pt-600 mechanized plasma cutting torch

F-15-646 October, 2011

Installation, Operation, and Maintenance for the

PT-600 Mechanized Plasma Cutting Torch

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 F15646 November 2001 updated spare parts June 2002 boot part number changed Dec 2002 Added no underwater cut with H-35 tp process data

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, 2000

Printed in U.S.A.

DECLARATION OF CONFORMITY according to the EC Low Voltage Directive 73/23/EEC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE enligt lågspänningsdirektivet 73/23/EEG

Fill in and put a cross in appropriate boxes Fyll i och kryssa tillämpliga rutor Type of equipment Materialslag Plasma Cutting Torch Brand name or trade mark Fabrikatnamn eller varumärke ESAB Type designation etc. Typbeteckning etc. PT-600 AY, (8)0558001827, (8)0558001828, (8)0558001829, (8)0558001830, (8)0558001831, (8)0558001832, (8)0558001833, Manufacturer’s name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB Welding & Cutting Products 411 South Ebenezer Road, Florence, South Carolina 29501, USA Phone: +1 843 669 4411, Fax: +1 843 664 4258 Manufacturer’s authorised representative established within the EEA; Name, address, telephone No, telefax No: Tillverkarens representant inom EES; Namn, adress, telefon, telefax: ESAB AB Box 8004, 402 77 Göteborg, Sweden Phone: +46 31 50 90 00, Fax: +46 31 50 92 61 The following harmonised standards or technical specifications (designations) which comply with good engineeringpractice in safety matters in force within the EEA have been used in the design: Följande harmoniserande standarder eller tekniska specifikationer (beteckningar) som uppfyller god säkerhetsteknisk praxis inom EES har använts i konstruktionen: EN 60 974-7 Arc welding equipment - Part 7: Torches

1. The equipment conforms completely, with the above stated harmonised standards or technical specifications. Materielen överensstämmer helt med ovan angivna harmoniserade standarder eller tekniska specifikationer.

OR ELLER

2. The equipment conforms only partially with the above stated harmonised standards or technical specifications but complies with good engineering practice in safety matters in force within the EEA. Materielen överensstämmer endast delvis med ovan angivna harmoniserade standarder eller tekniska specifikationer men uppfyller god säkerhetsteknisk praxis inom EES.

Additional information Övriga uppgifter

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above. Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Manufacturer Tillverkare

Or Manufacturer’s authorised representative eller Tillverkarens representant

Date Datum Göteborg 2003-01-10

Signature Underskrift

Position Befattning

Managing Director

Clarification namnförtydligande

Henry Selenius

PT-600 Plasma Cutting Torch Table of Contents

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Page

Section 1 Safety

1.1 Introduction 1

1.2 Safety Notations And Symbols 1

1.3 General Safety Information 2

1.4 Electrical Grounding 3

1.5 Operating A Plasma Cutting Machine 4

1.6 Service Precautions 8

1.7 Safety References 10

Section 2 Description

2.1 General 1

2.2 Scope 1

2.3 Package Options Available 1

2.4 Technical Specifications

2.4.1 Plasma Gas 2

2.4.2 Start Gas 2

2.4.3 Secondary Gas 2

2.4.4 PT-600 Torch 2

2.5 Parts Kits

2.5.1 Starter Kit 3

2.5.2 Spare Parts Kit 4

Section 3 Installation 3.1 General 1

3.2 Connection of Hose and Cable Bundle to Torch Body 1

3.3 Disassembly of Torch Bundle from Torch Body 3

3.4 Torch Mounting “Precaution” 4


ii

Page

Section 4 Operation

Safety Precautions 1

4.1 Set Up 2

4.1.1 Mirror Cutting Requirements 2

4.2 Cut Quality 3

4.2.1 Introduction 3

4.2.2 Cut Angle 3

4.2.3 Cut Flatness 4

4.2.4 Surface Finish 5

4.2.5 Dross 6

4.2.6 Dimensional Accuracy 7

4.3 Torch Flow Passages 8

4.4 Influence of Gas Options on Cut Quality


4.4.2 Aluminum 10

4.4.3 Carbon Steel 11

4.4.4 Stainless Steel 12

4.5 Process Data


4.5.2 Process Data Settings

Carbon Steel 14

Aluminum 34

Stainless Steel 66

Section 5 Maintenance

5.1 Introduction 1

5.2 Torch Body 1

5.3 Torch Front End Disassembly 2

5.4 Front End Assembly 5


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Page

Section 6 Troubleshooting

6.1 Reduced Consumable Life 1

6.2 No Pilot Arc 2

6.3 No Arc Transfer 2

6.4 No Preflow Plasma 2

6.5 No Preflow Shield 2

6.6 Torch Fails To Fire 3

6.7 No High Frequency in Torch 3

Section 7 Replacement Parts

7.1 General 1

7.2 Ordering 1

7.3 PT-600 Torch Front End 2

7.4 Hoses and Cables 4

7.5 Complete Assemblies and Tools 6

7.6 Parts Kits 8

Customer/Technical Information Back Manual Cover


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SECTION 1 SAFETY

1-1

DANGER!

WARNING!

CAUTION!

CAUTION

NOTICE

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.

1.2 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 in concurrence with other symbols and information.

Used to call attention to immediate hazards which, if not avoided, will result in serious personal injury or loss of life.

Used to call attention to potential hazards that could result in personal injury or loss of life.

Used to call attention to hazards that could result in minor personal injury or equipment damage.

Used to call attention to minor hazards to equipment.

Used to call attention to important installation, operation or maintenance information not directly related to safety hazards.

SECTION 1 SAFETY

1-2

1.3 General Safety Information

WARNING!

Cutting Machine starts automatically.

This torch may be mounted on a mechanized cutting This torch may be mounted on a mechanized cutting This torch may be mounted on a mechanized cutting This torch may be mounted on a mechanized cutting machine. This equipment moves in various directions machine. This equipment moves in various directions machine. This equipment moves in various directions machine. This equipment moves in various directions and speeds and may start automatically.and speeds and may start automatically.and speeds and may start automatically.and speeds and may start automatically.

• Moving machinery can crush.Moving machinery can crush.Moving machinery can crush.Moving machinery can crush.

• Only qualified personnel should oOnly qualified personnel should oOnly qualified personnel should oOnly qualified personnel should operate or service perate or service perate or service perate or service equipment.equipment.equipment.equipment.

• Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not Keep all personnel, materials, and equipment not involved in production process clear of entire involved in production process clear of entire involved in production process clear of entire involved in production process clear of entire system area.system area.system area.system area.

• Keep gear racks and rails clear of debris or Keep gear racks and rails clear of debris or Keep gear racks and rails clear of debris or Keep gear racks and rails clear of debris or obstructions, such as tools or clothing.obstructions, such as tools or clothing.obstructions, such as tools or clothing.obstructions, such as tools or clothing.

• Fence off entire work cell to prFence off entire work cell to prFence off entire work cell to prFence off entire work cell to prevent personnel event personnel event personnel event personnel from passing through area or standing in the from passing through area or standing in the from passing through area or standing in the from passing through area or standing in the working envelope of the equipment. working envelope of the equipment. working envelope of the equipment. working envelope of the equipment.

• Post appropriate WARNING signs at every work Post appropriate WARNING signs at every work Post appropriate WARNING signs at every work Post appropriate WARNING signs at every work cell entrance. cell entrance. cell entrance. cell entrance.

• Follow lockout procedure before servicing.Follow lockout procedure before servicing.Follow lockout procedure before servicing.Follow lockout procedure before servicing.

WARNING!

Failure to follow operating instructions could result in death or serious injury.

Read and understand this operator’s manual before Read and understand this operator’s manual before Read and understand this operator’s manual before Read and understand this operator’s manual before using machine.using machine.using machine.using machine.

• Read entire procedure before operating or Read entire procedure before operating or Read entire procedure before operating or Read entire procedure before operating or performing any system maintenance. performing any system maintenance. performing any system maintenance. performing any system maintenance.

• Special attention must be given to allSpecial attention must be given to allSpecial attention must be given to allSpecial attention must be given to all hazard hazard hazard hazard warnings that provide essential information warnings that provide essential information warnings that provide essential information warnings that provide essential information regarding personnel safety and/or possible regarding personnel safety and/or possible regarding personnel safety and/or possible regarding personnel safety and/or possible equipment damage.equipment damage.equipment damage.equipment damage.

• All safety precautions relevant to electrical All safety precautions relevant to electrical All safety precautions relevant to electrical All safety precautions relevant to electrical equipment and process operations must be equipment and process operations must be equipment and process operations must be equipment and process operations must be strictly observed by all having system strictly observed by all having system strictly observed by all having system strictly observed by all having system responsibility orresponsibility orresponsibility orresponsibility or access. access. access. access.

• Read all safety publications made available by Read all safety publications made available by Read all safety publications made available by Read all safety publications made available by your company.your company.your company.your company.

SECTION 1 SAFETY

1-3

WARNING!

Failure to follow safety warning label instructions could result in death or serious injury.

Read and understand all safety warning labelRead and understand all safety warning labelRead and understand all safety warning labelRead and understand all safety warning labels on s on s on s on machine.machine.machine.machine.

Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety Refer to operator’s manual for additional safety information.information.information.information.

1.4 Electrical Grounding

Electrical grounding is imperative for proper machine operation and SAFETY. Refer to your power source manual’s Installation section for detailed grounding instructions.

WARNING!

Electric shock hazard.

Improper grounding can cause severe injury or deImproper grounding can cause severe injury or deImproper grounding can cause severe injury or deImproper grounding can cause severe injury or death.ath.ath.ath.

Machine must be properly grounded before put into Machine must be properly grounded before put into Machine must be properly grounded before put into Machine must be properly grounded before put into service.service.service.service.

WARNING!

Improper grounding can damage machine and electrical components.

• Machine must be properly grounded before put Machine must be properly grounded before put Machine must be properly grounded before put Machine must be properly grounded before put into service. into service. into service. into service.

• Cutting table must be properly grounded toCutting table must be properly grounded toCutting table must be properly grounded toCutting table must be properly grounded to a good a good a good a good earth ground rod.earth ground rod.earth ground rod.earth ground rod.

SECTION 1 SAFETY

1-4

1.5 Operating A Plasma Cutting Machine

WARNING!

Flying debris and loud noise hazards.

• Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear Hot spatter can burn and injure eyes. Wear goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying goggles to protect eyes from burns and flying debris generated durdebris generated durdebris generated durdebris generated during operation.ing operation.ing operation.ing operation.

• Chipped slag may be hot and fly far. Bystanders Chipped slag may be hot and fly far. Bystanders Chipped slag may be hot and fly far. Bystanders Chipped slag may be hot and fly far. Bystanders should also wear goggles and safety glasses.should also wear goggles and safety glasses.should also wear goggles and safety glasses.should also wear goggles and safety glasses.

• From plasma arc can damage hearing. Wear From plasma arc can damage hearing. Wear From plasma arc can damage hearing. Wear From plasma arc can damage hearing. Wear correct ear protection when cutting above water. correct ear protection when cutting above water. correct ear protection when cutting above water. correct ear protection when cutting above water.

WARNING! Burn hazard.

Hot metal can burn.Hot metal can burn.Hot metal can burn.Hot metal can burn.

• Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after Do not touch metal plate or parts immediately after cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with cutting. Allow metal time to cool, or douse with water.water.water.water.

• Do not touchDo not touchDo not touchDo not touch plasma torch immediately after plasma torch immediately after plasma torch immediately after plasma torch immediately after cutting. Allow torch time to cool.cutting. Allow torch time to cool.cutting. Allow torch time to cool.cutting. Allow torch time to cool.

WARNING! Hazardous voltages. Electric shock can kill.

• Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable Do NOT touch plasma torch, cutting table or cable connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.connections during plasma cutting process.

• Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies before touching or servicing plasma torch. before touching or servicing plasma torch. before touching or servicing plasma torch. before touching or servicing plasma torch.

• Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies Always turn power off to plasma power supplies before openbefore openbefore openbefore opening or servicing plasma plumbing or ing or servicing plasma plumbing or ing or servicing plasma plumbing or ing or servicing plasma plumbing or flow control box.flow control box.flow control box.flow control box.

• Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.Do not touch live electrical parts.

• Keep all panels and covers in place when machine Keep all panels and covers in place when machine Keep all panels and covers in place when machine Keep all panels and covers in place when machine is connected to power source.is connected to power source.is connected to power source.is connected to power source.

• Insulate yourself from workpiece and electrical Insulate yourself from workpiece and electrical Insulate yourself from workpiece and electrical Insulate yourself from workpiece and electrical ground: wear insulating gloves, shoes aground: wear insulating gloves, shoes aground: wear insulating gloves, shoes aground: wear insulating gloves, shoes and nd nd nd clothing.clothing.clothing.clothing.

• Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and Keep gloves, shoes, clothing, work area, and equipment dry.equipment dry.equipment dry.equipment dry.

SECTION 1 SAFETY

1-5

WARNING! Pinch hazard.

Moving verMoving verMoving verMoving vertical slides can crush or pinch.tical slides can crush or pinch.tical slides can crush or pinch.tical slides can crush or pinch.

Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.Keep hands clear of torch and slide during operation.

WARNING!Fume hazard.

Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting Fumes and gases generated by the plasma cutting process can be hazardous to your health.process can be hazardous to your health.process can be hazardous to your health.process can be hazardous to your health.

• Do NOT breathe fumes.Do NOT breathe fumes.Do NOT breathe fumes.Do NOT breathe fumes.

• Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal Do not operate plasma torch without fume removal system operating properly. system operating properly. system operating properly. system operating properly.

• Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if Use additional ventilation to remove fumes if necessary.necessary.necessary.necessary.

• Use apprUse apprUse apprUse approved respirator if ventilation is not oved respirator if ventilation is not oved respirator if ventilation is not oved respirator if ventilation is not adequate.adequate.adequate.adequate.

SECTION 1 SAFETY

1-6

WARNING!

WARNING! Radiation hazard.

Arc rays can injure eyes and burArc rays can injure eyes and burArc rays can injure eyes and burArc rays can injure eyes and burn skin.n skin.n skin.n skin.

• Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.Wear correct eye and body protection.

• Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side Wear dark safety glasses or goggles with side shields. Refer to following chart for recommended shields. Refer to following chart for recommended shields. Refer to following chart for recommended shields. Refer to following chart for recommended lens shades for plasma cutting:lens shades for plasma cutting:lens shades for plasma cutting:lens shades for plasma cutting:

Arc CurrentArc CurrentArc CurrentArc Current Lens Shade Lens Shade Lens Shade Lens Shade Up to 100 AmpsUp to 100 AmpsUp to 100 AmpsUp to 100 Amps Shade No. 8Shade No. 8Shade No. 8Shade No. 8 100100100100----200 Amps200 Amps200 Amps200 Amps ShadShadShadShade No. 10e No. 10e No. 10e No. 10 200200200200----400 Amps400 Amps400 Amps400 Amps Shade No. 12Shade No. 12Shade No. 12Shade No. 12 Over 400 AmpsOver 400 AmpsOver 400 AmpsOver 400 Amps Shade No. 14Shade No. 14Shade No. 14Shade No. 14

• Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or Replace glasses/goggles when lenses are pitted or brokenbrokenbrokenbroken

• Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc Warn others in area not to look directly at the arc unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.unless wearing appropriate safety glasses.

• Prepare cutting area to reduce reflectioPrepare cutting area to reduce reflectioPrepare cutting area to reduce reflectioPrepare cutting area to reduce reflection and n and n and n and transmission of ultraviolet light.transmission of ultraviolet light.transmission of ultraviolet light.transmission of ultraviolet light.

• Paint walls and other surfaces with dark colors to Paint walls and other surfaces with dark colors to Paint walls and other surfaces with dark colors to Paint walls and other surfaces with dark colors to reduce reflections.reduce reflections.reduce reflections.reduce reflections.

• Install protective screens or curtains to reduce Install protective screens or curtains to reduce Install protective screens or curtains to reduce Install protective screens or curtains to reduce ultraviolet transmission.ultraviolet transmission.ultraviolet transmission.ultraviolet transmission.

Ruptured Gas Cylinders Can Kill

Mishandling gas cylinders can Mishandling gas cylinders can Mishandling gas cylinders can Mishandling gas cylinders can rupture and violently rupture and violently rupture and violently rupture and violently release gas. release gas. release gas. release gas.

• Avoid rough handling of cylinders.Avoid rough handling of cylinders.Avoid rough handling of cylinders.Avoid rough handling of cylinders.

• Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.Keep cylinder valves closed when not in use.

• Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.Maintain hoses and fittings in good condition.

• Always secure cylinders in an upright position by Always secure cylinders in an upright position by Always secure cylinders in an upright position by Always secure cylinders in an upright position by chain or strap to a suitable stable objectchain or strap to a suitable stable objectchain or strap to a suitable stable objectchain or strap to a suitable stable object not part of not part of not part of not part of an electrical circuit.an electrical circuit.an electrical circuit.an electrical circuit.

• Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and Locate cylinders away from heat, sparks and flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.flames. Never strike an arc on a cylinder.

• Refer to CGA Standard PRefer to CGA Standard PRefer to CGA Standard PRefer to CGA Standard P----1, “Precautions for Safe 1, “Precautions for Safe 1, “Precautions for Safe 1, “Precautions for Safe Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”, Handling of Compressed Gases in Cylinders”, available from Compressed Gas Associatiavailable from Compressed Gas Associatiavailable from Compressed Gas Associatiavailable from Compressed Gas Association.on.on.on.

SECTION 1 SAFETY

1-7

WARNING! Spark hazard.

Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns. Heat, spatter, and sparks cause fire and burns.

• Do not cut near combustible matDo not cut near combustible matDo not cut near combustible matDo not cut near combustible material.erial.erial.erial.

• Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.Do not cut containers that have held combustibles.

• Do not have on your person any combustibles (e.g. Do not have on your person any combustibles (e.g. Do not have on your person any combustibles (e.g. Do not have on your person any combustibles (e.g. butane lighter).butane lighter).butane lighter).butane lighter).

• Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle Pilot arc can cause burns. Keep torch nozzle away from yourself and others when activating away from yourself and others when activating away from yourself and others when activating away from yourself and others when activating plasma process.plasma process.plasma process.plasma process.

• Wear correct eye and boWear correct eye and boWear correct eye and boWear correct eye and body protection.dy protection.dy protection.dy protection.

• Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.Wear gauntlet gloves, safety shoes and hat.

• Wear flameWear flameWear flameWear flame----retardant clothing that covers all retardant clothing that covers all retardant clothing that covers all retardant clothing that covers all exposed areas.exposed areas.exposed areas.exposed areas.

• Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks Wear cuffless trousers to prevent entry of sparks and slag.and slag.and slag.and slag.

WARNING! Explosion hazard.

Certain molten aluminumCertain molten aluminumCertain molten aluminumCertain molten aluminum----lithium (Allithium (Allithium (Allithium (Al----Li) alloys can Li) alloys can Li) alloys can Li) alloys can cause explosions when plasma cut with water. cause explosions when plasma cut with water. cause explosions when plasma cut with water. cause explosions when plasma cut with water.

Do not plasma cut the following AlDo not plasma cut the following AlDo not plasma cut the following AlDo not plasma cut the following Al----Li alloys with Li alloys with Li alloys with Li alloys with water:water:water:water:

Alithlite (Alcoa)Alithlite (Alcoa)Alithlite (Alcoa)Alithlite (Alcoa) X8192 (Alcoa)X8192 (Alcoa)X8192 (Alcoa)X8192 (Alcoa) Alithally (Alcoa)Alithally (Alcoa)Alithally (Alcoa)Alithally (Alcoa) Navalite (US Navy)Navalite (US Navy)Navalite (US Navy)Navalite (US Navy) 2090 Alloy (Alcoa)2090 Alloy (Alcoa)2090 Alloy (Alcoa)2090 Alloy (Alcoa) Lockalite (Lockheed)Lockalite (Lockheed)Lockalite (Lockheed)Lockalite (Lockheed) X8090A (Alcoa)X8090A (Alcoa)X8090A (Alcoa)X8090A (Alcoa) Kalite (Kaiser)Kalite (Kaiser)Kalite (Kaiser)Kalite (Kaiser) X8092 (Alcoa)X8092 (Alcoa)X8092 (Alcoa)X8092 (Alcoa) 8091 (Alcan)8091 (Alcan)8091 (Alcan)8091 (Alcan)

• These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.These alloys should only be dry cut on a dry table.

• DO NOT dry cut over water.DO NOT dry cut over water.DO NOT dry cut over water.DO NOT dry cut over water.

• Contact yoContact yoContact yoContact your aluminum supplier for additional ur aluminum supplier for additional ur aluminum supplier for additional ur aluminum supplier for additional safety information regarding hazards associated safety information regarding hazards associated safety information regarding hazards associated safety information regarding hazards associated with these alloyswith these alloyswith these alloyswith these alloys.

SECTION 1 SAFETY

1-8

DANGER!

Hydrogen explosion hazard.

• Do not cut under water with Hydrogen gas!

• Hydrogen explosions can cause personal injury or death.

• Hydrogen can create explosive gas pockets in the water table. These pockets will explode when ignited by sparks or the plasma arc.

• Before cutting, be aware of possible hydrogen sources in the water table – molten metal reaction, slow chemical reaction and some plasma gases.

• Explosive gas pockets accumulate underneath the cutting plate and inside the water table.

• Clean slag (especially fine particles) from bottom of table frequently. Refill table with clean water.

• Do not leave plate on table overnight.

• If water table has not been used for several hours, vibrate or jolt it to break up hydrogen pockets before laying plate on the table.

• If possible, change water level between cuts to break up hydrogen pockets.

• Maintain water pH level near 7 (neutral).

• Programmed part spacing should be a minimum of twice the kerf width to ensure material is always under the kerf.

• When cutting above water, use fans to circulate air between plate and water surface.

1.6 Service Precautions

CAUTION Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A Establish and adhere to preventive maintenance. A ccccomposite program can be established from omposite program can be established from omposite program can be established from omposite program can be established from recommended schedules in the instruction literature.recommended schedules in the instruction literature.recommended schedules in the instruction literature.recommended schedules in the instruction literature.

Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on Avoid leaving test equipment or hand tools on machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage machine. Severe electrical or mechanical damage could occur to equipment or machine.could occur to equipment or machine.could occur to equipment or machine.could occur to equipment or machine.

SECTION 1 SAFETY

1-9

CAUTION! Extreme caution should Extreme caution should Extreme caution should Extreme caution should be used when probing be used when probing be used when probing be used when probing circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuitry with an oscilloscope or voltmeter. Integrated circuits are susceptible to over voltage damage. circuits are susceptible to over voltage damage. circuits are susceptible to over voltage damage. circuits are susceptible to over voltage damage. Power off before using test probes to prevent Power off before using test probes to prevent Power off before using test probes to prevent Power off before using test probes to prevent accidental shorting of components.accidental shorting of components.accidental shorting of components.accidental shorting of components.

All circuit boards securely seated in sockets, All circuit boards securely seated in sockets, All circuit boards securely seated in sockets, All circuit boards securely seated in sockets, all cables all cables all cables all cables properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all properly connected, all cabinets closed and locked, all guards and covers replaced before power is turned guards and covers replaced before power is turned guards and covers replaced before power is turned guards and covers replaced before power is turned on.on.on.on.

Never plug or unplug a printed circuit board while Never plug or unplug a printed circuit board while Never plug or unplug a printed circuit board while Never plug or unplug a printed circuit board while machine power is on. Instantaneous surges of voltage machine power is on. Instantaneous surges of voltage machine power is on. Instantaneous surges of voltage machine power is on. Instantaneous surges of voltage and current can damage electroand current can damage electroand current can damage electroand current can damage electronic components.nic components.nic components.nic components.

SECTION 1 SAFETY

1-10

1.7 Safety References

The following nationally 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.

• “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.

NOTES: • Control lead from the power source to customer CNC is supplied based on customer order. • See Replacement Parts for assembly components.• See Process Data Sheets for a list of front-end torch consumable parts.• See end of section or replacement parts for information on torch part kits.

Torch For Mini-Bevel Head 12 ft (3.7 m) lead 12 ft. (3.7 m) 0560935685

Torch For Mini-Bevel Head 14 ft (4.3 m) lead 14 ft. (4.3 m) 0558005850

Torch Assemblies 4.5 ft. (1,3 m) 0558001827

6 ft. (1,8 m) 0558001828

7.2 ft. (2,2 m) 0558004123

12 ft. (3,7 m) 0558001829

15 ft. (4,6 m) 0558001830

17 ft. (5,2 m) 0558001831

20 ft. (6,1 m) 0558001832

25 ft. (7,6 m) 0558001833

2.3 Package Options Available

PT-600 package options available through your ESAB dealer, see section 7 for replacement component part numbers.

2.2 Scope

The purpose of this manual is to provide the operator with all the information required to install and operate the PT-600 Mecha-nized Plasma Cutting Torch. Technical reference material is also provided to assist in troubleshooting the cutting package.

2.1 General

The PT-600 Mechanized Plasma Cutting Torch is a plasma arc torch factory assembled to provide torch component concentric-ity and consistent cutting accuracy. For this reason, the torch body can not be rebuilt in the Only the torch front-end has replaceable parts.

SECTION 2 DESCRIPTION

2-1

Torch For Mini-Bevel Head 14 ft (4.3 m) lead 14 ft. (4.3 m) 0558007580( Karben - Replacement Parts 7.8 )

Technical Speci�cations


2-2

2.4 PT-600 Technical Specifications

2.4.1 Plasma Gas Technical Specifications

Type O2, N2, Air, H-35

Pressure 100 to 125 psig (6,9 – 8,6 bars)

Flow 250 cfh (118 l/min) max. at 600A (varies with application)

Purity Required*

O2-99.5% N2-99.995% H-35 Specialty gas Air-clean, dry and oil free

Recommended Liquid Cylinder Service Regulators

Oxygen: R-76-150-540LC (P/N 19777) Inert gas: R-76-150-580LC (P/N 19977)

Recommended Cylinder 2-Stage Regulators

Oxygen: R-77-150-540 (P/N 998337 Hydrogen/Methane:R-77-150-350 (P/N 998342) Nitrogen: R-77-150-580 (P/N 998344) Industrial Air: R-77150-590 (P/N 998348)

Recommended Heavy –Duty Hi-flow Station or Pipeline Regulators Oxygen: R-76-150-024 (P/N 19151)

Recommended High-capacity Station or Pipeline Regulators R-6703 (P/N 22236)

Gas Filter Required 25 micron w/bowl guard (P/N 56998133)

2.4.2 Start Gas Technical Specifications

Type N2, Air, H-35

Pressure 100 to 125 psig (6,9 – 8,6 bars)

Flow 250 cfh (118 l/min) max @ 600A (varies with application)

Minimum Purity Required 99.995% clean, dry, oil free

2.4.3 Secondary Gas Technical Specifications

Type N2, Air

Pressure 100 to 125 psig (6.9 – 8,6 bars)

Flow 485 cfh (228,9 l/min) max (varies with application)

Minimum Purity Required 99.995% clean, dry, oil free (Same source as start gas)

Gas Filter Required 25 micron w/bowl guard (P/N 56998133)

2.4.4 PT-600 Torch Technical Specifications

Type Water-Cooled, Dual Gas

Rating 600 amps @ 100 % duty cycle

Dimensions See Package Options (2.3). This section.


2-3

2.5 PT-600 ACCESSORIES / KITS 2.5.1 200A Startup Kits P/N 0558002478 and 0558004907

0558002478 consisting of:

QTY P/N DESCRIPTION 4 0558001624 Electrode O2 1 17672 Lubricant 1 37082 Nozzle Retaining Cup 1 996568 Tool, Nut Driver 1 0558004611 Tool, Electrode Holder 4 0558002499 Electrode PT-19 600A Tungsten 2 0558001881 Nozzle 50A 2 0558001883 Nozzle 150A 2 0558001884 Nozzle 200A 2 0558001882 Nozzle 100A 2 21795 Shield 50A 1 21796 Diffuser 50A 2 21802 Shield 100-250A 2 21944 Diffuser 100-360A 1 37081 Shield Retainer 2 0558002533 Baffle, Gas Swirl 4 639575 O-ring .364 ID x .070 2 996528 O-ring 1.614 ID x .070 1 0558003858 Contact Ring Assembly 1 37073 Contact Ring Screw


QTY P/N DESCRIPTION 5 0558001624UL Electrode, 02 (Ultra-life)

1 17672 Lubricant 1 37082 Nozzle, Retaining Cup

1 996568 Tool, Nut Driver

1 0558004611 Tool, Electrode Holder

1 0558001628 Electrode Holder, PT-600 3 0558001624 Electrode, 250A, PT-600

2 0558002499 Electrode, 600A, PT-600

5 0558005456 Nozzle, 50A, PT-600 5 0558001881 Nozzle, 50A, PT-600

5 0558001882 Nozzle, 100A

5 0558001883 Nozzle, 150-200A 5 0558001884 Nozzle, 200A, PT-600

2 21795 Shield, 50A, PT-19XL

5 0558004678 Shield, 100-200A, EPP 5 21802 Shield, 100-250A, PT-19XL

2 0558005458 Shield, Dia. .120”, PT-600

1 37081 Shield Retainer 2 21944 Diffuser, 100-360A

1 21796 Diffuser, 50A, PT-19XL

2 0558002533 Baffle, Gas Swirl, 4X032P 2 0558005457 Baffle, Gas Swirl, 20-50A

2 996528 O-ring 1.614” ID x .07” Dia.

1 0558003858 Contact Ring Assembly 1 37073 Contact Ring Screw


2-4

2.5.2 Spare Parts Kit P/N 0558002479

Consisting of:

QTY P/N DESCRIPTION 1 17672 Silicone Lubricant 1 0558004611 Electrode Holder Tool 1 996568 Electrode Tip Tool

5 996528 O-rings

2 0558002533 Baffle, 4 hole 2 0558001625 Baffle, 8 hole

1 0558002532 Baffle, 32 hole

1 0558002534 Baffle, 4 hole reverse 1 0558002530 Baffle, 8 hole reverse

1 0558002531 Baffle, 32 hole reverse

5 86W99 O-ring 1 0558001621 Electrode Holder w/O-ring

5 0558001624 Electrode 250 Amp

2 0558002516 Electrode 360/400 Amp 2 0558002499 Electrode, N2, H-35,

5 181W89 Nozzle O-rings

2 0558001881 Nozzle, 50 Amp 2 0558001882 Nozzle, 100 Amp

2 0558001883 Nozzle, 150 Amp


5 0558001885 Nozzle, 360 Amp


1 37082 Nozzle Retaining Clip

1 21796 Gas Diffuser, 50 Amp 1 21944 Gas Diffuser, 100 to 360 Amp

1 22496 Gas Diffuser, 100 to 360 Amp reverse

2 21795 Shield, 50 Amp 5 21802 Shield, 260 Amp

2 21945 Shield, 360 Amp

1 37081 Shield Retainer 1 0558003858 Contact Ring Assembly

1 37073 Contact Ring Screw

SECTION 3 INSTALLATION

3-1

3.1 General

The PT-600 Torch comes with the front-end completely assembled with 250A consumables. Pilot arc cable and hoses may have to be assembled.

3.2 Connection of Hose and Cable Bundle to Torch Body

1. Unscrew the PT-600 torch sleeve and slide it on the torch bundle until the pilot arc connection point is exposed.

NOTE: It will be necessary to slide the outer sleeve NOTE: It will be necessary to slide the outer sleeve NOTE: It will be necessary to slide the outer sleeve NOTE: It will be necessary to slide the outer sleeve of the torch bundle toward the power source to of the torch bundle toward the power source to of the torch bundle toward the power source to of the torch bundle toward the power source to expose the pilot arc connection.expose the pilot arc connection.expose the pilot arc connection.expose the pilot arc connection. 2. Connect the cooling water IN (left-hand threads)

and cooling water OUT (right-hand threads) hoses to torch body. A 1/2" open end wrench is required.

NOTE: Coolant hoses (IN and OUT) are the same NOTE: Coolant hoses (IN and OUT) are the same NOTE: Coolant hoses (IN and OUT) are the same NOTE: Coolant hoses (IN and OUT) are the same part number. The assembly requires two. The part number. The assembly requires two. The part number. The assembly requires two. The part number. The assembly requires two. The hoses are designed with a right hanhoses are designed with a right hanhoses are designed with a right hanhoses are designed with a right hand threaded nut d threaded nut d threaded nut d threaded nut on one end and a left hand threaded nut on the on one end and a left hand threaded nut on the on one end and a left hand threaded nut on the on one end and a left hand threaded nut on the other. Reverse one hose endother. Reverse one hose endother. Reverse one hose endother. Reverse one hose end----forforforfor----end to make the end to make the end to make the end to make the proper connections.proper connections.proper connections.proper connections. NOTE: The cooling water tubes are shorter than the NOTE: The cooling water tubes are shorter than the NOTE: The cooling water tubes are shorter than the NOTE: The cooling water tubes are shorter than the gas tubes.gas tubes.gas tubes.gas tubes. 3. Connect gas fittings. To prevent cross

attachment, the cut gas fitting is smaller in diameter than the shield gas fitting. 7/16" and 1/2" wrenches are needed.

NOTE: It is possible to cross one of the water NOTE: It is possible to cross one of the water NOTE: It is possible to cross one of the water NOTE: It is possible to cross one of the water connections with one of the gas connections. Each connections with one of the gas connections. Each connections with one of the gas connections. Each connections with one of the gas connections. Each water hose has a cable inside for carrying voltage.water hose has a cable inside for carrying voltage.water hose has a cable inside for carrying voltage.water hose has a cable inside for carrying voltage. 4. Insert exposed pilot arc cable into the copper

high frequency connector (H.F.). Tighten set screws using a 1/16" internal hex wrench. (i.e. Allen Wrench)

Cooling Water/Plasma Current Connections

Gas Connections

Pilot Arc Cable

Torch Body

Torch Bundle

Pilot arc connection exposed

Sleeve slid up on torch bundle

Torch Insulator Sleeve


3-2

5. Slide the 0.56" diameter PVC tubing down over the copper HF connector. Secure with PVC electrical tape by wrapping pilot arc cable enough times to prevent the PVC insulator from sliding up.

6. Slide torch sleeve down over pilot arc cable connection and hose fittings. Thread sleeve onto torch body.

Note: If it was necessary to reNote: If it was necessary to reNote: If it was necessary to reNote: If it was necessary to remove the black tape move the black tape move the black tape move the black tape securing the metal braided shield for torch sleeve securing the metal braided shield for torch sleeve securing the metal braided shield for torch sleeve securing the metal braided shield for torch sleeve clearance, replace this tape with electrical grade clearance, replace this tape with electrical grade clearance, replace this tape with electrical grade clearance, replace this tape with electrical grade PVC tape.PVC tape.PVC tape.PVC tape.

Torch

Pilot Arc Connection Insulator

Torch Sleeve

Torch Body

Tape Securing Braided Shield

Torch Bundle


3-3

DANGER!

7. Slide the black rubber torch bundle sleeve down

to the torch sleeve. Stretch the bundle sleeve over the end of the torch sleeve till an over-lap of 1" to 1½" (25mm to 38mm) is achieved.

8. Secure with stainless hose clamp (1.56" I.D. x 2.5" O.D.)

Electric Shock Can Kill!

Disconnect primary power source before servicing torch. Do not touch front-end torch parts (nozzle, shield retaining cup, etc.) without turning primary power off.

3.3 Disassembly of Torch Bundle From Torch Body Reverse assembly order.

1. Loosen hose clamp holding the bundle sleeve.

2. Slide the bundle sleeve up the bundle. It may be necessary to unwrap electrical tape securing braided shield if it interferes with sliding the torch sleeve up the torch bundle.

3. Unscrew torch sleeve and slide it up the torch bundle to expose the pilot arc connection point.

4. Remove electrical tape securing pilot arc connection insulator.

5. Slide pilot arc connection insulator up cable and loosen screws in HF connector.

6. Disconnect hoses.

Torch Bundle Sleeve


3-4

WARNING!

AUTION: CLAMP TORCH ABOVE THIS LAPT-600

PLASMARC TORCH

BELC

3.4 Mounting Torch to Machine Refer to machine manual.

Clamping on Torch Body May Cause

Dangerous Current To Flow Through Machine Chassis.

• Do not mount on stainless steel torch body.

• Torch body is electrically insulated, however high frequency start current may arc through to find a ground.

• Clamping near torch body may result in arcing between body and machine.

• When this arcing occurs, torch body may require non-warranty replacement.

• Damage to machine components may result.

• Clamp only on insulated torch sleeve not less than 1.25" (31.75mm) from the torch end of the sleeve.

DO NOT mount on steel torch body here

Mount torch on insulated sleeve here

SECTION 4 OPERATION

4-1

DANGER!

Electric Shock Can Kill! • Disconnect primary power source before

making any adjustments. • Disconnect primary source before doing

maintenance on system components. • Do not touch front-end torch parts (nozzle,

retaining cup, etc.) without turning primary power off.

WARNING! Radiation hazard.

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.

• Paint walls and other surfaces with dark colors to reduce reflections.

• Install protective screens or curtains to reduce ultraviolet transmission.

SECTION 4 OPERATION

4-2

WARNING!

Oil And Grease Can Burn Violently! • Never use oil or grease on this torch. • Handle torch clean hands only on clean

surface. • Use silicone lubricant only where directed. • Oil and grease are easily ignited and burn

violently in the presence of oxygen under pressure.

4.1 Set Up

• Select an appropriate condition from the process data (SDP File) and install recommended torch front-end parts (nozzle, electrode, etc.) See process data to identify parts and settings.

• Position torch over material at desired start

location. • See Power Source Manual for proper settings. • See Flow Control Manual for gas control

procedures. • See Control and Machine Manuals for startup

procedures.

4.1.1 Mirror Cutting When mirror cutting, a reverse swirl gas baffle and

reverse diffuser are required. These reverse parts will “spin” the gas in the opposite direction, reversing the “good” side of the cut.

Reverse 4 Hole Baffle



0558002534

0558002530

0558002531

Reverse Diffuser 22496

SECTION 4 OPERATION

4-3

4.2 Cut Quality

4.2.1 Introduction

Causes affecting cut quality are interdependent. Changing one variable affects all others. Determining a solution may be difficult. The following guide offers possible solutions to undesirable cutting results. To begin select the most prominent condition:

�� 4.2.2 Cut angle, negative or positive

�� 4.2.3 Cut not flat, rounded or undercut

�� 4.2.4 Surface roughness

�� 4.2.5 Dross

Usually the recommended cutting parameters will give optimal cut quality. Occasionally conditions may vary and slight adjustments will be required. If so:

• Make small incremental adjustments when making corrections.

• Adjust arc voltage in one volt increments, up or down as required.

Adjust cutting speed 5% or less as required, until conditions improve.

NOTICE Before attempting ANY corrections, check cutting variables with the factory recommended settings/consumable part numbers listed in Process Data.

4.2.2 Cut Angle

Negative Cut Angle Top dimension is greater than the bottom.

• Misaligned torch

• Bent or warped material

• Worn or damaged consumables

• Standoff low (arc voltage)

• Cutting speed slow (machine travel rate)

Part Drop

Part

SECTION 4 OPERATION

4-4

Positive Cut Angle Top dimension is less than the bottom dimension.

• Misaligned torch

• Bent or warped material


• High standoff high (arc voltage)

• Cutting speed fast

• Current high or low. (See process data for recommended current level for specific nozzles).

• Wrong secondary gas flow.

4.2.3 Cut Flatness

Top And Bottom Rounded Condition usually occurs when material is 0.25" thick (6,4mm) or less.

• High current for given material thickness (See process data for proper settings).

Part Drop

Part

Part Drop

SECTION 4 OPERATION

4-5

Top Edge Undercut Standoff low (arc voltage)

4.2.4 Surface Finish

Process Induced Roughness Cut face is consistently rough and may be confined to one axis.

• Incorrect shield gas mixture (See process data)


MMMMachine Induced Roughness Can be difficult to distinguish from process induced roughness and is often confined to one axis. Roughness is inconsistent.

• Dirty rails, wheels and/or drive rack/pinion. (Refer to maintenance section in machine owner’s manual).

• Carriage wheel adjustment

or

Machine Induced Roughness

Part Drop

Top View

Cut Face

Process Induced Roughness

SECTION 4 OPERATION

4-6

4.2.5 Dross Dross is a by-product of the cutting process. It is the

undesirable material that remains attached to the part. In most cases, dross can be reduced or eliminated with proper torch and cutting parameter setup. Refer to Process Data.

High Speed Dross

Material weld or rollover on bottom surface along kerf. Difficult to remove. May require grinding or chipping. “S” shaped lag lines.

• Standoff high (arc voltage)


Slow Speed Dross Forms as globules on bottom along kerf. Removes easily.

• Cutting speed slow

Cut Face

Lag Lines

Side View

Rollover

Lag Lines

Cut Face

Globules

Side View

SECTION 4 OPERATION

4-7

Top Dross Appears as splatter on top of material. Usually removes easily.


• Standoff high (arc voltage).

Intermittent Dross Appears on top or bottom along kerf. Non-continuous. Can appear as any kind of dross

• Possible worn consumables

Other Factors Affecting Dross:

• Material temperature

• Heavy mill scale or rust

• High carbon alloys

4.2.6 Dimensional Accuracy

Generally, using the slowest possible speed (within approved levels) will optimize part accuracy. Most material thickness overlap for different voltages. Select consumables to allow a lower arc voltage and slower cutting speed.

NOTICE Recommended cutting speed and arc voltage Recommended cutting speed and arc voltage Recommended cutting speed and arc voltage Recommended cutting speed and arc voltage will will will will give optimal cutting performance.give optimal cutting performance.give optimal cutting performance.give optimal cutting performance. Small incremental adjustments may be needed due to material quality, material temperature and specific alloy. The operator should remember that all cutting variables are interdependent. Changing one setting affects all others and cut quality could deteriorate. Always start at the recommended settings. Before attempting ANY corrections, check cutting variables with the factory recommended settings/ consumable part numbers listed in the process data.

Side View Splatter

Cut Face

SECTION 4 OPERATION

4-8

4.3 Torch Flow Passages

Gas Flow Coolant Water Flow

Plasma Gas

Shield Gas

Coolant Water IN

Coolant Water OUT

SECTION 4 OPERATION

4-9

DANGER!

4.4 Influence of Gas Options Cut Quality 4.4.1 Introduction All gases are not suitable for all situations. Certain

gases assist in cutting specific materials and thickness. The following explains why certain gases are selected and their influence on the finished part. Other influences such as arc voltage and gas flow/pressure are covered in the process data.

Hydrogen explosion hazard.

• Do not cut under water with Hydrogen gas!

• Hydrogen explosions can cause personal injury or death.

• Hydrogen can create explosive gas pockets in the water table. These pockets will explode when ignited by sparks or the plasma arc.

• Before cutting, be aware of possible hydrogen sources in the water table – molten metal reaction, slow chemical reaction and some plasma gases.

• Explosive gas pockets accumulate underneath the cutting plate and inside the water table.

• Clean slag (especially fine particles) from bottom of table frequently. Refill table with clean water.

• Do not leave plate on table overnight.

• If water table has not been used for several hours, vibrate or jolt it to break up hydrogen pockets before laying plate on the table.

• If possible, change water level between cuts to break up hydrogen pockets.

• Maintain water pH level near 7 (neutral).

• Programmed part spacing should be a minimum of twice the kerf width to ensure material is always under the kerf.

• When cutting above water, use fans to circulate air between plate and water surface.

SECTION 4 OPERATION

4-10

4.4.2 Aluminum and Process Gases

Material Thickness: .188 through 1.00 inches

Cut Qualities: Good

Start Gas: Plasma: Shield:

Air Air Air

Discussion: Dark cut face, potential dross, good cut angles


Cut Qualities: Good


N2 H-35 N2

Discussion: Smooth cut face, virtually dross free up to 1.5 in. thick , cut angles slightly larger with top edge rounding


Cut Qualities: Good


N2 H-35 Air

Discussion: Slightly darker cut Face, virtually dross, cut angles slightly larger with top edge rounding

Material Thickness: .625 through 1.5

Cut Qualities: Good


H-35 H-35 Air

Discussion: Slightly darker cut Face, virtually dross, cut angles slightly larger with top edge rounding


Cut Qualities: Good


N2 N2 Air

Discussion: Darker cut face, dross could be formed above 1 in. material, good cut angles, slight top edge rounding.


Cut Qualities: Good


N2 N2 N2

Discussion: Darker cut face, dross could be formed above .75 in. material, good cut angles, slight top edge rounding.

SECTION 4 OPERATION

4-11

4.4.3 Carbon Steel


Cut Qualities: Excellent

Start Gas:Plasma:Shield:

N2 O2 Air

Discussion: Smooth shiny cut face, virtually no dross, good cut angles, sharp top edge

Material Thickness: .062 through .250 inches

Cut Qualities: Good

Start Gas:Plasma:Shield:

Air Air Air

Discussion: Smooth gray cut face, virtually dross free, larger cut angles do to plate thickness, cut speed and cutting amperage.

SECTION 4 OPERATION

4-12

4.4.4 Stainless Steel

Material Thickness: .062 through .750 inches

Cut Qualities: Good


N2 N2 N2

Discussion: Dark cut face, virtually dross free, good cut angles, Beveled on gauge material do to thickness, speed and amperage


Cut Qualities: Good


Air Air Air

Discussion: Dark cut face, virtually dross free, good cut angles, beveled on gauge material do to thickness, speed and amperage

Material Thickness: .250 through 3.000

Cut Qualities: Good


N2 N2 Air

Discussion: Dark cut face, virtually dross free, good cut angles, slight top edge rounding


Cut Qualities: Good


N2 H-35 N2

Discussion: Shiny gold color cut face, virtually dross free up to 1.5 inch material, greater thickness may have dross, cut angle slightly larger do to H-35 plasma gas.

SECTION 4 OPERATION

4-13

NOTICE

NOTICE

4.5 Process Data

4.5.1 Introduction The following information is a result of many hours of testing and is a general guide for setting up and cutting with a PT-600 Mechanized Plasma Arc Torch. The machine’s control manages gas flow using Smart Flow II, a proportional valve flow control system.

In most cases these settings will provide a quality cut. The data contains values for:

�� cutting aluminum, carbon and stainless steel

�� arc voltage (standoff)

�� cutting speed

�� current (amperes)

�� gas flow rates for plasma/shield gas combinations

This same data is contained in SDP files. (See your machine and programming manuals for more information on SDP files.)

Also included is information on consumable part numbers for all possible current settings.

Speed, voltage, kerf, and current can be used any time for a PT-600 torch application. Process data was derived using the Smart Flow II, a programmable gas flow control. This same information is used in creating Vision CNC process control (SDP) files. Only gas flow rates are given for reference when using Smart Flow II. Speed, arc voltage, kerf, and current (amperes) remain applicable when cutting with manual gas regulation systems.

Underwater Cutting Speeds Must Slowed by 10%. As a general rule, above water cutting speeds can be applied to underwater cutting by reducing speeds by 10%. There are two underwater examples offered for reference in the following data. (p4-31, p4-91)

SECTION 4 OPERATION

4-14

Material: Carbon SteelAmperes: 50Start Gas: Air* @ 100 psi / 6,9 Bar

Cut Gas: Air* @ 100 psi / 6,9 Bar

PT-600 Plasma Arc Cutting Torch

Shield Gas: Air* @ 60 psi / 4,1 Bar

*Do not use shop Air. Use bottled/compressed.

Torch Sleeve P/N 0558001626

Torch Body P/N 0558001825 (Ref.) 2 EA. O-rings P/N 996528 (Ref.)

Gas Baffle P/N 0558002533 “4 Hole”

O-ring Supplied with Electrode Holder P/N 86W99 (Ref.)

Electrode Holder w/O-ring P/N 0558001621

O-ring Supplied with Electrode P/N 86W99 (Ref.)

Electrode P/N 0558001624 “250A”

O-ring Supplied w/Nozzle P/N 181W89 (Ref.)

Nozzle P/N 0558001881 “50A”


Nozzle Retaining Cup P/N 37082

Gas Diffuser P/N 21796 “50A”

Shield P/N 21795 “50A”

Shield Retainer P/N 37081

SECTION 4 OPERATION

4-15

50 Amperes PT-600 Process Data Carbon Steel

�Except where noted, data is for above water

cutting. Reduce speed approximately 10% when cutting under water.

Start Gas

Cut Gas

Shield Gas

Material Thickness Air Air Air

IN 0.063

MM 1,6

Timers

Rise On Pierce (sec.) 0

Pierce Delay (sec.) 0

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 40

Plasma Start Gas BAR 2,76

PSI 50 Plasma Cut Gas

BAR 3,45

PSI 10 Shield Start Gas

BAR 0,69

PSI 10 Shield Cut Gas

BAR 0,69

Height Readings IN. .375

Initial Height MM 9,5

Arc Voltage (standoff) 113

Travel Speed IPM 220

MM/MIN 5588

Kerf Width

Inches .05

Millimeters 1,3

Notes: Pilot Arc Set to Low

SECTION 4 OPERATION

4-16

Material: Carbon SteelAmperes: 65Start Gas: Air* @ 100 psi / 6,9 Bar











Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001881 “50A”



Gas Diffuser P/N 21796



SECTION 4 OPERATION

4-17




Start Gas

Cut Gas

Shield Gas


IN 0.125 0.188 0.250

MM 3,2 4,7 6,4

Timers

Rise On Pierce (sec.) 0 0 0.1

Pierce Delay (sec.) 0 0 0.4

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 40 40 40

Plasma Start Gas BAR 2,76 2,76 2,76

PSI 50 50 50 Plasma Cut Gas

BAR 3,45 3,45 3,45

PSI 10 10 10 Shield Start Gas

BAR 0,69 0,69 0,69

PSI 10 10 10 Shield Cut Gas

BAR 0,69 0,69 0,69

Height Readings IN. .375 .375 .375

Initial Height MM 9,5 9,5 9,5

Arc Voltage (standoff) 115 118 130

Travel Speed IPM 150 100 75

MM/MIN 3810 2540 1905

Kerf Width

Inches .065 .075 .085

Millimeters 1,7 1,9 2,2


SECTION 4 OPERATION

4-18

Material: Carbon SteelAmperes: 100Start Gas: Nitrogen (N2) @ 100 psi / 6,9 Bar

Cut Gas: Oxygen (O2) @ 100 psi / 6,9 Bar






Gas Baffle P/N 0558002533 “4 Hole” (0558002534 “Reverse”)




Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001882 “100A”



Gas Diffuser P/N 21944 (22496 “Reverse”)

Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-19




Start Gas

Cut Gas

Shield Gas

Material Thickness N2 O2 Air

IN 0.125 0.188 0.250 0.313 0.375 0.500 0.625 0.750

MM 3,2 4,7 6,4 7,9 9,5 12,7 15,9 19,1

Timers

Rise On Pierce (sec.) 0 0 0 0 0.2 0.4 0.5 0.3

Pierce Delay (sec.) 0 0 0 0 0.2 0.5 0.6 0.7

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 25 25 25 25 25 25 25 25

Plasma Start Gas BAR 1,7 1,7 1,7 1,7 1,7 1,7 1,7 1,7

PSI 46 46 44 46 46 46 48 46 Plasma Cut Gas

BAR 3,2 3,2 3,0 3,2 3,2 3,2 3,3 3,2

PSI 20 20 20 20 20 20 20 18 Shield Start Gas

BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4 1,2

PSI 10 18 18 10 16 10 12 10 Shield Cut Gas

BAR 0,7 1,2 1,2 0,7 1,1 0,7 0,8 0,7

Height Readings IN. .375 .375 .375 .375 .375 .500 .500 .500 Initial Height MM 9,5 9,5 9,5 9,5 9,5 12,7 12,7 12,7

Arc Voltage (standoff) 123 135 133 134 149 141 159 162

Travel Speed IPM 190 150 120 100 80 60 38 20

MM/MIN 4826 3810 3048 2540 2032 1524 965 508

Kerf Width

Inches .08 .075 .100 .085 .012 .100 .14 .145

Millimeters 2,0 1,9 2,5 2,2 3,0 2,5 3,6 3,7


SECTION 4 OPERATION

4-20












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001883 “150A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-21




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000

MM 4,7 6,4 7,9 9,5 12,7 15,9 19,1 25,4

Timers


Pierce Delay (sec.) 0 0 0 0 0.4 0.5 0.8 1.0




BAR 2,6 2,6 2,6 2,6 2,6 3,0 2,6 2,6


BAR 1,4 1,4 1,4 1,4 1,4 1,5 1,2 1,2


BAR 1,2 1,2 1,2 1,2 1,1 1,2 0,7 1,1



Travel Speed IPM 160 150 120 90 75 55 45 25

MM/MIN 4064 3810 3048 2286 1905 1397 1143 635

Kerf Width

Inches .085 .095 .095 .120 .105 .125 .150 .165

Millimeters 2,2 2,4 2,4 3,0 2,7 3,2 3,8 4,2

Notes: Pilot Arc Set to High

SECTION 4 OPERATION

4-22












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-23




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.313 0.375 0.500 0.625 0.750 1.000 1.250

MM 6,4 7,9 9,5 12,7 15,9 19,1 25,4 31,8

Timers

Rise On Pierce (sec.) 0 0 0 0.1 0.2 0.3 0.3 0.6

Pierce Delay (sec.) 0 0.2 0 0.2 0.3 0.3 0.5 1.0




BAR 2,8 3,0 2,8 3,0 2,8 2,8 2,8 3,0


BAR 1,4 1,4 1,4 1,4 1,4 1,2 1,2 1,5


BAR 0,6 1,0 1,2 0,7 0,8 0,5 0,8 1,5



Travel Speed IPM 170 140 110 90 65 55 40 20

MM/MIN 4318 3556 2794 2286 1651 1397 1016 508

Kerf Width

Inches .095 .105 .110 .136 .120 .150 .170 .190

Millimeters 2,4 2,7 2,8 3,5 3,0 3,8 4,3 4,8


4-Insert

SECTION 4 OPERATION

Material: Carbon Steel PT-600 Amperes: 200

PLASMARC™ Cutting Torch Stat Gas: Nitrogen (N2) @ 125 psi/8.6 bar

WITH Cut Gas: Oxygen (O2) @ 125 psi/8.6 bar

Shield Gas 1: Air @ 100psi/6.9 bar @ 95cfhEPP-200Plasma Power Console Shield Gas 2: Not used

High Speed CuttingTorch Sleeve P/N 0558001825

Torch Body P/N 0558001825 (Ref) 2 ea. O-Rings P/N 996528 (Ref)

Gas Baffle 4 Hole(See note next page)

O-Ring Supplied with Electrode Holder P/N 86W99 (Ref)

Electrode Holder with O-RingP/N 0558001621

O-Ring Supplied with ElectrodeP/N 86W99 (Ref)

Electrode 250 Amp P/N 0558001624UL

O-Ring Supplied with Nozzle P/N 181W89 (Ref)

Nozzle 200 PR 150 AMP P/N 0558001883

O-Ring Supplied with Nozzle P/N 181W89 (Ref)


Gas Diffuser P/N 21944Reverse Swirl P/N 22496

Shield, .160 Ø P/N 0558004678


200 AmperesPT-600/EPP 200 High SpeedProcess Data Carbon Steel

StartGas

Cut Gas ShieldGas1

ShieldGas2

N2 O2 Air Notused

IN 0.250 0.375 0.500 0.750 1.000

Mat

.T

hic

k

MM 6.4 9.5 12.7 19.1 25.4

Rise On Pierce 0 0.1 0.1 0.3 0.3

Pierce Delay 0 0.2 0.2 0.3 0.5

Tim

ers

(sec

on

ds)

Auto Height Delay 0.4 0.4 0.4 0.4 0.4

22psi@ 140 cfh 22psi@ 140 cfh 22psi@ 140 cfh 22psi@ 140 cfh 22psi@ 140 cfhPlasma Start Gas

1.5bar@ 4.0 cmh 1.5bar@ 4.0 cmh 1.5bar@ 4.0 cmh 1.5bar@ 4.0 cmh 1.5bar@ 4.0 cmh

49psi@ 66 cfh 49psi@ 66 cfh 49psi@ 66 cfh 49psi@ 66 cfh 49psi@ 66 cfhPlasma Cut Gas

[email protected] cmh [email protected] cmh [email protected] cmh [email protected] cmh [email protected] cmh

13psi@ 190 cfh 13psi@ 190 cfh 14psi@ 220 cfh 12psi@ 180 cfh 13psi@ 190 cfhShield Start Gas

0.9bar@ 5.4 cmh 0.9bar@ 5.4 cmh 1.0bar@ 6.2 cmh 0.8bar@ 5.1 cmh 0.9bar@ 5.4 cmh

13psi@ 190 cfh 13psi@ 190 cfh 19psi@ 220 cfh 12psi@180 cfh 13psi@ 180 cfhShield Cut Gas 1 -- Air 0.9bar@ 5.4 cmh 0.9bar@ 5.4 cmh 1.3bar@ 6.2 cmh 0.8bar@ 5.1 cmh 0.9bar@ 5.1 cmh

Not

Set

up

Par

amet

ers

Pre

ssu

re @

Flo

w

Shield Cut Gas 2 – Used

IN. 0.375 0.375 0.500 0.500 0.500InitialHeight MM 9.5 9.5 12.7 12.7 12.7

Hei

gh

tR

ead

ing

s

Arc Voltage(standoff) 126 130 145 149 149

IPM 250 155 121 76 51

Tra

vel

Sp

eed

MM/MIN 6350 3937 3073 1930 1295

Inches .06 .09 .10 .11 .13

Ker

fW

idth

Millimeters 1.5 2.3 2.5 2.8 3.3

Notes:� Pilot Arc Set to LOW � Use the 150 amp nozzle when cutting at 200 amp high speed, P/N 0558001883.� Up to 1 inch thick material use Gas Baffle 4 Hole P/N 0558002533, Reverse 4 hole P/N 0558002534

4-Insert

SECTION 4 OPERATION

SECTION 4 OPERATION

4-24












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001623 “250A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-25




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.625 0.750 1.000 1.250 1.500

MM 6,4 9,5` 12,7 15,9 19,1 25,4 31,8 38,1

Timers

Rise On Pierce (sec.) 0 0 0 0.2 0.3 0.3 0.5 0.8

Pierce Delay (sec.) 0 0 0.2 0.1 0.2 0.4 0.8 1.2




BAR 2,6 2,6 3,0 2,8 2,6 2,6 3,0 3,0


BAR 1,2 1,2 1,4 1,0 1,2 1,2 1,5 1,5


BAR 0,8 0,8 1,1 0,8 0,8 0,8 1,5 1,5



Travel Speed IPM 170 125 115 80 65 50 33 22

MM/MIN 4318 3175 2921 2032 1651 1270 838 558

Kerf Width

Inches .110 .135 .135 .130 .150 .160 .170 .200

Millimeters 2,8 3,5 3,5 3,3 3,8 4,1 4,3 5,1


SECTION 4 OPERATION

4-26












Electrode P/N 0558002516 “360A/400A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-27




Start Gas

Cut Gas

Shield Gas


IN 0.500 0.625 0.750 1.000 1.250 1.500

MM 12,7 15,9 19,1 25,4 31,8 38,1

Timers

Rise On Pierce (sec.) 0.3 0.3 0.3 0.4 0.5 0.7

Pierce Delay (sec.) 0.2 0.3 0.3 0.6 0.9 1.0

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 26 25 25 25 25 25

Plasma Start Gas BAR 1,8 1,7 1,7 1,7 1,7 1,7

PSI 37 37 31 31 31 36 Plasma Cut Gas

BAR 2,6 2,6 2,1 2,1 2,1 2,5

PSI 22 22 22 22 22 22 Shield Start Gas

BAR 1,5 1,5 1,5 1,5 1,5 1,5

PSI 22 22 22 22 22 22 Shield Cut Gas

BAR 1,5 1,5 1,5 1,5 1,5 1,5

Height Readings IN. .500 .500 .500 .625 .625 .625

Initial Height MM 12,7 12,7 12,7 15,9 15,9 15,9

Arc Voltage (standoff) 125 135 132 142 146 156

Travel Speed IPM 125 100 90 60 37 25

MM/MIN 3175 2540 2286 1524 939 635

Kerf Width

Inches .140 .150 .160 .175 .200 .210

Millimeters 3,6 3,8 4,1 4,5 5,1 5,3


SECTION 4 OPERATION

4-28












Electrode P/N 0558002516 “360A/400A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-29




Start Gas

Cut Gas

Shield Gas


IN 0.500 0.625 0.750 1.000 1.250 1.500

MM 12,7 15,9 19,1 25,4 31,8 38,1

Timers


Pierce Delay (sec.) 0.2 0.3 0.3 0.7 0.9 1.0




BAR 2,6 2,6 2,4 2,4 2,6 2,5


BAR 1,5 1,5 1,5 1,5 1,5 1,5


BAR 1,5 1,5 1,5 1,5 1,5 1,5




Travel Speed IPM 135 115 100 65 45 32

MM/MIN 3429 2921 2540 1651 1143 813

Kerf Width

Inches .140 .140 .165 .180 .205 .210

Millimeters 3,6 3,6 4,2 4,6 5,2 5,3


SECTION 4 OPERATION

4-30












Electrode P/N 0558002516 “360A/400A”


Nozzle P/N 0558001886 “400A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-31


UNDER WATER Start Gas

Cut Gas

Shield Gas


IN 0.500 0.625 0.750 1.000 1.250 1.500

MM 12,7 15,9 19,1 25,4 31,8 38,1

Timers


Pierce Delay (sec.) 0.2 0.3 0.3 0.3 0.7 1.2




BAR 2,7 2,6 2,6 2,6 2,6 2,5


BAR 1,5 1,5 1,5 1,5 1,5 1,5


BAR 1,5 1,5 1,5 1,5 1,5 1,5




Travel Speed IPM 130 120 110 75 55 37

MM/MIN 3556 3175 2794 1905 1397 940

Kerf Width

Inches .145 .150 .195 .195 .205 .220

Millimeters 3,7 3,8 5,0 5,0 5,2 5,6


SECTION 4 OPERATION

4-32












Electrode P/N 0558002516 “360A/400A”


Nozzle P/N 0558001886 “400A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-33




Start Gas

Cut Gas

Shield Gas


IN 0.500 0.625 0.750 1.000 1.250 1.500

MM 12,7 15,9 19,1 25,4 31,8 38,1

Timers


Pierce Delay (sec.) 0.2 0.3 0.3 0.3 0.7 1.2




BAR 2,7 2,6 2,6 2,6 2,6 2,5


BAR 1,5 1,5 1,5 1,5 1,5 1,5


BAR 1,5 1,5 1,5 1,5 1,5 1,5




Travel Speed IPM 140 125 115 80 60 43

MM/MIN 3556 3175 2794 1905 1397 940

Kerf Width

Inches .145 .150 .195 .195 .205 .220

Millimeters 3,7 3,8 5,0 5,0 5,2 5,6


SECTION 4 OPERATION

4-34

Material: AluminumAmperes: 65Start Gas: Air* @ 100 psi / 6,9 Bar











Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001881 “50A”






SECTION 4 OPERATION

4-35

65 Amperes PT-600 Process Data Aluminum



Start Gas

Cut Gas

Shield Gas


IN 0.063 0.125 0.250

MM 1,6 3,2 6,4

Timers


Pierce Delay (sec.) 0 0.2 0.4




BAR 4,14 4,14 4,14


BAR 0,7 0,7 0,7


BAR 0,7 0,7 0,7





MM/MIN 5080 2794 1524

Kerf Width

Inches .063 .08 .100



SECTION 4 OPERATION

4-36












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001882 “100A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-37




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.375 0.500 0.750

MM 4,7 6,4 9,5 12,7 19,1

Timers

Rise On Pierce (sec.) 0 0.1 0.1 0.1 0.2

Pierce Delay (sec.) 0.1 0.2 0.3 0.3 0.4

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 25 25 25 25 25

Plasma Start Gas BAR 1,7 1,7 1,7 1,7 1,7

PSI 42 42 42 42 42 Plasma Cut Gas

BAR 2,9 2,9 2,9 2,9 2,9

PSI 20 20 20 20 20 Shield Start Gas

BAR 1,4 1,4 1,4 1,4 1,4

PSI 18 18 18 18 18 Shield Cut Gas

BAR 1,24 1,24 1,24 1,24 1,24

Height Readings IN. .375 .375 .375 .500 .500

Initial Height MM 9,5 9,5 9,5 12,7 12,7

Arc Voltage (standoff) 151 157 157 182 185

Travel Speed IPM 120 95 70 50 25

MM/MIN 3048 2413 1778 1270 635

Kerf Width

Inches .115 .120 .130 .130 .135

Millimeters 2,9 3,0 3,3 3,3 3,5


SECTION 4 OPERATION

4-38












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001883 “150A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-39




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.313 0.375 0.500 0.750 0.875 1.000

MM 4,7 6,4 7,9 9,5 12,7 19,1 22,2 25,4

Timers


Pierce Delay (sec.) 0 0.1 0.2 0.2 0.3 0.5 0.6 0.7




BAR 2,8 2,8 2,8 2,8 2,8 2,8 2,8 2,8


BAR 1,0 1,0 1,0 0,7 1,0 0,7 0,7 0,7


BAR 1,0 1,0 1,0 0,7 1,0 0,7 0,7 0,7



Travel Speed IPM 200 140 120 100 80 45 37 30

MM/MIN 5080 3556 3048 2540 2032 1143 940 762

Kerf Width

Inches .110 .110 .120 .130 .140 .140 .150 .150

Millimeters 2,8 2,8 3,0 3,3 3,6 3,6 3,8 3,8


SECTION 4 OPERATION

4-40












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-41




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.313 0.375 0.500 0.625 0.750 1.000

MM 6,4 7,9 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0.1 0.1 0.2 0.2 0.2 0.3

Pierce Delay (sec.) 0.2 0.2 0.3 0.3 0.3 0.5 0.6

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 25 25 25 25 25 25 25

Plasma Start Gas BAR 1,7 1,7 1,7 1,7 1,7 1,7 1,7

PSI 44 44 44 44 44 44 44 Plasma Cut Gas

BAR 3,0 3,0 3,0 3,0 3,0 3,0 3,0

PSI 14 14 14 14 14 14 14 Shield Start Gas

BAR 1,0 1,0 1,0 1,0 1,0 1,0 1,0

PSI 15 15 15 15 15 15 15 Shield Cut Gas

BAR 1,0 1,0 1,0 1,0 1,0 1,0 1,0

Height Readings IN. .375 .375 .375 .500 .500 .500 .500

Initial Height MM 9,5 9,5 9,5 12,7 12,7 12,7 12,7

Arc Voltage (standoff) 155 160 160 167 170 175 186

Travel Speed IPM 125 125 110 85 70 60 40

MM/MIN 3175 3175 2794 2159 1778 1524 1016

Kerf Width

Inches .110 130 .130 .130 .140 .140 .140

Millimeters 2,8 3,3 3,3 3,3 3,6 3,6 3,6


SECTION 4 OPERATION

4-42

Material: AluminumAmperes: 150Start Gas: Nitrogen (N2) @ 100 psi / 6,9 Bar

Cut Gas: Argon/Hydrogen (H-35) @100 psi / 6,9 Bar


Shield Gas: Nitrogen (N2) @ 60 psi / 4,1 Bar







Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001883 “150A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-43


DO NOT CUT UNDERWATER WITH H-35 Start Gas

Cut Gas

Shield Gas

Material Thickness N2 H-35 N2

IN 0.250 0.375 0.500 0.625 0.750 1.000

MM 6,4 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0.1 0.1 0.1 0.1 0.2

Pierce Delay (sec.) 0.2 0.3 0.2 0.5 0.4 0.5




BAR 3,7 3,7 3,7 3,7 3,7 3,7


BAR 0,7 0,7 0,7 0,7 0,7 0,7


BAR 0,7 0,7 0,7 0,7 0,7 0,7




Travel Speed IPM 150 110 90 55 45 25

MM/MIN 3810 2794 2286 1397 1143 635

Kerf Width

Inches .140 .120 .130 .150 .160 .170

Millimeters 3,6 3,0 3,3 3,8 4,1 4,3


SECTION 4 OPERATION

4-44











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-45



Cut Gas

Shield Gas


IN 0.375 0.500 0.625 0.750 1.000

MM 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0 0.1 0.2 0.3

Pierce Delay (sec.) 0.2 0.4 0.4 0.5 0.8




BAR 3,4 3,4 3,4 3,4 3,4


BAR 1,0 1,0 1,0 1,0 1,0


BAR 1,0 1,0 1,0 1,0 1,0





MM/MIN 3048 2540 2159 1651 889

Kerf Width

Inches .130 .140 .150 .160 .170

Millimeters 3,3 3,6 3,8 4,1 4,3


SECTION 4 OPERATION

4-46











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-47



Cut Gas

Shield Gas


IN 0.375 0.500 0.625 0.750 1.000 1.250 1.500 1.750

MM 9,5 12,7 15,9 19,1 25,4 31,8 38,1 44,5

Timers

Rise On Pierce (sec.) 0 0 0.1 0.1 0.2 0.3 0.4 0.5

Pierce Delay (sec.) 0.3 0.3 0.3 0.4 0.8 1.0 1.0 1.4




BAR 3,8 3,8 3,8 3,8 3,8 3,8 3,8 3,8


BAR 1,9 1,9 1,9 1,9 1,9 1,9 1,9 1,9


BAR 1,9 1,9 1,9 1,9 1,9 1,9 1,9 1,9



Travel Speed IPM 175 155 130 90 60 45 33 25

MM/MIN 4445 3937 3302 2286 1524 1143 838 635

Kerf Width

Inches .160 160 .180 .180 .190 .210 .240 .260

Millimeters 4,1 4,1 4,6 4,6 4,8 5,3 6,1 6,6


SECTION 4 OPERATION

4-48











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001887 “600A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-49



Cut Gas

Shield Gas


IN 1.000 1.500 2.000 3.000

MM 25,4 38,1 50,8 76,2

Timers

Rise On Pierce (sec.) 0.3 0.4 0.5 0.6

Pierce Delay (sec.) 0.5 0.8 1.0 1.2

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 46 46 46 46

Plasma Start Gas BAR 3,2 3,2 3,2 3,2

PSI 46 46 46 46 Plasma Cut Gas

BAR 3,2 32 32 3,2

PSI 35 35 35 35 Shield Start Gas

BAR 2,4 2,4 2,4 2,4

PSI 35 35 35 35 Shield Cut Gas

BAR 2,4 2,4 2,4 2,4

Height Readings IN. .750 .750 .750 .750

Initial Height MM 19,1 19,1 19,1 19,1

Arc Voltage (standoff) 172 177 192 212

Travel Speed IPM 80 65 30 15

MM/MIN 2032 1651 762 381

Kerf Width

Inches .320 .330 .357 .390

Millimeters 8,1 8,4 9,1 9,9


SECTION 4 OPERATION

4-50












Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001623 “250A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-51



Cut Gas

Shield Gas

Material Thickness N2 H-35 Air

IN 0.625 0.750 1.000

MM 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0.1 0.2 0.3

Pierce Delay (sec.) 0.3 0.4 0.8




BAR 1,7 1,7 1,7


BAR 0,55 0,55 0,55


BAR 0.8 0.8 0.8





MM/MIN 2159 1778 1143

Kerf Width

Inches .100 .100 .100



SECTION 4 OPERATION

4-52












Electrode P/N 0558002516 “360A/400A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-53



Cut Gas

Shield Gas

Material Thickness N2 H-35 Air

IN 0.500 0.625 0.750 0.875 1.000 1.250 1.500 1.750

MM 12,7 15,9 19,1 22,2 25,4 31,8 38,1 44,5

Timers

Rise On Pierce (sec.) 0 0.1 0.1 0.1 0.2 0.3 0.4 0.5

Pierce Delay (sec.) 0.3 0.3 0.4 0.5 0.8 1.0 1.0 1.4




BAR 3,8 3,8 3,8 3,8 3,8 3,8 3,8 3,8


BAR 1,9 1,9 1,9 1,9 1,9 1,9 1,9 1,9


BAR 1,9 1,9 1,9 1,9 1,9, 1,9 1,9 1,9



Travel Speed IPM 150 130 90 75 60 45 33 25

MM/MIN 3810 3302 2286 1905 1524 1143 838 635

Kerf Width

Inches .160 .180 .180 .180 .190 .210 .240 .260

Millimeters 4,1 4,6 4,6 4,6 4,8 5,3 6,1 6,6


SECTION 4 OPERATION

4-54

Material: AluminumAmperes: 600Start Gas: Argon/Hydrogen (H-35) @100 psi / 6,9 Bar











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001887 “600A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-55



Cut Gas

Shield Gas

Material Thickness H-35 H-35 Air

IN 1.500

MM 38,1

Timers

Rise On Pierce (sec.) 0.5

Pierce Delay (sec.) 1.1

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 46

Plasma Start Gas BAR 3,2

PSI 46 Plasma Cut Gas

BAR 3,2

PSI 34 Shield Start Gas

BAR 2,4

PSI 34 Shield Cut Gas

BAR 2,4

Height Readings IN. .750

Initial Height MM 19,1

Arc Voltage (standoff) 172

Travel Speed IPM 75

MM/MIN 1905

Kerf Width

Inches .320

Millimeters 8,1


SECTION 4 OPERATION

4-56


Cut Gas: Nitrogen (N2) @ 100 psi / 6,9 Bar










Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-57




Start Gas

Cut Gas

Shield Gas

Material Thickness N2 N2 Air

IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000

MM 4,7 6,4 7,9 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0 0 0 0 0.1 0.2 0.2

Pierce Delay (sec.) 0 0.2 0.2 0.3 0.3 0.4 0.5 0.8




BAR 3,04 3,04 3,04 3,04 3,04 3,04 3,04 3,04


BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,24 1,24 1,24 1,24 1,24 1,24 1,24 1,24



Travel Speed IPM 240 170 105 90 70 62 55 30

MM/MIN 6096 4318 2667 2286 1778 1575 1397 676

Kerf Width

Inches .110 .110 .120 .130 .130 .140 .150 .160

Millimeters 2,8 2,8 3,0 3,3 3,3 3,6 3,8 4,1


SECTION 4 OPERATION

4-58












Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001623 “250A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-59




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.625 0.750 1.000

MM 6,4 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0.1 0.1 0.1 0.1 0.2

Pierce Delay (sec.) 0.2 0.3 0.3 0.5 0.6 0.8




BAR 3,0 3,0 3,0 3,0 3,0 3,0


BAR 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,2 1,2 1,2 1,2 1,2 1,2




Travel Speed IPM 200 125 100 75 65 45

MM/MIN 5080 3175 2540 1905 1651 1143

Kerf Width

Inches .120 .130 .130 .150 .150 .160

Millimeters 3,0 3,3 3,3 3,8 3,8 4,1


SECTION 4 OPERATION

4-60












Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-61




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.750 1.000 1.250

MM 6,4 9,5 12,7 19,1 25,4 31,8

Timers

Rise On Pierce (sec.) 0 0 0 0.2 0.3 0.3

Pierce Delay (sec.) 0.1 0.2 0.3 0.4 0.7 0.8




BAR 2,7 2,7 2,7 2,7 2,7 2,7


BAR 3,0 3,0 3,0 3,0 3,0 3,0


BAR 3,0 3,0 3,0 3,0 3,0 3,0




Travel Speed IPM 230 180 160 90 60 40

MM/MIN 5842 4572 4064 2286 1524 1016

Kerf Width

Inches .120 .130 .130 .140 .150 .200

Millimeters 3,0 3,3 3,3 3,6 3,8 5,1


SECTION 4 OPERATION

4-62












Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001887 “600A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-63




Start Gas

Cut Gas

Shield Gas


IN 1.000 1.500

MM 25,4 38,1

Timers

Rise On Pierce (sec.) 0.5 0.5

Pierce Delay (sec.) 1.0 1.1

Setup Parameters Pounds per Square Inch (PSI - Pressure) PSI 27 27

Plasma Start Gas BAR 1,9 1,9

PSI 27 27 Plasma Cut Gas

BAR 1,9 1,9

PSI 34 34 Shield Start Gas

BAR 2,4 2,4

PSI 34 34 Shield Cut Gas

BAR 2,4 2,4

Height Readings IN. .625 .625

Initial Height MM 15,9 15,9

Arc Voltage (standoff) 158 168

Travel Speed IPM 100 60

MM/MIN 2540 1524

Kerf Width

Inches .177 .189

Millimeters 4,5 4,8


SECTION 4 OPERATION

4-64











Electrode P/N 0558001624 “N2, H-35, 600A”


Nozzle P/N 0558001881 “50A”






SECTION 4 OPERATION

4-65




Start Gas

Cut Gas

Shield Gas

Material Thickness N2 N2 N2

IN 16GA 0.125 0.250

MM 1,6 3,2 6,4

Timers


Pierce Delay (sec.) 0 0 0.4




BAR 4,0 4,0 4,0


BAR 0,7 0,7 0,7


BAR 0,7 0,7 0,7





MM/MIN 4572 3048 1778

Kerf Width

Inches .055 .075 .095



SECTION 4 OPERATION

4-66

Material: Stainless Steel Amperes: 65Start Gas: Nitrogen (N2) @ 100 psi / 6,9 Bar


PT-600 Plasma Arc Cutting Shield Gas: Nitrogen (N2) @ 60 psi / 4,1 Bar




O-ring Supplied with Electrode Holder P/N 86W99 Ref.


O-ring Supplied with Electrode P/N 86W99 Ref.

Electrode* P/N 0558001624 “250A”

O-ring Supplied w/Nozzle P/N 181W89 Ref.

Nozzle P/N 0558001881 “50A”






*Note: Special application for electrode

SECTION 4 OPERATION

4-67

65 Amperes PT-600 Process Data Stainless Steel



Start Gas

Cut Gas

Shield Gas


IN 16GA 0.125 0.187 0.250

MM 1,6 3,2 4,7 6,4

Timers

Rise On Pierce (sec.) 0 0 0.2 0.2

Pierce Delay (sec.) 0 0 0.4 0.4




BAR 4,0 4,0 4,0 4,0


BAR 0,7 0,7 0,8 0,7


BAR 0,8 0,8 0,8 0,76

Height Readings IN. .375 .375 .375 .375 Initial Height MM 9,5 9,5 9,5 9,5



MM/MIN 6350 1905 1778 1397

Kerf Width

Inches .082 .090 .085 .090



SECTION 4 OPERATION

4-68










Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001882 “100A”




Shield P/N 21802 “100 to 250A”


SECTION 4 OPERATION

4-69




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.625 0.750

MM 6,4 9,5 12,7 15,9 19,1

Timers

Rise On Pierce (sec.) 0.1 0.2 0.3 0.3 0.5

Pierce Delay (sec.) 0.3 0.4 0.5 0.5 1.2




BAR 3,5 3,5 3,5 3,5 3,5


BAR 1,4 1,4 1,4 1,4 1,4


BAR 1,5 1,5 1,5 1,5 1,5





MM/MIN 1397 1067 762 384 248

Kerf Width

Inches .120 .120 .130 .140 .150

Millimeters 3,0 3,0 3,3 3,6 3,8


SECTION 4 OPERATION

4-70

Material: Stainless Steel Amperes: 65Start Gas: Air* @ 100 psi / 6,9 Bar


PT-600 Plasma Arc Cutting Shield Gas: Air* @ 60 psi / 4,1 Bar








Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001881 “50A”






SECTION 4 OPERATION

4-71




Start Gas

Cut Gas

Shield Gas


IN 0.062 0.125 0.250

MM 1,6 3,2 6,4

Timers


Pierce Delay (sec.) 0 0.2 0.5




BAR 4,0 4,1 4,0


BAR 0,7 0,7 0,7


BAR 0,8 0,7 0,7





MM/MIN 6350 2032 1524

Kerf Width

Inches .050 .065 .075



SECTION 4 OPERATION

4-72











Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001882 “100A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-73




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750

MM 4,7 6,4 7,9 9,5 12,7 15,9 19,1

Timers


Pierce Delay (sec.) 0.2 0.3 0.4 0.4 0.6 0.8 1.2




BAR 2,6 2,6 2,6 2,6 2,6 2,6 2,6


BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,2 1,2 1,2 1,2 1,2 1,2 1,2




Travel Speed IPM 100 55 45 35 25 18 10

MM/MIN 2540 1397 1143 889 635 457 254

Kerf Width

Inches .100 .115 .120 .135 .140 .145 .150

Millimeters 2,5 2,9 3,0 3,4 3,6 3,7 3,8


SECTION 4 OPERATION

4-74











Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001883 “150A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-75




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000

MM 4,7 6,4 7,9 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0 0.1 0.1 0.2 0.3 0.4 0.4

Pierce Delay (sec.) 0.1 0.3 0.3 0.3 0.4 0.4 0.8 1.0




BAR 2,5 2,5 2,5 2,5 2,5 2,5 2,5 2,5


BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5



Travel Speed IPM 180 130 110 90 60 40 25 15

MM/MIN 4572 3302 2794 2286 1524 1016 635 381

Kerf Width

Inches .100 .105 .115 .120 .125 .130 .140 .145

Millimeters 2,5 2,6 2,9 3,0 3,2 3,3 3,6 3,7


SECTION 4 OPERATION

4-76











Electrode P/N 0558001624 “250A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-77




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.313 0.375 0.500 0.625 0.750 1.000

MM 4,7 6,4 7,9 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0.1 0.1 0.1 0.1 0.2 0.3 0.4

Pierce Delay (sec.) 0.2 0.2 0.3 0.3 0.4 0.5 0.8 1.0




BAR 2,6 2,6 2,6 2,6 2,6 2,6 2,6 2,6


BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,5 1,5 1,5 1,5 1,5 1,5 1,5 1,5



Travel Speed IPM 200 135 130 125 85 70 55 20

MM/MIN 5080 3429 3302 3175 2159 1778 1397 508

Kerf Width

Inches .105 .110 .105 .130 .125 .130 .135 .175

Millimeters 2,6 2,8 2,6 3,3 3,1 3,3 3,5 4,5


SECTION 4 OPERATION

4-78











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001882 “100A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-79




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.313 0.375 0.500 0.625 0.750

MM 6,4 7,9 9,5 12,7 15,9 19,1

Timers

Rise On Pierce (sec.) 0.1 0 0.1 0.2 0.4 0.5

Pierce Delay (sec.) 0.3 0.3 0.4 0.4 0.8 1.0




BAR 3,1 3,1 3,1 3,1 3,1 3,1


BAR 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,5 1,5 1,5 1,5 1,5 1,5




Travel Speed IPM 55 48 42 35 16 8

MM/MIN 1397 1219 1066 889 406 203

Kerf Width

Inches .105 .115 .115 .120 .140 .150

Millimeters 2,6 2,9 2,9 3,0 3,6 3,8


SECTION 4 OPERATION

4-80











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001883 “150A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-81




Start Gas

Cut Gas

Shield Gas


IN 0.188 0.250 0.375 0.500 0.625 0.750 1.000

MM 4,7 6,4 9,5 12,7 15,9 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0 0 0.2 0.4 0.4 0.5

Pierce Delay (sec.) 0.1 0.2 0.3 0.4 0.8 1.0 1.2




BAR 2,8 2,8 2,8 2,8 2,8 2,8 2,8


BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4


BAR 0,6 0,6 0,6 0,6 0,6 0,6 0,6




Travel Speed IPM 180 135 85 60 35 18 10

MM/MIN 4572 3429 2159 1524 889 457 254

Kerf Width

Inches .110 .115 .120 .125 .145 .165 .175

Millimeters 2,8 2,9 3,0 3,2 3,7 4,2 4,5


SECTION 4 OPERATION

4-82











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-83




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.750 1.000

MM 6,4 9,5 12,7 19,1 25,4

Timers

Rise On Pierce (sec.) 0 0.1 0.2 0.5 0.6

Pierce Delay (sec.) 0.2 0.3 0.2 1.0 1.2




BAR 3,3 3,3 3,3 3,3 3,3


BAR 1,4 1,4 1,4 1,4 1,4


BAR 1,1 1,1 1,1 1,1 1,1





MM/MIN 4191 2667 1778 1143 508

Kerf Width

Inches .100 .115 .100 .140 .150

Millimeters 2,5 2,9 2,5 3,6 3,8


SECTION 4 OPERATION

4-84











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001623 “250A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-85




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.625 0.750 1.000 1.250

MM 6,4 9,5 12,7 15,9 19,1 25,4 31,8

Timers


Pierce Delay (sec.) 0.2 0.3 0.5 0.6 0.6 0.9 1.3




BAR 3,2 3,2 3,2 3,2 3,2 3,2 3,2


BAR 1,4 1,4 1,4 1,4 1,4 1,4 1,4


BAR 1,2 1,2 1,2 1,2 1,2 1,2 1,2




Travel Speed IPM 170 135 110 70 50 30 15

MM/MIN 4318 3429 2794 1778 1270 762 381

Kerf Width

Inches .110 .110 .115 .120 .130 .140 .160

Millimeters 2,8 2,8 2,9 3,0 3,3 3,6 4,1


SECTION 4 OPERATION

4-86











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-87




Start Gas

Cut Gas

Shield Gas


IN 0.250 0.375 0.500 0.625 0.750 1.000 1.250

MM 6,4 9,5 12,7 15,9 19,1 25,4 31,8

Timers

Rise On Pierce (sec.) 0 0 0.1 0.2 0.2 0.4 0.4

Pierce Delay (sec.) 0 0.1 0.4 0.4 0.4 1.0 1.0




BAR 3,0 3,0 3,0 3,0 3,0 3,0 3,0


BAR 1,2 1,2 1,2 1,2 1,2 1,2 1,2


BAR 1,2 1,2 1,2 1,2 1,2 1,2 1,2




Travel Speed IPM 230 150 125 95 75 45 25

MM/MIN 5842 3810 3175 2413 1905 1143 635

Kerf Width

Inches .100 .105 .125 .125 .135 .145 .175

Millimeters 2,5 2,5 3,2 3,2 3,5 3,7 4,5


SECTION 4 OPERATION

4-88











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001886 “400A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-89




Start Gas

Cut Gas

Shield Gas


IN 0.750 1.000 1.250 1.500

MM 19,1 25,4 31,8 38,1

Timers


Pierce Delay (sec.) 0.3 .07 0.7 1.2




BAR 2,4 2,4 2,4 2,4


BAR 2,1 2,1 2,1 2,1


BAR 2,1 2,1 2,1 2,1

Height Readings IN. .625 .625 .625 .625

Initial Height MM 15,9 15,9 15,9 15,9



MM/MIN 2540 1778 1321 838

Kerf Width

Inches .175 .180 .185 .196



SECTION 4 OPERATION

4-90











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001886 “400A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-91


UNDER WATER Start Gas

Cut Gas

Shield Gas


IN 0.750 1.000 1.250 1.500

MM 19,1 25,4 31,8 38,1

Timers






BAR 2,4 1,9 2,4 2,4


BAR 2,1 2,4 2,1 2,1


BAR 2,1 2,4 2,1 2,1




MM/MIN 2159 1778 1143 838

Kerf Width

Inches .160 .180 185 .196



SECTION 4 OPERATION

4-92











Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001887 “600A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-93




Start Gas

Cut Gas

Shield Gas


IN 1.000 1.500

MM 25,4 38,1

Timers






BAR 1,9 1,9


BAR 2,4 2,4


BAR 2,4 2,4

Height Readings IN. .625 .625 Initial Height MM 15,9 15,9



MM/MIN 1778 1016

Kerf Width

Inches .175 .183

Millimeters 4,5 4,6


SECTION 4 OPERATION

4-94


Cut Gas: Argon/Hydrogen (H-35) @ 100 psi / 6,9 Bar








Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001883 “150A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-95


DO NOT CUT UNERWATER WITH H-35 Start Gas

Cut Gas

Shield Gas


IN 0.500 0.750

MM 12,7 19,1

Timers






BAR 3,3 3,3


BAR 1,1 1,1


BAR 0,8 0,55

Height Readings IN. .500 .625 Initial Height MM 12,7 15,9



MM/MIN 1016 508

Kerf Width

Inches .145 .185

Millimeters 3,7 4,7


SECTION 4 OPERATION

4-96










Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001884 “200A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-97



Cut Gas

Shield Gas


IN 0.375 0.500 1.000

MM 9,5 12,7 25,4

Timers

Rise On Pierce (sec.) 0.1 0.2 0.3

Pierce Delay (sec.) 0.4 0.4 0.8




BAR 3,7 3,7 3,7


BAR 1,1 1,0 1,1


BAR 1,5 0,9 1,5

Height Readings IN. .375 .500 .750 Initial Height MM 9,5 12,7 19,1



MM/MIN 1397 1270 432

Kerf Width

Inches .135 .145 .175



SECTION 4 OPERATION

4-98










Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001623 “250A”




Shield P/N 21802 “100A to 250A”


SECTION 4 OPERATION

4-99



Cut Gas

Shield Gas


IN 0.500 0.625 0.750 1.000 1.250

MM 12,7 15,9 19,1 25,4 31,8

Timers


Pierce Delay (sec.) 0.4 0.5 0.6 1.2 1.2




BAR 4,5 4,5 4,5 4,5 4,5


BAR 0,55 0,55 0,55 0,55 0,55


BAR 0,28 0,28 0,28 0,28 0,28

Height Readings IN. .500 .625 .625 .750 .750 Initial Height MM 12,7 15,9 15,9 19,1 19,1



MM/MIN 1270 1143 762 508 254

Kerf Width

Inches .180 .180 .185 .195 .225

Millimeters 4,6 4,6 4,7 4,9 5,7


SECTION 4 OPERATION

4-100










Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001885 “360A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-101



Cut Gas

Shield Gas


IN 0.500 0.750 1.000 1.250 1.500

MM 12,7 19,1 25,4 31,8 38,1

Timers


Pierce Delay (sec.) 0.6 0.8 1.0 1.2 1.2




BAR 3,6 4,14 4,14 4,14 5,5


BAR 0,4 0,97 0,97 0,97 0,97


BAR 0,3 0,8 0,8 0,8 0,55

Height Readings IN. .500 .625 .750 .750 .750 Initial Height MM 12,7 15,9 19,1 19,1 19,1



MM/MIN 2032 1143 762 508 381

Kerf Width

Inches .175 .225 .250 .300 .345

Millimeters 4,5 5,7 6,3 7,6 8,8


SECTION 4 OPERATION

4-102

Material: Stainless Steel Amperes: 600Start Gas: Argon/Hydrogen (H-35) @ 100 psi / 6,9 Bar









Electrode P/N 0558002499 “N2, H-35, 600A”


Nozzle P/N 0558001887 “600A”




Shield P/N 21945 “360A”


SECTION 4 OPERATION

4-103



Cut Gas

Shield Gas

Material Thickness H-35 H-35 N2

IN 1.000 1.500 2.000 3.000

MM 25.4 38.1 50.8 76.2

Timers






BAR 3,2 3,2 3,2 3,2


BAR 2,4 2,4 1,5 1,5


BAR 2,4 2,4 1,5 1,5




MM/MIN 1016 457 305 229

Kerf Width

Inches .303 .346 .380 .383



4-insert

SECTION 4 OPERATION

Table 4-1. 50 - 65 Amp Data

Nozzle - 50 Amp P/N 0558001881 Electrode - Hafnium P/N 0558001624 Gas Baffle - 4 hole P/N 0558002533

Shield - 50 Amp P/N 21795Diffuser - 50 Amp P/N 21796Pilot Arc - LOW

MaterialType-Thickness

in.(mm)Current(Amps)

PierceHeight

in. (mm)

CuttingHeight

in.(mm)

Arc Voltage(Volts)

CS - 1/16 (1.6) 50 220 (5.6) 1/4 (6.4) 5/32 (4) 115 Air - 40 (2.76) Air - 60 (4.14) Air - 30 (2.07) CS - 1/8 (3.2) 120 (3) 112

CS - 1/8 (3.2) 65 120 (3) 1/8 (3.2) 110 CS - 3/16 (4.8) 95 (2.4) 5/32 (4) 118

CS - 1/4 (6.4) 80 (2) 120 Air - 65 (4.48)

CS - 3/8 (9.6) 40 (2) 5/16 (8) 122

SS - 1/16 (1.6) 50 180 (4.6) 1/4 (6.4) 5/32 (4) 111 Air - 40 (2.76) Air - 60 (4.14) Air - 30 (2.07)

SS - 1/8 (3.2) 65 80 (2) 119

SS - 1/4 (6.4) 60 (1.5) 118 Air - 65 (4.48)

AL - 1/16 (1.6) 50 180 (4.6) 1/4 (6.4) 1/8 (3.2) 116 Air - 40 (2.76) Air - 60 (4.14) Air - 45 (3.1)

AL - 1/8 (3.2) 110 (2.8) 115

AL - 1/4 (6.4) 65 65 (1.6) 5/32 (4) 128 Air - 65 (4.48)

AL - 1/16 (1.6) 50 180 (4.6) 1/4 (6.4) 1/8 (3.2) 118 N2 - 40 (2.76) N

2 - 60 (4.14) N

2 - 30 (2.07)

AL - 1/8 (3.2) 120 (3) 117

AL - 1/4 (6.4) 65 70 (1.8) 125 N2 - 65 (4.48)

SS - 1/16 (1.6) 50 180 (4.6) 1/4 (6.4) 5/32 (4) 119 N2 - 40 (2.76) N

2 - 60 (4.14) N

2 - 30 (2.07)

SS - 1/8 (3.2) 65 80 (2) 125 N2 - 45 (3.1)

SS - 1/4 (6.4) 55 (1.4) 127 N2 - 65 (4.48)

Start GasType/Pressure

psi (bar)

Plasma GasType/Pressure

psi (bar)

Shield GasType/Pressure

psi (bar)

NOTES:CS - Carbon Steel, SS - Stainless Steel, AL - AluminumAir Plasma/Air Shield, 50 - 65 Amp cuts on Stainless Steel and Aluminum have rough surfaces.N

2 Plasma/N

2 Shield, 50 - 65 Amp cuts of Stainless Steel and Aluminum have fair to good surfaces.

* - uses electrode p/n 0558002499

CUTTING PARAMETERS FOR THE ESP-150 & ESP-200

Travel Speed

ipm(m/min)

*

4-insert

SECTION 4 OPERATION

CS - 3/16 (4.8) 100 150 (3.8) 3/8 (9.6) 1/8 (3.2) 148 Air - 30 (2.07) Air - 50 (3.45) Air - 110 (7.6) CS - 1/4 (6.4) 120 (3) 5/32 (4) 154 Air - 85 (5.86)

CS - 3/8 (9.6) 65 (1.65) 3/16 (4.8) 159

CS - 1/2 (12.7) 50 (1.27) 162 Air - 65 (4.48)

CS - 5/8 (15.8) 35 (.89) 1/2 (12.7) 9/32 (7.1) 175

CS - 3/4 (19) 20 (.50) 5/16 (8) 184

SS - 1/4 (6.4) 100 55 (1.4) 3/8 (9.6) 1/8 (3.2) 154 Air - 30 (2.07) Air - 45 (3.1) Air - 85 (5.86)

SS - 3/8 (9.6) 35 (.89) 3/16 (4.8) 165

SS - 1/2 (12.7) 25 (.6) 5/16 (8) 180 Air - 65 (4.48)

SS - 3/4 (19) 10 (.25) 1/2 (12.7) 189

AL - 1/4 (6.4) 100 100 (2.5) 3/8 (9.6) 3/16 (4.8) 154 Air - 30 (2.07) Air - 50 (3.45) Air - 65 (4.48)

AL - 3/8 (9.6) 70 (1.78) 1/4 (6.4) 174 Air - 85 (5.86)

AL - 1/2 (12.7) 50 (1.27) 5/16 (8) 183

AL - 3/4 (19) 30 (.76) 1/2 (12.7) 189 Air - 65 (4.48)

CS - 3/16 (4.8) 100 150 (3.8) 3/8 (9.6) 5/32 (4) 135 N2 - 30 (2.07) O

2 - 50 (3.45) Air

- 85 (5.86)

CS - 1/4 (6.4) 120 (3) 133

CS - 3/8 (9.6) 80 (2) 1/4 (6.4) 149

CS - 1/2 (12.7) 60 (1.5) 3/16 (4.8) 141 Air - 65 (4.48)

CS - 5/8 (15.8) 37 (.94) 1/2 (12.7) 5/16 (8) 159

CS - 3/4 (19) 20 (.50) 162

SS - 1/4 (6.4) 100 55 (1.4) 3/8 (9.6) 1/8 (3.2) 153 N2 - 30 (2.07) N

2 - 35 (2.4) N

2 - 85 (5.86)

SS - 3/8 (9.6) 45 (1.1) 3/16 (4.8) 157

SS - 1/2 (12.7) 35 (.89) 162

SS - 3/4 (19) 13 (.33) 1/2 (12.7) 5/16 (8) 185 N2 - 65 (4.48)

SS - 1/4 (6.4) 100 55 (1.4) 3/8 (9.6) 1/8 (3.2) 153 N2 - 30 (2.07) N

2 - 35 (2.4) Air - 85 (5.86)

SS - 3/8 (9.6) 45 (1.1) 3/16 (4.8) 157

SS - 1/2 (12.7) 35 (.89) 162

SS - 3/4 (19) 13 (.33) 1/2 (12.7) 5/16 (8) 185 Air - 65 (4.48)

Table 4-2. 100 Amp Data


in.(mm)

Current(Amps)

PierceHeight

in.(mm)

CuttingHeight

in.(mm)

NOTES: When using a 50 ft torch, a dwell of approx. 3 sec. is required to allow the N2 start gas to be purged out by the O

2 cut gas.

CS - Carbon Steel, SS - Stainless Steel, AL - Aluminum All Air Plasma/Air Shield, 100 Amp cuts on Aluminum have good surfaces except 3/4" (19mm) AL that has poor surface. All Air Plasma/Air Shield, 100 Amp cuts on Stainless Steel have fair surface except 3/4" (19mm) SS that is very rough. All N

2 Plasma/N

2 Shield, 100 Amp cuts on Stainless Steel have fairly good surfaces except 3/4" (19mm) SS that is fair.


psi((bar)

Arc Voltage(Volts)


psi (bar)


psi(bar)

Travel Speed

ipm(m/min)

* - uses electrode p/n 0558002499

********

Nozzle - 200 Amp P/N 0558001882 Shield 100 - 250 Amp P/N 21802 Electrode - Hafnium P/N 0558001624 Diffuser 100 - 360 Amp P/N 21944Gas Baffle - 4 Hole P/N 0558002533 Pilot Arc - HIGH

4-insert

SECTION 4 OPERATION

CS - 3/16 (4.8) 150 160 (4.1) 3/8 (9.6) 1/8 (3.2) 143 Air - 25 (1.7) Air - 50 (3.45) Air - 85 (5.86) CS - 1/4 (6.4) 140 (3.6) 145 Air - 55 (3.8)

CS - 3/8 (9.6) 90 (2.3) 3/16 (4.8) 156 CS - 1/2 (12.7) 75 (1.9) 1/4 (6.4) 160 Air - 65 (4.48)

CS - 5/8 (15.8) 50 (1.3) 1/2 (12.7) 164

CS - 3/4 (19) 45 1.1) 3/8 (9.6) 179

CS - 1 (25.4) 25 (.64) 184

SS - 3/16 (4.8) 150 200 3/8 (9.6) 1/8 (3.2) 138 Air - 25 (1.7) Air - 50 (3.45) Air - 85 (5.86)

SS - 1/4 (6.4) 165 3/16 (4.8) 146 Air - 65 (4.48)

SS - 3/8 (9.6) 95 1/4 (6.4) 155

SS - 1/2 (12.7) 60 5/16 (8) 163

SS - 3/4 (19) 25 1/2 (12.7) 3/8 (9.6) 175

SS - 1 (25.4) 15 185

AL - 3/16 (4.8) 150 200 (5.1) 3/8 (9.6) 3/16 (4.8) 148 Air - 25 (1.7) Air - 45 (3.1) Air - 85 (5.86)

AL - 1/4 (6.4) 140 (3.6) 149

AL - 3/8 (9.6) 105 (2.7) 1/4 (6.4) 159 Air - 65 (4.48)

AL - 1/2 (12.7) 80 (2) 5/16 (8) 174 Air - 85 (5.86)

AL - 3/4 (19) 45 (1.1) 1/2 (12.7) 180 Air - 65 (4.48)

AL - 1 (25.4) 30 (.76) 184

CS - 3/16 (4.8) 150 160 (4.1) 3/8 (9.6) 1/8 (3.2) 127 N2 - 25 (1.7) O

2 - 45 (3.1) Air

- 85 (5.86)

CS - 1/4 (6.4) 150 (3.8) 3/16 (4.8) 130 Air - 45 (3.1)

CS - 3/8 (9.6) 90 (2.3) 134 Air - 65 (4.48)

CS - 1/2 (12.7) 75 (1.9) 1/4 (6.4) 142

CS - 5/8 (15.8) 55 (1.4) 1/2 (12.7) 5/16 (8) 151 Air - 85 (5.86)

CS - 3/4 (19) 45 (1.1) 3/8 (9.6) 157 Air - 65 (4.48)

CS - 1 (25.4) 25 (.64) 5/16 (8) 160


Current(Amps)

PierceHeight

in.(mm)

CuttingHeight

in.(mm)

Arc Voltage(Volts)


2 cut gas.


2 Plasma/N



in. (mm)


psi(bar)


psi(bar)


psi(bar)

Travel Speed

ipm(m/min)

Nozzle - 200 Amp P/N 0558001883 Shield 100 - 250 Amp P/N 21802 Electrode - Hafnium P/N 0558001624 Diffuser 100 - 360 Amp P/N 21944Gas Baffle - 4 Hole P/N 0558002533 Pilot Arc - HIGH

4-insert

SECTION 4 OPERATION

SS - 1/2 (12.7) 60 (1.5) 1/4 (6.4) 154

SS - 3/4 (19) 18 (.45) 1/2 (12.7) 164 Air - 65 (4.48)

SS - 1 (25.4) 10 (.25) 5/16 (8) 179

SS - 1/2 (12.7) 150 40 (1.0) 3/8 (9.6) 5/16 (8) 160 N2 - 25 (1.7) H-35 - 55 (3.8) N

2 - 65 (4.48)

SS - 3/4 (19) 25 (.64) 1/2 (12.7) 3/8 (9.6) 175 N2 - 45 (3.1)

SS - 1 (25.4) 12 (.30) NR 180 N2 - 20 (1.37)

AL - 3/16 (4.8) 150 200 (5.1) 3/8 (9.6) 3/16 (9.6) 136 N2 - 25 (1.7) H-35 - 55 (3.8) N

2 - 65 (4.48)

AL - 1/4 (6.4) 150 (3.8) 1/4 (6.4) 141

AL - 3/8 (9.6) 110 (2.8) 145

AL - 1/2 (12.7) 90 (2.3) 5/16 (8) 155

Al - 3/4 (19) 50 (1.3) 1/2 (12.7) 3/8 (9.6) 166

AL - 1 (25.4) 30 (.76) 171

SS - 3/16 (4.8) 150 200 (5.1) 3/8 (9.6) 1/8 (3.2) 132 N2 - 25 (1.7) N

2 - 45 (3.1) Air - 85 (5.86)

SS - 1/4 (6.4) 130 (3.3) 3/16 (4.8) 140

SS - 3/8 (9.6) 85 (2.16) 143

Nozzle - 150 Amp P/N 0558001883 Shield 100 - 250 Amp P/N 21802Gas Baffle - 4 Hole P/N 0558002533 Diffuser 100 - 360 Amp P/N 21944 Pilot Arc - HIGH

Current(Amps)

PierceHeight

in.(mm)

CuttingHeight

in.(mm)

Arc Voltage(Volts)

Table 4-3. 150 Amp Data (Continued)


2 cut gas.


2 Plasma/N



in. (mm)


psi(bar)


psi(bar)


psi(bar)

Travel Speed

ipm(m/min)

Electrode - Hafnium P/N 0558002499

4-insert

SECTION 4 OPERATION

Nozzle - 200 Amp P/N 0558001884 Pilot Arc - HIGH Electrode - Hafnium P/N 0558001624 Gas Baffle - 4 Hole P/N 0558002533 Not a drop cut Shield 100 - 250 Amp P/N 21802 Piercing thicker than 1" (25.4mm) is not recommended. Diffuser 100 - 360 Amp P/N 21944 If attempting set shield gas to 85 psi (5.86 bar) or higher

CS - 1/4 (6.4) 200 150 (3.8) 3/8 (9.6) 1/8 (3.2) 143 Air - 30 (2.07) Air - 45 (3.1) Air - 65 (4.48) CS - 3/8 (9.6) 100 (2.54) 146

CS - 1/2 (12.7) 95 (2.4) 7/32 (5.5) 158 CS - 5/8 (15.8) 75 (1.9) 1/2 (12.7) 160 Air - 55 (3.8)

CS - 3/4 (19) 65 (1.65) 1/4 (6.4) 165

CS - 1 (25.4) 35 (.89) 3/8 (9.6) 180 Air - 65 (4.48)

CS - 1/4 (6.4) 200 170 (4.3) 3/8 99.6) 1/8 (3.2) 129 N2 - 30 (2.07) O

2 - 45 (3.1) Air - 65 (4.48)

CS - 3/8 (9.6) 110 (2.8) 3/16 (4.8) 133

CS - 1/2 (12.7) 95 (2.4) 7/32 (5.5) 136

CS - 5/8 (15.8) 75 (1.9) 1/2 (12.7) 139 Air - 55 (3.8)

CS - 3/4 (19) 55 (1.4) 1/4 (6.4) 142

CS - 1 (25.4) 40 (1.0) 3/8 (9.6) 155 Air - 65 (4.48)

SS - 1/4 (6.4) 200 140 (3.6) 3/8 (9.6) 1/8 (3.2) 142 Air - 30 (2.07) Air - 52 (3.6) Air - 85 (5.86)

SS - 3/8 (9.6) 125 (3.2) 3/16 (4.8) 150

SS - 1/2 (12.7) 85 (2.2) 154

SS - 3/4 (19) 55 (1.4) 1/2 (12.7) 3/8 (9.6) 174

SS - 1 (25.4) 20 (.50) 180

AL - 1/4 (6.4) 200 125 (3.2) 3/8 (9.6) 3/16 (4.8) 155 Air - 30 (2.07) Air - 52 (3.6) Air - 85 (5.86)

AL - 3/8 (9.6) 110 (2.8) 1/4 (6.4) 165

AL - 1/2 (12.7) 85 (2.2) 167

Al - 3/4 (19) 60 (1.5) 1/2 (12.7) 3/8 (9.6) 182

AL -1 (25.4) 40 (1.02) 189


Current(Amps)

PierceHeight

in.(mm)

CuttingHeight

in.(mm)

Arc Voltage(Volts)

Travel Speed

ipm(m/min)


psi(bar)


psi(bar)


psi(bar)

NOTES: CS - Carbon Steel, SS - Stainless Steel, AL - Aluminum All N

2 Plasma/Air Shield, 200 Amp cuts on Aluminum and Stainless Steel have fair surfaces except 1" (25.4mm) AL that is poor.


in.(mm)

4-insert

SECTION 4 OPERATION

SS - 1/2 (12.7) 200 50 (1.27) 1/2 (12.7) 3/8 (9.6) 163 N2 - 30 (2.07) H-35 - 52 (3.6) N

2 - 85 (5.86)

SS - 5/8 (15.8) 47 (1.2) 5/16 (8) 162

SS - 3/4 (19) 32 (.8) 3/8 (9.6) 169

SS - 1 (25.4) 17 (.43) 175

AL - 1/4 (6.4) 200 155 (3.9) 3/8 (9.6) 5/16 (8) 146 N2 - 30 (2.07) H-35 - 52 (3.6) N

2 - 65 (4.48)

AL - 3/8 (9.6) 120 (3) 1/4 (6.4) 148 N2 - 45 (3.1)

AL - 1/2 (12.7) 110 (2.8) 5/16 (8) 155

AL - 3/4 (19) 60 (1.5) 1/2 (12.7) 3/8 (9.6) 166 N2 - 85 (5.86)

AL - 1 (25.4) 40 (1.01) 169

AL - 1/4 (6.4) 200 180 (4.6) 3/8 (9.6) 3/16 (4.8) 151 N2 - 30 (2.07) N

2 - 35 (2.4) Air - 65 (4.48)

AL - 3/8 (9.6) 110 (2.8) 155

AL - 1/2 (12.7) 70 (1.8) 159

AL - 3/4 (19) 55 (1.4) 1/2 (12.7) 1/4 (6.4) 170

AL - 1 (25.4) 30 (.76) 177

SS - 1/4 (6.4) 200 165 (4.2) 3/8 (9.6) 1/4 (6.4) 148 N2 - 30 (2.07) N

2 - 35 (2.4) Air - 85 (5.86)

SS - 3/8 (9.6) 105 (2.7) 3/16 (4.8) 149

SS - 1/2 (12.7) 90 (2.3) 150 Air - 65 (4.48)

SS - 3/4 (19) 45 (1.1) 1/2 (12.7) 1/4 (6.4) 159 Air - 45 (3.1)

SS - 1 (25.4) 20 (.50) 169 Air - 65 (4.48)


in.(mm)

Current(Amps)

Table 4-4. 200 Amp Data (Continued)


psi(bar)

CuttingHeight

in.(mm)

PierceHeight

in.(mm)


psi(bar)


psi(bar)

Arc Voltage(Volts)

NOTES: SS - Stainless Steel, AL - Aluminum Stainless Steel 3/8" (9.6mm) and thinner is NOT recommended for H-35 plasma gas - heavy dross

Travel Speed

ipm(m/min)

Nozzle - 200 Amp P/N 0558001884 Pilot Arc - HIGH Gas Baffle - 4 Hole P/N 0558002533 Shield 100 - 250 Amp P/N 21802 Diffuser 100 - 360 Amp P/N 21944

Electrode - Hafnium P/N 0558002499

4-110

SECTION 4 OPERATION

PT-600 Components

The PT-600 is a mechanized plasma cutting torch designed for cutting without water injection. Cutting can be performed using air, oxygen, nitrogen or H-35 as the cut gas at currents ranging from 50 to 360 amperes. Underwater cutting can be performed with the PT-600 by using an Air Curtain at 150 amps or higher. Refer to F15-475 for Air Curtain information.

CUTTING PARAMETERS FOR THE ESP-1000

Nozzle Retainer Cup - 37082

Gas Bafflesee chart

Electrode Holder - 37068

Electrodesee chart

Shield see chart

Nozzle Assemblysee chart

Shield Retainer - 37081

Diffusersee chart

Torch Sleeve

Torch Body

O-ring (supplied with electrode holder)

O-ring (supplied with electrode)

O-ring (supplied with nozzle)

O-ring (supplied with nozzle)

4-111

SECTION 4 OPERATION

Current & Thickness Shield Diffuser Nozzle Electrode Gas BafflePlasma Gas & Material

50-65A 1.16 to 6mm 50A 50A 0558001881 0558001624 or 0558002533Air & N

2 CS, SS, AL 21795 21796 0558001624 (UL) 4 Hole STD

100A 4 to 19mm 100A-250A 100-360A 0558001882 0558001624 or 0558002533Air, N

2, O

2 CS, SS, AL 21802 21944 0558001624 (UL) 4-Hole STD

0558002534 22496Rev. 4 Hole Rev

150A 6 to 25mm 100A-250A 100 -360A 0558001883 0558001624 or 0558002533Air, N

2, O

2 CS, SS, AL 21802 21944 0558001624 (UL) 4 Hole STD

0558002534 22496Rev. 4 Hole Rev.

150A 6 to 25mm 100A-250A 100-360A 0558001883 0558002499 0558002533N

2, H35 SS, AL 21802 21944 4 Hole STD

0558002534 22496Rev. 4 Hole Rev.

200A 6 to 50mm 100A - 250A 100 - 360A 0558001884 0558001624 0558002533Air, N

2, O

2 CS, SS, AL 21802 21944 4 Hole STD

0558002534 22496Rev. 4 Hole Rev.

200A 6 to 38mm 100A-250A 100-360A 0558001884 0558002499 0558002533N

2, H35 SS, AL 21802 21944 4 Hole STD

0558002534 22496Rev. 4 Hole Rev.

250A 6 to 50mm 100A-250A 100-360A 0558001623 0558001624 0558001625Air, O

2 CS, SS, AL 21802 21944 8 x .047

0558002530 22496Rev. 8 x .047 Rev.

250A 6 to 50mm 100A-250A 100-360A 0558001623 0558002499 0558001625N

2, H35 SS, AL 21802 21944 8 x .047

0558002530 22496Rev. 8 x .047 Rev.

325-360A 13 to 50mm 360A 100-360A 0558001885 0558001624 0558001625Air, N

2, O

2 CS, SS, AL 21945 21944 8 x .047

0558002530 22496Rev. 8 x .047 Rev.

325-360A 13 to 50mm 360A 100A-360A 0558001885 0558002499 0558001625N

2,H35 CS, SS, AL 21945 21944 8 x .047

0558002530 22496Rev. 8 x .047 Rev.

400-450A 19 to 50mm 360A 100A-360A 0558001886 0558002516 or 22194O

2 CS, SS, AL 21945 21944 0558002516 (UL) 32 x .023

400-450A 19 to 50mm 360A 100A-360A 0558001886 0558002499 0558001625N

2, H35 AL, SS 21945 21944 8 x .047

0558002530 22496Rev. 8 x .047Rev.

600A 25 to 75mm 360A 100-360A 0558001887 0558002499 0558001625N

2, H35 CS, SS, AL 21945 21944 8 x .047

0558002530 22496Rev. 8 x .047Rev.

Application Recommended Replacement Parts

COMPONENT SELECTION FOR PT-600

4-112

SECTION 4 OPERATION

Figure 4-1. PT-600 Regulator Assembly

ADAPTOR999304

B-OXY -F*

1/4 NPTM*

1/4 NPTF*

CHECK VALVEASSEMBLY - 21124

1/4 NPTM*

HEX. NIPPLE639501

AIR REGULATORASSEMBLY -522368

(2) 1/8" NPTPIPE PLUGS643792

1/4 NPTF*

CONNECTOR3389

1/4 NPTM*B-OXY-M*

* Use Locktite pipe sealant on threads, DO NOT use Teflon tape.

LOW CURRENT CUTTING WITH AIR (50 to 100 Amps)

1. Ensure that the correct components are assembled in the PT-600 for the cutting conditions.

2. To cut with air, disconnect N2 supply from the Flow Control. Connect a supply of clean, filtered air (approximately 100

psig to the N2 inlet on the Flow Control.

3. For low current cutting with the PT-600 and ESP-1000 a cut gas regulator system is required for air. See figure 4-1 for assembly details.

4. Set the O2/N

2 switch to N

2 position.

5. Place CUT WATER switch to OFF.

6. Set CUT GAS Flow Rate.

7. Position TEST/RUN switch to RUN 1.

8. Set start gas pressure as follows:

A. TEST/RUN switch to START GAS TEST.

B. Adjust start gas regulator to 30 psig.

C. Return TEST/RUN switch to RUN 1.

9. Set cut gas pressure as follows:

A. TEST/RUN switch to CUT GAS TEST

B. Adjust cut gas regulator to 60 psig.

C. Return TEST/RUN switch to RUN 1 position.

4-113

SECTION 4 OPERATION

OXYGEN AND AIR CUTTING WITH PT-600 (100-360AMPS)

1. Ensure that the torch is assembled correctly for oxygen or air cutting at the selected current level. See Table 4-5 for parts and setup information.

2. If using PT-600 air curtain, see Form F15-475 for correct installation and setup.3. Set Flow Control O

2/N

2 switch to O

2 position.

4. Set Flow Control Cut Water ON/OFF switch to OFF.5. Set CUT GAS Flow per Cutting Tables starting on page 50.6. Set Flow Control TEST/RUN switch to CUT GAS TEST. Check that O

2 regulator is set at 100 psig.

7. Set Flow Control TEST/RUN switch to START GAS TEST switch. Adjust Start Gas regulator, on Plumbing Box, to 25 psig. Check that N

2 regulator is set to 100 psig.

8. Purge torch in START GAS TEST position for at least 60 seconds before cutting after changing consumables.9. Set Flow Control TEST/RUN switch in the RUN 1 position. The system is ready for cutting.

ELECTRIC SHOCK CAN KILL! BEFORE TOUCHING TORCH, BE SURE POWER SOURCE IS SHUT OFF BY TURNING OFF THE 3-PHASE POWER INPUT TO THE POWER SOURCE.

PT-600 NITROGEN CUTTING AT 150 AND 250 AMPS

1. Ensure that the torch is assembled correctly for nitrogen cutting at the selected current level. See Table 4-5 for parts and setup information.

2. If using a PT19XLS air curtain, see Form F15-475 for correct installation and setup.3. Set Flow Control O

2/N

2 switch to N

2 position.

4. Set Flow Control CUT WATER ON/OFF switch to OFF position.5. Set CUT GAS flow per Cutting Tables starting on page 50.6. Set Flow Control TEST/RUN switch to START GAS TEST. Adjust Start Gas Regulator, on Plumbing Box, to 26 psig. Check

that N2 regulator is set to 100 psig

7. Purge torch in CUT GAS TEST position for at least 60 seconds after changing consumables before cutting.8. Set Flow Control TEST/RUN switch to RUN 1. The system is now ready to cut.

PT-600 H-35 CUTTING AT 150 TO 300 AMPS

H-35 is a mixture of hydrogen and argon that can be used with the PT-600 for cutting stainless and aluminum. This mixture is flammable requiring certain precautions. Underwater cutting with H-35 is not recommended.

1. Install H-35 torch parts for the chosen current level per Table 4-5.2. Set the Flow Control O

2/N

2 switch in the N

2 position.

3. Set Flow Control CUT WATER ON/OFF switch to OFF.4. Purge gas lines:

A. Disconnect O2, with the Flow Control in the CUT GAS TEST position, purge with N

2 for three minutes.

B. Connect H-35 to the Flow Control N2 Inlet connection and purge N

2 from the lines for 60 seconds.

5. Check H-35 regulator for setting of 100 psig.6. Adjust gas setting per Cutting Tables. The system is now ready to cut.

WARNING

4-114

SECTION 4 OPERATION

3-8. HIGH CURRENT CUTTING CONDITIONS PT-600

By using special components in the front end assembly of the PT-600 cutting can be accomplished at higher current and faster speeds. Cutting carbon steel can be performed either above water of underwater, cutting stainless steel and aluminum underwater is not recommended.

The cutting speeds listed in the following tables are average values. Variations may occur depending on material composition, surface conditions, etc. Practice cuts in a scrap area of new material are recommended before starting production cuts.

TORCH COMPONENTS FOR HIGH CURRENT CUTTING

NOZZLE 360A P/N 0558001885

ELECTRODE 360A P/N 0558002516 UL

HEAT SHIELD 360A P/N 21945

DIFFUSER 360A P/N 21944

BAFFLE 8-HOLE P/N 0558001625

START GAS N2 @ 25 PSIG

4-115

SECTION 4 OPERATION

CUTTING TABLES FOR PT-600A. To use the 50A or 100A nozzles with the ESP-1000 System, you must install a regulator at the Cut Gas connection on

the Plumbing Box.

B. Cut Gas & Start Gas input pressures to the flow control should be 100 psig (6.9 Bar) for all Nozzles and Gases.

PROCESS PARAMETERS MATERIAL GAS SET UP ARC ARC TRAVEL THICKNESS STANDOFF VOLTAGE CURRENT SPEED START CUT SHIELD PIERCE CUT IN MM PSI/BAR PSI/BAR @ 60 PSI/4BAR IN MM IN MM IPM MM/MIN

.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 111 50 180 4572 .125 3 30/2.1 60/4 2.2 .250 6 .156 4 119 65 80 2032 .250 6 30/2.1 60/4 3.5 .250 6 .156 4 118 65 60 1524


.063 1.6 30/2.1 60/4 2.2 .250 6 .125 3 115 50 180 4572

.125 3 30/2.1 60/4 2.2 .250 6 .125 3 115 50 110 2294

.250 6 30/2.1 60/4 3.5 .250 6 .156 4 128 65 65 1651


.063 1.6 30/2.1 60/4 2.2 .250 6 .125 3 118 50 180 4572

.125 3 30/2.1 60/4 2.2 .250 6 .125 3 117 50 120 3048

.250 6 30/2.1 60/4 3.5 .250 6 .125 3 125 65 70 1778

Cutting Data:NOZZLEMATERIAL

START GASCUT GASSHIELD GAS

50ALUMINUM

AIRAIRAIR

PT-60050-65 AMP



50ALUMINUM

N2

N2

N2

PT-60050-65 AMP



50STAINLESS STEEL

AIRAIRAIR

PT-60050-65 AMP

4-116

SECTION 4 OPERATION PROCESS PARAMETERS

MATERIAL GAS SET UP ARC ARC TRAVEL THICKNESS STANDOFF VOLTAGE CURRENT SPEED START CUT SHIELD PIERCE CUT IN MM PSI/BAR PSI/BAR @ 60 PSI/4BAR IN MM IN MM IPM MM/MIN

.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 119 50 180 4572

.125 3 30/2.1 60/4 2.2 .250 6 .156 4 125 65 80 2032

.250 6 30/2.1 60/4 3.5 .250 6 .156 4 127 65 55 1397


.063 1.6 30/2.1 60/4 2.2 .250 6 .156 4 115 50 220 5588

.125 3 30/2.1 60/4 2.2 .250 6 .125 3 112 50 120 3048

.125 3 30/2.1 60/4 2.2 .250 6 .125 3 110 65 120 3048

.187 5 30/2.1 60/4 2.2 .250 6 .156 4 118 65 95 2413

.250 6 30/2.1 60/4 3.5 .250 6 .156 4 120 65 80 2032



50ALUMINUM

N2

N2

N2



100ALUMINUM

AIRAIRAIR

PROCESS PARAMETERSMATERIAL GAS SET UP ARC ARC TRAVEL THICKNESS STANDOFF VOLTAGE CURRENT SPEED START CUT SHIELD PIERCE CUT IN MM PSI/BAR PSI/BAR @ 60 PSI/4BAR IN MM IN MM IPM MM/MIN

.250 6 25/1.7 45/3.1 3.5 .375 10 .187 5 154 100 100 2540.375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 174 100 70 1778.500 13 25/1.7 45/3.1 4.4 .375 10 .312 8 183 100 50 1270.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 30 762



50CARBON STEEL

AIRAIRAIR

PT-60050-65 AMP

PT-60050-65 AMP

PT-600100 AMP

4-117

SECTION 4 OPERATION


.250 6 25/1.7 35/2.4 4.4 .375 10 .125 3 153 100 55 1397

.375 10 25/1.7 35/2.4 4.4 .375 10 .187 5 157 100 45 1143

.500 13 25/1.7 35/2.4 4.4 .375 10 .187 5 162 100 35 889

.750 19 25/1.7 35/2.4 3.5 .500 13 .312 8 185 100 13 330


.250 6 25/1.7 45/3.1 4.4 .375 10 .125 3 154 100 55 1397

.375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 165 100 35 889

.500 13 25/1.7 45/3.1 3.5 .375 10 .312 8 180 100 25 635

.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 189 100 10 254



100STAINLESS STEEL

AIRAIRAIR

PT-600100 AMP


.250 6 25/1.7 35/2.4 4.4 .375 10 .125 3 153 100 55 1397

.375 10 25/1.7 35/2.4 4.4 .375 10 .187 5 157 100 45 1143

.500 13 25/1.7 35/2.4 4.4 .375 10 .187 5 162 100 35 889

.750 19 25/1.7 35/2.4 3.5 .500 13 .312 8 185 100 13 330



100STAINLESS STEEL

N2

N2

AIR

PT-600100 AMP



100STAINLESS STEEL

N2

N2

N2

PT-600100 AMP

4-118

SECTION 4 OPERATION

PROCESS PARAMETERS


.188 4 25/1.7 45/3.1 4.4 .375 10 .156 4 135 100 150 3810

.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 133 100 120 3048

.375 10 25/1.7 45/3.1 4.4 .375 10 .250 6 149 100 80 2032

.500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 141 100 60 1524

.625 16 25/1.7 45/3.1 3.5 .500 13 .312 8 159 100 37 940

.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 162 100 20 508


.188 4 20/1.4 LOW 3 4.4 .375 10 .187 5 148 150 200 5080

.250 6 20/1.4 LOW 3 4.4 .375 10 .187 5 149 150 140 3556

.375 10 20/1.4 LOW 3 3.5 .375 10 .250 6 159 150 105 2667

.500 13 20/1.4 LOW 3 4.4 .375 10 .312 8 174 150 80 2032

.750 19 20/1.4 LOW 3 3.5 .500 13 .312 8 180 150 45 1143 1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 184 150 30 762

PROCESS PARAMETERS MATERIAL GAS SET UP ARC ARC TRAVEL THICKNESS STANDOFF VOLTAGE CURRENT SPEED START CUT SHIELD PIERCE CUT IN MM PSI/BAR PSI/BAR @ 60 PSI/4BAR IN MM IN MM IPM MM/MIN.188 4 25/1.7 45/3.1 5.2 .375 10 .125 3 148 100 150 3810.250 6 25/1.7 45/3.1 4.4 .375 10 .156 4 154 100 120 3048.375 10 25/1.7 45/3.1 4.4 .375 10 .187 5 159 100 65 1651.500 13 25/1.7 45/3.1 3.5 .375 10 .187 5 162 100 50 1270.625 16 25/1.7 45/3.1 3.5 .500 13 .281 7 175 100 35 889.750 19 25/1.7 45/3.1 3.5 .500 13 .312 8 184 100 20 508

PT-600100 AMP



100CARBON STEEL

AIRAIRAIR



150ALUMINUM

AIRAIRAIR



100CARBON STEEL

N2

O2

AIR

PT-600100 AMP

PT-600 150 AMP

4-119

SECTION 4 OPERATION


.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 132 150 200 5080

.250 6 20/1.4 LOW 3 4.4 .375 10 .187 5 140 150 130 3302

.375 10 20/1.4 LOW 3 4.4 .375 10 .187 5 143 150 85 2159

.500 13 20/1.4 LOW 3 4.4 .375 10 .250 6 154 150 60 1524

.750 19 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 18 457 1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 179 150 10 254


.188 4 20/1.4 LOW 3 4.4 .375 10 .187 5 138 150 200 5080

.250 6 20/1.4 LOW 3 3.5 .375 10 .187 5 146 150 165 4191

.375 10 20/1.4 LOW 3 3.5 .375 10 .250 6 155 150 95 2413

.500 13 20/1.4 LOW 3 3.5 .375 10 .312 8 163 150 60 1524

.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 175 150 25 635 1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 185 150 15 381



150STAINLESS STEEL

AIRAIRAIR

PT-600150 AMP

PROCESS PARAMETERS MATERIAL GAS SET UP ARC ARC TRAVEL

THICKNESS STANDOFF VOLTAGE CURRENT SPEED START CUT SHIELD PIERCE CUT IN MM PSI/BAR PSI/BAR @ 60 PSI/4BAR IN MM IN MM IPM MM/MIN.188 4 20/1.4 LOW 4 3.5 .375 10 .187 5 136 150 200 5080.250 6 20/1.4 LOW 4 3.5 .375 10 .250 6 141 150 150 3810.375 10 20/1.4 LOW 4 3.5 .375 10 .250 6 145 150 110 2794.500 13 20/1.4 LOW 4 3.5 .375 10 .312 8 155 150 90 2286.750 19 20/1.4 LOW 4 3.5 .500 13 .375 10 166 150 50 1270 1 25 20/1.4 LOW 4 3.5 .500 13 .375 10 171 150 30 762



150ALUMINUM

N2 OR H-35

H-35N

2



150STAINLESS STEEL

N2

N2

AIR

PT-600150 AMP

PT-600 150 AMP

4-120

SECTION 4 OPERATION


.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 127 150 160 4064

.250 6 20/1.4 LOW 3 2.6 .375 10 .187 5 130 150 150 3810

.375 10 20/1.4 LOW 3 3.5 .375 10 .187 5 134 150 90 2286

.500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 142 150 75 1905

.625 16 20/1.4 LOW 3 4.4 .500 13 .312 8 151 150 55 1397

.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 157 150 45 1143 1 25 20/1.4 LOW 3 3.5 .500 13 .312 8 160 150 25 635


.188 4 20/1.4 LOW 3 4.4 .375 10 .125 3 143 150 160 4064

.250 6 20/1.4 LOW 3 3.1 .375 10 .125 3 145 150 140 3556

.375 10 20/1.4 LOW 3 3.1 .375 10 .187 5 156 150 90 2286

.500 13 20/1.4 LOW 3 3.5 .375 10 .250 6 160 150 75 1905

.625 16 20/1.4 LOW 3 3.5 .500 13 .250 6 164 150 50 1270

.750 19 20/1.4 LOW 3 3.5 .500 13 .375 10 179 150 45 1143 1 25 20/1.4 LOW 3 3.5 .500 13 .375 10 184 150 25 635


.250 6 25/1.7 LOW 4 3.5 .375 10 .312 8 146 200 155 3937

.375 10 25/1.7 LOW 4 2.6 .375 10 .250 6 148 200 120 3048

.500 13 25/1.7 LOW 4 2.6 .375 10 .312 8 155 200 110 2794 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 166 200 60 1524 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 40 1016 1.25 32 25/1.7 LOW 4 4.4 NR NR .375 10 175 200 26 660



150CARBON STEEL

N2

O2

AIR



200ALUMINUM

N2 or H-35

H-35N

2



150CARBON STEEL

AIRAIRAIR

PT-600 150 AMP

PT-600 200 AMP

PT-600 150 AMP

4-121

SECTION 4 OPERATION


.250 6 25/1.7 LOW 4 3.5 .375 10 .187 5 151 200 180 4572

.375 10 25/1.7 LOW 4 3.5 .375 10 .187 5 155 200 110 2794

.500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 159 200 70 1778 .750 19 25/1.7 LOW 4 3.5 .500 13 .250 6 170 200 55 1397 1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 177 200 30 762


.250 6 25/1.7 LOW 4 4.4 .375 10 .187 5 155 200 125 3175

.375 10 25/1.7 LOW 4 4.4 .375 10 .250 6 165 200 110 2794

.500 13 25/1.7 LOW 4 4.4 .375 10 .250 6 167 200 85 2159 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 182 200 60 1524 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 189 200 40 1016



200ALUMINUM

AIRAIRAIR


.500 13 25/1.7 LOW 4 4.4 .500 13 .375 10 163 200 50 1270

.625 19 25/1.7 LOW 4 4.4 .500 13 .312 8 162 200 47 1194

.750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 169 200 32 813 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 175 200 17 4321.25 32 25/1.7 LOW 4 3.5 NR NR .500 13 191 200 10 254 1.50 38 25/1.7 LOW 4 3.5 NR NR .625 16 203 200 8 203



200STAINLESS STEEL

N2 OR H-35

H-35N

2



200ALUMINUM

N2

N2

AIR

PT-600 200 AMP

PT-600 200 AMP

PT-600 200 AMP

4-122

SECTION 4 OPERATION


.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 143 200 150 3810

.375 10 25/1.7 LOW 4 3.5 .375 10 .125 3 146 200 100 2540

.500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 158 200 95 2413 .625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 160 200 75 1905 .750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 165 200 65 1651 1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 180 200 35 8891.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 182 200 25 635 1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 189 200 15 3801.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 201 200 10 255 2 50 25/1.7 LOW 4 2.2 NR NR .375 10 211 200 6 152


.250 6 25/1.7 LOW 4 4.4 .375 10 .250 6 158 200 165 4191

.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 149 200 105 2667

.500 13 25/1.7 LOW 4 3.5 .375 10 .187 5 150 200 90 2286 .750 19 25/1.7 LOW 4 2.6 .500 13 .250 6 159 200 45 1143 1 25 25/1.7 LOW 4 3.5 .500 13 .250 6 169 200 20 508


.250 6 25/1.7 LOW 4 4.4 .375 10 .125 3 142 200 140 3556

.375 10 25/1.7 LOW 4 4.4 .375 10 .187 5 150 200 125 2667

.500 13 25/1.7 LOW 4 4.4 .375 10 .187 5 154 200 85 2159 .750 19 25/1.7 LOW 4 4.4 .500 13 .375 10 174 200 55 1397 1 25 25/1.7 LOW 4 4.4 .500 13 .375 10 180 200 20 508



200STAINLESS STEEL

AIRAIRAIR



200STAINLESS STEEL

N2

N2

AIR



200STAINLESS STEEL

AIRAIRAIR

PT-600 200 AMP

PT-600 200 AMP

PT-600 200 AMP

4-123

SECTION 4 OPERATION


.250 6 25/1.7 LOW 5 4.0 .375 10 .125 3 130 250 170 4318

.375 10 25/1.7 LOW 5 4.0 .375 10 .187 5 135 250 125 3175

.500 13 25/1.7 LOW 5 4.0 .500 13 .219 5.6 138 250 100 2540 .750 19 25/1.7 LOW 5 4.0 .500 13 .250 13 142 250 65 1650 1 25 25/1.7 LOW 5 4.0 .500 13 .375 10 155 250 50 1270


.250 6 25/1.7 LOW 4 3.5 .375 10 .125 3 129 200 170 4318

.375 10 25/1.7 LOW 4 3.5 .375 10 .187 4 133 200 110 2794

.500 13 25/1.7 LOW 4 3.5 .375 10 .218 5.5 136 200 95 2413 .625 16 25/1.7 LOW 4 3.1 .500 13 .218 5.5 139 200 75 1905 .750 19 25/1.7 LOW 4 3.1 .500 13 .250 6 142 200 55 1397 1 25 25/1.7 LOW 4 3.5 .500 13 .375 10 155 200 40 10161.25 32 25/1.7 LOW 4 2.2 NR NR .375 10 164 200 25 635 1.50 38 25/1.7 LOW 4 2.2 NR NR .375 10 166 200 20 5081.75 45 25/1.7 LOW 4 2.2 NR NR .375 10 185 200 10 255 2 50 25/1.7 LOW 4 2.2 NR NR .500 13 205 200 5 127


.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 130 325 130 4572

.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 132 325 90 2286 1 25 25/1.7 LOW 5 7.5 .625 16 .250 6 141 325 55-65 1.25 32 25/1.7 LOW 5 7.5 .625 16 .250 6 146 325 35-40



200STAINLESS STEEL

N2

O2

AIR

PT-600 200 AMP



360CARBON STEEL

N2

O2

AIR

PT-600 325 AMP



250CARBON STEEL

N2

O2

AIR

PT-600 250 AMP

4-124

SECTION 4 OPERATION


1 25 25/1.7 HIGH 5 8.7 .625 16 .625 16 190 360 30 762


.250 6 25/1.7 HIGH 5 8.7 .500 13 .250 6 160 360 230 5842

.500 13 25/1.7 HIGH 5 7.5 .625 16 .250 6 163 360 110 2794 .750 19 25/1.7 HIGH 5 8.7 .625 16 .375 10 176 360 80 2032 1 25 25/1.7 HIGH 5 8.7 .625 16 .500 13 192 360 45 1143



360STAINLESS STEEL

N2

N2

AIR



360STAINLESS STEEL

H-35 or N2

H-35 N

2

PT-600 360 AMP


.500 13 25/1.7 LOW 5 6.7 .625 16 .187 4 132 360 140 3556

.750 19 25/1.7 LOW 5 6.7 .625 16 .187 4 135 360 90-100 1 25 25/1.7 LOW 5 8.7 .625 16 .250 6 141 360 65-70 1.25 32 25/1.7 LOW 5 8.7 .625 16 .250 6 146 360 45 1143 1.50 38 25/1.7 LOW 5 8.7 .625 16 .312 8 153 360 30-35



360CARBON STEEL

N2

O2

AIR

PT-600 360 AMP

PT-600 360 AMP

4-125

SECTION 4 OPERATION


.250 6 25/1.7 LOW 7 9.5 .500 13 .375 10 158 360 250 6350

.500 13 25/1.7 LOW 7 9.5 .625 16 .375 10 160 360 160 4064 .750 19 25/1.7 LOW 7 9.5 .625 16 .375 10 164 360 90 3386 1 25 25/1.7 LOW 7 9.5 .625 16 .375 10 171 360 60 1524



360ALUMINUM

N2

N2

N2

PT-600 360 AMP



H-35H-35 or N

2

N2


.500 13 25/1.7 HIGH 1 9.5 .625 16 .375 10 157 360 150 3810 .750 19 25/1.7 HIGH 1 9.5 .625 16 .375 10 176 360 90 2286 1 25 25/1.7 HIGH 1 9.5 .625 16 .375 10 180 360 60 1524

360STAINLESS STEEL


.750 19 25/1.7 LOW 7 7 .625 16 .188 4 134 400 110 2794 1 25 25/1.7 LOW 7 7 .625 16 .250 6 140 400 80 2032 1.25 32 25/1.7 LOW 7 4.5 .625 16 .438 11 150 400 60 15241.50 38 25/1.7 LOW 7 3 .625 16 .438 11 155 400 42 1067



400CARBON STEEL

N2

O2

AIR

PT-600 400 AMP

PT-600 360 AMP

4-126

SECTION 4 OPERATION


.750 19 25/1.7 LOW 7 7 .625 16 .375 10 160 450 100 2540 1 25 25/1.7 LOW 7 7 .625 16 .250 6 163 450 70 1778 1.25 32 25/1.7 LOW 7 4.5 .625 16 .375 10 176 450 52 13211.50 38 25/1.7 LOW 7 3 .625 16 .500 13 192 450 33 838


1 25 RUN 2 HIGH 4 8* .750 19 .625 16 172 600 80* 2032*1.50 38 RUN 2 HIGH 4 8* .750 19 .625 16 177 600 65* 1651* 2 50 RUN 2 HIGH 4 8* moving .750 19 192 600 30* 762* 3 75 RUN 2 HIGH 4 8 moving .750 19 212 600 15 381



450STAINLESS STEEL

N2

N2

AIR

PT-600 450 AMP

H-35 H-35 N

2


.750 19 25/1.7 HIGH 0 6.5 .625 16 .312 8 132 410 140 3556 1 25 25/1.7 HIGH 0 6.5 .625 16 .438 11 135 410 110 2794 1.25 32 25/1.7 HIGH 0 6.5 .625 16 .500 13 141 410 85 21591.50 38 25/1.7 HIGH 0 6.5 .625 16 .500 13 146 410 65 1651 2 50 25/1.7 HIGH 0 6.5 .625 16 .500 13 153 410 45 1143



400ALUMINUM

H-35H-35N

2

PT-600 410 AMP


600ALUMINUM

PT-600 600 AMP

PROCESS PARAMETERS

PROCESS PARAMETERS

4-127

SECTION 4 OPERATION


1.50 38 RUN 2 HIGH 4 8 .750 19 .625 16 172 600 75 1905 2 50 RUN 2 HIGH 4 6 moving .750 19 192 600 40 1016 3 75 RUN 2 HIGH 4 8 moving .750 19 205 600 20 508



600ALUMINUM

H-35H-35Air

PT-600 600 AMP



N2

N2

AIR

PT-600 600 AMP PROCESS PARAMETERS


1 25 RUN 2 HIGH 0 8 .625 16 .375 10 158 600 100 25401.50 38 RUN 2 HIGH 0 7 .625 16 .375 10 168 600 60 1524

600ALUMINUM


1 25 RUN 2 HIGH 4 8 .750 19 .500 13 163 600 40 10161 .50 38 RUN 2 HIGH 4 8 .750 19 .625 16 186 600 18 457 2 50 RUN 2 HIGH 4 6 moving .750 19 204 600 12 305 3 75 RUN 2 HIGH 4 8 moving .750 19 206 600 9 229



600STAINLESS STEEL

H-35H-35N

2

PT-600 600 AMP

4-128

SECTION 4 OPERATION



N2

N2

AIR

PT-600 600 AMP PROCESS PARAMETERS


1 25 RUN 2 HIGH 0 8 .625 16 .500 13 160 600 70 17781.5 38 RUN 2 HIGH 0 8 .625 16 .500 13 163 600 40 1016

600STAINLESS STEEL

Notes on 600A Cutting

H-35 plasma gas/nitrogen shield produces good to excellent cut quality on 1" to 3" aluminum. H-35 plasma gas/air shield produces cut quality nearly as good on 1-1/2" to 3" aluminum. Nitrogen plasma gas/air shield produces fair quality cuts on 1“ to 1-1/2 “ aluminum.

H-35 plasma gas/nitrogen shield yields the best quality on 1“ to 3“ stainless steel, with smooth surfaces and moderate quantities of dross. Nitrogen plasma gas/air shield may be used to achieve good cuts on 1“ and fair cuts on 1-1/2“ stainless steels at higher speeds than H-35.

Piercing of plate 2" to 3" thick is best accomplished with the moving pierce technique: Start the arc at 3/4" standoff, 250 amps, and 35 to 40 ipm. Immediately upon arc transfer, raise the standoff to a cutting voltage of 225 to 240 volts. After the arc has been on about one second, ramp the current up to 600 amps over a two second interval. After another two second delay, reduce the speed to about half the recommended cutting speed until the arc burns through the plate.

SECTION 5 Maintenance

5-1

WARNING!

–

Electric Shock Can Kill!

Before performing torch maintenance:

• Turn power switch of the power source console to the OFF position

• Disconnect primary input power. 5.1 Introduction

Wear on torch parts is a normal occurrence to plasma cutting. Starting a plasma arc is an erosive process to both the electrode and nozzle. Regularly scheduled inspection and replacement of PT-600 parts must take place to maintain cut quality and consistent part size.

5.2 Torch Body

O-Ring Locations

• Inspect O-rings daily and replace if damaged or worn.

• Apply a thin coat of silicone grease, P/N 77500101 to O-rings before assembling torch. This facilitates easy future assembly and disassembly for service.

• O-ring part number 996528 (1.61 I.D. X .070 BUNA-70A)

Contact Ring

Contact Ring

• Keep electrical contract ring (P/N 0558003858) contact points free of grease and dirt.

• Inspect ring when changing nozzle. • Clean with cotton swab dipped in isopropyl

alcohol.


5-2

CAUTION

WARNING! Hot Torch Will Burn Skin!

Allow torch to cool before servicing.

5.3 Torch Front End Disassembly

Gas Diffuser Shield

Shield Retainer

1. Remove shield retainer.

NOTE: If the shield retainer is difficult to remove, try to screw the nozzle retainer tighter to relieve pressure on the shield.

2. Inspect mating metal surface of shield and retainer for nicks or dirt that might prevent these two parts from forming a metal to metal seal. Look for pitting or signs of arcing inside the shield. Look for melting of the shield tip. Replace if damaged.

3. Inspect diffuser for debris and clean as necessary. Wear on the top notches does occur, effecting gas volume. Replace this part about every other shield replacement. Heat from cutting many small parts in a concentrated area or when cutting material greater than 0.75" (19.1mm) may require more frequent replacement.

Incorrect assembly of the diffuser in the

shield will prevent the torch from working properly. Diffuser notches must be mounted away from the shield as illustrated.


5-3

–

Nozzle

Nozzle retainer

4. Unscrew nozzle retainer and pull nozzle straight out of torch body.

Inspect insulator portion of the nozzle retainer for cracks or chipping. Replace if damaged.

Inspect nozzle for:

• melting or excessive current transfer,

• gouges from internal arcing

• nicks or deep scratches on the O-ring seating surfaces.

• O-ring (P/N996528) cuts, nicks, or wear

• Remove hafnium particles (from the electrode) with steel wool.

Replace if any damage is found.

NOTE: Discoloration of internal surfaces and small black starting marks are normal and do not effect cutting performance.

Electrode Holder

Gas Baffle

Electrode

Electrode Removal Tool

5. Remove electrode using electrode removal tool (P/N 996568). If the holder was tightened sufficiently, the electrode should unscrew without being attached to the electrode holder as shown. When installing the electrode, use only sufficient force to create a water seal on the electrode O-ring

Electrode Holder Removal Tool


5-4

6. Disassemble electrode from electrode holder. Insert flats on the holder into the slot cut in the end of holder tool. Using the electrode tool, rotate electrode counter-clockwise to remove. Replace electrode if center insert is pitted more than 0.09" (3/32").

Lugs on holder removal tool

Electrode Holder Removal Tool

Slots in Holder

7. Remove electrode holder from torch body. Lugs on the end of the holder removal tool (P/N 0558001628) will engage in slots on the holder (inside the gas baffle)

O-Ring

Gas Baffle

NOTE: The electrode holder is manufactured in two pieces. Do not disassemble. If the holder is damaged, replace the holder assembly, P/N 0558001621

Electrode Holder

8. Disassemble electrode holder and gas baffle. Carefully remove O-ring from electrode holder and slide baffle from holder. Inspect nozzle seating surface (front edge) for chips. Look for cracks or plugged holes. Do not attempt to clear holes. Replace baffle if damaged.

NOTE: Check all O-rings for nicks or other damage that might prevent O-ring forming a gas/water tight seal.


5-5

CAUTION Over tightened Parts Will Be Difficult To Disassemble And May Damage Torch. Do not over tighten parts during reassembly. Threaded parts are designed to work properly when hand tightened, approximately 40 to 60 inch/pounds

5.4 Assembly Of Torch Front End

Nozzle

• Reverse order of disassembly.

• Apply a thin coat of silicone grease, P/N 77500101 to O-rings before assembling mating parts. This will facilitate disassembly in the future.

• Hand-tighten threaded parts.

• Installing the electrode requires only moderate hand tightening. Electrode holder should always be made tighter than the electrode.

NOTE: When assembling, place the nozzle inside the nozzle retainer and thread the retainer/nozzle combination on the torch body. This will help align the nozzle with the assembly.

Nozzle Retainer


5-6

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SECTION 6 Troubleshooting

6-1

6.1 Reduced Consumable Life

Cutting Up SkeletonsCutting Up SkeletonsCutting Up SkeletonsCutting Up Skeletons Cutting skeletons (discarded material left after all pieces have been removed from a plate). Their removal from the table can adversely affect electrode life by:

• Causing the torch to run off the work.

• Continuous pilot Arc edge starts

• Greatly increasing the start frequency. This is mainly a problem for O2 cutting and can be alleviated by choosing a path with a minimum number of starts.

• Increasing 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.

If possible, use a gas torch for skeleton cutting.

Height Control ProblemsHeight Control ProblemsHeight Control ProblemsHeight Control Problems • Torch diving is usually caused by a change in arc voltage when an automatic height control is used. The voltage change is usually the result of plate falling away from the arc. Disabling the height control and extinguishing the arc earlier when finishing the cut on a falling plate can effectively eliminate these problems.

• Diving can also be caused by a faulty height control.

Piercing Standoff Too LowPiercing Standoff Too LowPiercing Standoff Too LowPiercing Standoff Too Low Increase pierce standoff.

Starting on edges with Starting on edges with Starting on edges with Starting on edges with continuous pilot arccontinuous pilot arccontinuous pilot arccontinuous pilot arc

Position torch more carefully or start on adjacent scrap material.

Work FlippingWork FlippingWork FlippingWork Flipping The nozzle may be damaged if the torch hits a flipped up part.

Catching on Pierce SpatterCatching on Pierce SpatterCatching on Pierce SpatterCatching on Pierce Spatter Increase standoff or start with longer lead-in

Pierce not complete before startingPierce not complete before startingPierce not complete before startingPierce not complete before starting Increase initial delay time.


6-2

6.2 No Pilot Arc

Smart FSmart FSmart FSmart Flow IIlow IIlow IIlow II

• No high frequency arc for starting • Start gas pressure too high. • Spark gap electrodes need to be cleaned and

adjusted

Power SupplyPower SupplyPower SupplyPower Supply • Pilot arc contactor not energizing • Pilot arc resistor open • Power supply main contactor not energizing

TorchTorchTorchTorch

• Worn electrode and nozzle • Open pilot arc wire • Open torch leads • Damaged contact ring assembly

TableTableTableTable High water conductivity when cutting under water

6.3 No Arc Transfer TorchTorchTorchTorch Pierce height too high above workpiece

MaterialMaterialMaterialMaterial • Heavy mill scale on top surface of plate • Work plate primed with paint top/bottom

Power SupplyPower SupplyPower SupplyPower Supply Work lead between power supply and table open.

CNC ControlCNC ControlCNC ControlCNC Control • High frequency pulse needs to be set too longer time in CNC

6.4 No Preflow Plasma

TorchTorchTorchTorch • Plasma gas hose restricted • Gas baffle restricted

SupplySupplySupplySupply Plasma gas supply off

Smart Flow IISmart Flow IISmart Flow IISmart Flow II Proportional valve in flow control not open

6.5 No Preflow Shield

TorchTorchTorchTorch

• Shield gas hose restricted • Shield cup opening blocked by pierce splatter • Diffuser missing, shield gas being capped off • Diffuser deformed due to heat

SupplySupplySupplySupply Shield gas supply off

Smart Flow IISmart Flow IISmart Flow IISmart Flow II Shield gas solenoid in Smart Flow II open


6-3

6.6 Torch Fails to Fire

Smart Flow IISmart Flow IISmart Flow IISmart Flow II

• Low start gas pressure • Cooling water flow switch not satisfied in Smart

Flow II. Minimum of 1 GPM flow required. • No high frequency

Water Cooler (WC7)Water Cooler (WC7)Water Cooler (WC7)Water Cooler (WC7) Cooling water pump pressure too low. Should be 135 psi (9.32 bars)

TorchTorchTorchTorch Electrode restricting coolant flow through torch

6.7 No High Frequency in Torch

TorcTorcTorcTorchhhh • Open pilot arc cable • Open torch leads • Damaged contact ring assembly

Smart Flow IISmart Flow IISmart Flow IISmart Flow II No 115 VAC present to H.V. transformer in Smart Flow II


6-4

This page intentionally left blank.

SECTION 7 REPLACEMENT PARTS

7-1

7.1 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.

7.2 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.


7-2

7.3 PT-600 Torch Replacement Front End Parts

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15


7-3

Item

Number Part Number Quantity Description

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

0558001626

0558001825

996528

0558002533 0558001625 0558002532 0558002534 0558002530 0558002531

86W99

0558001621

86W99

0558001624 0558002516 0558002499

181W89

0558001881 0558001882 0558001883 0558001884 0558001623 0558001885 0558001886 0558001887

37082

21796 21944 22496

21795 21802 21945

37081

0558003858

1

1

2

1 1 1 1 1 1

1

1

1

1 1 1

2

1 1 1 1 1 1 1 1

1

1

1 1 1

1

1

PT-600 Torch Sleeve

PT-600 Torch Body w/O-Rings

O-rings supplied with body

Baffle, 4 Hole Baffle, 8 Hole Baffle, 32 Hole Baffle, 4 Hole, Reverse Swirl Baffle, 8 Hole, Reverse Swirl Baffle, 32 Hole, Reverse Swirl O-Ring supplied with Electrode Holder Electrode Holder w/O-Ring O-Ring Supplied With Electrode Electrode, 250 Amp Electrode, 360/400 Amp Electrode, N2, H-35, 600 AMP O-Rings supplied with nozzle Nozzle, 50 Amp Nozzle, 100Amp Nozzle, 150 Amp Nozzle, 200 Amp Nozzle, 250 Amp Nozzle, 360 Amp Nozzle, 400 Amp Nozzle, 600 Amp Nozzle Retaining Cup Gas Diffuser, 50 Amp Gas Diffuser, 100 to 360 Amp Gas Diffuser, 100 to 360 Amp Reverse Shield, 50 Amp Shield, 260 Amp Shield, 360 Amp

Shield Retainer

Contact Ring Assembly


7-4

7.4 Hoses And Cables

3

45

6

89 10

12

1314

15

16

17

18

19

1 2

7


7-5

Item No. Part Number Quantity Description 1 37075 Pilot Arc Buss Assembly

2 37076 Pilot Arc Buss Insulator

3 20408 H.F. Connector

4 61330980 SCR 6-32 X .125 Hex Socket Set

5 0558001626 PT-600 Sleeve (Handle)

6 996565 Hose Clamp, 1.56 I.D. X 2.5 O.D. Stainless

7 20409 Insulator –H.F. Connection

8

0558003840 0558003841 0558003842 0558003843 0558003844 0558003845 0558003846 0558003847

Torch Lead Sleeving, 4.5 ft. (1,4 m) Torch Lead Sleeving, 6 ft. (1,8 m) Torch Lead Sleeving, 7.2 ft. (2,2 m) Torch Lead Sleeving, 12 ft. (3,7 m) Torch Lead Sleeving, 15 ft. (4,6 m) Torch Lead Sleeving, 17 ft. (5,2 m) Torch Lead Sleeving, 20 ft. (6,1 m) Torch Lead Sleeving, 25 ft. (7,6 m)

9 Electrical tape

10 0558001505 1.5’ Expandable braid

11

12 954063 Electrical Warning Tag

13 951168 Band Clamp

14 33030 Shield Connector Nipple

15 33029 Shield Nut Connector

16 34775 996248

0558004131 34363 33209 34364 33210 33211

Power Cable, 4.5 ft (1,3 m) Power Cable, 6 ft (1,8 m) Power Cable, 7.2 ft. (2,2m) Power Cable, 12 ft (3,7 m) Power Cable, 15 ft (4,6 m) Power Cable, 17 ft (5,2 m) Power Cable, 20 ft (6,1 m) Power Cable, 25 ft (7,6 m)

17 0558005882 0558005883 0558005884 0558005885 0558005886 0558005887 0558005888 0558005889 0558005890

Pilot Arc Cable, 4.5 ft. (1,4 m) Pilot Arc Cable, 6 ft (1,8 m) Pilot Arc Cable, 7.2 ft (2,2 m) Pilot Arc Cable, 12 ft. (3,7 m) Pilot Arc Cable, 15 ft. (4,6 m) Pilot Arc Cable, 17 ft. (5,2 m) Pilot Arc Cable, 20 ft. (6,1 m) Pilot Arc Cable, 24.5 ft (7,5 m) Pilot Arc Cable, 25 ft. (7,6 m)

18 34776 34360

0558004133 34361 33203 34362 33204 33205

Gas Hose, 4.5 ft. (1,3 m) Gas Hose, 6 ft (1,8 m) Gas Hose, 7.2 ft. (2,2m) Gas Hose, 12 ft. (3,7 m) Gas Hose, 15 ft. (4,6 m) Gas Hose, 17 ft. (5,2 m) Gas Hose, 20 ft. (6,1 m) Gas Hose, 25 ft. (7,6 m)

19 37192 37193

0558004134 37194 37195 37196 37197 37198

Shield Gas Hose, 4.5 ft. (1,3 m) Shield Gas Hose, 6 ft (1,8 m) Shield Gas Hose, 7.2 ft. (2,2m) Shield Gas Hose, 12 ft. (3,7 m) Shield Gas Hose, 15 ft. (4,6 m) Shield Gas Hose, 17 ft. (5,2 m) Shield Gas Hose, 20 ft. (6,1 m) Shield Gas Hose, 25 ft. (7,6 m)


7-6

1

2 3

4

5

7.5 Complete Assemblies and Tools


7-7

Item

Number Part Number Description

1

2

3

4

5

Not Shown

Not Shown

Not Shown

0560935685 0558001827 0558001828 0558004123 0558001829 0558001830 0558001831 0558001832 0558001833

954917

996568

0558001628

93750006

93750010

953782

08N65

77500101

Mini-Bevel PT-600 Torch w/12 ft (3,7 m) leads PT-600 Torch Assembly w/4.5 ft. (1.3 m) leads PT-600 Torch Assembly w/6 ft. (1,8 m) leads PT-600 Torch Assembly w/7.2 ft. (2,2 m) leads PT-600 Torch Assembly w/12 ft. (3,7 m) leads PT-600 Torch Assembly w/15 ft. (4,6 m) leads PT-600 Torch Assembly w/17 ft. (5,2 m) leads PT-600 Torch Assembly w/20 ft. (6,1 m) leads PT-600 Torch Assembly w/25 ft. (7,6 m) leads PT-600 Label Nut Driver (Electrode Tool) Electrode Holder Tool Hex Key Wrench, .0625" Short arm Hex Key Wrench, .109" Warning Label, “EXPLOSION” Nozzle Compound Dow Silicon DC-111 Grease


7-8

7.6 Parts Kits

1

2


7-9

Item number Quantity P/N Description

1 0558002478 200 Amp Starter Kit 4 0558001624 Electrode O2 1 17672 Lubricant 1 37082 Nozzle Retaining Cup 1 996568 Tool, Nut Driver 1 0558004611 Tool, Electrode Holder 4 0558002499 Electrode PT-19 600A Tungsten 2 0558001881 Nozzle 50A 2 0558001883 Nozzle 150A 2 0558001884 Nozzle 200A 2 0558001882 Nozzle 100A 2 21795 Shield 50A 1 21796 Diffuser 50A 2 21802 Shield 100-250A 2 21944 Diffuser 100-360A 1 37081 Shield Retainer 2 0558002533 Baffle, Gas Swirl 4 639575 O-ring, .364 ID x .070 2 996528 O-ring, 1.614 ID x .070 1 0558003858 Contact Ring Assembly 1 37073 Contact Ring Screw

2 0558002479 PT-600 Spare Parts Kit 1 17672 Silicone Lubricant 1 0558001628 Electrode Holder Tool 1 996568 Electrode Tip Tool 5 996528 O-rings 2 0558002533 Baffle, 4 hole 2 0558001625 Baffle, 8 hole 1 0558002532 Baffle, 32 hole 1 0558002534 Baffle, 4 hole reverse 1 0558002530 Baffle, 8 hole reverse 1 0558002531 Baffle, 32 hole reverse 5 86W99 O-ring 1 0558001621 Electrode Holder w/Oring 5 0558001624 Electrode 250 Amp 2 0558002516 Electrode 360/400 Amp 2 0558002499 Electrode, N2, H-35, 5 181W89 Nozzle O-rings 2 0558001881 Nozzle, 50 Amp 2 0558001882 Nozzle, 100 Amp 2 0558001883 Nozzle, 150 Amp 5 0558001884 Nozzle, 200 Amp 5 0558001623 Nozzle, 250 Amp 5 0558001885 Nozzle, 360 Amp 2 0558001886 Nozzle, 400 Amp 2 0558001887 Nozzle, 600 Amp 1 37082 Nozzle Retaining Clip 1 21796 Gas Diffuser, 50 Amp 1 21944 Gas Diffuser, 100 to 360 Amp 1 22496 Gas Diffuser, 100 to 360 Amp reverse 2 21795 Shield, 50 Amp 5 21802 Shield, 260 Amp 2 21945 Shield, 360 Amp 1 37081 Shield Retainer 1 Reference Tool Box 1 0558003858 Contact Ring Assembly 1 37073 Contact Ring Screw


7-10

7.6 200A STARTER KIT 0558004907 - EPP


QTY P/N DESCRIPTION 5 0558001624UL Electrode, 02 (Ultra-life) 1 17672 Lubricant 1 37082 Nozzle, Retaining Cup 1 996568 Tool, Nut Driver 1 0558004611 Tool, Electrode Holder 1 0558001628 Electrode Holder, PT-600 3 0558001624 Electrode, 250A, PT-600 2 0558002499 Electrode, 600A, PT-600 5 0558005456 Nozzle, 50A, PT-600 5 0558001881 Nozzle, 50A, PT-600 5 0558001882 Nozzle, 100A 5 0558001883 Nozzle, 150-200A 5 0558001884 Nozzle, 200A, PT-600 2 21795 Shield, 50A, PT-19XL 5 0558004678 Shield, 100-200A, EPP 5 21802 Shield, 100-250A, PT-19XL 2 0558005458 Shield, Dia. .120”, PT-600

1 37081 Shield Retainer

2 21944 Diffuser, 100-360A

1 21796 Diffuser, 50A, PT-19XL

2 0558002533 Baffle, Gas Swirl, 4X032P

2 0558005457 Baffle, Gas Swirl, 20-50A

2 996528 O-ring 1.614” ID x .07” Dia.

1 0558003858 Contact Ring Assembly

1 37073 Contact Ring Screw


7-11

7.7 0560935685 - Complete PT-600 Mini-Bevel Torch with 12 ft. (3.7m) Leads 0558005850 - Complete PT-600 Mini-Bevel Torch with 14 ft. (4.3m) Leads 0560939255 - Lead Assembly without Torch


7-12

Item No. Part Number Qty. Description

1 0558001825 1 PT-19P TORCH BODY MACHINED

2A 0560935676 1 SLEEVE TORCH PT-600 MINI BEVEL, 12FT

2B 0558003844 1 SLEEVE TORCH PT-600 MINI BEVEL, 15FT

3 837082 1 NOZZLE RETAINING CUP AY

4A 0560935680 2 CABLE POWER 12FT

4B 0558005848 2 CABLE POWER 14FT

5 17974 1 CONNECTOR H.F. 0.25 OD X 0.78 LNG

6A 0560935678 1 HOSE GAS 12FT

6B 0558005847 1 HOSE GAS 14FT

7 821944 1 DIFFUSER 100-360A

8A 80558003942 1 CABLE PILOT ARC MIN BEVEL, 12FT

8B 0558005846 1 CABLE PILOT ARC MIN BEVEL, 14FT

10 837081 1 SHIELD RETAINER

12 80558003858 1 CONTACT RING AY PT-36

13 80558001621 1 ELECTRODE HOLDER AY PT-600

14 61330980 2 SCR #6-52 X 1/8 HEX SOCKET SET

15 0560987638 1 INSULATOR HF PT-600 MINI-BEVEL

16 837073 1 CONTACT RING SCREW

17 8996565 1 CLAMP HOSE W/D 1.56 ID X 2.50 0D SS

18 0560935682 1 ASSY SLEEVE LEATHER MINI BEV

19 90863004 3.5” TBG SHRINK SRCDPO BLK .50 ID

25 33029 1 NUT SHIELD CONNECTOR

24 80558001624 1 ELECTRODE 250A PT-600

25 80558001625 1 BAFFLE GAS STD 8 X 0.047 PT-600

27 80558001623 1 NOZZLE 250AMP PT-600

30 821802 1 SHIELD 100-250 AMP

31 951168 1 CLAMP, BAND-IT

32 33030 1 NIPPLE, SHIELD

35 954917 1 LABEL, PT-600

34 954063 1 TAG, ELECTRICAL WARNING

41A 0560935679 1 HOSE SHIELD GAS 12FT

41B 0558005849 1 HOSE SHIELD GAS 14FT

7-13


TORCH

PLASMA

ESABAMP

ABOVE

8REF

4REF

8REF

4REF

6REF

41REF

3REF

10REF

30REF

7REF

27REF

24REF

AMP TORCH ABOVE

PLASMA

ESAB

4034

28

23

33

PWR #1

PWR #2

PILOT A

RC

14

515

217

3119

18

7.8 0558007580 - PT-600 Mini-Bevel Torch with 14 ft. (4.2m) Leads

7-14


TORCH

PLASMA

ESABAMP

ABOVE

8REF

4REF

8REF

4REF

6REF

41REF

3REF

10REF

30REF

7REF

27REF

24REF

AMP TORCH ABOVE

PLASMA

ESAB

4034

28

23

33

PWR #1

PWR #2

PILOT A

RC

14

515

217

3119

18

7-15


F

FG

G

H H

35REF

PILOT ARC

7

11

SECTION F-F

WA

TER

OU

T

WA

TER

IN

13

27

3

SECTION G-G

PLASMA ARC BUS WIRE

1612

1

SECTION H-H

SHIELD GAS INPLASMA GAS IN

10

30

24

25

POWER CABLE

SHIELD GAS

POWER CABLE

GAS HOSE

4

6

41

8

7-16


F

FG

G

H H

35REF

PILOT ARC

7

11

SECTION F-F

WA

TER

OU

T

WA

TER

IN

13

27

3

SECTION G-G

PLASMA ARC BUS WIRE

1612

1

SECTION H-H

SHIELD GAS INPLASMA GAS IN

10

30

24

25

POWER CABLE

SHIELD GAS

POWER CABLE

GAS HOSE

4

6

41

8

7-17


BILL OF MATERIALSDESCRIPTION

ITEMN0.

PART OR CODE N0.

SYMBOL(ELEC-AY DESCRIPTION

1 PT-600 TORCH BODY MACHINED2 SLEEVE TORCH PT-600

SLEEVE TORCH PT-600 MINI BEVEL3 NOZZLE RETAINING CUP AY4 CBL PWR AY W/GND RH 4.5FT PT-600

CBL PWR AY W/GND RH 6FT PT-600CBL PWR AY W/GND RH 7.2FT PT-600CBL PWR AY W/GND RH 12FT PT-600CBL PWR AY W/GND RH 14FT PT-600CBL PWR AY W/GND RH 15FT PT-600CBL PWR AY W/GND RH 17FT PT-600CBL PWR AY W/GND RH 20FT PT-600CBL PWR AY W/GND RH 25FT PT-600

5 CONNECTOR H.F.17974 CONNECTOR H.F. 0.25 OD X 0.78 LNG

6 HOSE GAS AY 4.5FTHOSE GAS AY 6FTHOSE GAS AY 7.2FTHOSE GAS AY 12FT

80558005847 HOSE CUT GAS AY BEV 14FTHOSE GAS AY 15FTHOSE GAS AY 17FTHOSE GAS AY 20FTHOSE GAS AY 25FT

7 DIFFUSER 100-360A8 CBL PILOT ARC W/G 4.5FT PT-600

CBL PILOT ARC W/GND 6FT PT-600CBL PILOT ARC W/GND 7.2FT PT-600CBL PILOT ARC W/GND 12FT PT-600CBL PILOT ARC BEV 14FT PT-600CBL PILOT ARC W/GND 15FT PT-600CBL PILOT ARC W/GND 17FT PT-600CBL PILOT ARC W/GND 20FT PT-600CBL PILOT ARC W/GND 25FT PT-600

9 7/64- HEX ALLEN WRENCH10 SHIELD RETAINER11 CBL PWR AY W/GND LH 4.5FT PT-600

CBL PWR AY W/GND LH 6FT PT-600CBL PWR AY W/GND LH 7.2FT PT-600CBL PWR AY W/GND LH 12FT PT-600CBL PWR AY W/GND LH 14FT PT-600CBL PWR AY W/GND LH 15FT PT-600CBL PWR AY W/GND LH 17FT PT-600CBL PWR AY W/GND LH 20FT PT-600CBL PWR AY W/GND LH 25FT PT-600

12 CONTACT RING AY PT-3613 ELECTRODE HOLDER AY PT-60014 SCR #6-32 X 1/8 HEX SOCKET SET15 INSULATOR H.F. CONNECTION

0560987638 INSULATOR H.F. PT-600 MINI-BEVEL16 CONTACT RING SCREW

MODEL N0.

(8)0

5580

0758

2

(8)0

5580

0758

3

(8)0

5580

0758

4

(8)0

5580

0758

5

(8)0

5580

0758

0

(8)0

5580

0758

6

(8)0

5580

0758

7

(8)0

5580

0758

8

(8)0

5580

0758

9

QUANTITY1111111111111111

11111111111

11

11

11

11

11111111

11

11

11

11

11111111111

11

11

11

11

1111111111111111111

11

11

11

11

11111111111111111144442444411111111

1111111111

MODEL N0.

(8)0

5580

0758

2

(8)0

5580

0758

3

(8)0

5580

0758

4

(8)0

5580

0758

5

(8)0

5580

0758

0

(8)0

5580

0758

6

(8)0

5580

0758

7

(8)0

5580

0758

8

(8)0

5580

0758

9

QUANTITY111111111111111111111111111

ARARARARARARARARAR111111111111111111

1.5'1.5'1.5'1.5'1.5'1.5'1.5'1.5'1.5'111111111111111111111111111111111111

ARARARARARARARARAR

111111111111111111

111111111111111111

REFREFREFREFREFREFREFREFREF3333333331111111111111111111111111111

11

111

11

11

11

11

11

11

ITEMN0.

PART OR CODE N0.


17 CLAMP HOSE W/D 1.56ID X 2.5OD SS18 33029 NUT SHIELD CONNECTOR19 33030 NIPPLE SHIELD CONNECTOR20 #11 COMPOUND SILICONE GREASE21 .06 HEX ALLEN WRENCH22 .437 HEX NUT DRIVER23 0558001505 EXPANDABLE BRAIDED SLEEVING24 ELECTRODE 250A PT-60025 BAFFLE GAS STD 8X.047 PT-60026 TOOL ELECT HOLDER PT-60027 NOZZLE 250AMP PT-60028 TAPE ELECTRICAL2930 SHIELD 100-250A31 BAND CLAMP3233 954917 LABEL PT-60034 954063 TAG ELECTRIC WARNING35 951000 O-RING .176 ID X .050 WLL NEOPR36 953782 DECAL WARNING37 PRECAUTIONS & SAFE PRACTICES BOOKLET38 LITERATURE H2 EXPLOSION39 INSTRUCTION LITERATURE PT-600 40 SLEEVING LEATHER TORCH 4.5FT

SLEEVING LEATHER TORCH 6FTSLEEVING LEATHER TORCH 7.2FTSLEEVING LEATHER TORCH 12FTSLEEVING LEATHER TORCH 15FTSLEEVING LEATHER TORCH 17FTSLEEVING LEATHER TORCH 20FTSLEEVING LEATHER TORCH 25FT

41 HOSE SHIELD GAS 4.5 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 6 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 7.2 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 12 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS AY BEL 14 FTHOSE SHIELD GAS 15 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 17 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 20 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 25 FT (REF-SEE FAM DWG 37199)

DESCRIPTIONS FOR PT-600 TORCH AY'S REV(8)0558007582 PT-600 TORCH AY W/G 4.5FT(8)0558007583 PT-600 TORCH AY W/G 6FT(8)0558007584 PT-600 TORCH AY W/G 7.2FT(2.2M)(8)0558007585 PT-600 TORCH AY W/G 12FT(8)0558007580 PT-600 TORCH AY W/G 14FT BEV(8)0558007586 PT-600 TORCH AY W/G 15FT(8)0558007587 PT-600 TORCH AY W/G 17FT(8)0558007588 PT-600 TORCH AY W/G 20FT(8)0558007589 PT-600 TORCH AY W/G 25FT


7-18



ITEMN0.

PART OR CODE N0.


1 PT-600 TORCH BODY MACHINED2 SLEEVE TORCH PT-600

SLEEVE TORCH PT-600 MINI BEVEL3 NOZZLE RETAINING CUP AY4 CBL PWR AY W/GND RH 4.5FT PT-600

CBL PWR AY W/GND RH 6FT PT-600CBL PWR AY W/GND RH 7.2FT PT-600CBL PWR AY W/GND RH 12FT PT-600CBL PWR AY W/GND RH 14FT PT-600CBL PWR AY W/GND RH 15FT PT-600CBL PWR AY W/GND RH 17FT PT-600CBL PWR AY W/GND RH 20FT PT-600CBL PWR AY W/GND RH 25FT PT-600

5 CONNECTOR H.F.17974 CONNECTOR H.F. 0.25 OD X 0.78 LNG

6 HOSE GAS AY 4.5FTHOSE GAS AY 6FTHOSE GAS AY 7.2FTHOSE GAS AY 12FT

80558005847 HOSE CUT GAS AY BEV 14FTHOSE GAS AY 15FTHOSE GAS AY 17FTHOSE GAS AY 20FTHOSE GAS AY 25FT

7 DIFFUSER 100-360A8 CBL PILOT ARC W/G 4.5FT PT-600

CBL PILOT ARC W/GND 6FT PT-600CBL PILOT ARC W/GND 7.2FT PT-600CBL PILOT ARC W/GND 12FT PT-600CBL PILOT ARC BEV 14FT PT-600CBL PILOT ARC W/GND 15FT PT-600CBL PILOT ARC W/GND 17FT PT-600CBL PILOT ARC W/GND 20FT PT-600CBL PILOT ARC W/GND 25FT PT-600

9 7/64- HEX ALLEN WRENCH10 SHIELD RETAINER11 CBL PWR AY W/GND LH 4.5FT PT-600

CBL PWR AY W/GND LH 6FT PT-600CBL PWR AY W/GND LH 7.2FT PT-600CBL PWR AY W/GND LH 12FT PT-600CBL PWR AY W/GND LH 14FT PT-600CBL PWR AY W/GND LH 15FT PT-600CBL PWR AY W/GND LH 17FT PT-600CBL PWR AY W/GND LH 20FT PT-600CBL PWR AY W/GND LH 25FT PT-600

12 CONTACT RING AY PT-3613 ELECTRODE HOLDER AY PT-60014 SCR #6-32 X 1/8 HEX SOCKET SET15 INSULATOR H.F. CONNECTION

0560987638 INSULATOR H.F. PT-600 MINI-BEVEL16 CONTACT RING SCREW

MODEL N0.

(8)0

5580

0758

2

(8)0

5580

0758

3

(8)0

5580

0758

4

(8)0

5580

0758

5

(8)0

5580

0758

0

(8)0

5580

0758

6

(8)0

5580

0758

7

(8)0

5580

0758

8

(8)0

5580

0758

9

QUANTITY1111111111111111

11111111111

11

11

11

11

11111111

11

11

11

11

11111111111

11

11

11

11

1111111111111111111

11

11

11

11

11111111111111111144442444411111111

1111111111

MODEL N0.

(8)0

5580

0758

2

(8)0

5580

0758

3

(8)0

5580

0758

4

(8)0

5580

0758

5

(8)0

5580

0758

0

(8)0

5580

0758

6

(8)0

5580

0758

7

(8)0

5580

0758

8

(8)0

5580

0758

9

QUANTITY111111111111111111111111111

ARARARARARARARARAR111111111111111111

1.5'1.5'1.5'1.5'1.5'1.5'1.5'1.5'1.5'111111111111111111111111111111111111

ARARARARARARARARAR

111111111111111111

111111111111111111

REFREFREFREFREFREFREFREFREF3333333331111111111111111111111111111

11

111

11

11

11

11

11

11

ITEMN0.

PART OR CODE N0.


17 CLAMP HOSE W/D 1.56ID X 2.5OD SS18 33029 NUT SHIELD CONNECTOR19 33030 NIPPLE SHIELD CONNECTOR20 #11 COMPOUND SILICONE GREASE21 .06 HEX ALLEN WRENCH22 .437 HEX NUT DRIVER23 0558001505 EXPANDABLE BRAIDED SLEEVING24 ELECTRODE 250A PT-60025 BAFFLE GAS STD 8X.047 PT-60026 TOOL ELECT HOLDER PT-60027 NOZZLE 250AMP PT-60028 TAPE ELECTRICAL2930 SHIELD 100-250A31 BAND CLAMP3233 954917 LABEL PT-60034 954063 TAG ELECTRIC WARNING35 951000 O-RING .176 ID X .050 WLL NEOPR36 953782 DECAL WARNING37 PRECAUTIONS & SAFE PRACTICES BOOKLET38 LITERATURE H2 EXPLOSION39 INSTRUCTION LITERATURE PT-600 40 SLEEVING LEATHER TORCH 4.5FT

SLEEVING LEATHER TORCH 6FTSLEEVING LEATHER TORCH 7.2FTSLEEVING LEATHER TORCH 12FTSLEEVING LEATHER TORCH 15FTSLEEVING LEATHER TORCH 17FTSLEEVING LEATHER TORCH 20FTSLEEVING LEATHER TORCH 25FT

41 HOSE SHIELD GAS 4.5 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 6 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 7.2 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 12 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS AY BEL 14 FTHOSE SHIELD GAS 15 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 17 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 20 FT (REF-SEE FAM DWG 37199)HOSE SHIELD GAS 25 FT (REF-SEE FAM DWG 37199)

DESCRIPTIONS FOR PT-600 TORCH AY'S REV(8)0558007582 PT-600 TORCH AY W/G 4.5FT(8)0558007583 PT-600 TORCH AY W/G 6FT(8)0558007584 PT-600 TORCH AY W/G 7.2FT(2.2M)(8)0558007585 PT-600 TORCH AY W/G 12FT(8)0558007580 PT-600 TORCH AY W/G 14FT BEV(8)0558007586 PT-600 TORCH AY W/G 15FT(8)0558007587 PT-600 TORCH AY W/G 17FT(8)0558007588 PT-600 TORCH AY W/G 20FT(8)0558007589 PT-600 TORCH AY W/G 25FT


revision history

1. Revision05/2004– updatedsparepartskitp/n0558002478perdneco#043105.2. Revision10/2004- added2pageinsertinsection4forEPP-200/PT-600cuttingdataperJoeWarren.3. Revision04/2005- AddedcuttingparametersfortheESP-150&ESP-200(section4). Addedpages7-11&7-12showingPT-60012”torchbreakdownandpartscall-outs. Changedtorchformini-bevelheadp/nfrom:0560998589to:0560935685.4. Revision08/2005- Changeo-ringpartnumberfrom14K07to639575perECN#053095onpages 2-3and7-9. AddedcutdatafortheESP-1000frombook#F-15-116perR.Chico.5. Revision11/2005- Addedpartnumberstosupport14footlongtorchassemblyformini-bevelhead. ReplacementPartsPages7-11and7-12affected. Alsoadded itemtoSubsection2.3

PackageOptionsAvailableTableonPage2-1. Changedp/ninsection5andsection7from:37071to:0558003858.6. Revision12/2005- Updatedtorchassemblyandhose/cablepartnumbers.7. Revision02/2006- AddedStartupKit0558004907perECN#063020.8. Revision10/2011- chgdp/nfrom:2499to:1624onp.4-64,Alum65AperJ.Warren.

Customer // Technical Support

(843) 664-4405 (800) ESAB-123 (372-2123)

ESAB Welding and Cutting Products

PO BOX 100545 Ebenezer Road Florence, SC 29501-0545

http://www.esab.com

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

Printed in U.S.A

pt-600 mechanized plasma cutting torch

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