1 MCPWR
4 2 2
AC100 BUSY
-240V 5 C2 C2
INPUT 6 3 3
L2/N
7 C3 C3

8 4 4

9 C4 C4
PERIPHERAL 10 5 5

11 C5 C5
12 6 6

13 C6 C6
14 7 7
NC
15 C7 C7

COM NC NC

NC COM NC NC

AC100V
7mA 50Hz AC250V 2A AC250V 2A
PORT 8mA 60Hz DC24V 2A DC24V 2A

116
SECTION 8 REPLACEMENT PARTS
Item Part Number Quantity Description
Number

1 0558003755 1 OMRON Power supply

2 0558003756 1 CPU

3 0558003758 1 AC Input Module

4 0558003757 2 Relay Output Module

5 0558003633 1 Flash Memory

117
SECTION 8 REPLACEMENT PARTS
8.6 Power Source Power Module

1
7

118
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 35914GY Base Power Module

2 37102 Bracket, PCB KYDEX

3 35799 Wire Kit, Power Module

4 951339 PCB1 P1, 5 Plug, Female 12 Position

951340 PCB1 P2, 6 Plug, Female 14 Position

5 37101GY Deck, Power Module

6 951981 Heat Sink

7 35700 L1 Inductor, Power Factor

119
SECTION 8 REPLACEMENT PARTS

5
A
6

Section A-A

120
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 2234877 J3,4 Block Terminal 10 Position

2 951182 M1 Fan, Axial

3 950487 TB2 Terminal Strip 2 Position

4 950823 Bushing, Snap

5 35700 L1 Inductor, Power Factor

6 17280215 R2 Resistor 1.5K OHM 100W

7 35680 L2 Inductor Assembly Output

8 35681 T3 Transformer Assembly, Main

121
SECTION 8 REPLACEMENT PARTS

6 1

122
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 2234518 J2 Block Terminal, 8 Position

2 38047 SH1 Shunt, Feedback

3 2234519 J1 Block Terminal, 16 Position

4 35917GY Baffle Heatsink

5 951981 Heatsink

6 2234877 J3, 4 Block Terminal, 10 Position

7 674156 TB3 Adaptor

123
SECTION 8 REPLACEMENT PARTS

12 11 8
10 13 10 9 7
14

15
5

16

4
17

18

19
2
20

1
19

21
22 26 27
21 23 24 21 25

124
SECTION 8 REPLACEMENT PARTS
Item Part Number Symbol Description
Number (Elec-Ay)
1 35940 T1 Transformer Control
2 951978 BR1 Bridge Diode 3PH 130A
951192 Pad Thermal Bridge
3 35794 Busbar Input Bridge
4 951979 SCR1 SCR 90A
951196 Pad Thermal SCR Module
5 951980 Q1,2 IGBT 300A 600V
6 17750020 R4,5 Resistor 20OHM 50W NI
951194 Pad Thermal Power Resistor 50W
7 647345 Bushing Snap 1.31 I.D. X 1.5 MH .44 L
8 17250005 Resistor 5OHM 50W
9 951940 C6,7 Capacitor 1uf 600VDC
10 951983 C4,5 Capacitor 3300 uf
11 35793 Busbar IGBT (-)/Capacitor
12 950823 Bushing Snap .687
13 35792 Busbar IGBT (+)/Capacitor
14 5844 Nomex Insulator
15 951191 Pad Thermal IGBT 1200V
16 35799 Wire Kit Module
17 35918 Busbar Shunt
18 639533 Bushing Snap .875 I.D. X 1.093 MH
19 17721020 R6,7,8,9 Resistor 20 OHM 25W NI
20 951185 D1,2 Module Diode 100A 600V
21 647345 Bushing Snap 1.31 I.D. X 1.5 MH .44 L
22 36873 Busbar Capacitor/IGBT
23 952255 C8,9 Capacitor Film 40uf 400VDC
24 36872 Busbar Capacitor
25 32958 T2 Transformer, Current
26 950711 TS1,2 Switch Thermal 194 Deg. F.
27 35790 Busbar Jumper

125
SECTION 8 REPLACEMENT PARTS

8, 9 1 3 4 6 3 3 5 13 16 12

10 16 12 15 5 6 7, 8 6 13 12 15 14

Figure 8-1. Flow Control Box, P/N 37416 (Left, Front and Right Side
Views)

Item Qty. Part Circuit

No. Req. No. Description Symbol

1 1 32189 BOX, FLOW CONTROL

2 1 35862 COVER, FLOW CONTROL BOX (NOT SHOWN)
3 3 21898 FLOW METER W/TUBE 1/4-33-G-5
4 1 952140 FLOW METER W/TUBE 1/4-15-G-5
5 6 21711 GAUGE 1.50 #160PSI
6 6 22228 VALVE ASSY
7 1 952220 SWITCH TOGGLE 3PDT 3 POS 15A 125V SW1
8 3 951474 SEAL SWITCH BLACK
9 2 634518 SWITCH TOGGLE DPDT 2 POS15A 125V SW2, 3
10 1 6271128 CONN BOX RCPT 14MP SHELL 20 J1
11 2 672528 SPACER .26 ID x .38D x 1.50 LG STL
12 4 08030281 ADAPTOR B/I-G F 1/8 NPTM
13 2 23101300 SPACER .28ID x .50D x .38 LG NYL
14 1 1006733 CONN BOX RCPT 19FS SHELL 22 J2
15 2 11Z93 ADAPTOR B/ACETM 1/8 NPTM
16 2 952202 ADAPTOR B/OXY M 1/8 NPTM
17 53A61 STAINLESS STEEL INDICATOR BALL (not shown)

126
SECTION 8 REPLACEMENT PARTS

25 26 25

DETAIL 'B' DETAIL 'C'

(See Fig. 8-3.) (See Fig. 8-3.)

22 21
23

24 24

23 23

A A
23, 27, 28 23

SECTION A-A

Figure 8-2. Flow Control Box, P/N 37416 (Top and Inside Views)

Item Qty. Part Circuit

No. Req. No. Description Symbol

21 1 950760 RELAY ENCLOSED DPDT 24VAC 10A ICR

22 1 635686 TERM. BLOCK 8 POS TB1
23 12 952087 FITTING 1/8 NPTM SWIVEL ELBOW
24 4 952172 FITTING 1/4 NPTM STRAIGHT
25 2 952086 FITTING 1/4 NPTM SWIVEL ELBOW
26 2 952084 FITTING 1/4 NPTM SWIVEL TEE
27 1 21897 VALVE CHECK ASSEMBLY
28 1 44151300 COUPLING PIPE BND 1/8 BRS

127
SECTION 8 REPLACEMENT PARTS

35,38 34 45 40
32
37 33

33 34 35

34

35, 46
39 33
32
41
36, 35 35, 45
46
44
40 34
35 35, 46
48 42 35, 45 46 47 34 35, 46
DETAIL 'B'
DETAIL 'C'
43
43

37
34
31

Figure 8-3. Flow Control Box, P/N 37416 (Inlet and Outlet Manifold As-
semblies)
Item Qty. Part Circuit
No. Req. No. Description Symbol

31 1 35867 BLOCK INLET MANIFOLD

32 2 21897 VALVE CHECK
33 7 44151300 COUPLING PIPE BND 1/8 BRS
34 8 952087 FITTING 1/8NPTM SWIVEL ELBOW
35 14 67100030 NIPPLE PIPE 1/8 x .75 LG
36 3 950390 TEE BRASS 1/8 NPTF
37 2 952083 FITTING 1/8 NPTM STRAIGHT
38 1 952697 VALVE SOLENOID 3 WAY SOL1
39 1 11Z93 ADAPTOR B/ACET M 1/8NPTM
40 6 21711 GAUGE 1.50 160 PSI
41 1 08030281 ADAPTOR B/I-G F 1/8NPTM
42 1 952202 ADAPTOR B/OXY M 1/8 NPTM
43 3 951982 SWITCH PRESSURE 10 - 100PSI PS1, 2, 3
44 1 35868 BLOCK OUTLET MANIFOLD
45 5 92140024 ELBOW PIPE ST 90° 1/8 BRS
46 5 952703 VALVE SOLENOID SOL2, 3, 4, 5, 6
47 1 952085 FITTING 1/8 NPTM SWIVEL TEE
48 1 672528 SPACER .26 ID x .380 x 1.50 LG STL

128
SECTION 8 REPLACEMENT PARTS

PLASTIC TUBING, .250 OD x .040 WALL (TYP.)

90858003 (14.5' TOTAL)

Figure 8-4. Flow Control Box, Tubing Network

TUBING 90858003

FROM TO LENGTH
FM1(OUT) NV1(IN) 10.50
FM4(OUT) NV4(IN) 10.50
FM2(OUT)R NV2(IN) 12.50
FM3(OUT)L NV5(IN) 12.50
FM1(IN) O2 (OUT)BOT 8.00
FM2(IN) N2 (OUT)TOP 8.00
FM3(IN) N2 (OUT)BOT 8.00
FM4(IN) SOL1 01 10.50
FM2(OUT)L NV3(IN) 10.50
FM3(OUT)R NV6(IN) 8.00
NV6(OUT) SOL6 01 12.50
NV3(OUT) SOL4 01 10.50
NV1 OUT) SOL3 01 12.50
NV2(OUT) SOL2 01 12.50
NV5(OUT) SOL5 01 10.50
NV4(OUT), SOL5 01 10.50
02(OUT) SOL1 03 6.00

129
SECTION 8 REPLACEMENT PARTS

67
66
68

74

65

80

64

71

72

73

WORK

61
62
63
75

76

Figure 8-5. Junction Box, P/N 37400 (Inlet View)

ITEM QTY PART CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

61 1 6271128 CONN. BOX RECPT. 14MP SHELL 20 J1

62 1 11Z93 ADAPTOR B/FG M X 1/8 NPTM SPEC
63 1 11Z62 ADAPTOR B/OXYM X 1/8 NPTM SPEC
64 1 674969 PCB FILTER ASS'Y PCB1
65 1 677905 SPARK GAP ASS'Y SG1
66 1 37250 TRANSFORMER H.F. AUTO T1
67 1 37387 BUSBAR TORCH CABLE
68 1 951188 LOCKNUT CONDUIT 2 NPT
69 1 37386 COVER KYDEX (NOT SHOWN)
70 1 HOSE FEED THROUGH
71 1 37385 BAFFLE KYDEX
72 1 37391 BULKHEAD 1/8 NPTF LHX 1/4 NPTF LH
73 1 2062119 CONN 9 POS AMP J2
74 1 37392 BULKHEAD 1/4 NPTF LH X 1/4 NPTM
75 1 993426 GROMMET RUBBER 1.5 ID X 1.75 OD
76 1 23610197 PLUG HOLE .875DH .125 CT NYBLK
77 1 32288 CABINET JUNCTION BOX SCREENED
78 1 35861 COVER JUNCTION BOX HINGED
79 1 37384 BASE KYDEX JUNCTION BOX
80 1 950256 CAP MICA .002 mf 10KWV

130
SECTION 8 REPLACEMENT PARTS

84
85
GND 84
83

89

86

87

81

82

86

88

Figure 8-6. Junction Box (Outlet View)

ITEM QTY PART CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

81 1 952697 VALVE SOLENOID 3-WAY SOL1

82 1 952083 CONNECTOR MALE 1/8 NPT
83 1 37382 MANIFOLD
84 2 21711 GAUGE 1.50 160 PSI
85 4 22364 COUPLING 1/8 FLOW 1/4 NPT
86 2 951982 SWITCH PRESSURE 10 - 100 PSI PS1, 2
87 1 37388 BUSBAR PILOT ARC
88 1 37361 TORCH CONNECTION SHIELD
89 1 951179 HV TRANSFORMER T2

131
SECTION 8 REPLACEMENT PARTS

START CUT

SHIELD 1 SHIELD 2

COM/COM
COM/COM 408
SHIELD2
SHIELD1
CUT
START

403 407
SIL 405 406
BLU YEL

404 404
ORN ORN

402 401 401 405 406 401

BLU YEL
SHIELD 1 SHIELD 2
START GAS CUT GAS
SHIELD GAS SOLENOIDS SOLENOID SOLENOID

Figure 8-9A. SOLENOID ASSEMBLY, PT-24, P/N 22376

ITEM QTY PART CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

401 3 952697 SOLENOID 3-WAY

402 1 952703 SOLENOID 2-WAY
403 1 22364 CONNECTOR QUICK DISCONNECT SILVER
404 2 22365 CONNECTOR QUICK DISCONNECT ORANGE
405 2 22366 CONNECTOR QUICK DISCONNECT BLUE
406 2 22367 CONNECTOR QUICK DISCONNECT YELLOW
407 1 952931 PLUG BLOCK 6 POS
408 1 593985 O-RING 1.42 ID X .103 NEOP 70A

132
SECTION 8 REPLACEMENT PARTS

1 2
3

Relay 24 VAC Common

1 2 3 4 5 6 7 8

Shield 2 and Relay NC

Plasma 1 and 2 Common Solenoid
Shield 1 and 2 Common and
Shield 1 and 2 Relay 24VAC Relay
Relay NC Wires
Plasma 2
Plasma 1
5
4

6 7

Figure 8-9B. T GAS SHUT-OFF VALVE, PT-24, P/N 0558001335

ITEM QTY PART CIRCUIT

NO. REQ. NO. DESCRIPTION SYMBOL

1 2 0558001458 SOLENOID 3-WAY

2 2 9852921 SOLENOID 2-WAY
3 1 0558001502 FLANGE
4 2 593986 O-RING 1.42 ID X .103 NEOP 70A
5 2 REF PLUG CONNECTOR, 8 POSITION
6 2 REF PLUG, 8 POSITION
7 1 REF RELAY

133
 20

13
9
10

5
6
8

24
11

22
12

15

20
29

21

27
1

2
26

23
14

25

7
3

NOTE:
Torch is supplied with 70 amp
consumables assembled in place.
Table 8-9. Precision Plasma PT-24 Torch Assembly

ITEM PART OR
NO. QTY CODE NO. DESCRIPTION

1 1 21758 BODY & TUBE AY PT-24 TORCH

2 1 22568 SLEEVE TORCH PT-24
3 1 21761 POWER CABLE 4.5FT (1,4m) PT-24
1 22424 POWER CABLE 12FT (3,7m) PT-24
1 22398 POWER CABLE 17FT (5,2m) PT-24
4 1 21762 CABLE PILOT ARC 4.5FT (1,4m) PT-24
1 22425 CABLE PILOT ARC 12FT (3,7m) PT-24
1 22396 CABLE PILOT ARC 17FT (5,2m) PT-24
5 1 22381 GAS LINE START (BLU)
6 1 22380 GAS LINE CUT (YEL)
7 1 REF SHROUD SHIELDING PT-24
8 1 21539 ELECTRODE
9 1 21692 SWIRL BAFFLE 50/70 AMP
10 1 21543 NOZZLE
11 1 22007 RETAINER/DIFFUSER NOZZLE PT-24
12 1 22010 INSULATOR SHIELD CUP PT-24
13 1 21712 SHIELD RETAINER
14 1 77500101 LUB GREASE DOW DC-111
15 1 21765 TOOL ELECTRODE & NOZZLE PT-24
20 1 22531 CUP SHIELD PT-24
21 1 22376 T SHUT-OFF GAS VALVE ASS'Y (See Fig. 8-9B)
22 1 22375 PROTECTOR GORTIFLEX SENSOR 7IN LG
23 1 2234133 CLAMP WORM DRIVE
24 1 22382 GASLINE SHIELD (ORN)
25 1 22378 CABLE SOLENOID 4.5FT (1,4m) PT-24
1 22427 CABLE SOLENOID 12FT (3,7m) PT-24
1 22389 CABLE SOLENOID 17FT (5,2m) PT-24
26 1 37663 GAS TUBING ASS'Y QUICK DISC 4.5FT (1,4m) PT-24
1 0558001878 GAS TUBING ASS'Y QUICK DISC 12FT (3,7m) PT-24
1 37664 GAS TUBING ASS'Y QUICK DISC 17FT (5,2m) PT-24
27 1 951168 CLAMP BAND-IT
29 1 8996565 CLAMP HOSE

NOT SHOWN -- CABLE BUNDLE, INCLUDES ITEMS 3,4,25, AND 26

30 1 0558001503 CABLE ASSEMBLY BUNDLE 4.5FT (1,4m) PT-24

1 0558001876 CABLE ASSEMBLY BUNDLE 12FT (3,7m) PT-24
1 0558001504 CABLE ASSEMBLY BUNDLE 17FT (5,2m) PT-24
 ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

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Telephone: (800) 235-4012/ Fax: (888) 586-4670

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Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
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F-15-800 03/03